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Page 3: Table Of Contents
Installation overview - assembly mountings ........permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Removing and installing engine mountings .
Page 4 17 - Lubrication ............200 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.
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Page 9: Technical Data
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Page 10: Safety Precautions During Road Tests In Which Testing And Measuring Equipment Is Used
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Page 11: Safety Precautions When Working On Exhaust System
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Page 13: Identification
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Page 14 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ticu‐ 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 15 Tor‐ 380/1800 … 55 350/1700 … 58 380/1850 to permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with 5700 respect to the correctness of information in this document. Copyright by SEAT S.A. Cyl‐...
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Page 17: Repair Instructions
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Page 18: Installing Radiators And Condensers
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Page 19: Removing And Installing Engine
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Page 23 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Loosen nuts -1, 3- and push to rear. (Illustration shows engine permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with removed.) respect to the correctness of information in this document.
Page 24 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Release pressure: place clean cloth around connection and permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with carefully open connection.
Page 25 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not top left from the radiator. 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 26 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 27 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 For gearbox neutral position sender - G701- respect to the correctness of information in this document.
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 To ensure that the cable is not a hindrance when removing ♦...
Page 29 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 32 Note 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 Disregard -item 2-. respect to the correctness of information in this document. Copyright by SEAT S.A.
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Page 36 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 37: Separating Engine And Gearbox
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Page 38 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 41 Special tools and workshop equipment required 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 ♦ Workshop hoist - VAS 6100- respect to the correctness of information in this document.
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Page 43 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not gear oil cooler. 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 44: Separating Engine And Gearbox - Models With Automatic Gearbox
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Page 45: Securing Engine To Engine And Gearbox Support
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Page 47: Installing Engine
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Page 48 Operation process 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. Copyright by SEAT S.A.
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Page 50 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 40 ; Subframe; Removing and installing subframe without 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 51 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 52: Assembly Bracket
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Page 53: Removing And Installing Engine Mountings
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Page 54 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 – Remove bolts -arrows- and detach engine mounting -1-.
Page 55: Removing And Installing Gearbox Mounting
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Page 56 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Different types of brackets are fitted depending on version. 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 57 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 58: Removing And Installing Pendulum Support
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Page 59: Supporting Engine In Installation Position
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Page 63: Adjusting Assembly Mounting
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Page 64: Checking Adjustment Of Assembly Mountings
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Page 65: Engine Cover
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Page 66: Crankshaft Group
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Page 67 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 68: Removing And Installing Poly V-Belt
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Page 69: Removing And Installing Tensioner For Poly V-Belt
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Page 75: Removing And Installing Ancillary Bracket
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Page 77: Removing And Installing Engine Support
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Page 78: Renewing Seal For Vibration Damper
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Page 81: Cylinder Block, Gearbox End
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Page 82: Removing And Installing Flywheel
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Page 83: Removing And Installing Sealing Flange (Gearbox End)
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Page 84 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 86 Then (and only then) fill the engine with engine oil. 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 87: Crankshaft
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Page 88: Crankshaft Dimensions
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Page 89: Arrangement Of The Crankshaft Bearing Shells
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Page 90: Renewing Needle Bearing In Crankshaft
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Page 91 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 92: Measure Axial Play Of Crankshaft
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Page 93: Measure Radial Play For Crankshaft
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Page 95: Balancing Shaft
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Page 96: Removing And Installing Balance Shaft
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Page 97 – Remove idler gear -1-. 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 – Remove bearing mounting -1-.
Page 98 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 100: Renewing Oil Seal For Balance Shaft (Inlet Side)
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Page 101 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 102 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 103: Pistons And Conrods
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Page 104 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 105 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 106: Removing And Installing Pistons
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Page 108: Checking Pistons And Cylinder Bores
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Page 109 ♦ Deviation from nominal dimension: max. 0.08 mm 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 Piston ∅...
Page 110: Separating Parts Of New Conrod
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Page 111 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 – Unscrew pressure relief valve -1- using bit - T10545- .
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Page 113: Cylinder Head, Valve Gear
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Page 116: Removing And Installing Cylinder Head
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Page 123: Removing And Installing Vacuum Pump
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Page 124: Check Compression Pressure
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Page 127: Timing Chain Cover
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Page 129: Removing And Installing Timing Chain Cover
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Page 136: Chain Drive
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Page 138: Assembly Overview - Drive Chain For Balancer Shaft
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Page 140: Fitting And Removing Bearing Support Module
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Page 142: Removing And Installing Camshaft Timing Chain
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Page 156: Removing And Installing Drive Chain For Balancer Shaft
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Page 160: Checking Timing Chain
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Page 161: Valve Gear
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Page 166: Removing And Installing Camshaft
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Page 171 - T40266- 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 -arrow 1-.
