SEAT Workshop Service and Repair Manuals

Removal: –  Remove the engine cover / air filter → Chapter.   WARNING t  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. t  For safety reasons, before opening the fuel system, first remove the fuse from the control unit on the fuel pump -J538- in the fuse holder, thus preventing the contact switch on the driver's door from starting up the fuel pump. Fuse allocation → Current flow diagrams, Electrical fault finding and Fitting locations

–  Disconnect the vacuum pipe -1- and the fuel pipe -2-. To do so, press the tabs.

–  Remove the breather hoses -1- and -2-. Remove the activated carbon filter -A- with the hoses from its bracket by pulling upwards.   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. –  In order to relieve the pressure, the coolant expansion tank must now be opened and closed again.

–  Loosen the clamp -arrow- and release the coolant hose. Clean up any spilt coolant with a cloth.

–  Pull out the plug -1-. Release the coolant reservoir, and leave to one side. –  Remove Poly V-belt → Chapter.

–  Unscrew the tensioning device on the Poly-V belt-A- and fit the mount -T10339- in the two upper threaded drill holes.

–  Place the mount -U-30025E- on the base of the wings, as shown. Hold he engine in the mounting position. –  Place the spindle hook in the right-hand suspension eyebolt and pre-tension the mount -T10339- slightly   Caution Take care not to damage the edges of the wings. –  Remove the central soundproofing pan → Bodywork, exterior fitting work; Rep. Gr.50.

–  Disassemble the front section of the right-hand side wheel housing.

–  Turn the crankshaft until the camshaft sprocket reaches the TDC position. The mark on the camshaft sprocket must be aligned with the arrow on the notched belt guard.

–  Remove the supercharger air hose -arrow- from the intercooler.

–  Loosen the bolts -arrows-, and remove the air duct.

–  Remove vibration damper/belt pulley.

–  Loosen the bolts of the lower guard of the notched belt -arrows-.

–  Loosen the lower bolt -3-.   Note t  The following operations are necessary in order to raise the engine sufficiently. t  Lubricate the threads of the turbo/exhaust before loosening the bolts

–  Separate the primary exhaust pipe with catalytic converter from the fastenings to the turbo-charger -arrows-.

–  Unscrew bolts -2- and -3- of the pendulum arm support. –  Installing drive shafts: → Running gear, shafts, direction; Rep. Gr.40   Note The air-conditioner need not be opened.

–  Remove the air-conditioning hose clamps from the bodywork -arrows-.

–  Remove the bolts securing the support assembly/engine support -arrows-, and disassembly the whole support assembly.   Caution When raising the engine with the support -U-30025E-, prevent the components/hoses from being damage, excessively stretched or pulled off.

–  Raise engine using the support -U-30025E- until the two upper bolts -1- and- 2- of the engine mounting can be loosened and removed. –  Raise the engine further until the engine mounting can be removed from the top.

–  Loosen the remaining bolts of the notched belt guard -arrows-, and remove the guard from the engine. –  Mark the toothed belt D.O.R. –  Release the tension roller and remove the notched belt. –  Turn crankshaft back slightly.   WARNING Once the timing belt is removed you should never turn the camshaft nor the crankshaft.