SEAT Workshop Service and Repair Manuals

Engine: fitting   WARNING Important information for using an engine with one of the designated spare parts (replacement engine): t  Take note that the roller tappet → Item is not included in the scope of supply of the new replacement engine. t  When exchanging the replacement engine, the roller tappet → Item has to be used, as long as this is possible. t  The following parts will be influenced if the roller tappet is not installed: Camshaft, high-pressure pump and cylinder head cover. t  The cylinder head may also be influenced as a result of damage to the bolt of the high-pressure pump. t  The engine will be damaged permanently if the valves make contact with the piston. Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter Special tools and workshop equipment required

t  Torque wrench -VAG 1331-, see equivalent → Anchor.

t  Torque wrench -VAG 1332-, see equivalent → Anchor. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  All parts used must be greased. t  Tolerance for tightening torques: ± 15 %.

Component			Nm
Bolts/nuts		M6	9
		M8	20
		M10:	40
		M12	65

Engine/gearbox mountings

Item	Bolt.	Nm
1, 3, 4	M12 x 75	65
2	M12 x 90	65
5, 6	M12 x 110	65
7 … 10	M10 x 45	45
11	M12 x 130	65
A	Centering handles

Operation process   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts and bolts, and seals, O-rings and gaskets. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure hose unions with hose clamps the same as those of the series → Electronic parts catalogue. t  To secure the charge air hoses at their connections, spray rust remover onto the worm thread of the used hose clips before installing. t  The cable ties must be installed in their same place again. –  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. –  Before installing gearbox, remove residue from threaded holes for engine/gearbox bolts in cylinder block using a thread tap. –  The following preparations must be made before joining the engine and gearbox:

–  Ensure that intermediate plate is engaged on sealing flange and pushed onto dowel sleeves -arrows-.   Note t  Bolt -2- secures the starter to the gearbox and is provided with a spacer sleeve -arrow-. t  Pay attention to the spacer sleeve -arrow- when removing and installing engine. The spacer sleeve must be fitted between starter and gearbox.

t  Position the starter between the cylinder head and engine block in all cases. –  Guide the gearbox and engine together and tighten the top connecting screws of the engine and gearbox. Tightening torques → Anchor

–  Slacken spindle of the support bracket -10 222A-. –  Use the workshop crane -VAS 6100- to lower the engine / gearbox assembly onto engine bearings.   Note Different mounting holes are provided for the different engine versions.

–  Screw in the nuts -1- at the bottom on the engine mountings to the left and right.

–  Screw in the top nut -arrow- on left engine mounting.   Note Before screwing in, check the bolt lengths and assignment for re-installation purposes.

–  Screw in the bolts -arrows- that can be accessed from underneath on the engine / gearbox flange. Tightening torques → Anchor

–  Plug in electrical connector -3-. –  Attach the electrical wire -2- to the starter. –  Screw in the bolts -1- and -4- of the starter. –  Attach the workshop crane -VAS 6100- and lifting tackle -2024A-. –  Install catalytic converter → Chapter. –  Align exhaust system without tension → Chapter –  Install the climate control compressor → Rep. gr.87. –  Install power steering pump → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48. –  Installing the Poly-V belt → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Fit engine control unit → Chapter. –  Observe correct procedure after connecting battery → Rep. gr.27.   Caution Overvoltage can cause irreparable damage to control units. Do not use charger for boost starting, –  Install air cleaner housing → Chapter. –  Install the lock carrier → Rep. gr.50. Tightening torque: → Chapter „Assembly mountings - exploded view“ –  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten bolts -arrows-. Check oil level → Booklet301. –  Fill up with coolant → Chapter.   Note t  The removed coolant should never be used again in the following cases: t  the cylinder head or cylinder block have been renewed. t  If the coolant is dirty. –  Install noise insulation and wheel housing liners → Rep. gr.66. –  Check the headlight setting → Booklet301.