SEAT Workshop Service and Repair Manuals

Engine: dismounting   Note t  The engine is removed towards front with the lock carrier removed. t  During assembly, all the cable ties that are released or cut must be placed in the same position. t  Collect drained coolant in a clean container for re-use or disposal. Operation process –  Move selector lever to position „N“ on vehicles with automatic gearbox.   Caution When disconnecting battery, observe safety measures → Electrical system; Rep. gr.27.

–  With ignition switched off, disconnect earth wire -arrow- at battery.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open cap on coolant expansion tank. –  Remove both front wheels.

–  Release quick-fasteners -1- and -2- and take off front noise insulation. –  If fitted, release quick fasteners -3- and remove rear noise insulation.

–  Unbolt bracket for soundproofing -arrows-. –  Remove the front bumper cover → exterior body installation work; Rep. gr.63.

–  Remove air ducts in front of charge air coolers (left and right) -arrows-. –  Place the drip tray -VAS 6208- under the engine.

–  Open the drain screw -Arrow- on the coolant hose and let the coolant drain.

–  Remove the coolant hose under the radiator -arrow-.

–  Remove the air hose -1- between the charged air cooler left and the lock carrier.   WARNING The air conditioning refrigerant circuit must not be opened. –  Disengage refrigerant line at bracket -2-.

–  Detach air intake hose -1- going to turbocharger (bottom right). –  Separate the air hose to the charged air cooler at the lock carrier -2-.

–  Unclamp the hydraulic hoses to the cooling coil of the servo steering by using the counterhold -3094-. –  Place catch vessel -VAS 6208- below. –  Disconnect coolant hoses -arrows-. –  Pull off engine cover panel -arrows-.

Vehicles with automatic gearbox:   Note Observe rules for cleanliness when working on automatic gearbox → Rep. gr.00. –  Place used oil collection and extraction unit -VAG 1782- underneath. –  Detach ATF lines -2 and 3- at connections. –  Unbolt bracket -1- for ATF lines at engine. All vehicles (continued):

–  Pull off engine cover panel -arrows-.

–  Unscrew both bolts-arrows- for the air pipes -1- on the lock carrier plate. –  Remove the air conduit -1- from the air filter housing.

–  Disconnect top coolant hose -1- at radiator. –  Pull out the connector -2- of the airbag sensors to the left and right of the lock carrier.

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

–  Take electrical connectors -1- and -2- out of retainer and disconnect them. –  Move electrical wiring clear.

–  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-.

–  Suspend the temperature sensor for outside temperature -G17--2- from the bracket. –  Unscrew bolts -3- and -4- and remove power steering cooling pipe. –  Detach electrical connector -1- at high-pressure sender -G65-.   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.

–  Thread off the screws -Arrow- on the left and right side of the lock carrier. –  Hang out the control cable on the engine hood lock. –  Remove the engine hood seal on the lock carrier and on the mudguard edges.   Note You will need support from a colleague to remove the lock carrier. –  Remove the lock carrier and put it down such that it cannot topple. –  Remove poly V-belt → Chapter.

–  Unscrew the bracket of the refrigerant line -Arrow- from the oil sump.

–  Unplug the connector -1- of the line to the magnetic clutch of the air conditioning compressor.   Caution The air conditioning refrigerant circuit must not be opened. –  Unbolt air conditioner compressor from bracket -arrows-.   Note In order to avoid damage to the condenser or the pipes/hoses of the refrigerant, avoid pulling, bending or twisting excessively. –  Tie up air conditioner compressor and condenser with pipes attached to right side of vehicle.

–  Unscrew earth connection -1-. –  Disconnect vacuum hose going to brake servo at bulkhead -2-. –  Disconnect ACF hose -3-.

–  Disconnect coolant hoses -1 and 2- and detach coolant expansion tank -arrow-. –  Separate the connector of the switch for coolant shortage indicator -F66- below on the coolant compensation tank.

–  Unplug electrical connector from charge air pressure sender -G31--1-. –  Remove charge air hose (left-side) -2-.

