SEAT Workshop Service and Repair Manuals

Removal: –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27.

–  Remove the engine cover upwards -arrows-. –  Remove air filter housing → Chapter. –  Remove the battery and its mount → Electrical system; Rep. gr.27. –  Remove the cowling with the radiator fan -V7- and the radiator fan, right side -V35- → Chapter. –  Remove connecting hose on »cold side« → Item from charge air cooler. –  Remove the cylinder head cover → Chapter.

–  Pull connector off throttle valve module -J338--2-. –  Unscrew the oil level control screw -4-.   Note Ignore items -1- and -3-. –  Remove the vacuum line from the vacuum pump.

–  Unscrew bolts -2, 5- and -arrows-. –  Free electrical lines and hoses on left air pipe using removal lever -80 - 200-. –  Release hose clip -3- and remove left air pipe.   Note Ignore items -1- and -4-.

–  Remove bolts -arrows- and detach the impulse absorber -2-.   Note Item -1- can be disregarded.

–  Remove centre noise insulation -fastening points 1 ... 3-. –  Drain coolant → Chapter. –  Unplug electrical connector -4- at coolant temperature sender -G62-.

–  Pull coolant hoses off the connections For this purpose undo hose clamps -1- and -2-.

–  Disconnect electrical connector -1- on oil pressure switch -F1-. –  Unscrew bolt -arrow-. –  Pull off vacuum hose -2-.

–  Remove electrical connector -3- from bracket and disconnect. –  Free electrical lines on turbocharger.   Note Ignore items -1- and -2-. –  Remove the air duct with the radiator fan → Chapter.

–  Unscrew securing bolts -arrows- from charge air pipe and disconnect connector from charge air pressure sender -G31--1-. –  Open the clamp -2- and lay the coolant hose -3- free and remove the supercharger air hose.   Caution Ensure that decoupling element of connecting pipe is not bent and thus stretched. There is a danger of cracking.

–  Remove connecting pipes for exhaust gas recirculation -A- using socket -T10385-.

–  Unscrew securing nuts -arrows- of bracket for particulate filter -A- at crankcase.

–  Unscrew union nut -2- and unscrew bolt -3-.   Note Item -1- can be disregarded.

–  Unscrew bolt -arrow- from rear toothed belt guard. –  Release connecting clamp between turbocharger and diesel particulate filter.

–  Unscrew securing bolt from bracket on cylinder head -arrow- and push diesel particulate filter to side.

–  Unplug the connector of the Hall sender -G40--arrow-. –  Remove the toothed belt from the camshaft → Chapter. –  Remove the camshaft sprocket and extract the hub of the camshaft using the extractor tool -T10052-. –  Unscrew securing nut of toothed belt tensioning roller.

–  Unplug the connector of the Hall sender -G40--arrow-.

–  Follow the sequence -1 ... 10- for loosening the cylinder head bolts.   Note t  A second mechanic is required to remove the cylinder head. t  The toothed belt tensioning roller is pulled off the stud when the cylinder head is lifted out. t  The oil return line of the turbocharger is pulled out of the support when the cylinder head is lifted out. –  Lift the cylinder head on the gearbox side and disconnect from the toothed gear guard. Make sure that toothed belt tensioner does not fall down. –  Place cylinder head down taking care not to bend oil return line. If necessary, place a piece of wood under exhaust manifold.