SEAT Workshop Service and Repair Manuals

Engine: remove (Engine codes ASZ, ATD, BPX, BLT, BUK, AXR) Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Engine/gearbox crane -SAT 1040-, see equivalent → Anchor

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

t	Recipient tray -T20173-, see equivalent → Anchor

t	Pliers -T20174- or pliers -T20029-, see equivalent → Anchor

t	counterhold -T20205-, see equivalent → Anchor

t  Centre guide -T20070-   Note t  To carry out this work it will be necessary to disconnect battery earth strap. Therefore check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. t  All the cable fixings that are opened or cut during removal of the cylinder head must be fitted in the same position when reinstalling the engine. 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. –  The engine is removed from underneath together with the gearbox.   WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: All the various lines (e.g. fuel, hydraulic system, active carbon filter system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring must be installed in their original positions. Ensure sufficient clearance for all moving or hot components. Procedure:

–  Remove the engine sound proofing cover, pulling upwards forcefully (-arrows A-) and remove forwards, from the rear attachment (-arrow B-).   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. Gr.27. –  With the ignition OFF, disconnect the earth connection from the battery –  Remove the battery and the battery support: → Electrical system; Rep. Gr.27 –  Remove air filter → Chapter .   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 front right-hand wheel.

–  Remove noise insulation: → Bodywork, exterior fitting work; Rep. Gr.50

–  Loosen the spring-type clamp -arrow- with pliers -T20174- and remove the pipe from the turbocharger. –  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!

–  Disconnect the pipes -2- and -3- for the fuel supply and return along with the cooling pipes -1-.

–  Remove supercharging tube -1- with connecting hose -2-, releasing the brackets -arrows- in doing so. Engine identification letters AXR and BLT –  Disconnect the plug from the Intake manifold flap motor -V157- . Engine identification letters BPX and BUK –  Separate the coolant hose coming from the exhaust gas radiator expansion drum. All vehicles (continued)

–  Remove the breather hose for the crankshaft sump -6- from the air conduction pipe. –  Leave the hoses for low pressure loose. –  Open the spring-type clamp -5- and remove the hose leading to the air filter. –  Unscrew bolts -1 and 2-. –  Separate air conduit from the vehicle -4-. Vehicles with engine code AXR, BLT, BPX and BUK –  Separate the coolant hose coming from the exhaust recirculation radiator with the counterhold -T20174- or pliers to open the flexible hose clips -T20029-. All vehicles (continued) –  Remove the flexible tubes of the radiator from the engine using the counterhold -T20174- or pliers to open the flexible clips -T20029-. –  Remove the coolant expansion tank. –  Disconnect the suction and vacuum pipes from the solenoid valve holder.

–  Unplug the connector -1- of the engine control unit as well as connectors -2- and -3-. Loosen -arrows- the cable ties -4-. –  Remove the gear mechanism from the gearbox: → 0A8 6-speed manual 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 –  Remove the wheel housing moulding: → Bodywork, exterior fitting work; Rep. Gr.66 –  Removing front bumper trim: → Bodywork, exterior fitting work; Rep. Gr.63 –  Disconnect the connector of theIntake manifold pressure sender -G71- and Air intake temperature sender -G72-. –  Remove the electric reverse gear switch from the gearbox. –  Unplug the radiator fan thermal switch -F18- connector and the radiator fan connector.

–  Move the lock carrier in service position: → Bodywork, exterior fitting work; Rep. Gr.50.   Note The ventilation tube must be disconnected from the supercharger for vehicles with → Item engine codes BPX and BUK. For this purpose, the bracket of the bumper must be released and, after removal, the ventilation tube must be refitted with both top screws. –  Remove the connection tube between the intercooler and the exhaust gas turbocharger. –  Remove Poly V-belt → Chapter.

–  Remove connector -2- from the alternator. –  Unscrew the electrical cable nut -1- and the cable bracket. –  Remove the articulated shaft to the left and right from the gearbox and tie up: → Running gear, axles, steering; Rep. Gr.40   Caution In order to avoid damage to the electric cables take care not to bend, twist or stretch excessively.

–  Unscrew earth connection -1-. –  Detach wires -2- and -3- from starter motor.

–  Release the connectors -2- and -3- from the starter motor and remove them from the bracket -1-. –  Move all electric cables to one side. Vehicles fitted with air conditioning   Caution The air conditioning cooling 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. All vehicles (continued)

–  Unscrew bolts -arrows- and remove pendulum arm support -1-. –  Remove the forward section of the exhaust tube → Chapter .

–  Move the support -T20205- close to 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- as 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 support -T20205-. –  Raise the engine and gearbox slightly using the hydraulic jack -SAT 1040-.   Note To remove securing bolts use a ladder.

–  Extract the bolts -arrows- from the engine support of the drive train, to the right-hand side from above.

–  Extract the bolts -arrows- of the engine support of the drive train, to the left-hand side from above.   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.