SEAT Workshop Service and Repair Manuals

Engine: removal, vehicles with engine code AZV, BKD Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Hydraulic jack -SAT 1040-, with adapter -SAT 1040/1-, see equivalent → Anchor

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Counterhold -T20205-, see equivalent → Anchor

t	counterhold -T10038-, see equivalent → Anchor

t	Centre guide -T10093-, see equivalent → Anchor

t	Collecting tray -T20173-, see equivalent → Anchor

t  counterhold -T20174-, see equivalent → Anchor

t  Pressure tool -U-30042-, see equivalent → Anchor t  Step ladder Removal:   Note t  The engine is removed from underneath together with the gearbox. t  All the wire clamps that are loosened or cut during dismounting should be placed again in the same location previously occupied during the fitting. t  Collect drained coolant in a clean container for re-use or disposal.

–  Take out the oil dipstick -1- from its guide tube. –  Lift the engine cover on one side -arrows 2- and remove it forwards -arrow 3-. –  Replace the oil dipstick in the guide tube.

–  Remove the cover -1- above the battery. To do this press the release tab -arrow-.   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. Gr.27.

–  Disconnect battery earth strap -arrow- with the ignition switched off.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open the cap of the coolant expansion tank. –  Remove both front wheels.

–  Remove centre noise insulation -mounting parts 1 ... 3-.

–  Remove left and right hand side soundproofing -fastening points 1 ... 3-.

–  Remove the connector -2- from the supercharger pressure sender -G31-/output air temperature sender -G42-. –  Unscrew bolt -4-. –  Remove the front air conduit with the air hose; to do this, lift the retaining clips -1- and -3-.

–  Disconnect electrical connection -2- for the reversing light switch. –  Unscrew the nut -1- and take out bracket with electrical connections pin.

–  Remove the right hand side air conduit hose; to do this, lift the retainers slightly -arrows-   WARNING Cover the intercooler opening, for example, using a clean cloth made of spongy material so that coolant does not enter. –  Place the drip tray -T20173- under the engine.

–  Separate the coolant hose from the radiator; to do this, extract the lower retainer -arrow-.

–  Unplug electrical connector -2- at air mass meter -G70-. –  Disconnect the breather hose -1- and the air conduit hoses -3- and -5-. –  Screw out bolt -4- and detach air cleaner housing.

–  Additionally take coolant hose on upper part of oil cooler off -arrow- and drain off remaining coolant. –  Next, remove the coolant hose that was disconnected.

–  Remove battery → Electrical system; Rep. Gr.27 –  Remove the battery tray -arrows-.

–  Disconnect the connection element -2- from the group of hoses on the solenoid valve block; to do this, press on the release button. –  Disconnect the vacuum hose -1- on the oil retention valve for the brake servo.

–  Disconnect the vacuum hose -arrow- for the brake servo on the tandem pump.

–  On the bulk head, remove coolant hoses going to the heat exchanger -arrows-. Vehicles with Manual gearbox

–  Unclip securing clips -1- and -2- on both control cables. –  Remove the securing elements for the control cables from the selection and relay rods.

–  Remove the control cable bracket -arrows- from the gear box and set the cables aside, taking care not to damage them.

–  Pinch off the pressure pipe to the clutch slave cylinder using a hose pincers -U-30042-. –  Extract the pressure tube -1- from the hose connection; to do this, pull the securing clip -arrow- upwards.   WARNING Do not depress clutch pedal after removing slave cylinder. Vehicles with automatic gearbox –  Separate the coolant hoses and remove all of the necessary electrical connections. –  Remove the gearchange mechanism from the gearbox → 02E 6 speed automatic gearbox; Rep. Gr.37. Continued for all vehicles

–  Unscrew the earth cable -1-. –  Separate the cables -2- and -3- from the starter.

–  Disconnect the coolant hoses at the points marked with -arrows-.

–  Disconnect electrical connection -arrow- from the coolant temperature sender -G62-.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Disconnect the centre connector for the injector pump units and the glow plugs. –  Open the cable harness; to do this, disconnect the fuel supply hose on the tandem pump.

–  Disconnect electrical connection -arrow- from the fuel temperature sender -G81-. –  Move cable clear.

–  Extract the electric connection from the bracket -arrow-. –  Disconnect the electrical connection from the Hall sender -G40-. –  Bring lock carrier into service position: → Bodywork, exterior assembly work; Rep. Gr.50

–  Disconnect electrical connection -arrow-fromoil pressure switch -F1-.

