SEAT Workshop Service and Repair Manuals

Removal: » Carry out the following work sequence« –  Remove engine cover → Chapter –  With the ignition switched off, disconnect the battery earth lead → Electrical system; Rep. gr.27.

–  Disconnect the vacuum lines with bracket -1- from the air filter. –  Separate the plug connection on the charge pressure control solenoid valve -N75--3-. –  Unbolt charge pressure control solenoid valve -N75- with bracket -2-. –  Place charge pressure control solenoid valve -N75- with vacuum hoses on engine. –  Remove charge air pipe »hot« side → Chapter. –  Remove charge air pipe »cold« side → Chapter.

–  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. –  Drain coolant → Chapter.

–  Unscrew bolts -arrows- and remove pulsation damper -2-.   Note Disregard: -Pos. 1-.

–  Unplug electrical connector -1- at oil pressure switch -F1-. –  Pull off vacuum hose -2-, unscrew vacuum hose connection -arrow-.

–  Unplug electrical connector -4- at coolant temperature sender -G62-. –  Remove the coolant hose. Loosen the hose clips -1- and -2- for this purpose.

–  Detach the connectors -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-

–  Disconnect the electric connector -2- on the side of the pressure differential sender -G505-. –  Unscrew bolt -3- from pressure differential sender -G505- bracket. –  Lay pressure differential sender -G505- with lines down to rear.

–  Disconnect the fuel supply line and return line -arrows- from the high-pressure pump.

–  Unscrew the bolts of the coolant return line -arrows-, lay the coolant return line aside. –  Remove cylinder head cover → Chapter

–  High-pressure line -2- between rail element (high-pressure accumulator) and high-pressure pump.

–  Unclip engine pre-wiring harness from bracket -arrow-. –  Separate all remaining connectors to engine. –  Lay engine wiring to side. –  Unscrew bolt from oil dipstick connection -arrow-.   Caution Ensure that decoupling element of connecting pipe is not bent and thus stretched. There is a danger of cracking.

Remove the particulate filter and fix:

1.	Remove securing clamp between particulate filter and turbocharger
2.	Unscrew bolts and nuts -2 … 3-
3.	Remove bolts -4-.
4.	Unscrew nuts -5-

–  Secure particulate filter to plenum chamber bulkhead.

–  Remove connecting pipes -A- for exhaust gas recirculation. –  Install oil supply line and turbocharger support → Chapter.

–  Separate connector Hall sender -G40--arrow-. –  Take toothed belt off camshaft and high-pressure pump → Chapter.

–  Disconnect the vacuum lines with bracket -1- upwards completely from the air filter. –  Separate the plug connection on the charge pressure control solenoid valve -N75--3-. –  Unbolt charge pressure control solenoid valve -N75- with bracket -2-. –  Place charge pressure control solenoid valve -N75- with vacuum hoses on engine.

–  Counterhold hub with counterhold tool -T10051- and loosen the securing bolt -1- of the hub. –  Unscrew securing bolt of hub approx. 2 turns.

–  Position puller -T10052- and align with hub holes. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.   Note Hold puller with a spanner 30 mm whilst doing this. –  Remove the hub cone from the camshaft.

–  Unscrew securing bolt -arrow- from toothed belt guard.

–  Unscrew nut -1- for belt tensioner. –  Unscrew cylinder head bolts.

–  Maintain sequence when loosening cylinder head bolts.   Note t  A second mechanic is required to remove the cylinder head. t  The toothed belt tensioning roller is detached from the stud when the cylinder head is lifted out. –  First raise cylinder head on gearbox side and remove from the toothed belt guard. Make sure toothed belt tensioning roller does not drop out.