SEAT Workshop Service and Repair Manuals

Removing and positioning the engine t  Removing → Anchor t  Installing → Anchor Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Lifting tackle -2024 A-, see equivalent → Anchor

t	attachment tool -T10038-

t	Centring pin -T10093-

t	Workshop crane -VAS 6100-, see equivalent → Anchor

t	Collector tray for workshop crane -VAS 6208-, see equivalent → Anchor

t	Base -VAS 6340-, see equivalent → Anchor

Removing   Note t  The engine is removed upwards together with the gearbox. t  All the cable fixings that are opened or cut during removal of the cylinder head must be fitted in the same position when reinstalling the engine. –  Remove battery → Electrical system; Rep. gr.27 –  Remove air filter → Chapter.

–  Remove nuts -1- and the bolt -2- and remove the support from the battery lifting upwards.

–  Disconnect the engine cable harness connector -1- from the engine control unit -J623-. –  Open the cable guide catches on the sill. –  Disconnect connection -3- from the engine wiring harness. –  Remove the engine cable harness from the cable guide and place it on the engine. Vehicles with anti-theft engine control unit –  Remove engine control unit → Chapter. All other vehicles continued –  Remove the gear selection mechanism: → 5-speed manual gearbox 02T; Rep. gr.34

–  Unscrew the bolts -arrows- and remove the slave cylinder; do not open the pipe system.   WARNING Do not depress clutch pedal after removing slave cylinder.

–  Separate the pressure hose -arrow- in the servo-brake amplifier. –  Open and close expansion tank cap to release pressure in cooling system.   WARNING Fuel supply pipes are pressurised. Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then eliminate the pressure by carefully separating the pipe.

–  Remove the fuel supply line and venting tube -arrows-. –  Seal lines so that no dirt is able to enter fuel system. –  Observe rules for cleanliness → Chapter.

–  Unscrew earth connection -1-. –  Detach wires -2- and -3- from starter motor.

–  Remove the securing bolts -arrows- and remove the engine anti-splash cover. –  Drain coolant → Chapter –  Pull coolant hoses off radiator → Item and → Item.

–  Disconnect the coolant hoses -2- and -3- to the heating heat exchanger by releasing the spring type clips.

–  Remove bolts -arrows-.   Note Disregard item -1-. –  Remove the expansion tank and place it on the engine.

–  Disconnect the DF cable connector -1- and remove the protection -2-.

–  Unbolt the battery positive cable -arrow- of the alternator. –  Remove the front bumper → Remove and fit the trim of the front bumper; Rep. gr.63. –  Bring lock plate carrier into service position: → Lock carrier in service position; Rep. gr.50. Vehicles with air conditioning/heating –  Follow the additional instructions and assembly work → Chapter. –  Remove poly V-belt → Chapter.

–  Unplug the connector -1- and move the cable to one side. –  Unscrew the attachment bolts -arrows- (25 Nm).   Note t  The air conditioning system lines must not be opened. t  Ensure that lines are not kinked.

–  Fasten the compressor to the lock carrier using the counterhold -T10038-. All other vehicles continued –  Disconnect the connector from the thermo-switch and the coolant fan -V7-.

–  Unscrew nuts -arrows- and remove support together with cable harness.

–  Unscrew bolt -1- and nut -3- and remove support -2-. –  Remove the front exhaust tube from the exhaust manifold % page –  Disconnect electrical connection of the lambda probe -G39-. –  Disconnect electrical connection of the lambda probe after catalytic converter -G130-.

–  Unscrew nut -arrows-.

–  Remove the electric connector -1- from the reverse gear switch of the gearbox. –  Remove the support -2- and move the cable to one side.

–  Unbolt left and right half shafts from gearbox flange or the intermediate bearing. –  Tie the left half-shaft leaving it suspended. –  Turn the steering toward the right. –  Tilt the right-half shaft forwards and strap it to the sill -arrow-, as shown in the image.

–  Unscrew bolts -arrows- and remove pendulum arm support.   Caution Bolt -1- must not be loosened.

–  Hook the counterhold -2024 A- as described below and lift slightly with the workshop crane. Pulley side: First hole of the perforated flange in position 2 Flywheel end: 2nd hole on support bar in position 6.   Caution Insert safety pins into the hooks and bolts to prevent damage to the engine and vehicle.   Note t  The positions numbered 1... 4 of the hoisting bar face the pulley. t  The holes in the perforated flanges are counted starting from the hook. –  Unscrew earth connection -1-.   Caution Nut -2- must not be loosened.

–  Unscrew securing bolts -arrows- for engine mounting.

–  Unscrew bolts -B-. –  Lower the engine until it is released from the gearbox mounting. –  Undo the bolts -A- and remove the gearbox support unit. –  Remove the assembly upwards. It may be necessary to turn the unit for this purpose.   Note When the assembly is lifted out, it must be carefully guided to prevent damage to bodywork. When performing assembly work, secure the engine to the engine and gearbox support -VAS 6095- → Chapter. Installing Install in reverse order to dismantling, noting the following:   Caution When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: All conduits (for example for fuel, hydraulics, carbon filter, liquid cooler and cooling agent, brake fluid, low pressure) and the electric cables must be placed in such a way that they return to their original position. Ensure that there is sufficient clearance to all moving or hot components. –  Check clutch release bearing for wear and renew if necessary. –  Lightly grease with lubricant grease → Parts catalogue the clutch release bearing, release bearing guide sleeve and the input shaft teeth. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary. –  Fit intermediate plate onto sealing flange and slide onto dowel sleeves. –  When inserting the engine, ensure that enough clearance exists with the drive shafts. –  Align the engine using a shaking movement so that the supports are not under any tension.   Note Tightening torques of the engine assembly → Chapter → Chapter Vehicles with air conditioner –  Position the air conditioning air compressor: → Heating and air conditioning; Rep. gr.87 All other vehicles continued –  Electrical connections and routing: → Electrical system; Rep. gr.97. –  Install poly V-belt → Chapter. –  Install the gear selection mechanism: → 5-speed manual gearbox 02T; Rep. gr.34 –  Observe the safety measures after connecting and disconnecting the battery → Electrical system; Rep. gr.27 –  Fill up coolant → Chapter. –  Install air filter → Chapter. –  Connecting the central diagnosis -VAS 505X- –  Erase learnt values and adapt engine control unit -J623- to throttle valve module → Vehicle diagnostic tester„Guided functions“. –  Carry out the vehicle system test „Guided fault finding“. –  Finish the vehicle system test so that any fault entries stored during assembly can be erased automatically. Observe applicable safety precautions during road test. –  Take vehicle for a test drive. –  Then carry out vehicle system test again and rectify any faults which may have occurred.