SEAT Workshop Service and Repair Manuals

Engine: dismounting

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required t  counterhold -2024A-, see equivalent → Anchor t  Hose clamp -3094-, see equivalent → Anchor t  Hydraulic jack -VAG 1383A-, see equivalent → Anchor t  Collecting tray -VAS 6208-, see equivalent → Anchor t  Workshop crane -VAS 6100-, see equivalent → Anchor t  Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor

t  counterhold -T10038-, see equivalent → Anchor

t  Adjustment tool -T40098-, please see Correspondence → Anchor t  Torque wrench (5... 50 Nm) -V.A.G 1331-, see equivalent → Anchor t  Torque wrench (40... 200 Nm) -V.A.G 1332-, see equivalent → Anchor Operation process   WARNING Danger of the vehicle overturning when engine removed! Secure the vehicle. The luggage compartment must be empty during this. –  Secure the vehicle with support tool -T10038- on both sides of the lifting platform.   Note t  The engine is removed towards the front together with the gearbox with the lock carrier removed. t  Collect the leaking coolant in a clean container for re-use or disposal. t  All the wire clamps that are loosened or cut during dismounting should be placed again in the same location previously occupied during the fitting.   Caution Risk of damage to the electronic components when disconnecting the battery! Observe the measures to be adopted when disconnecting the battery → Rep. gr.27.

–  Disconnect battery earth cable -arrow- with ignition switched off.   WARNING Risk of burn injuries due to hot steam or hot coolant! t  The cooling system is under pressure when the engine is hot. t  To reduce the excess pressure, cover the filler cap of the coolant expansion tank with a cloth and open carefully. –  Open the filler cap of the coolant expansion tank.

–  Disconnect the engine cover-arrow-.

–  Unscrew bolts -arrows-. –  Detach air ducts -1- and -2-.

–  Disconnect the connector -1- from the air mass meter -G70-. –  Loosen hose clip -2- of the air intake hose going to the exhaust turbocharger and separate the hose from the air mass gauge -G70-. –  Disconnect expansion clip -arrow- → Item –  Release retainer for bottom section of air cleaner housing (press in rubber on left and right side and pull upwards). –  Remove front wheels.

–  Release the quick fasteners -1... 3- and remove the noise insulation in the front and back. –  Remove the front bumper trim → Rep. gr.63.

–  Remove air duct (left-side) in front of charge air cooler -arrows-.   Note t  In engines with the engine code CAGA, the right charged air cooler is no longer required from 09.2009. t  The engines with the engine codes CAGA and CAGC are equipped with one charged air cooler and the engine CAHA, with two charged air coolers.

For engines with the engine code CAHA –  Remove air duct (right-side) in front of charge air cooler -arrow-.

Continue for all engines –  Unbolt bracket for soundproofing -arrows-.

–  Place the drip tray -VAS 6208- under the engine. –  Unscrew the drain plug -Arrow- at the bottom left coolant hose and drain off the coolant.

–  Pull to release the connection with the safety fastener -Arrow- and disconnect the coolant hose below from the cooler.

–  Remove the air intake hose -1- to the bottom left charge air cooler on the lock carrier.   WARNING The air conditioning refrigerant circuit must not be opened. –  Remove the refrigerant line from the bracket -2-.

–  Remove vent hose -1- at right bottom from lock carrier.

–  Unclamp the hydraulic hoses to the cooling coil of the servo steering by using the counterhold -3094-. –  Place used oil collection and extraction unit -VAG 1782- under the hydraulic hoses. –  Disconnect the hydraulic hose-arrow-.

–  Remove the coolant hose -1- at the top of the cooler. –  Unplug the connector -2- of the airbag sensors on the left and right of the lock carrier.

–  Unplug the connector -Arrow- of the headlight on both sides of the vehicle.

–  Detach the electrical connectors -1- and -2- from the bracket and unplug them. –  Move electrical wiring clear. –  Unlock control line on engine hood at front of lock.

–  Unplug electrical connectors (left and right) -1- for horns -2-. –  Unscrew nuts -3- and remove alarm horns -2-. –  Unscrew bolts-4- and remove front cross member -5-.

–  Unbolt left and right air guides from radiator -arrows-.

