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. –  Remove centre as well as the left and right-hand sound insulation trays: → General body repairs, exterior; Rep. Gr.50 –  The engine is removed upwards along with the gearbox. –  Removing front bumper: → General body repairs; Repair; Rep. Gr.63 –  Removing lock carrier → General body repairs; Rep. Gr.50

–  Move lock carrier to service position; Use centralizing pins -T20089- for this. –  All the cable ties which have been opened or cut open when removing the engine, must be renewed in the same position when installing the engine again. –  Removing air cleaner → Chapter. –  Drain coolant → Chapter. –  Remove ribbed belt → Chapter.

–  Remove fuel supply and fuel return lines -1- and -2- (press locking button).   Caution The fuel supply lines are under pressure! Wrap a cloth around the connection before removing from hose connection. Then release pressure by carefully pulling hose off connection. –  Seal the lines so that the fuel system is not contaminated by dirt. –  Remove, release or separate the following components: t  the hose to the activated charcoal filter system canister from throttle valve control part t  the vacuum hose to brake servo from intake manifold/pipe t  the ignition cable and earth strap from ignition transformer t  the Lambda probe connector (on front right of subframe) and pull connector out of retainer. t  the connector from coolant temperature sender –  Pull off/disconnect all other electrical wiring from engine required and place to side. –  Remove centre as well as the left and right-hand sound insulation trays: → General body repairs, exterior; Rep. Gr.50 –  Release spring-type clamps and pull coolant hoses off the thermostat housing. –  Remove securing clamps for power assisted steering pressure lines.

–  Remove power assisted steering vane pump and secure with wire to the subframe. Hoses remain connected: → Running gear; Rep. Gr.48 Vehicles with an air conditioning system –  Observe additional notes and assembly work → Chapter. Continuation for all vehicles –  Disconnect clutch cable: → 5-speed manual gearbox 085; Rep. Gr.30 –  Removing selector mechanism from gearbox: → 5-speed manual gearbox; Rep. Gr.34 –  Release/disconnect hoses on expansion tank. –  Pull vacuum and breather hoses off engine. –  Pull off/disconnect all other electrical wiring from gearbox, alternator and starter and place to side. –  Unbolt front exhaust pipe from exhaust manifold → Chapter, Exhaust manifold, front exhaust pipe with catalytic converter, Lambda probe –  Disconnect left and right drive shaft at gearbox and tie up correctly → Running gear; Rep. Gr.40 –  Remove bonnet → General body repairs, exterior; Rep. Gr.55

–  Attach lifting beam -U-30034- as follows and lift slightly with workshop crane: Belt pulley end:    2nd hole in hook position 1 Flywheel end:    1st hole in hook position 3   Caution The hooks and locating pins must be secured with locking pins/clips.   Note! t  The positions 1 and 2 marked on the beam must face the belt pulley. t  The holes in the hook are counted up from the hook.

–  Remove the subframe out forwards. Remove bolts -arrows- for this.

–  Unbolt assemblies on gearbox mounting and on engine mounting -arrows-. –  Turn assembly slightly to the left (engine forwards, gearbox to rear) and lift assembly carefully out upwards.   Note! The assembly must be carefully guide when lifting out so that no damage is caused to the bodywork.