SEAT Workshop Service and Repair Manuals

Engine: dismounting

Special tools and workshop equipment required

t	Hose clamps -3094-, see equivalent → Anchor

t	Torque wrench -V.A.G 1331-, see equivalent → Anchor.

t	Torque wrench -V.A.G 1332-, see equivalent → Anchor.

t	Engine/gearbox crane -V.A.G 1383 A-, see equivalent → Anchor

t	Stepladder -VAS 5085-, see equivalent → Anchor

t	Engine bracket -T40076-, see equivalent → Anchor

t	Transport lock for the decoupling element -T10403-, see equivalent → Anchor

t	Torque wrench -V.A.G 1332-, see equivalent → Anchor.

t	Engine sealing plug set -VAS 6122-, see equivalent → Anchor

t	Collector tray for workshop crane -VAS 6208-, see equivalent → Anchor

t	Hose clamp pliers -VAS 6340-, see equivalent → Anchor

t	Grease (vehicles with manual gearbox) -G 000 100-

t

Cable tie

t  Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor

t  counterhold -T10038-, see equivalent → Anchor Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter   Note 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.   WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route lines of any kind and cables so that original routing can be restored. t  Ensure that there is sufficient clearance to all moving or hot components. Removal: –  Remove engine cover panel → Chapter.   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. gr.27. –  With ignition switched off, disconnect earth connection from battery. → Electrical system; Rep. gr.27 –  Remove battery → Electrical system; Rep. gr.27

–  Remove all vacuum lines together with their brackets -1- upwards from the air filter. –  Separate the plug connection on the charge pressure control solenoid valve -N75--3-. –  Unscrew the bolt -2- of the charge pressure control solenoid valve -N75-. –  Place charge pressure control solenoid valve -N75- with vacuum hoses on engine.

–  Unscrew the securing bolts -arrows- for the air intake -1-. Remove connecting hose -2- running to the air filter.

–  Open the hose clamp -1- and remove the hose leading to the exhaust gas turbocharger. –  Unplug connector -2- from air mass meter -G70-. –  Remove bolt -arrows-. –  Remove the air duct -5- from the front plate and take away the entire air filter housing.   Note Disregard: -Items 3 and 4-.

–  Remove the connecting hose -2- from the cylinder head cover. –  Unscrew bolt -3- (attached) and screw intake hose clockwise out of and remove from its bracket.

–  Remove the vacuum line -arrow 1- between the vacuum pump and the servo brake. –  Remove the vacuum line -arrow 1- from the bracket -arrow 2- on the cylinder head.

–  Remove the vacuum line -1- from the vacuum pump.

–  Unscrew the screws -1- and -2- and remove the bottom battery support upwards. –  Open cap on coolant expansion tank.

–  Separate the following connections: -1 ... 4-. t  -1-Exhaust gas temperature sender 1 -G235- t  -2-Exhaust gas temperature sender 3 -G495- t  -3-Exhaust gas temperature sender 4 -G648- t  -4-Lambda probe -G39- –  Remove the line from the bracket on the front side of the plenum chamber and from the exhaust gas turbocharger.

–  Disconnect electrical connector -2- at pressure differential sender -G505-. –  Unscrew bolt -3- from pressure differential sender -G505- bracket. –  Lay pressure differential sender -G505- with lines down to rear. –  Remove the underbody protection → Bodywork, exterior assembly work; Rep. gr.50.

–  Unscrew the -fixing elements 1 ... 3- of the right and left soundproofing.

–  Remove the charged air connecting hose »hot« side; loosen clips -arrows- to do this.

–  Remove the charged air connecting hose »cold« side; loosen clips -arrows- to do this.   Note Block the intercooler with a clean cloth to prevent coolant from entering. –  Place drip tray for workshop cranes -VAS 6208- beneath engine.

–  Detach the connector -1- of the coolant fan -V7-. –  Remove the coolant hose underneath the radiator and drain the coolant.

–  Remove the coolant hose -arrows- and electric connector of theCoolant temperature element at the coolant outlet -G83--1-.

–  Unscrew coolant line bolts -arrows-. –  Remove the connecting hoses from the radiator for the exhaust gas recirculation → Item and → Item. –  Remove the pump for the coolant circulation, lines and connecting hoses.

–  Disconnect connector -1-. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50. Vehicles with air conditioner

–  Unplug electrical connector -2- at air conditioner compressor regulating valve -N280-. –  Remove bolts -arrow-, detach air conditioner compressor -1- with refrigerant lines connected and tie up to front.   WARNING The air conditioning refrigerant circuit must not be opened. To prevent damage to the air conditioning compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

–  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.