–  Loosen the outside temperature sensor -G17--Item 2- from the bracket. –  Unplug the connector -1- at high-pressure sender -G65-. –  Unscrew the bolts -3- and -4-, and detach the power steering cooling pipe.   WARNING The air conditioning refrigerant circuit must not be opened. –  Unscrew securing bolts -arrows- for condenser.   Note In order to avoid damage to the condenser or the pipes/hoses of the refrigerant, avoid pulling, bending or twisting excessively. –  Move the condenser with the connected lines downwards.

–  Unscrew the bolts -Arrows- on the left and right of the lock carrier.   Note A second mechanic is required for removing lock carrier. –  Remove lock carrier and place down aside (secure against falling).   Caution If the poly V-belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of operation of poly V-belt with chalk or felt-tipped pen in preparation for re-installation.

–  Move tensioning element with wrench -T20126- in -direction of arrow-, remove poly-V-belt from generator pulley, align openings and arrest tensioning element with aid of adjustment tool -T40098-.   Note

Place the holes -arrows- above each other and lock the clamping element using the retention tool -T40098-. –  Remove the ribbed belt.

–  Disconnect connector -arrow- from oil level and oil temperature sensor -G266- (if installed).

–  Unscrew the bracket of the refrigerant line -Arrow- from the oil sump.   Caution The air conditioning refrigerant circuit must not be opened.

–  Unplug the connector -1- of the line to the magnetic clutch of the air conditioning compressor. –  Remove compressor bolts -arrows-.   Note A second mechanic is required for fixing the unit comprising condenser and air conditioner compressor to the right wheel housing.   WARNING Risk of injury due to refrigerant. The air conditioning refrigerant circuit must not be opened.   Caution Danger of damage to condenser, refrigerant lines and hoses. Do not stretch, kink or bend refrigerant pipes and hoses. Do not over tension the tensioning strap -T10038- in order to prevent damage being caused by the bottom fixing nuts of the steering knuckle.

–  Place a cloth -2- between the condenser -3- and the steering knuckle. –  Fix the unit comprising the condenser -3- and air compressor -1- to the right wheel housing of the vehicle using the tensioning strap -T10038- without separating the refrigerant lines.

–  Extract air hose -1-. –  Disconnect electrical connector -2- from charge air sensor -G31- / intake air temperature sensor -G42-and electric line.

–  Detach coolant hoses -1 ... 3- and unfasten coolant expansion tank -arrow-. –  Unplug the connector of the Coolant shortage indicator switch -F66- at the bottom of the coolant expansion tank. –  Remove expansion reservoir.

–  Unbolt pulley of power steering pump -arrows-. Secure the pulley with a mandrel for this purpose.

–  Unscrew the power steering pump -arrows-. –  Mount the pump for the power steering to the left charged air cooler without disconnecting the line. –  Remove strip below windscreen → Rep. gr.50.

–  Unscrew bolts -arrows- from cover on electrical box in water reservoir.

–  Use screwdriver to pry off retaining strap -arrows-.

–  Unlock the capture hooks -arrows- toward outside and remove retaining bracket.

–  Disconnect all plug connections from the bar -2-. –  Unscrew the nut at connection -1-.

–  Release retaining clips -arrows- and lift auxiliary relay carrier out of electronics box. –  Clip-out the supplementary fuse of the E-Box and remove.   WARNING Correctly fasten engine control unit to engine so that it is not subjected to jolts when removing the engine and cannot fall down.

–  Release catches -arrows A- and lift off wiring protector -1--arrow B-. –  Unhook engine wiring harness from electronics box and expose.

–  Place the wiring harness on the engine together with the control unit -1- and secure correctly -arrows- in order to prevent it from falling down or knocking.

–  Unscrew nut -2-, remove ground line. –  Remove the vacuum hose to the brake servo at the bulkhead -1-. –  Fix the wiring harness together with engine control unit on engine and secure in order to prevent it from falling down or knocking.

–  Separate the coolant hoses -arrows-.

–  Separate the fuel supply line -1- and the fuel return line -2- and seal using the engine plug set -VAS 6122-. –  Remove the bracket of the fuel filter. For this purpose unscrew nuts -arrows- → Chapter. –  Push filter holder with fuel lines to right.   Caution Observe the rules for cleanliness when working on the fuel supply system!

–  Pull connector -3- from pressure differential sender -G505-. –  Unscrew bolt -4- of the pressure differential sender -G505-. –  Mark the position and remove the hoses of the pressure differential sender -G505-.

–  Unplug the plug connector -1- of the radiator outlet coolant temperature sender -G83--2-. –  Remove connector on supplementary fuel pump -V393- on right suspension strut.

