SEAT Workshop Service and Repair Manuals

Remove the engine (engine codes AMF, BNM and BNV)   Note t  To carry out this work it will be necessary to disconnect battery earth strap. For this purpose, first check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. t  The engine is removed from underneath together with the gearbox. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. t  Collect drained coolant in a clean container for re-use or disposal. t  Some components can not be removed, or only with a great deal of difficulty, while the engine is mounted. Therefore the fault memory should be consulted → Chapter, to detect all the faulty components while the engine has been removed, and to replace them before the engine is reassembled. Operation process

–  Remove the sound proofing from the engine by pulling forcefully upwards -arrows- .   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. gr.27. –  With ignition switched off, disconnect earth connection from battery.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open the Sealing plug of the coolant expansion tank. –  Remove front right-hand wheel. –  Remove front right hand side wheel housing moulding → Bodywork, exterior fitting work; Rep. gr.63.

–  Remove the central soundproofing → Bodywork, exterior installation work; Rep. gr.50. –  Drain coolant → Chapter.   WARNING The fuel and the fuel lines may become excessively hot (burn risk). The fuel supply system is also under pressure. Before opening the system, place a cloth over the junction and depressurise the system by gently loosening. For all assembly work carried out on the fuel supply system, protective glasses and gloves must be worn!

–  Separate the fuel feed and return lines -2- and -3- . –  Separate the coolant lines -1- .

–  Remove supercharging tube -1- with connecting hose -2-, releasing the brackets -arrows- . –  Remove battery and battery retainer: → Electrical system; Rep. gr.27 –  Remove air filter → Chapter. –  Remove coolant hoses from radiator. –  Separate the coolant tubes going to the heat exchanger. –  Separate the refrigerant tube from the coolant expansion tank. –  Disconnect the connection element from the group of hoses on the solenoid valve block; to do this, press on the release button → Chapter .

–  Remove the connector -1- of the engine control unit and connectors -2- and -3-, unfasten -arrows- the cable mounting -4- (depending on vehicle equipment).

–  Unplug the following electrical wiring connections: 1 -  Alternator plug 2 -  Glow-plug plug 3 -  Injected pump plug 4 -  Crankshaft impulse sensor plug 5 -  Camshaft impulse sensor plug 6 -  Oil pressure sensor plug 7 -  Fuel temperature sensor plug –  The electric connector from the coolant temperature sensor, the connector from the reverse gear switch on the gearbox and the connector for the compressor / air-conditioning. –  Move all electric cables to one side. –  Remove the gear control cables from the gearbox → Rep. gr.34 –  Remove the clutch master cylinder without opening the hydraulic circuit, and leave to one side (the clutch pedal should not be depressed) → Manual gearbox 02T; Rep. gr.30.   Note Do not press the clutch pedal –  Remove the earth cable from its fixing in the gear box. –  Remove the Poly V-belt → Chapter.

–  Screw out bolts -arrows- and remove alternator. –  Remove the alternator → Electrical system; Rep. gr.27 . Vehicles with air conditioner.   Caution The air conditioning refrigerant circuit must not be opened. To avoid damage to the condenser and refrigerant pipes/sleeves, take care not to bend, twist or stretch the pipes/sleeves excessively.   Note For removal and installation of the engine there is no need to open the refrigerant circuit. –  Remove the clip/s from the refrigerant hose/s.

–  Disconnect electrical connection -1- for magnetic coupling on air conditioner compressor. –  Remove compressor bolts -arrows-.

–  Leave the air conditioning compressor with refrigerant hoses still connected suspended above, secure it to the lock carrier plate; take special care not to damage the system.

Continued for all vehicles –  Loosen the bolts -arrows- fastening the mountings to the engine by a couple of turns.

–  Loosen the bolts -arrows- fastening the mountings to the gearbox by a couple of turns.

–  Release the connectors -2- and -3- from the starter motor and remove them from the bracket -1- .   Caution In order to avoid damage to the electric cables take care not to bend, twist or stretch excessively. –  Extract the electrical connections from the starter motor. –  Move all electric cables to one side. –  Removing the starter motor → Electrical system; Rep. gr.27. –  Remove the connection tube between the intercooler and the exhaust gas turbocharger → Item .   WARNING Cover the intercooler opening, for example, using a clean cloth made of spongy material so that coolant does not enter.   Note The exhaust damper system should not be bent more than 10° otherwise it will be damaged. –  Remove the front section of the exhaust pipe → Chapter.

–  Unscrew bolts -arrows- and remove pendulum arm support. –  Remove the right articulated drive shafts → Running gear, shafts, steering; Rep. gr.40. –  Remove left wheel drive shaft from the gearbox and support in a raised position:

–  Fit the washers of 13 X 24 X 2,5 -arrow-, between the bracket -T10012- and the attachment pin -2- .

–  Remove the lower bolt -1- from the compact bracket → Item   Note Fit the washers -2-, 10.5 X 21 X 2 between the bracket -T10012- and the compact support, so that the bracket -T10012- is flat against the compact bracket. –  Tighten the bracket -T10012- to the engine block using the attachment bolt -1-, tightening torque: 20 Nm.

–  Tighten with the attachment bolt -3- for the bracket -T10012- to the engine block. –  Insert hydraulic jack -SAT 1040- with adapter -SAT 1040/1- in engine bracket -T10012- and raise lightly.   Note To unscrew the bolts for gearbox mounting use the step ladder.

–  Remove bolts -arrows- fastening mountings to engine.

–  Remove bolts -arrows- fastening mountings to gearbox.   Note t  Ensure that all hose attachments and tubes between the engine, gearbox and the body have been loosened. t  To avoid damage, guide the engine/gearbox mounting carefully when lowering. –  Carefully lower the engine and gearbox. –  Pull engine/gearbox assembly as far as possible forwards and lower it slowly downwards.