–  Disconnect electrical connection from the engine speed sender -G28--arrow-.   Note To release the electrical connection, press, using a screwdriver, on the engine speed sender connector and, at the same time, lift the release button using a thin wire hook. –  Move cable clear.

–  Remove the air conduit hose on the intake manifold flap; to do this, lift the retainers slightly -1-. –  Disconnect electrical connection -2- from the intake manifold flap motor -V157-.

–  Unplug connector -2-. –  Unbolt electrical wire -1- on alternator. –  Disconnect retainer from alternator.

–  Disconnect the coolant hoses -1- and -2- at the front of the engine.

–  Disconnect the electrical connector -arrow- in the coolant temperature transmitter at the outlet of the radiator -G83-.

–  Disconnect the coolant hose -arrow- from the expansion tank.   WARNING t  For those vehicles fitted with an injector pump, the temperature of the fuel and the fuel lines may reach up to 100 ºC in extreme cases. Before opening the duct connections, allow the fuel to cool otherwise there is a risk of severe burns. t  Wear protection gloves. t  Wear eye protection.

–  Disconnect the fuel supply tube -2- and return tube -1-. To do this press release tabs.

–  Disconnect the fuel supply hose -2- and return hose -1- from the fuel pipes.

–  Extract the fuel filter to above the support -arrow- with the hoses connected.   Note

Before removing the ribbed belt, mark its direction of rotation with chalk or with a felt tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause it to rupture. –  Slacken ribbed belt, turn tensioning element in -direction of arrow-. –  Remove Poly-V belt.

–  Pull off vacuum hose -1-. –  Screw out bolt -2- and detach air cleaner housing.

–  Screw out bolts -arrows- and remove alternator.   WARNING The air conditioning refrigerant circuit must not be opened.   Note To prevent damage to the air conditioning compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Unscrew the bolts -2- and -3- on the bracket for the refrigerant tubes.

–  Unscrew air duct at lock carrier -arrows-.

–  Unplug connector -1-. –  Unscrew bolts -arrows- and take fan cowl out.

–  Remove bolts -arrows- from the rear of the radiator. –  Pull the radiator out upwards.   WARNING The air conditioning refrigerant circuit must not be opened.   Note To prevent damage to the air conditioning compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

–  Disconnect electrical connection -1- for magnetic coupling on air conditioner compressor. –  Remove compressor bolts -arrows-.

–  Suspend the air conditioner compressor above with refrigerant hoses still connected, securing it with the securing tool -T10038- to the lock carrier plate. Take special care not to damage the system. –  Leave the cable harnesses to the bodywork to one side.

–  Unscrew the bolts for the assembly mounting on engine -arrows-

–  ... and on gearbox -arrows- by approx. 2 turns.

–  Remove front crosspiece from vehicle underbody -arrows-.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged. –  Loosen exhaust system from double clamp -1-.

–  Unbolt the exhaust system bracket -arrows-.

–  Unscrew the brace for the front exhaust pipe -arrows-.

–  Loosen the bracket -arrow- and remove the exhaust tube from the turbocharger.

–  Unscrew bolts -1 ... 3- and remove pendulum arm support.

–  Unscrew bolts -1- and -2-. –  Remove the air conduit hose; to do this, lift the retainers slightly -arrows-.

–  Remove the air conduit hose from the exhaust gas turbocharger; to do this, lift the retainers slightly -arrow-.

–  Unscrew the link rod on the right of the stabiliser bar -arrow-.

–  Unbolt left and right drive shafts from gearbox flange and the intermediate bearing. –  Tie up left drive shaft upwards. –  Rotate the steering wheel all the way to the right. –  Pivot the right hand side drive shaft forwards and tie up on the longitudinal member, as shown in the image.

–  Bring the securing tool -T20205- with the hydraulic jack -SAT 1040- and turn the bolt -4- until it is parallel with the engine block. –  From the rear of the engine -A-, first insert the fixed column -1-, then adjust the mobile column -2- (when necessary) and then screw on the nuts -arrows-. –  From the front of the engine -B-, position the mobile column -6- and adjust the bolt -5-. –  Adjust the bolt -3- to immobilise the securing tool -T20205-.   Note To unscrew the bolts for gearbox mounting use the step ladder.

–  Unscrew the bolts for the assembly mounting on engine -arrows- ...

–  ... and on gearbox -arrows-.   Note t  t  Check that all hose and other connections between engine, gearbox and body have been detached. t  To avoid damage, guide the engine/gearbox mounting carefully when lowering. t  Pay special attention to the clearance for the air conditioning compressor. –  Lower the engine and gearbox assembly slightly. –  Next, rotate the engine and gearbox assembly forwards and then continue to lower.