–  Remove the air duct hoses from the turbocharger. For this purpose, loosen the hose clamp -arrow-.   Note The flexible joint (de-coupling element) in the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged. For vehicles with particulate filter and front exhaust pipe, in two stages –  Remove front exhaust pipe → Chapter. For vehicles with particulate filter and front exhaust pipe, in one stage –  Unscrew the exhaust temperature sensor 4 -G648- after the particulate filter → Chapter. For vehicles with automatic gearbox –  Unscrew the exhaust temperature sensor 4 -G648- after the particulate filter → Chapter. Continued for all vehicles –  Put the exhaust temperature sensor 4 -G648- on the gearbox in order to avoid damage.

–  Remove the trim -1- of the left and right wheel housings.

–  Unscrew the heat protection plate -1- of the right cardan shaft. –  Unscrew left and right propeller shafts from gearbox flange → Chassis, axles and steering; Rep. gr.40. –  Tie up the drive shafts.

–  Unscrew earth wire -arrow- at engine support (right-side).

–  Pull out the plug -3-. –  Unscrew nuts -1- and -2-, and remove the electric cables. For vehicles with automatic gearbox –  Place below the collecting tray -VAS 6208-.

–  Unscrew the union nuts -1- and -2-, and disconnect ATF pipes. –  Remove the bracket -arrows- for ATF pipes.

–  Unbolt ATF filter from gearbox -arrows-.

–  Unscrew the union nuts -1- and -2-, and disconnect ATF pipes. –  Remove the bracket for ATF pipes -arrows-.

–  Unscrew bolt -arrow- and detach ATF pipes from gearbox. –  Remove the ATF pipes. –  Seal the openings on the gearbox as well as the ATF pipes using the engine plug set -VAS 6122-.

Continued for all vehicles –  Unscrew the nuts -3-.   Note Ignore positions -1- and -2-.

–  Place the telescope support of the Engine and gearbox jack -VAG 1383A- under the gearbox with the inserted block of wood -1- and support the gearbox.

–  First unscrew the bolts -1 - and then the bolts -2- of the tunnel cross-member. –  Lower the engine / gearbox assembly and remove the cross member.

For vehicles with automatic gearbox –  Unscrew the bolts -2- and remove the gearbox supports -1-.

–  Unlock connector -1- and separate from the gearbox.   Note t  The -arrows- can be disregarded. t  For illustration purposes here shown with gearbox removed.

–  Remove the ball joint -1- of the pull cable using the lever -80 200-. Then press in the -direction of the arrow- and separate the ball joint from the selector shaft lever. –  Unscrew bolt -3- from the selector shaft lever bracket.   Note Ignore position -2-.

–  Unscrew the bolts -2- and remove the gearbox supports -1-.

For vehicles with manual gearbox –  Unplug the connector -Arrow- Of the Reversing light switch -F4- and place the line aside.

–  Secure connecting rod -2- for selector rod. –  Unscrew the connecting rod -1-. Also unscrew the bolt with an 8 mm Allen key.

–  Unscrew nut -arrow- and detach selector shaft lever from selector shaft.

–  Unscrew the bolt -Arrow- and move the clutch slave cylinder downwards. Do not disconnect hoses/pipes. –  Tie up the clutch slave cylinder with the control linkages.   Caution Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.   WARNING The vehicle must be secured to the lifting platform, else the it could slip.

For engines with identification letters CAGA and CAGC   Note t  Ignore position -1-. t  In engines with the engine code CAGA, the right charged air cooler is no longer required from 09.2009. t  The engines with the engine codes CAGA and CAGC are equipped with one charged air cooler and the engine CAHA, with two charged air coolers. –  Unscrew hose lines -2- and -3- from the charged air system. Continue for all engines –  Secure the vehicle with support tool -T10038- on both sides of the lifting platform.

–  Mark the position of the bolt connections -1- and the fastening sleeves on the left and right -2- at the bottom of the left and right engine mounting.

–  Attach lifting tackle -2024A- to engine and workshop hoist -VAS 6100- as shown in illustration.   Note Take care not to damage the wiring harness or the engine control unit when removing the engine.

–  Remove bottom nuts -1- at engine mounting (left and right).   Note t  Ignore position -2-. t  Different mounting holes are provided for the different engine versions.   Note Check that all hoses and other connections between engine and body have been detached. –  Raise engine until engine mountings are clear. –  Disengage the engine together with the gearbox and lift it forwards from the engine compartment.