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Page 2 24 - Mixture preparation - injection Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with 26 - Exhaust system respect to the correctness of information in this document.
Page 3: Table Of Contents
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Page 4 Removing and installing the oil separator ........141 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document.
Page 5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Reducing fuel pressure in high-pressure section ....... . 208 respect to the correctness of information in this document.
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Page 7: Technical Data
1197 1197 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Engine output kW at rpm 77/4500-5500...
Page 8: Safety Instructions
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Page 9: Safety Precautions During Road Tests In Which Testing And Measuring Equipment Is Used
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Page 10: Repair Instructions
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Page 11: General Repair Instructions
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Page 12: Installing Radiators And Condensers
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Page 13: Removing And Installing Engine
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Page 24: Separating Engine And Gearbox
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Page 25: Securing Engine To Engine And Gearbox Support
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Page 27: Engine: Fitting
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Page 28 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 29 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not tioning; Rep. gr. 87 ; Air conditioner compressor; removing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with and installing A/C compressor .
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Page 31: Assembly Mountings
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Page 32: Supporting Engine In Installation Position
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Page 35: Removing And Installing Engine Mountings
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Page 37: Removing And Installing Pendulum Support
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Page 38: Checking Adjustment Of Assembly Mountings
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Page 41: Crankshaft Group
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Page 43: Exploded View - Poly V-Belt Drive
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Page 44: Removing And Installing Poly V-Belts
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Page 46: Removing And Installing Tensioner For Poly V-Belt
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Page 47: Removing And Installing Vibration Damper
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Page 48: Removing And Installing Engine Support
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Page 52: Crankshaft Oil Seal- Pulley Side: Replace
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Page 55: Cylinder Block, Gearbox End
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Page 56: Removing And Installing Flywheel
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Page 57: Removing And Installing Sealing Flange (Gearbox End)
– Insert counter-hold tool - 3067- in hole in cylinder block Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with -item A-.
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Page 59 To insert the sealing flange with sensor wheel Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Note respect to the correctness of information in this document.
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Page 62 – Tighten nut -B- on assembly tool - T10134- to 35 Nm. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
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Page 65: Crankshaft
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Page 66: Renewing Needle Bearing In Crankshaft
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Page 69: Pistons And Conrods
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Page 71: Removing And Installing Pistons
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Page 72: Checking Pistons And Cylinder Bores
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Page 73: Checking Radial Clearance Of Conrod Bearings
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Page 74: Removing And Installing Oil Spray Jet
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Page 75: Cylinder Head, Valve Gear
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Page 76: Exploded View - Camshaft Housing
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Page 78: Removing And Installing Cylinder Head
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Page 81 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not it is ready to be fitted. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 82: Removing And Installing Camshaft Housing
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Page 83 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with – Loosen the hose clip -2-, remove the coolant hose.
Page 84 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not tion elements for reinstallation. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 85: Test Compression Pressure
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Page 86 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
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Page 88: Toothed Belt Drive
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Page 89: Exploded View - Toothed Belt
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Page 90: Checking Distribution Timing
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Page 95: Detaching Toothed Belt From Camshaft
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Page 101: Timing Belt: Removing, Fitting, Tensioning
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Page 102 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove plug, and loosen securing bolt of camshaft adjuster permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with on inlet side by approx. one turn.
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Page 105 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not tioned exactly in adjustment window. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 106 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not direction«). permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 107 ♦ ⇒ “3.1 Exploded view - crankcase breather system”, permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with page 140 respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 108: Valve Control
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Page 110: Measuring Axial Play Of Camshaft
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Page 114: Removing And Installing Toothed Belt Pulley
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Page 117: Removing And Installing Camshaft Oil Seal
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Page 122: Valve 1 For Variable Distribution N205 Removing And Fitting
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Page 123: Removing And Installing Valve Stem Seals
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Page 130: Inlet And Exhaust Valves
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Page 131: Valve Dimensions
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Page 132: Lubrication
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Page 136: Engine Oil
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Page 140: Oil Pump: Removing And Installing
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Page 143: Removing And Installing Oil Level And Oil Temperature Sender G266
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Page 144: Engine Oil Radiator
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Page 146: Crankcase Breather System
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Page 147: Removing And Installing The Oil Separator
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Page 149: Oil Filter/Oil Pressure Switches
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Page 150: Check Oil Pressure And Oil Pressure Switch
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Page 151: Removing And Installing Oil Filter Housing
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Page 153: Cooling
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Page 156: Draining And Filling Coolant
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Page 161: Check The Cooling System For Leaks
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Page 163: Coolant Pump/Thermostat Assembly
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Page 165: Exploded View - Electric Coolant Pump
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Page 167: Exploded View - Coolant Temperature Sensors
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Page 168: Removing And Installing Coolant Pump
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Page 172: Removing And Installing Toothed Belt Pulley For Coolant Pump
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Page 174: Cooling System Thermostat: Removing And Installing
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Page 177: Removing And Installing Coolant Temperature Sender
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Page 180: Coolant Pipes
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Page 184: Radiator/Radiator Fans
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Page 186: Exploded View - Radiator Cowl And Radiator Fans
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Page 188: Removing And Installing Cooler For Charge Air Cooling Circuit
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Page 193: Removing And Installing Radiator Cowl
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Page 195: Turbocharging/Supercharging
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Page 197: Turbo Compressor: Removing And Fitting
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Page 201: Removing And Installing Charge Pressure Positioner V465
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Page 203: Supercharger Air System
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Page 205: Removing And Installing The Air Intake Pipe
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Page 206: Removing And Installing Charge Pressure Sender G31 / Intake Air Temperature Sender G42
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Page 208: Checking Charge Air System For Leaks
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Page 211: Mixture Preparation - Injection
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Page 214: Reducing Fuel Pressure In High-Pressure Section
CAUTION Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with The fuel system is under high pressure.
