SEAT Workshop Service and Repair Manuals

Remove the engine (Engine code BMS)   Note t  To carry out this work it will be necessary to disconnect battery earth strap. For this purpose, first check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. t  The engine is removed from underneath together with the gearbox. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. t  Collect drained coolant in a clean container for re-use or disposal. t  Some components can not be removed, or only with a great deal of difficulty, while the engine is mounted. Therefore the fault memory should be consulted → Chapter, to detect all the faulty components while the engine has been removed, and to replace them before the engine is reassembled.

Operation process –  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards.   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. gr.27. –  With ignition switched off, disconnect earth connection from battery.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open the Sealing plug of the coolant expansion tank. –  Remove front right-hand wheel. –  Remove front right hand side wheel housing moulding → Bodywork, exterior fitting work; Rep. gr.63.

–  Remove the central soundproofing → Bodywork, exterior installation work; Rep. gr.50.

–  Unscrew the bolts -arrows- and remove the heat protecting plate. –  Remove the right articulated drive shafts → Running gear, shafts, steering; Rep. gr.40. –  Drain coolant → Chapter.   WARNING The fuel and the fuel lines may become excessively hot (burn risk). The fuel supply system is also under pressure. Before opening the system, place a cloth over the junction and depressurise the system by gently loosening. For all assembly work carried out on the fuel supply system, protective glasses and gloves must be worn!

–  Separate the fuel feed and return lines -2- and -3- . –  Separate the coolant lines -1- .

–  Remove supercharging tube -2- with connecting hose -3-, releasing the brackets -arrows-. –  Disconnect connection -1- from the intake manifold air pressure sender -G71-.

–  Disconnect the electrical connector -1- on the exhaust gas recirculation valve -N18- with the potentiometer for regulating exhaust gases -G212-. –  Remove the electrical harness from the brackets and move to one side. –  Remove bolts -arrows-. –  Remove the exhaust gas recirculation valve -N18- with the potentiometer for exhaust gas recirculation -G212- from the intake manifold.   Note For improved understanding, it is shown from the rear in the illustration with engine removed.

–  Detach electrical connector -1- of the engine intake manifold flap -V157-. –  Unscrew the bolts -arrows- and remove the intake manifold flap motor -V157-.

–  Detach the connector -4- from the lambda probe -G39- and the connector -3-sender 2 of exhaust gas temperature, row 1 -G448-. –  Disconnect the electrical connector -1- for temperature sender -1 of the exhaust gas -G235-.

–  Unscrew the lambda probe -G39--1- with the lambda probe ring spanner -3337-. –  Unscrew the Sender 2 of exhaust gas temperature, row 1 -G448--2- and the pressure tube -3- from the particulate filter. –  Unscrew the bolts -arrows- and remove the particulate filter protection -4-. –  Unscrew the brackets -5- of the particle filter. –  Unscrew the pressure hoses -7- towards the pressure sensor 1 of the exhaust gases -G450-. –  Loosen the exhaust temperature sensor after particle filter -G527--8-,behind the particle filter.

–  Disconnect the electrical connector -arrow- for temperature sender 1 of the exhaust gases -G450-. –  Unscrew exhaust gas pressure sensor 1 -G450- and remove together with the pressure hoses.

–  Unscrew the nuts on the double clamp -1-.   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.

–  Remove the support bolts of the particle filter and the engine block, and remove the support. –  Free the front exhaust section from the tunnel bridge → Item   Note t  The mounting on the front section of the exhaust pipe with particle filter should not be bent by more than 10° otherwise there is a risk of damage. t  Pay attention to the electrical connections and routing the cables without damaging. –  Remove the front part of the exhaust pipe with the particulate filter and place it on the power steering. –  Remove battery and battery retainer: → Electrical system; Rep. gr.27 –  Remove air filter → Chapter. –  Remove coolant hoses from radiator. –  Separate the coolant tubes going to the heat exchanger. –  Separate the refrigerant tube from the coolant expansion tank.

–  Extract the vacuum hose to the brake servo from the tandem pump -arrow-. –  Release all low pressure hoses.

–  Remove the connector -1- of the engine control unit and connectors -2- and -3-, unfasten -arrows- the cable mounting -4- (depending on vehicle equipment). –  Unscrew the earth connection on the front left strut.

–  Unplug connector -2-. –  Unscrew the electrical cable nut -1- and the cable bracket.

–  Unscrew the earth wire -1-. –  Remove the lines -2- and -3- of the starter.

–  Separate the connector -3- and remove it from the bracket -1-. –  Remove the electric reverse gear switch from the gearbox. –  Unplug the coolant fan thermal switch -F18- connector and the radiator fan connector. –  Move all electric cables to one side. –  Remove the gear control cables from the gearbox → Rep. gr.34 –  Remove the clutch master cylinder without opening the hydraulic circuit, and leave to one side (the clutch pedal should not be pressed) → Rep. gr.30   Note Do not press the clutch pedal –  Remove front bumper covering → Bodywork, exterior installation work; Rep. gr.63. –  Bring lock plate carrier into service position: → Bodywork, exterior fitting work; Rep. gr.50. Vehicles with air conditioner.   Caution The air conditioning refrigerant circuit must not be opened. To avoid damage to the condenser and refrigerant pipes/sleeves, take care not to bend, twist or stretch the pipes/sleeves excessively.   Note For removal and installation of the engine there is no need to open the refrigerant circuit. –  Remove the clip/s from the refrigerant hose/s.

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

–  Leave the air conditioning compressor with refrigerant hoses still connected suspended above, secure it to the lock carrier plate; take special care not to damage the system.

Continued for all vehicles –  Loosen the bolts -arrows- fastening the mountings to the engine by a couple of turns.

–  Loosen the bolts -arrows- fastening the mountings to the gearbox by a couple of turns. –  Remove the connection tube between the intercooler and the exhaust gas turbocharger → Item .   WARNING Cover the intercooler opening, for example, using a clean cloth made of spongy material so that coolant does not enter.

–  Unscrew bolts -arrows- and remove pendulum arm support. –  Remove left wheel drive shaft from the gearbox and support in a raised position: –  Insert hydraulic jack -SAT 1040- with adapter -SAT 1040/1- in engine bracket -T40076- and raise lightly.

–  Fasten the engine bracket -T40076- with the fastening nut -1- and a bolt -2- (M10 x 30 mm). Use a nut (M12 x 20 mm) to gauge the distance to the engine block -3- only for vehicles without air conditioning.   Note To unscrew the bolts for gearbox mounting use the step ladder.

–  Remove bolts -arrows- fastening mountings to engine.

–  Remove bolts -arrows- fastening mountings to gearbox.   Note t  Ensure that all hose attachments and tubes between the engine, gearbox and the body have been loosened. t  To avoid damage, guide the engine/gearbox mounting carefully when lowering. –  Carefully lower the engine and gearbox. –  Pull engine/gearbox assembly as far as possible forwards and lower it slowly downwards.