–  Remove charge air hose (right-side) -1-.

–  Detach electrical connector -1- for Lambda probe after catalytic converter -G130- and Lambda probe 1 heater, after catalytic converter -Z29- (brown connector) from retainer. –  Detach electrical connector -2- for Lambda probe -G39- and Lambda probe heater -Z19- (black connector) from retainer.   Caution The fuel pressure must be reduced prior to opening any components in the high-pressure section of the fuel system. The flow → Rep. gr.24 must be absolutely maintained.

–  Disconnect fuel line -arrow- (catch escaping fuel and seal off open pipes immediately). –  Disconnect coolant hoses going to heat exchanger at rear of engine. –  Remove wind moulding → Outer body and assembly work; Rep. gr.50.

–  Remove cover for electronics box in plenum chamber -arrows-.

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

t  The engine control unit -1- and its connectors are protected by a safety system consisting of a sheet metal housing -4- and break-off head screws -3-. t  To ensure that the safety system does not have to be removed, remove the engine control unit with connectors attached to it.

–  Release retaining hooks -arrows- outwards and remove retaining strap.

–  Remove all plug connections from the bar -2-. –  Unscrew electrical line connector -1-.

–  Release retaining clips -arrows- and lift auxiliary relay carrier out of electronics box. –  Disengage engine wiring harness at electronics box and bulkhead and move clear.   WARNING Correctly fasten engine control unit to engine so that it is not subjected to jolts when removing the engine and cannot fall down. –  Place wiring harness together with engine control unit on engine and secure against falling down and jolts.

–  Thread off the front screws -arrow- of the propeller pump through the openings of the V ribs belt pulley.

–  Thread off the rear screws -arrow- of the propeller pump. –  Put down the propeller pump on the side on the longitudinal spar. Lines remain connected.

–  Detach electrical connectors -1 and 2- and move wire clear. –  Detach intake hose -3- (air cleaner/turbocharger).

–  Remove the electrical connector -1- from the air mass meter -G70-. –  Detach wiring harness from air cleaner housing and remove air cleaner housing -arrow-.

–  Unscrew earth cable -arrow- from longitudinal member (right-side).

–  Unscrew the heat protection plate -1- of the right cardan shaft.   Note The flexible joint (de-coupling element) in the exhaust system must not be bent more than 10° – otherwise it can be damaged.

–  Loosen clamp -arrow- and push to rear.

–  Detach front exhaust pipe/catalytic converter -arrows-. –  Remove bolt -1- on bracket for front exhaust pipe and then detach front exhaust pipe.

–  Unplug electrical connector -arrow- from reversing light switch -F4- and move wire leading to wiring harness clear.

–  Remove engine/gearbox bolts -1 ... 3- and -7 ... 11- accessible from below.

–  Detach starter and swivel aside. –  Disconnect connector -3-. –  Unscrew nut -1- for clamp. –  Unscrew nut -2- and remove electrical wiring. –  Take out starter motor.

–  Mark positions of bolt connections -1- and locating sleeves -2- on bottom of engine mountings (left and right).   Note Different mounting holes are provided for the different engine versions. –  Unscrew nuts -1- (bottom) at engine mountings (left and right).

–  Slacken off top nut on left-side engine mounting several turns. –  Unscrew top bolts on engine/gearbox assembly flange; leave one bolt in place (finger-tight).

–  Hook the support tool -2024A- on the engine and on the workshop crane -VAS 6100-, as shown in the illustration.   Note To adjust to the centre of gravity of the assembly, the perforated rails of the support hooks must be positioned as shown.   WARNING The hook attachments and locating pins on the lifting tackle must be secured with locking pins. –  Unscrew and remove the last connecting screw on the flange of the engine/gear. –  Position hydraulic lifter below gearbox without making contact (do not raise vehicle).   Note Check that all hoses and other connections between engine and body have been detached. –  Lift the engine with the garage crane -VAS 6100- until the engine bearing thread bolts are free. –  Position hydraulic lifter upward until gearbox makes contact. –  Detach engine from gearbox and lift engine forwards out of engine compartment.