SEAT Workshop Service and Repair Manuals

Engine: fitting Operation process l  Engine fitted on the counterhold -T20205-. Installation is carried out in the reverse order of removing, when doing this note the following.   Note t  When fitting, replace the self-locking nuts and bolts. t  Renew bolts which have a specified tightening angle, as well as seals and gaskets. t  Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue. t  Clean input shaft splines and, for used clutch plates, hub splines; remove corrosion and apply a thin coat of grease -G 000 100- to the splines. Then move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. Excess grease must be removed.

–  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary. –  Observe that the intermediate plate is fitted on sealing flange and is slid onto the dowel sleeves -arrows-. Vehicles with manual gearbox: –  Ensure that the clutch drive plate is centred correctly → Manual gearbox 02Q ; Rep. Gr.30 –  Check clutch release bearing for wear. Renew release bearing and slave cylinder if necessary.

–  Replace the O-ring -1- on the right hand side insert axle and grease the splines -2- using universal grease → Parts catalogue. Vehicles with DSG gearbox: –  Clean the teeth of the gearbox primary shaft and the teeth of the double mass inertial steering, eliminate the corrosion and apply over the teeth a fine layer of universal grease → Spares catalogue. Excess grease must be removed. –  In engines for vehicles with DSG gearbox, there should be a gear needle bearing fitted on the crankshaft. Fit it if necessary → Chapter. All vehicles (continued): –  Screw the gearbox to the engine.   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Use is never to be made of degreased parts. t  Tolerance for tightening torques: ± 15 %.

Fitting engine/manual gearbox

Item	Bolt	Nm
1 → Note → Note, 2 → Note → Note	M12×55	80
3 → Note, 4 → Note	M12×165	80
5 → Note	M12×105	80
6 → Note, 7 → Note	M10×50	40
8 → Note	M10×70	40

1)  M8 thread bolt 2)  Replace bolt A -  Dowel sleeves to centre

Fitting engine/DSG gearbox

Item	Bolt	Nm
1 1), 3 1), 10 1)	M12x55	80
5 1), 9 1)	M12x70	80
6 … 8 1)	M10x50	40
A	Centering handles
l  1) Renew bolts

Vehicles with four wheel drive: –  Mount the angular gear support → Rep. Gr.34 –  Mount the right short axle → Rep. Gr.40 –  Insert the engine/gearbox assembly into the body.

All vehicles (continued): –  Screw in the bolts for the assembly mounting on engine -arrows- ...

–  ... and gearbox -arrows- initially by hand. –  Use new bolts.   Note The bolts are tightened to the specified torque only after adjusting the engine mountings → Chapter. –  Remove the securing tool -T20205- from the engine. –  Install the driveshafts → Running gear - front-wheel drive and 4WD; Rep. Gr.40. –  Fit the right connecting rod → final group 0AV; Rep. Gr.39 Vehicles with four wheel drive –  Couple the front section of the cardan shaft → Rep. Gr.39. All vehicles (continued):

–  Screw the pendulum support to the gearbox and engine assembly with bolts -1 ... 3-. –  Use new bolts. –  Mount the exhaust system and adjust it without pressure codes AZV BKD → Chapter codes BMN → Chapter. Vehicles with engine codes BMN, –  Mount the particle filter → Chapter All vehicles (continued): –  Install the air conditioner compressor → air conditioning system ; Rep. Gr.87. –  Install the radiator → Chapter. –  To facilitate the positioning of the alternator drive bushes for securing bolts a bit back. –  Fit the alternator → Electrical system; Rep. Gr.27 –  Install poly V-belt → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. Vehicles with manual gearbox:

–  Insert the tubes and hoses -4- of the clutch mechanism with a new O-ring -3- on the breather connection -1-, until the securing clip clicks audibly into place -2-. –  To test, pull on the tubes/hoses.   WARNING The clutch pedal must not be operated before bleeding the clutch installation of air. –  Remove the pressure tool -U-30042-. –  Purge the clutch hydraulics → Manual gearbox 02Q; Rep. Gr.30. –  Install selector mechanism on gearbox and adjust → Manual gearbox 02Q; Rep. Gr.34 Vehicles with DSG gearbox: –  Mount the control wire of the selector lever and adjust it → Rep. Gr.34. All vehicles (continued): –  Fit the charge air system lines, follow the instructions during this → Chapter. –  Adjust engine mountings → Chapter. –  Install battery → Electrical system; Rep. Gr.27. –  Put the lock carrier plate into service position: → Bodywork, exterior fitting work; Rep. Gr.50. –  Check oil level . → Chapter. –  Fill up coolant → Anchor.   Note t  The drained coolant can only be reused if the cylinder head or the cylinder block have not been replaced. t  Do not re-use soiled coolant.   WARNING Do not use a battery charger to start the engine! The control units of the vehicle may be damaged. –  Check headlight adjustment → Electrical system; Rep. Gr.94 Observe the necessary safety precautions when carrying out a road test. –  Perform test drive, and interrogate fault memory afterwards → Chapter Specified torques .

Component		Nm
Bolts and nuts	M6	10
	M7	15
	M8	20
	M10:	40
	M12	65
Except for the following:
DSG gearbox: Starter motor to gearbox		40
discrepancies:
Gearbox mounting to gearbox		60 + 90° → Note → Note
Left supercharger air tube to the oil sump		10
Pendulum support to gearbox		40 + 90° → Note → Note
Pendulum support to subframe		100 + 90° → Note → Note
Lock carrier to the bodywork		10
Terminal B+ to starter motor		16
Earth wire to gearbox		22
Front supercharger air tube to the engine block		22

3)  Replace bolts 4)  90º is equivalent to a quarter turn