SEAT Workshop Service and Repair Manuals

Engine: dismounting   Note t  Before carrying out further work, disconnect battery earth strap. To this end, it is necessary to check whether the vehicle has a coded radio. If so, refer to the anti-theft coding. 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. t  The extracted coolant must go into a clean receptacle, whether for disposal or recycling. –  Remove air cleaner:

Engine codes AZQ, BME and BXV → Chapter. Engine code letters BBM → Chapter –  With the ignition OFF, disconnect the earth connection from the battery   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. gr.27. –  Remove battery → Electrical system; Rep. gr.27.

–  Unscrew the bolts -arrows- and remove battery bracket.

–  Detach the cable for the gearbox connection -B-, releasing the safety washer. –  Separate the selection cable -A- with the relay lever from the gearbox releasing the securing washer -arrow 1-. –  Release the nut -arrow 2- and separate the engagement/selection lever from the selection shaft.

–  Release the support for connection and gear-selection cables from the gearbox casing -arrows- and place it to one side. –  Remove the pipe -A- from the bracket on the gearbox. –  Remove the bracket securing the pipe -A- on the gearbox. –  Detach the cylinder -B- from the gearbox casing, without opening the hydraulic circuit, and place it to one side.   Note Do not operate the clutch pedal during this operation.

–  Extract the connector -arrow- from the speedometer sender -G22-. –  Open the expansion tank sealing cap to release pressure in cooling system.

–  Remove the lower engine protection → Bodywork, exterior fitting work; Rep. gr.50. –  Separate the Lambda probe -G39-connector underneath the starter motor support. –  Separate the connector for the lambda probe behind the catalytic converter -G130-,which is underneath the starter motor support. –  Remove front exhaust pipe from exhaust manifold → Item. –  Remove left and right-hand drive shaft from the gearbox and support in a raised position → Running gear; Rep. gr.40.

–  Remove pendulum support -arrows-. –  Drain coolant → Chapter. –  Separate the upper and lower coolant hoses from the radiator. –  Loosen spring clips and and remove the coolant hose pipes to the heat exchanger and to the expansion tank from their fixing to the engine.

–  Remove the earth cable from the lower engine/gearbox attachment bolt -1-. –  Release the connector -2- for the reversing light switch -F4-. –  Remove the bracket -3- from the gearbox -arrow- and secure it to the side along with the cables. Vehicles with air conditioning/heating –  Follow the additional instructions and assembly work → Chapter.   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. –  Remove poly V-belt → Chapter.

–  Separate the air conditioner compressor and secure it to the bodywork. All other vehicles continued –  Pull 3 pin connector off radiator fan thermo switch -F18-. –  Extract the connector for the coolant fan -V7- and the right coolant fan -V35-. –  Remove the front bumper → Exterior body installation work; Rep. gr.63. –  Remove the headlamp and fog lamp connectors. –  Bring lock plate carrier into service position: → Bodywork, exterior fitting work; Rep. gr.50. Extract the electrical connections from the starter motor.

–  Release and detach the connection -1- of terminal 50. –  Remove the plastic cap -2-. –  Unscrew the rear fastening nut and remove the cable -3- of the magnetic switch of terminal 30. Extract the electrical connectors of the alternator:

–  Open the cable fastener -1- and remove the cable. –  Unlock the connector -2- and separate.

–  Remove the protective cap -arrow-. –  Unscrew the rear fastening nut and remove the positive cable of the alternator. Separate the connectors from the following components:

–  Separate the connector -arrow- of the knock sensor I -G61-.

–  Separate the connector -arrow- of the engine speed sender -G28-. –  Separate the connector of the oil level and temperature sender -G266- engine codes AZQ, BME and BXV → Item.

–  Separate the connectors -arrows- of the cylinder injector 1 -N30-,cylinder injector 2 -N31- andcylinder injector 3 -N32-.

–  Separate the connectors -arrows- of the Ignition coil 1 with output stage -N70-, ignition coil 2 with output stage -N127- and ignition coil 3 with output stage -N291-

–  Release earth cable -1- and separate the connector -arrow- of the Hall sensor -G40-.

–  Separate the connector -arrow- of the coolant temperature sender -G62-. –  Separate the connector of the oil pressure sender -F1- engine codes AZQ, BME and BXV → Item. –  Separate the connector of the oil pressure sender -F1- engine codes BBM → Item .

–  Separate the connector -arrow- of the throttle valve control unit -J338-. –  Separate the connector of the intake manifold pressure sender -G71- engine code BBM → Item. –  Separate the connector of the intake manifold pressure sender -G71- engine identification letters AZQ, BME and BXV → Item. –  Separate the connector of the solenoid valve 1 for the active carbon filter (pulsed) -N80- → Item. –  Separate the connector of the exhaust gas recirculation valve -N18- with the exhaust gas recirculation potentiometer -G212-, engine code AZQ, BME and BXV → Item. –  Separate the other necessary electrical cables from the engine and leave the cable harness on one side of the engine compartment.

–  Separate the fuel distributor feeder pipe from the connector beside the shock absorber turret, -arrow-, press buttons on hose couplings to do this.   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 safety goggles and appropriate clothing to avoid injury and contact with skin. –  Pull vacuum and breather flexible hoses off the engine.   Note

To correct the centre of gravity of the group, fit the counterhold -T20127- to points -13- and -14-. –  Fit suspension tool -T20127- as indicated in the illustration and lift slightly with the workshop crane.   DANGER! Ensure that the hooks are closed with the security rings.

–  Remove the fixing bolts from the engine mounting -arrows-, to do so, partially separate the coolant expansion tank.

–  Separate the gearbox bracket bolts -arrows-. –  Lower the engine assembly until it comes free of the engine assembly bracket housing, gearbox side. –  Pull the engine assembly a little forwards and then up.   Note When the assembly is lifted out, it must be carefully guided to prevent damage to bodywork.