All other vehicles continued –  Unscrew the bolts of the coolant return line -arrows-. –  Lay the coolant return line aside.

–  Disconnect the fuel supply line and return line -arrows- from the high-pressure pump. –  Remove charge air pipe »hot« side → Chapter. –  Remove charge air pipe »cold« side → Chapter.

–  Unplug connector -arrow-. –  Undo the nut -1- and remove the hose -2- from the generator.

–  Disconnect the connector -3- from the reversing light switch -F4-. Gearbox for vehicles with Start-Stop system –  Unplug the electrical connector -2- from the gearbox neutral position sender -G701-.

All other vehicles continued –  Set aside the wiring harness.

–  Release and separate the connector -arrow- of the engine control unit. → Chapter

–  Unplug connector -arrow-.

–  Carefully separate the engine wiring harness at its fastening points -arrows-. –  Leave the cable harness on the power unit.

–  Remove the lock washers -1- and -2- from the gearshift and selection control cable. –  Remove the securing elements for the control cables from the selection and relay rods.

–  Separate the selector cable support bracket of the gearshift and selection control cable from the gearbox housing. For this purpose, unscrew the bolt -arrow- and move the counter holder to one side.

–  Remove the slave cylinder from the gearbox casing by extracting the bolts -arrows- and put the assembly aside.   Caution Risk of damage to clutch slave cylinder. The clutch pedal must not be operated when the slave cylinder is removed! –  Place engine wiring harness on engine.

–  Disconnect quick-release couplings for heat exchanger -arrows- on plenum chamber bulkhead. –  Separate all remaining connectors to engine.

–  Unscrew securing bolts -arrows- for pendulum support.   Caution Bolt -1- must not be loosened.   Note Make sure you do not damage surface coating on drive shaft.

–  Remove heat shield for right drive shaft -1-. –  Remove right-hand articulated shaft: → Running gear, shafts, steering; Rep. gr.40. –  Unbolt the left drive shaft from the gearbox flange.

–  Fix the left-hand side drive shaft -arrow-.

–  Remove the particulate filter and fix:

1.	Remove the fixing bracket -1- between the particle filter and the exhaust gas turbocharger.
2.	Remove bolts -2 ... 3-.
3.	Remove bolts -4-.
4.	Unscrew nuts -5-

Note The flexible joint in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

Always mount a protective sleeve or the Transport lock -T10403--arrow- to the decoupling element of the front exhaust pipe. –  Separate subframe suspension.

–  Unscrew the fastening nuts -arrows- of the clamping sleeve and then lower the exhaust pipe to the rear. –  Detach front exhaust pipe from mounting brackets. –  Push the particle filter to the side and fix to the front side of the plenum chamber using a suitable system.

–  Unscrew bolts -arrows- on engine mounting approx. 2 turns. –  Disconnect the earth wire -1-.   Note Disregard item -2-.

–  Unscrew the bolts -arrows- in the gearbox mounting by approx. 2 turns . –  Seal open lines and connections with clean plugs from the Engine sealing plug set -VAS 6122-.

–  Disconnect the connector from the oil level and temperature sender -G266-.

–  Release fasteners -arrows- and remove noise insulation -1- for the oil sump.

–  Unscrew the bolt -6-. –  At this point, -6- the engine bracket -T40076- is screwed together with a longer screw.   Note Items -1, 2, 3, 4 and 5- can be disregarded.

–  Screw the engine bracket -T40076- to the cylinder block (tighten to approx. 20 Nm) with nut -1-. –  Fit M12 nut -3- between engine bracket -T40076- and cylinder block. –  Secure engine bracket -T40076- with M10 X 50 nut -2- on cylinder block. –  Insert engine and gearbox jack -V.A.G 1383 A- in engine support -T40076-. –  Insert engine bracket -T40076- in engine and gearbox jack -V.A.G 1383/A-. –  Raise engine/gearbox assembly slightly.   Note To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

–  Completely unscrew securing bolts -arrows- for engine mounting. –  Completely remove the engine mounting.   Caution Danger of damage to hose and line connections as well as engine compartment. t  Check that all hose and line connections between engine, gearbox, subframe and body have been disconnected. t  When lowering, carefully guide engine out of engine compartment. –  Carefully lower the engine and gearbox. –  Pull engine/gearbox assembly as far as possible forwards and lower it slowly downwards.