SEAT Workshop Service and Repair Manuals

Removing the engine:   Note The engine is removed from underneath together with the gearbox. –  Switch ignition OFF. –  Remove the battery → Disconnect and connect the battery; Disconnect and connect the batteries; Rep. gr.27 .. –  Remove air filter → Chapter.

–  Unscrew the bolts -arrows- and remove battery mounting.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  Cover filler cap on expansion tank with a cloth and open carefully to release pressure. –  Open filler cap on expansion tank. –  Remove front wheels.

–  Remove the sound insulation in the middle, release the fasteners -1- and -2- for this purpose.

–  Remove connector -2- on the coolant temperature sender -G83 - at the radiator outlet. –  Place the drip tray -T20173 - under the engine. –  Lift retaining clip, disconnect coolant hose -1- from radiator (bottom) and drain off coolant.

–  Lift retaining clip, disconnect coolant hose -arrow- (bottom right) from water radiator for charge air cooler and drain off remaining coolant.

–  Remove the coolant hose from the upper part of the radiator by removing the securing clips -arrow-.

–  Disconnect coolant hose -arrow- (top right) from water radiator for charge air cooler (pull out retaining clip).

–  Detach coolant hoses -1- and -2- from heat exchanger for heater (lift retaining clips).

–  Detach coolant hose -arrow- from coolant expansion tank and guide downwards as far as possible to allow remaining coolant to drain off.

–  Remove the coolant pipe -1- from the coolant expansion tank. –  Disconnect vacuum hose -2- from activated charcoal filter and move hose clear.   WARNING Fuel supply line is pressurised. Wear safety goggles and appropriate clothing to avoid injury and contact with skin. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. t  Do not open the high-pressure section of the injection system when removing the engine. t  However, if the engine has to be removed for repair procedures which necessitate opening the high-pressure section, the fuel pressure in the high-pressure section must be reduced in a controlled manner to a residual pressure prior to opening. The procedure is described in the chapter "Reduction of high pressure system pressure" → Chapter.

–  Remove the fuel supply tube -2-. To do so, press the unlock tabs.   Note Ignore -item 1-.

–  Hang out the retaining clip -1- from the gear selection rod. –  Hang out the retaining clip -2- from the relay lever made of „metal“.   Note There are two different relay lever models: Made of „metal“ or „plastic“. „Plastic“ relay lever

–  Press down the lever -2- to the lower limit.   Note Item -1- can be disregarded.

–  Place a flat tipped screwdriver-A- between the bushing -B- and the rod, pressing it out until it comes free of the pivot. –  Pull off selector cable support elements from gearbox selector lever and relay lever.

–  Unscrew the bolts -arrows- of the counter bearing and move to one side.

–  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.

–  Press release tabs and disconnect vacuum line -3- from intake manifold.   Note -Items 1 and 2- can be disregarded. –  Remove the front bumper → Front bumper trim: Removing and fitting ; Rep. gr.63 –  Bring lock plate carrier into service position: → Lock carrier in service position; Rep. gr.50 . –  Remove the plate of the front right-hand side wheel housing → Remove and fit the front wheel housing; Rep. gr.50 . –  Remove poly V-belt → Chapter.

–  Separate the connector -1- of the air conditioner compressor. –  Unscrew the securing bolts -arrows- of the compressor.   Note t  Do not open the air conditioning pipes. t  Check that the conducts have not been bent.

–  Fasten the compressor to the lock carrier using the counterhold -T10038-.   Caution Take care not to damage the system.

–  Pull rubber seal -2- off plenum chamber cover.

–  Remove bolts -1-.

–  Remove parting wall for plenum chamber -arrows-.

–  Unlock and remove the plug connectors -1 and 2- on the engine control unit → Chapter.

–  Release the engine wiring harness guide -arrow- and pull out upwards.

–  Open the clips on the cable guide -arrows-.

–  Unlock and remove the electric connector -1-. –  Open the wiring guide of the bracket -2- lying underneath. –  Remove the wiring harness from wiring duct in the direction of the engine control unit and place on engine.

–  Unplug electrical connector -arrow- at longitudinal member (bottom left).   Note For illustration purposes, the installation position is shown from below.

–  Remove cover for engine compartment electronics box. To do so, slide both catches in direction of -arrows-.

–  Remove nut -arrow-, detach terminal 30 wire from electronics box in engine compartment and move it clear.

–  Loosen bolts -arrows- of assembly mounting at engine approx. 2 turns.

–  Loosen bolts -arrows- securing gearbox mounting to gearbox support approx. 2 turns.

–  Remove nut -1- and detach earth wire. –  Remove nut -3-, detach electrical wiring and move clear.   Note Depending on the model, the earth wire may be screwed to the engine mounting. –  Unplug electrical connector -2- and move clear.

–  Unplug electrical connector -2- for Lambda probe -G39 -. –  Unplug electrical connector -4- for reversing light switch -F4 -. –  Move engine wiring harness clear at bracket -3-. –  Unscrew nut -arrow- and detach bracket with electrical wiring from stud. 1  -  Electrical connector for Lambda probe after catalytic converter -G130-

–  Depending on the version, unplug electrical connector -1- of the oil level and oil temperature sender -G266 -. –  Separate the bracket -2- for electrical cable to oil level and oil temperature sender -G266- from the subframe.

–  Unscrew nuts -1- and -2-. –  Move clear electrical wiring for Lambda probe -G39--arrows-.   Caution Risk of damage to the coupling element! The coupling element of the main exhaust pipe must not be bent more than 10°.

–  Remove nuts -2- and -3- and separate exhaust system. –  Remove bolts -1- and -5-. –  Pull bracket -4- for exhaust system off pins on front exhaust pipe. –  Remove the exhaust primary tube.

–  Remove bolts -1, 2, 3- and detach pendulum support.

–  Pull out the plug -1-.   Note The -arrows- can be disregarded.

–  Remove nuts -arrow- on both sides and detach coupling rods from anti-roll bar.

–  Unbolt left and right half shafts from gearbox flange or the intermediate bearing. –  Tie up drive shaft to longitudinal member -arrow-. –  Turn the steering toward the right. –  Tilt the right-half shaft forwards and strap it to the sill -arrow-, as shown in the image.   Note Make sure you do not damage surface coating on drive shaft.

–  Remove bolt -1-.   Note Ignore -item 2-.

–  Remove bolts -1- and move coolant circulation pump -V50 - clear to one side.   Note -Items 2, 3- and the -arrows- can be ignored.

–  Remove bolt -3- for support -T40075/1- on engine support -T40075 - –  Fit support -T40075/1- into vacant threaded hole for catalytic converter. –  Attach engine support -T40075- to engine as shown in illustration and secure with bolt -3- to support -T40075/1 -. –  Fit the engine support -T40075- to rear of engine with an M8 x 45 screw -item 1-, place washers and two M10 nuts -item 2- in between and secure to cylinder block to tightening torque of 20 Nm. –  Fit engine support -T40075- onto engine and gearbox jack -V.A.G 1383 A-.   Note To unscrew the bolts for engine mounting use the step ladder.

–  Remove bolts -arrows- of assembly mounting at engine.

–  Remove bolts -arrows- securing gearbox mounting to gearbox support.   Note t  Check that all hoses and wiring connections between engine, gearbox and body have been detached. t  Carefully guide engine assembly when lowering to avoid damage. –  Pull the engine assembly forwards as far as possible and lower it downwards slowly.