SEAT Workshop Service and Repair Manuals

Removing engine   Note The engine is removed downwards together with the gearbox.

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Engine support -T10416-with adapters /1, /2, /3, see equivalent → Anchor

t	Torque wrench -VAG 1331-, see equivalent → Anchor.

t	Hydraulic jack -VAG 1383A-, see equivalent → Anchor

t	Engine and gearbox support -VAS 6095-, see equivalent → Anchor

t	Collecting tray -VAS 6208-, see equivalent → Anchor

t	Base -VAS 6340-, see equivalent → Anchor

t	Stepladder -VAS 5085-, see equivalent → Anchor

t	Torque wrench -VAG 1332-, see equivalent → Anchor.

t	Centre guide -T10093-, see equivalent → Anchor

Note To carry out this work it will be necessary to disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding if necessary. –  Remove air filter → Chapter. –  Open and close the lid of the expansion tank again for releasing the pressure in the cooling system. –  Drain coolant → Chapter. –  Observe rules for cleanliness → Chapter.

–  Remove the fuel supply line -1- and the wire, which leads to the activated carbon container -2-. To do so, press the tabs.   WARNING Fuel supply line is 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 release pressure by carefully pulling hose off connection.

–  Detach the hose -1- leading to the activated carbon container, of solenoid valve 1 for the activated charcoal filter -N80-. –  Undo the securing bolts -2- and remove the activated carbon container upwards.

–  Remove the spring-type hose and the coolant hoses -1- and -2-. –  Press the retainer -3- beneath the coolant hoses and pull the hose upwards. –  Move the coolant hoses to the rear.

–  Release the coolant hoses on the heat exchanger -arrow- and remove.

–  Release the coolant hoses -arrow- on the gearbox ends and disconnect.

–  Remove the Lambda probe -G39--1-. –  Unscrew the upper securing screw for the alternator -2- and press the alternator slightly downwards. –  Unscrew the fastening bolts -arrows- and remove the heat protection plate from the turbocharger.

–  Unscrew the securing bolts on the exhaust gas turbocharger -arrows-.

–  Unscrew the securing bolts -arrows- of the splash guard cover of the engine.

–  Unscrew the -fixing elements 1 ... 3- of the right and left soundproofing.

–  Separate the coolant hose -1- from the coolant for the supercharger system and remove the coolant pipe -2-. –  Open the spring-type hose and remove the coolant hose -1-.

–  Unplug the connector -2- from the coolant circulation -V50-. –  Detach the connector -3- of the knock sensor 1 -G61- y -4- of the engine speed sender -G28-.

–  Disconnect the connector -1- of the oil level and temperature sender -G266-. –  If an auxiliary heater is set, the coolant hoses -2- must be removed. –  Place the lock carrier into the service sleeves → Bodywork, exterior fitting work; Rep. gr.50.

–  Unscrew the exhaust pipe with the decoupling element -arrow-.

–  Unscrew the securing bolts of the double clamp -arrows- and pull the exhaust pipe to the back.

–  Unplug connectors -1-. –  Unscrew the securing nuts -2- and press the exhaust pipe to the back using an assembly lever in order to remove it from the rubber mountings. –  Withdraw the exhaust pipe towards the front. –  Undo the securing nuts -3- and remove the catalytic converter downwards. –  Disconnect battery → Electrical system; Rep. gr.27 –  Remove battery and battery holder → Electrical system; Rep. gr.27. –  All the cables, that are opened or cut during dismounting, should be placed again in the same location previously occupied during the fitting. –  Remove all of the electrical cables from the gearbox, alternator, and starter motor leaving them uncovered. –  Pull off or disconnect all other electrical connections as necessary from engine and lay to side. –  Pull vacuum and breather hoses off engine. –  Pull connector off thermo-switch and radiator fan.

–  Unscrew the pendulum support -arrows-: –  Remove the gear mechanism from the gearbox: → Rep. gr.34 –  Remove the slave cylinder from the hydraulic clutch: → Rep. gr.30   Note Do not depress the clutch pedal. –  Remove the drive shaft on the right and left from the gearbox and tie up → Running gear, shafts, steering; Rep. gr.40 –  Remove poly V-belt → Chapter. –  Removing air conditioning compressor → Heating, Air conditioning; Rep. gr.87.   Note Do not open the air conditioning pipes. –  Secure AC compressor to lock carrier. –  Check that the conducts have not been bent.

The engine support is required to drain off the engine -T10416-with the gearbox using the adapters -/1-, -/2- and -/3-.

–  Tighten the adapters -T10416/1- until they make contact with the crank case. –  Assemble the engine bracket -T10416- using the adapters -/2- and -/3- on the cylinder block. –  Assemble the engine bracket -T10416- using a screw -1- on the cylinder block and manually tighten it.

–  Tighten all bolts on the engine bracket -T10416- to 20 Nm.   Note Using the adjusting nut -2-, the right angle on the engine support -T10416- between the bolts and the engine and the gearbox jack -VAG 1383A- is adjusted. –  Mount the engine and gearbox jack -VAG 1383A- to the engine support -T10416-. –  Raise the engine and gearbox slightly using the engine and gearbox jack -VAG 1383A-.   Note To loosen the mounting bolts, use the stepladder -VAS 5085-.

–  Unscrew the assembly mountings on the engine side from upwards -arrows-.

–  Raise the cable guide above the gearbox mounting. –  Unscrew the assembly mountings on the gearbox side from upwards -arrows-.   Caution Danger of damage to hose and line connections as well as engine compartment. t  Check that all hose and line connections between engine, gearbox, subframe and body have been disconnected. t  Carefully guide the engine assembly until it is removed from the engine compartment. –  Carefully lower the engine and gearbox. –  Pull engine/gearbox assembly as far as possible forwards and lower it slowly downwards.   Note Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork.   Caution When it looks like the engine should remain removed for a longer period, align the lines of the air conditioning system tension free.