SEAT Workshop Service and Repair Manuals

Work sequence

• ‒ The engine is removed downwards together with the gearbox.

• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• ‒ Remove engine cover.
• ‒ First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.

• ‒ With ignition switched off disconnect battery earth strap.
• ‒ Remove battery.
• ‒ In preparation for further dismantling work, disconnect the connectors -arrows- behind the battery.

• ‒ → Remove air duct trim -1-.
• ‒ Unbolt battery trim -2- with coolant expansion tank and lay to side without opening cooling system.
• ‒ Remove battery tray.
• ‒ Pull off or disconnect other electrical connections as necessary from engine, gearbox and body and lay to one side.
• ‒ Remove air cleaner:

=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner.

• ‒ Remove air intake hose and air intake pipe between air mass meter and throttle valve control part:

=> Repair group 24; Servicing injection system; Dismantling and assembling air intake pipe.

• ‒ → Pull fuel supply pipe/hose -1- (with white marking) and fuel return pipe/hose -2- (with blue marking) off fuel rail and catch escaping fuel with a rag.

• ‒ Seal the pipes so that the fuel system is not contaminated by dirt etc.
• ‒ Observe rules for cleanliness .
• ‒ Unclip fuel pipes/hoses from cylinder head cover.
• ‒ Pull vacuum and breather hoses off engine as necessary.
• ‒ Remove noise insulation tray.
• ‒ Pull connectors off thermo-switch and radiator fan.
• ‒ Removing front bumper:

=> General body repairs, exterior, Repair group 63; Front bumper, Removing and installing front bumper

• ‒ Bring lock carrier into service position:

=> General body repairs, exterior; Repair group 50; Body, front; Lock carrier service position

• ‒ Remove intake manifold => Page 15-14, Removing and installing cylinder head cover.

Note:

Seal the intake ports in the intake manifold or in cylinder head with a clean cloth.

• ‒ Remove ribbed belt => Page 13-17.
• ‒ Remove power assisted steering vane pump on compact bracket and lay to side; hoses remain connected.

=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes

• ‒ Unbolt P.A.S. hydraulic pipe/hose on right-hand side of cylinder block.

Vehicles with air conditioner

• ‒ See additional information and removal instructions => Page 10-18.

Vehicles with manual gearbox

• ‒ Pull pipe/hose off slave cylinder on gearbox and lay to one side.

=> 6-speed manual gearbox 02N; Repair group 30; Assembly overview - Hydraulics and clutch release mechanism

• ‒ Remove operating cable from gearbox:

=> 6-speed manual gearbox 02N; Repair group 34; Servicing selector mechanism; Removing and installing operating cables

Vehicles with automatic gearbox

• ‒ Remove selector lever cable from gearbox:

=> Automatic gearbox 09B - 5-speed; Repair group 37; Servicing selector mechanism; Dismantling and assembling selector mechanism

Continuation for all vehicles

• ‒ Remove drive shafts:

=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft

• ‒ Remove front exhaust pipe => Page 26-1, Removing and installing parts of exhaust system.
• ‒ Drain coolant => Page 19-16.
• ‒ Pull coolant hoses quick release couplings off radiator.
• ‒ Pull off all coolant hoses to engine with assembly tool for spring-type clamps VAS 5024.
• ‒ Remove alternator and compact bracket:

=> Electrical system; Repair group 27; Removing and installing alternator

• ‒ Unbolt bracket for secondary air pump motor (V101) from sump and cylinder block => Page 26-25, item 14.
• ‒ Remove pendulum support.

=> Running gear, Axles, Steering; Repair group 40; Servicing front wheel suspension; I - Assembly overview, subframe, anti-roll bar, wishbone

• ‒ Insert engine bracket T 10102 in engine/gearbox jack V.A.G 1383 A.

• ‒ → Fit engine bracket T 10102 onto cylinder block and tighten securing nuts -1- to
  40 Nm.
• ‒ Lift engine and gearbox lightly using engine/gearbox jack V.A.G 1383 A.

• ‒ → Unbolt assembly mounting, right securing bolts -1-.

• ‒ → Unbolt securing bolts and nuts on left of subframe -arrows-.

Note:

To remove securing bolts use ladder VAS 5085.

• ‒ Carefully lower engine with gearbox.

Note:

Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork, hoses and wiring.