SEAT Workshop Service and Repair Manuals

Engine: dismounting –  Detach engine cover -arrows-.

–  In the versions with rigid battery protection, remove the cover -1-; press the release tab -arrow- to do so.   WARNING Note the precautionary instructions for disconnecting the battery → Electrical system; Rep. gr.27.

–  With ignition switched off, disconnect earth wire -arrow- at battery.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open cap on coolant expansion tank.

–  Remove central soundproofing -Anchorage points 1 ... 3-.

–  Remove left and right noise insulation -1- on coolant outlet temperature sender -G2-. –  Place the drip tray -T20173- under the engine. For engines with identification letters BLR and BLY –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection. –  Pull off bottom coolant hose retaining clip and remove hose -2- from radiator.

For engines with identification letters BVY and BVZ Release the quick connection -arrow-, and remove the coolant hose from the radiator.

Continue for all engines –  Disconnect the connector -1- of the oil pressure sender -F1-. –  Additionally take coolant hose on lower part of oil cooler off -2- and drain off remaining coolant.

–  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-.

–  Remove the flexible tube -1- from the air filter housing. –  Disconnect the connector -2- in the air filter housing. –  Remove bolt -3-. –  Disconnect the air hose -4- from throttle valve module. To do this, release the spring clamp using the counterhold -T20174-. –  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 battery tray -arrows-. –  Detach battery tray from air duct at front.

–  Pull rubber seal -2- off 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-.

–  Remove engine control unit → Chapter. –  Disconnect electrical connection -1- and -2- from engine wiring harness.

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

–  Remove the connectors -1- and -2- of the lambda probes in front of the catalytic converter of the support and disconnect them. (The number of connectors may vary depending on version).

–  Open cable guide retainer -arrows-.

–  Unlock connector -1- and separate.

–  Release and unplug connector -1-. –  Open the support -2- of the cable guide beneath. –  Open the cable guide support -3-. –  Take the engine wiring harness to the control unit out of the cable guide.

–  Unplug electrical connector -4- for reversing light switch. –  Unscrew earth connection -3-. –  Disconnect the connector -1- in the starter motor. –  Unbolt the connector -2- in the starter motor. –  Uncover cables.

–  Remove the cover on the fusebox, by pressing release tab -arrows-.

–  Remove the cable -arrow- and lay bare as far as the alternator and the air conditioner compressor.

–  Remove the coolant hose from the dash panel plate -1-. –  Remove the coolant hoses that go to the heat exchanger -2- and -3-.

–  Pull vacuum hose -3- off the brake servo on the intake pipe. –  Remove coolant hose -1-. –  In vehicles with engine code BLR and BLY, remove the coolant hose -2- towards throttle valve control unit.

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

–  Remove coolant hose -arrow-.

Vehicles with manual gearboxes –  Unclip securing clips -1- and -2- on both control cables. –  Pull off selector cable support elements from gearbox selector lever and relay lever. –  Remove cable support bracket from gearbox and lay to side -arrows-.

–  Remove strut -1-. –  Remove clutch slave cylinder -arrows- and place to one side; do not disconnect pipe.   WARNING Do not depress clutch pedal after removing slave cylinder. Vehicles with automatic gearbox –  Separate the gearbox cables → 6-speed automatic gearbox 09G; Rep. gr.37.

Continued for all vehicles –  Disconnect the coolant hoses -1- and -2- in the expansion tank.   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 eye protection and gloves to avoid injuries and skin contact.

–  Disconnect the hose to the active carbon filter -1-. –  Remove the fuel supply tube -2-.

–  Disconnect the vacuum pipe -1- to the active carbon filter (by pressing the release tab).

–  Take the active carbon filter out upwards with connected hoses -arrow-.

–  Release the coolant hose bracket on the right-hand longitudinal member -arrow-.   Note

Before removing the ribbed belt, mark its running direction with chalk or with a felt tipped pen. Running a used belt in the opposite direction could destroy it. –  To slacken off poly V-belt, swivel belt tensioner in -direction of arrow-. –  Remove the ribbed belt.

–  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.

–  Disconnect connector -1-. –  Open the cableguide clips -2- and -3- and lay the cables bare. –  Place the lock carrier plate into service position →  Bodywork, exterior fitting work ; Rep. gr.50   WARNING The air conditioning refrigerant circuit must not be opened. –  Remove left wheel housing moulding → Bodywork, exterior fitting work; Rep. gr.66.

–  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. –  Fasten the air conditioning compressor and the coolant hoses to the lock carrier.

–  Disconnect connector -1-. –  Remove the electric fan together with the radiator cowl. Remove bolts -arrows- on both sides for this purpose.

–  Remove coolant hose -2-, pull out retaining clip -1- for this purpose.

–  Remove right vehicle floor cover -arrows-.   Note

Before detaching the connectors of the lamda probes, mark the pairs, to avoid exchanging parts when reassembling ( the following diagram shows the position of the connectors for engine code BLR). –  Detach the connector (grey) -2- for lambda probe III behind the catalyser -G287- with heating of lamda probe 3, behind the catalyser -Z64- and leave the cable bare. –  Detach the connector (brown) -3- for lambda probe behind the catalyser -G130- with heating of lamda probe 1, behind the catalyser -Z29- and leave the cable bare. –  Detach the connector (black) -4- for lamda probe II behind the catalyser -G131- with heating of lamda probe 2, behind the catalyser -Z30- and expose the cable.

–  Remove the front cross member from the underbody -arrows-.   Note The vibration shock absorbing elements in the front exhaust pipe must not be bent more than 10° - otherwise they can be damaged.

–  Remove exhaust system from double clamp -arrows-.

–  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. –  Take exhaust pipe off with catalytic converter. –  Unbolt the drive shaft from the gearbox flange, to 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). –  Remove both front wheels.

–  Unscrew the bolts crossways -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.

–  Pull connector -1- out of bracket and set wiring aside. –  Unscrew the bolts crossways -2 ... 4-.

–  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.