SEAT Workshop Service and Repair Manuals

Notes on removing –  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. –  The engine is removed upwards together with the gearbox. –  Removing front bumper: → General Body Repairs; Rep. Gr.63. –  Remove engine cover. –  Bring lock carrier into service position: → General Body Repairs; Rep. Gr.50 –  All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. –  Open and close the expansion tank sealing cap to release pressure in cooling system. –  Remove air cleaner → Chapter.

–  Now separate fuel supply as well as fuel return pipes -item 1 and 2- (press release button).   Warning Fuel supply pipes are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. –  Seal the pipes so that the fuel system is not contaminated by dirt etc. –  Remove reservoir for windscreen washer system → Electrical system; Rep. Gr.92. –  Loosen or separate the following components: t  The hose from intake manifold to activated charcoal filter system t  The vacuum hose from inlet manifold to brake servo t  The connector from ignition coils, from Hall sender and pressure switch t  The two connectors for the Lambda probes (on right-hand engine mounting) and pull then out of their retainers –  Pull off/disconnect all other electrical connections as necessary from engine and lay to one side. –  Remove centre, left and right insulation tray → General Body Repairs, Exterior; Rep. Gr.50. –  Drain coolant → Chapter. –  Pull hoses off thermostat housing. –  Remove ribbed belt → Chapter. –  Remove securing clamps for power steering pressure pipes.

–  Remove securing bolts for power steering vane pump belt pulley. Use belt pulley counter-hold -U-40011- for this.

–  Remove secondary air pump. –  Pull off connector -arrow-. –  Remove the three bolts securing the secondary pump to the bracket -1- and remove the bolts for the bracket on the cylinder head. –  Unbolt power steering vane pump and secure to sub-frame with wire; hoses remain connected → Running gear; Rep. Gr.48. Vehicles with air conditioner –  Observe additional information and removal instructions → Chapter Continued for all vehicles –  Pull off hydraulic connection on master cylinder → 6-Speed Manual Gearbox 02M; Rep. Gr.30. –  Disconnect selector mechanism from gearbox → 6-Speed Manual Gearbox; Rep. Gr.34. –  Remove coolant system expansion reservoir and lay to one side. –  Pull vacuum and breather hoses off engine. –  Disconnect all electric wires from gearbox, alternator and starter and move clear. –  Separate front exhaust pipe from exhaust manifold → Chapter, Exhaust manifold, front exhaust pipe with catalytic converter and attachments. –  Remove left and right-hand drive shaft on gearbox and tie up → Running Gear; Rep. Gr.40.

–  Attach lifting beam -U-30034- as follows and lift slightly with workshop crane: Pulley end:    2nd hole in hook at position 1 Flywheel end:    3rd hole in hook at position 4   Note! t  The positions marked 1 and 2 on the beam must be towards the pulley end. t  The holes in the hook rails are counted up from the hook.

–  Remove the front assembly mounting. Remove the bolts -arrows- to do this.

–  Unbolt assembly at gearbox and engine mounting -arrows-. –  Turn assembly slightly to the left (engine towards front, gearbox to the rear) and lift assembly carefully out upwards.   Note! When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.