SEAT Workshop Service and Repair Manuals

Installing engine   Caution When installing a new partial engine, the clamping pieces of the injector must be tightened to the specified tightening torque following installation of the high pressure lines → Chapter. The clamping pieces are supplied tightened »hand tight« so that the position of the injectors can be adjusted during the installation of the high pressure lines. Non-observance of these details may lead to damage to the engine.

Procedure –  Hook the support tool -3033- on the engine and on the workshop crane -VAS 6100-, as shown in the figure. Flywheel end: Position 4. Vibration damper end: Position 8. –  Set the flywheel side lower than the V-belt / vibration damper side. Remove the respective spindle for this purpose. Installation is carried out in the reverse order of removing, when doing this note the following.   Note t  When fitting, replace the self-locking nuts and bolts. t  Renew bolts which have a specified tightening angle, as well as seals and gaskets. t  Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue. t  Clean input shaft splines and, for used clutch plates, hub splines; remove corrosion and apply a thin coat of grease → Parts Catalogue to the splines. Then move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. Excess grease must be removed.

–  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary. –  Observe that the intermediate plate is fitted on sealing flange and is slid onto the dowel sleeves -arrows-. Vehicles with manual gearbox –  Check the centring of the clutch drive plate → Rep. gr.30. –  Check clutch release bearing for wear. Renew release bearing and slave cylinder if necessary.

–  Replace the O-ring -1- on the right gearbox shaft and grease the gear teeth -2- with universal grease → Spare parts catalogue. Vehicles with direct shift gearbox –  Clean the teeth of the gearbox primary shaft and the teeth of the double mass inertial steering, eliminate the corrosion and apply over the teeth a fine layer of universal grease → Spares catalogue. Excess grease must be removed. –  In engines for vehicles with direct shift gearbox (DSG), there should be a gear needle bearing fitted on the crankshaft. Fit it if necessary → Chapter. Continuation for all vehicles –  Screw the gearbox to the engine.   Note t  Specified torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Do not use degreased parts. t  Tolerance for tightening torques: ± 15 %.

Fitting engine/manual gearbox

Item	Bolt	Nm
1 → Remark → Remark, 2 → Remark → Remark	M12×55	80
3 → Remark, 4 → Remark	M12×165	80
5 → Remark	M12×105	80
6 → Remark, 7 → Remark	M10×50	40
8 → Remark	M10×70	40

1)  M8 thread bolt 2)  Replace bolt A -  Dowel sleeves for centralising

Engine / direct shift gearbox mount

Item	Bolt	Nm
1 1), 3 1), 10 1)	M12x55	80
5 1), 9 1)	M12x70	80
6 … 8 1)	M10x50	40
A	Centering handles
l  1) Renew bolts

Vehicles with four-wheel drive –  Mount the angular gear support → Rep. gr.34 –  Mount the right short axle → Rep. gr.40 Continuation for all vehicles –  Insert the engine/gearbox assembly into the body.   Note t  When fitting the engine assembly, continue with care so that the bodywork is not damaged. t  The engine must be lowered together when fitting the engine to the front so that the lines of the particle filter do not remain hanging on the bodywork. t  Look through the right wheel housing to check if the hooks / supports of the particle filter do not obstruct the steering housing and if they have to be guided so that no damage is caused.

–  Mount the gearbox support and tighten the bolts -arrows- to 60 Nm + 90° (1/4 rotations). –  Fit the bearing of the engine assembly, engine and gearbox side. Specified torque → Chapter. –  Hang-out and remove the workshop crane -VAS 6100- and remove the suspension device -3033-. –  Fit the complete half-shafts → Running gear, axles, steering; Rep. gr.40. Vehicles with four-wheel drive –  Connect the front section of the cardan shaft → Final drive 0AV; Rep. gr.39.

Continuation for all vehicles –  Secure the pendulum support with the bolts -1 … 3- to the gearbox and subframe. Specified torque → Chapter. –  Install the exhaust system and align free of stress → Chapter. –  Install the air conditioner compressor → Heating and air conditioning; Rep. gr.87. –  Install poly V-belt → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.

Vehicles with manual gearbox –  Insert the tubes and hoses -4- of the clutch mechanism with a new O-ring -3- on the breather connection -1-, until the securing clip clicks audibly into place -2-. –  To test, pull on the tubes/hoses.   WARNING The clutch pedal must not be operated before bleeding the clutch installation of air. –  Remove thecounterholder -3094-. –  Bleed the clutch hydraulic system → Rep. gr.30. –  Gear mechanism: attach and adjust on the gearbox → Rep. gr.34. Vehicles with direct shift gearbox –  Mount the control wire of the selector lever and adjust it → Rep. gr.34. Continuation for all vehicles –  Adjust engine mountings → Chapter. –  Install battery → Electrical system; Rep. gr.27. –  Fit the lock carrier plate and move into service position → Bodywork, exterior fitting work; Rep. gr.50 –  Install charge air cooler → Chapter. –  Fit the supercharger air system hoses and observe the assembly instructions → Chapter. –  Install the lock carrier ready for use → Exterior body installation work ; Rep. gr.50. –  Check oil level → Chapter. –  Fill up coolant → Anchor.   Note t  The drained coolant can only be reused if the cylinder head or the cylinder block have not been replaced. t  Contaminated or dirty coolant must not be used again.   WARNING Do not use a battery charger to start the engine! The control units of the vehicle may be damaged. –  Check the headlight settings → Electrical system; Rep. gr.94. Observe applicable safety precautions during road test. –  Perform test drive, and interrogate fault memory afterwards → Chapter. Specified torques .

Component		Nm
Nuts/bolts	M6	10
	M7	15
	M8	20
	M10	40
	M12	65
Except for the following:
Direct shift gearbox: Starter motor gearbox		40
discrepancies:
Gearbox support to gearbox.		60 + 90° → Remark → Remark
Left supercharger air tube to the oil sump		10
Pendulum support to gearbox.		40 + 90° → Remark → Remark
Pendulum support to subframe		100 + 90° → Remark → Remark
Lock carrier to the bodywork		10
Terminal B+ to starter motor		16
Earth wire to gearbox		22
Front supercharger air tube to the engine block		22

3)  Replace bolts 4)  90º is equivalent to a quarter turn