SEAT Workshop Service and Repair Manuals > Leon Mk1 > Power unit | 4 cylinder injection engine (1.6l 4V, Chain control) | Engine assy,cylinder block,crankcase

Fitting

Installation is carried out in the reverse order. When installing, note the following:

Caution

When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:

t	All the various lines (e.g. fuel, hydraulic system, active carbon filter system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring must be installed in their original positions.

t	To prevent damaging the hoses, ensure that all mobile or hot components are easily accessible.

Vehicles with Manual gearbox

–	Check wear to the clutch release bearing and replace if necessary.

–	Lubricate clutch release bearing, guide sleeve for release bearing and splines of input shaft with a small quantity of G 000 100.

–	Check whether the dowel sleeves for centring engine/gearbox are in the cylinder block, install if necessary.

–	Fit intermediate plate onto sealing flange and slide onto dowel sleeves -arrows -.

–	When inserting the engine, ensure that enough clearance exists with respect to the drive shafts.

–	Align the engine using a shaking movement so that the supports are not under any tension.

Fahrzeug with dual clutch gearbox 0AM

–	Ensure that the intermediate plate is hooked to the sealing flange -arrow A- and pushed onto dowel sleeves -arrow B-.

Note

Always replace the circlips -1- for the control cable of the selector lever as they loose their internal tensionsing.

–	Always set the control cable for the selector lever → 7 gear dual clutch automatic gearbox 0AM; Rep. Gr.34.

All vehicles (continued)

Note

Engine assembly mounting tightening torques → Chapter

–	Fit articulated shaft: → Running gear, axles, steering; Rep. Gr.40

Vehicles with air conditioning:

–	Install the air conditioner compressor → Heating, air conditioning; Rep. Gr.87.

–	Poly-V belt: Fitting → Chapter.

All vehicles (continued)

–	Electrical connections and cable layout: → Electrical system; Rep. Gr.97

–	Fit the clutch slave cylinder with the hydraulic clutch: → 02T 5-speed manual gearbox; Rep. Gr.30

–	Fit the gear operating mechanism to the gearbox: → 02T 5-speed manual gearbox; Rep. Gr.34

–	Fit the engine antisplash cover.

–	Coolant: Fill → Chapter

–	Fit the air filter → Chapter.

–	Connecting the vehicle diagnostic, testing and information system -VAS 5051B- → Chapter.

–	Erase adaptive values, and adapt the engine control unit to the throttle control unit -J338- → Chapter“Guided function”

–	Carry out the vehicle system test → Chapter“Guided fault finding”.

–	Terminate the vehicle systems test so that the registered faults which may have been caused by the assembly are automatically erased.

Observe the necessary safety precautions when carrying out a road test .

–	Take vehicle for a test drive.

–	A check of the vehicle system test should be carried out immediately afterwards. Possible error messages must be deleted.

SEAT Workshop Service and Repair Manuals