SEAT Workshop Service and Repair Manuals

Engine: removing –  Detach engine cover -arrows- (according to version).   WARNING Note the precautionary instructions for disconnecting the battery → Electrical system; Rep. gr.27

Versions with rigid battery protection –  Remove cover -1- over battery. To do so, press release tab -arrow-.

–  Disconnect battery earth cable -arrow- with ignition switched off.

Versions with flexible battery protection –  Disconnect battery earth cable -arrow- with ignition switched off. Continue for all engines   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open cap of coolant expansion tank. –  Remove both front wheels.

–  Remove central soundproofing -Anchorage points 1 ... 3- (according to version).

–  Remove left and right hand side noise insulation -fastening points 1 ... 3-.

Engines with engine codes CCSA, CMXA –  Separate the connection -2-, by disconnecting the safety fastening. –  Unplug connector -3-. –  Push the cabling to one side. All vehicles (continued) –  Drain coolant → Chapter

–  Remove the air intake hose -arrow- at the bottom at the resonance pipe. To do this, release the spring clamp using the counterhold -T20174- and bolt-1-.

–  Disconnect hoses -1-, -3- and -4-. –  Remove air duct by loosening hose clips -2- and -5-.

–  Pull off the hoses -1- and -2- on air filter housing. –  Remove bolt -3-. –  Take out air cleaner housing. –  Remove air intake hose to the resonator from the lock carrier and take it out. –  Remove battery → Electrical system; Rep. gr.27.

–  Remove the battery tray -arrows-. –  Detach battery tray from air duct at front.

–  Pull off rubber seal -2- on plenum chamber cover.

–  Remove bolts -1-. –  Unhook the rear engine wiring harness on the parting wall for plenum chamber.

–  Remove parting wall for plenum chamber -arrows-.

–  Disconnect the engine cable harness connector -2- from the engine control unit.   Note The electrical connection -1- remains connected.

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

–  Take electrical connection -arrow- for lambda probe -G39- out (before catalytic converter) of the retainer and separate.

–  Open cable guide retainer -arrows-. –  Disconnect all the connectors of the engine/bodywork cable harness, and leave cable harness on top of the engine.

–  Unlock connector -1- and separate. –  Open the support -2- of the cable guide beneath. –  Take the engine wiring harness to the control unit out of the cable guide.

–  Unscrew the earth wire -1-. –  Separate the cables -2- and -3- from the starter. –  Lay bare cables.

–  Disconnect electrical connection -3- for the reversing light switch. –  Release the engine wiring harness from its support -2-. –  Unscrew nut -1- and remove bracket with wiring from the pin.

–  Disconnect the electrical connection -arrow- from the the secondary air pump motor -V101- (version). –  Expose the wiring.

–  On the bulk head, remove coolant hoses going to the heat exchanger -arrows-.

–  Separate the vacuum hose -arrow- to the brake servo on the intake manifold.

–  Unclip securing clips -1- and -2- on both control cables. –  Pull off selector cable support elements from gearbox selector lever and relay lever.

–  Remove the control cable support bracket from gearbox and put aside -arrows-.

–  Remove clutch slave cylinder -arrows- and place to one side; do not disconnect pipe.   WARNING Do not depress clutch pedal after removing slave cylinder.

–  Disconnect the coolant hose from the upper part of the radiator -arrow-.

–  Disconnect the coolant hoses -1- and -2-.

–  Separate the coolant hose -arrow- on expansion tank.

–  Disconnect the vacuum hose to the active carbon deposit at the position marked with an -arrow-, for this it will be necessary to remove the bracket. Some versions have an intermediate connector. If this is the case, loosen the clamp at this connector.   WARNING Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully pulling fuel hose from connection. Wear safety goggles and appropriate clothing to avoid injury and contact with skin.

–  Separate the fuel supply line -2-; to do this pull release tab. –  Disconnect the vacuum pipe -1- to the active carbon filter (by pressing the release tab).

–  Take the active carbon deposit out upwards with connected hoses -arrow-.   Note Before removing the ribbed belt, mark its running direction with chalk or with a felt tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause it to rupture.

–  To slacken the Poly-V belt, turn the tensioner in the direction of the -arrow-.

–  Lock tensioner with retention tool -T20167-. –  Take off poly V-belt.

–  Separate the connector -2- and the alternator cable -1-. –  Remove the cable clip from alternator and move wiring harness clear.

–  Screw out bolts -arrows- and remove alternator.

–  Unscrew bolts -arrows- Equipment mounting, engine side, approx. 2 turns.

–  Unscrew the securing bolts -arrows- of the engine assembly, gearbox side by approx. 2 rotations.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Disconnect electrical connection -1- for electromagnetic coupling on air conditioner compressor. –  Unscrew the bolts -arrow- for air conditioner compressor.   Note To avoid damage to the air conditioning compressor or in the flexible conduits/tubes of the cooling agent, the tubes must not be pulled, bent or stretched excessively.

–  Remove the bolt -1- and take off the grille on the air duct using the lever -U-30800--in the direction of the arrow-.

–  Protect the bumper with adhesive tape -arrow- to prevent scratches. –  Tie air conditioning compressor together with connected refrigerant hoses up to the bumper.

–  Remove right vehicle floor cover -arrows-.

–  Disconnect electrical connection -1- for lambda probe after catalytic converter -G130-. –  Take the connector out of the support -2- and move the lambda probe line clear.

–  Remove front crosspiece from vehicle underbody -arrows-. –  Loosen exhaust system from double clamp -1-.   Note The vibration shock absorbing elements in the front exhaust pipe must not be bent more than 10° - otherwise they can be damaged.

–  Unbolt the exhaust system bracket -arrows-.

–  Unbolt heat shield for right drive shaft -arrows-.

–  Remove securing nuts -arrows- for exhaust manifold to front exhaust pipe. –  Remove the exhaust primary tube. –  Unbolt the articulated drive shaft from the gearbox flange, left and right → Running gear - Front wheel drive and 4WD; Rep. gr.40. –  Fasten the left-hand drive shaft in a high position.   WARNING To loosen the combi bolt for drive shaft, the wheel bearing must not be loaded (the vehicle must not stand on the wheels).

–  Undo the combi bolt -2- on the right-hand drive shaft. To prevent rotation pump the brake (a second mechanic is necessary).

–  Extract bolts -1... 3- and remove the pendulum support. –  Dismount the right-hand drive shaft using the extractor -T20001A-. In order to separate the drive shaft it may be necessary to move the engine assembly in the opposite direction to the direction of travel.

–  Unscrew locking bolt -arrow- at front on cylinder block.

–  Bring the securing tool -T20205- with the hydraulic jack -SAT 1040- and turn the bolt -4- until it is parallel with the engine block. –  From the rear of the engine -A-, first insert the fixed column -1-, then adjust the mobile column -2- as necessary and then screw on the nuts -arrows-. –  From the front of the engine -B-, position the mobile column -6- and adjust the bolt -5-. –  Adjust the bolt -3- to immobilise the securing tool -T20205-.   Note To unscrew the bolts for gearbox mounting use the step ladder.

–  Unscrew the bolts -arrows- of the gearbox/engine mounting...

–  Release the securing bolts -arrows- of the engine assembly, gearbox side.   Note t  Check that all hoses and other connections between engine, gearbox and body have been detached. t  To avoid damage, guide the engine/gearbox mounting carefully when lowering. –  Pull engine/gearbox assembly as far as possible forwards and lower it slowly downwards.