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Page 193: Install Ball For Forked Sleeve
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Page 194: Removing And Installing Camshaft Control Valve 1 N205
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Page 195: Removing And Installing Exhaust Camshaft Control Valve 1 N318
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Page 196: Removing And Installing Valve Stem Seals
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Page 205 Further assembly is basically the reverse of the dismantling se‐ 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 quence. In the process, note the following: respect to the correctness of information in this document.
Page 206: Inlet And Exhaust Valves
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Page 207: Valves: Checking
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Page 208: Lubrication
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Page 211: Engine Oil
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Page 216: Removing And Installing Sump (Top Section)
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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 Danger of blocking lubrication system with excess sealant. Do not respect to the correctness of information in this document.
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Page 221: Oil Pump: Removing And Installing
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Page 223: Removing And Installing Oil Level And Oil Temperature Sender G266
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Page 224: Engine Oil Radiator
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Page 226: Removing And Installing Mechanical Switching Valve
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Page 227: Crankcase Breather System
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Page 228: Removing And Installing The Oil Separator
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Page 229: Oil Filter/Oil Pressure Switches
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Page 230: Exploded View - Oil Pressure Switches/Oil Pressure Control
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Page 231: Removing And Installing Piston Cooling Jet Control Valve N522
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Page 232: Removing And Installing Oil Pressure Switch F1
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Page 233: Removing And Installing Oil Pressure Switch For Reduced Oil Pressure F378
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Page 234: Removing And Installing Stage 3 Oil Pressure Switch F447
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Page 235: Checking Oil Pressure
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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 • Oil pressure at 2000 rpm: 1.2 … 1.6 bar 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 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not • Oil pressure tester - V.A.G 1342- is connected as described permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with in section ⇒ “4.7.1 Checking engine oil pressure”, page 227 respect to the correctness of information in this document.
Page 239: Removing And Installing Valve For Oil Pressure Control N428
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Page 241: Cooling
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Page 244 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ature regulation - N493- 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 247: Draining And Filling Coolant
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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.
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Page 252: Checking Cooling System For Leaks
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Page 253 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 254 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not sure of approx. 1.5 bar. 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 255: Flushing Cooling System
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Page 261 -0.85 bar. 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 – Close shut-off tap -B-.
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Page 265 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 3. Flushing heat exchanger for heater with distilled water: respect to the correctness of information in this document.
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Page 270 ⇒ 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. – The coolant level must be at the »weld seam« -arrow-.
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Page 273 ♦ 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 Use cleaning adapter ⇒ Item 13 (page 249) (13) for flushing.
Page 274: Flushing Cooling System, Quick Reference Guide
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Page 275 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 276: Coolant Pump/Thermostat Assembly
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Page 278: Exploded View - Electric Coolant Pump
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Page 281: Exploded View - Coolant Temperature Sensors
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Page 284: Removing And Replacing Coolant Pump
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Page 285: Removing And Installing Electric Coolant Pump
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Page 286: Removing And Installing Coolant Shut-Off Valve N82
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Page 288: Removing And Installing Coolant Valve For Gearbox - N488- , Vehicles With Dual Clutch Gearbox
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Page 290: Removing And Installing Actuator For Engine Temperature Regulation N493
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Page 292: Removing And Installing Coolant Temperature Sender G62
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Page 293: Removing And Installing Coolant Temperature Sender At Radiator Outlet G83
Replace the O-rings. 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 coolant level ⇒ page 240 respect to the correctness of information in this document.
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Page 295: Coolant Pipes
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Page 297: Removing And Installing Coolant Pipes (Top)
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Page 298 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 in the reverse order of removal, observing the following: respect to the correctness of information in this document.
Page 299: Radiator/Radiator Fans
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Page 300: Exploded View - Auxiliary Radiator
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Page 303: Exploded View - Radiator Cowl And Radiator Fans
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Page 308: Removing And Installing Radiator Cowl
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Page 310: Removing And Installing Radiator Fans
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Page 311: Removing And Installing Auxiliary Radiator
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Page 312 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ; permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Wheels, tyres; Wheel change .
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Page 315: Turbocharging/Supercharging
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Page 317: Turbo Compressor: Removing And Fitting
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Page 321 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 – Unscrew the bolts -arrows- and place the pressure lines to‐...
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Page 323 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 324: Adjusting Charge Pressure Positioner V465
If available, select the function ♦ Engine run-in oil pres- 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. sure Specified torques ♦...
Page 325 ♦ Open-end spanner insert (10 mm) - V.A.G 1783/1- 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 ♦ Open-jaw spanner (5 mm) respect to the correctness of information in this document.
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Page 327: Supercharger Air System
Observe rules for cleanliness ⇒ page 9 ♦ 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. 2. Supercharger air system:...