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Page 216: Injectors
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Page 217: Removing And Installing Fuel Rail
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Page 218: Removing And Installing Injectors
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Page 219 ♦ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Identifying supplier or part number: respect to the correctness of information in this document. Copyright by SEAT S.A.
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Page 221 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with this, cut the ring open using a knife.
Page 222 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with T10133/6- as far as it will go using assembly sleeve - respect to the correctness of information in this document.
Page 223 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 224 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 225 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 226 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with – If the torque limit of »5 Nm« has been reached and the injector respect to the correctness of information in this document.
Page 227 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with – Push combustion chamber ring seal onto assembly cone - respect to the correctness of information in this document.
Page 228: Cleaning Injectors
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with The combustion chamber ring seal -8- must not be lubricated.
Page 229 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 230 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 231: Air Filter
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 9 - Resonator for intake air permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 232: Removing And Installing Air Filter Housing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Do not pull out the air filter housing suddenly or to one side.
Page 233: Removing And Installing Resonator For Intake Air
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Page 234: Intake Manifold
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Page 235: Removing And Installing Intake Manifold
After throttle valve module - GX3- has been renewed, it must be re-adapted to engine control unit - J623- . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Use vehicle diagnostic tester respect to the correctness of information in this document.
Page 236 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 237 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 238: Removing And Installing Throttle Valve Module Gx3
⇒ “3.1 Exploded view - air cleaner housing”, page 225 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ♦...
Page 239: Cleaning Throttle Valve Module
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not air intake pipe from breaking off. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 240 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 241: Sensors
Tightening torque Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Intake manifold sender - GX9- 3 Nm respect to the correctness of information in this document.
Page 242: Checking Fuel Pressure Sender G247
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Page 243 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 244 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not tual value displayed on vehicle diagnosis tester . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 245: Engine Control Unit
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Page 246 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 247 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 248 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 249 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 250 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 251: High-Pressure Pump
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not cate lightly with clean permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with engine oil respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 252 ⇒ “7.2 Removing and in‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with stalling high-pressure respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 253: Removing And Installing High-Pressure Pump
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with – Check roller tappet for damage and renew if necessary.
Page 254: Removing And Installing High-Pressure Pipe
⇒ “3.1 Rules for cleanliness”, page 4 ♦ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A. Rep. gr.24 - Mixture preparation - injection...
Page 255 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 256: Lambda Probe
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Page 257: Removing And Installing Lambda Probe
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Page 259: Exhaust System
⇒ page 254 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with 4 - Secondary silencer respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 260 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 261 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 5 - Nut permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 262 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 263: Disconnecting Exhaust Pipes/Silencers
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Fit clamp in position shown. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 264 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 265: Removing And Installing Silencers
Removing and installing front silencer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Removing respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 266 – Seek help from a second a mechanic for the following work. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Leon SC, 5 door model respect to the correctness of information in this document.
Page 267: Align Exhaust System To Be Free Of Stress
♦ ⇒ “2.1 Assembly overview - emission control”, page 263 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A. ♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody trim;...
Page 268: Checking Exhaust System For Leaks
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Page 269: Emission Control
It may be damaged Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ❑ Install decoupling ele‐...
Page 270: Removing And Installing Catalytic Converter
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Page 274: Ignition System
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Page 275: Spark Plug Test Data
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Page 277: Removing And Installing Knock Sensor
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Page 278: Removing And Installing Engine Speed Sensor G28
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