SEAT Workshop Service and Repair Manuals

Engine: dismounting   Note 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. –  The engine is removed upwards together with the gearbox. –  With the ignition switched off, disconnect battery earth strap → Electrical system; Rep. Gr.27 –  Remove the battery and its mount → Electrical system; Rep. Gr.27. –  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. –  Remove the air filter housing → Chapter.   WARNING Steam may be released when opening the expansion tank. Wear safety goggles and appropriate clothing to avoid injury to eyes and burns. Cover the cap with a cloth and open carefully. –  Open and close the compensation tank cap to release pressure in cooling system. –  Remove all of the electrical cables from the gearbox, alternator, and starter motor leaving them uncovered. –  Disconnect all other electrical connections as necessary from engine and lay to one side.   WARNING Fuel supply pipes are pressurised. Wear safety goggles and appropriate clothing to avoid injury and contact with skin. Before loosening hose connections, wrap a cloth around the connection. Then eliminate the pressure by carefully separating the pipe.

–  Remove the fuel supply pipe -2- and the bleeding pipe -1-. To do so, press the release tabs. –  Cover the disconnected fuel lines immediately to avoid the penetration of dirt into the fuel system. –  Remove the solenoid 1 for active carbon filter -N80- hose from the throttle control unit. –  Cover the disconnected fuel lines immediately to avoid the penetration of dirt into the fuel system. –  Observe rules for cleanliness → Chapter. –  Disconnect the suction and vacuum hose connections. Altea - Altea XL - Leon –  Remove the front panel of the plenum chamber: → Bodywork, exterior fitting work; Rep. Gr.50 –  Remove engine control unit → Chapter.

–  Release the engine cable harness guide -arrow-, and pull out upwards.

–  Open all the locks of the side member cable guide -arrows-. –  Extract the cable harness from the engine control unit. –  Attach the cable harness to the engine with a cable tie. –  Disconnect all other electrical connections as necessary from engine and lay to one side. Continued for all vehicles –  Remove the centre soundproofing → Bodywork, exterior assembly work; Rep. Gr.50. –  Bring lock carrier into service position → General body repairs, exterior; Rep. Gr.50 –  Pull connector off thermo-switch and radiator fan. –  Remove the forward section of the exhaust tube → Chapter .

–  Unscrew the pendulum support -arrows-: Ibiza –  Remove the gear selection mechanism: → 5-speed manual gearbox 02T; Rep. Gr.34 –  Remove the slave cylinder of the hydraulic clutch: → 5-speed manual gearbox 02T; Rep. Gr.30 Altea - Altea XL - Leon –  Remove the gear mechanism from the gearbox: → 0AF 5 speed gearbox; Rep. Gr.34 –  Install the clutch slave cylinder with the hydraulic clutch: → 0AF 5 speed gearbox; Rep. Gr.30   Note Do not depress the clutch pedal. Continued for all vehicles –  Drain coolant → Chapter –  Remove the coolant hoses from the engine using the hose clip pliers -VAS 6340-. –  Remove the refrigerant element and leave it to one side (do not release the tubes). Vehicles fitted with air conditioning –  Remove the Poly V-belt → Chapter. –  Removing air conditioning compressor → Heating, Air conditioning; Rep. Gr.87   Note Do not open the air conditioning pipes. –  Attach the air conditioning compressor to the lock carrier plate. –  Check that the conducts have not been bent. –  Observe additional information and installation instructions → Chapter Continued for all vehicles –  Remove left and right-hand drive shaft from the gearbox and tie up → Running gear, shafts, steering; Rep. Gr.40.

–  Fit suspension tool -2024A- as indicated in the illustration and lift slightly with the workshop crane -VAS 6100-.   Caution Insert safety pins -arrows- into the hooks and bolts to prevent damage to the engine and vehicle.   Note t  The positions numbered 1 ... 4 of the hoisting bar face the pulley. t  The holes in the perforated flanges are counted starting from the hook. Ibiza

–  Unscrew the engine assembly from the gearbox mounting -B- and from the engine assembly mounting -A--arrows-. Altea - Altea XL - Leon –  Remove the hose which goes to solenoid valve 1 for activated carbon filter -N80- from the activated carbon filter.

–  Remove the activated carbon filter -1- from the support. –  Remove the filling mouth from the windscreen washer.

–  Remove the activated carbon filter support -arrows- from the engine support. –  Slacken the screws for the coolant tank and put it off to one side (screws remain closed).

–  Undo the bolts -A-, -B- and -C- of the support unit on the side of the pulley and remove the support unit completely.

–  Remove the engine assembly from the gearbox bearing -arrows-. Continued for all vehicles –  Remove the engine assembly lifting upwards. During this procedure, turn and lower the engine assembly as necessary.   Note When the assembly is lifted out, it must be carefully guided to prevent damage to bodywork.