Page 328 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Renew after removing 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 329: Exploded View - Hose Connections For Charge Air System
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Page 330 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 331 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 – Press cooler on the top edge in the direction of the engine.
Page 332 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 333 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 334: Removing And Installing Charge Pressure Sender G31
Hose connections and hoses for charge air system must be ♦ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with free of oil and grease before assembly. respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 335: Checking Charge Air System For Leaks
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Page 337: Removing And Installing Air Intake Pipe Between Turbocharger And Charge Air Cooler
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Removing and installing air intake pipe 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 339: Mixture Preparation - Injection
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not for cylinder 1 - N580- permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ❑ Exhaust cam actuator A respect to the correctness of information in this document.
Page 340 17 - Engine speed sensor - G28- 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 ❑ Location ⇒...
Page 341 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 342 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Cylinder 1 injector 2 - N532- 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 343 Brake light switch - F- / Brake pedal switch - F63- 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 344 5 - Exhaust cam actuator B for cylinder 3 - N597- 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 345 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 2 - Injector 2, cylinder 2 - N533- respect to the correctness of information in this document.
Page 346 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 351: Injectors
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Page 352 2 - O-ring 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 ❑ Renew after removing respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 353: Removing And Installing Fuel Rail
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Page 354: Injectors: Removing And Installing
⇒ ETKA (Electronic parts catalogue) . 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 Distinguishing between combustion chamber injectors respect to the correctness of information in this document.
Page 355 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Note 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 356 – Fit extraction hose ⇒ page 359 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 357 – Lay fuel hose -1- at intake manifold to one side. 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 358: Renewing Seals On Injectors
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Page 359 – Put new seal -1- on assembly cone - T10133/5- . 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 361: Cleaning Injectors
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Page 362 – Install combustion chamber injectors ⇒ page 346 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 363: Air Cleaner
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Page 364: Air Filter Housing: Removing And Fitting
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Page 365 – Re-install air cleaner 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 Note respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 366: Suction Hose
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 5 - Bolt 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 367: Removing And Installing Intake Manifold
❑ Qty. 2 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 ❑ 9 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 368 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Disconnecting and connecting battery . 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 369 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 371 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Vehicles with auxiliary radiators: unscrew bolts -arrows- and permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with slightly press the coolant line downwards.
Page 372 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 373: Throttle Valve Control Unit Gx3 : Removing And Fitting
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Throttle valve control unit - GX3- : re‐ 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 374 ♦ ⇒ “4.1 Exploded view - intake manifold”, page 358 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. – After throttle valve module - GX3- has been renewed, it must be re-adapted to engine control unit - J623- .
Page 375: Cleaning Throttle Valve Module
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Page 376: Sensors
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Structure-borne sound 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 377: Removing And Installing Fuel Pressure Sensor G247
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 ♦ Bit (27 mm) - T40218- or commercially available socket respect to the correctness of information in this document.
Page 378 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 379: Checking Fuel Pressure Sender G247
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 – Instead of fuel pressure sender - G247- , screw in adapter - respect to the correctness of information in this document.
Page 380 – Switch on digital pressure gauge - VAS 6394/1- by pressing 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 381: Removing And Installing Fuel Pressure Sender For Low Pressure G410
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 382: Remove And Install Intake Manifold Sender Gx9
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Screw adapter -2- onto fuel pressure sender for low pressure permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with - G410- -1-.
Page 383: Pressure Differential Sender For Particulate Filter G1037
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Page 384: Engine Control Unit
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Page 385 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not wiring harness repair set - VAS 1978 B- 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 386 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 388: 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 M8 bolts: 20 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 389: High-Pressure Pump: Removing And Fitting
High-pressure pump: removing and fit‐ 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 ting respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 390 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 392: Removing And Installing High-Pressure Pipe
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 Further assembly is basically a reverse of the dismantling se‐...
Page 393 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 394 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not nuts. 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 395: Lambda Probe
- GX10- 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 ❑ comprising: respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 396: Removing And Installing Lambda Probe
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Lambda probe open ring spanner set - 3337- 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 397 3337- . 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 Fitting respect to the correctness of information in this document. Copyright by SEAT S.A.
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Page 399: Exhaust System
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 406 Assembly overview - silencers, engine 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 codes CJXC, CJXH, CJXG, Leon SC, 5- respect to the correctness of information in this document.
Page 407 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 408 ⇒ page 401 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 ❑ Aligning exhaust sys‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 409: Removing And Installing Rear 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 respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 410 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 Risk of accident caused by high weight of silencers.
Page 411 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 in the reverse order of removal, observing the following: respect to the correctness of information in this document.
Page 412: Removing And Installing Centre Silencer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Unscrew bolts -1-. 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 413: Removing And Installing Front Silencer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not CJSA, CJSB, CJXC, CJXH, CJXG”, page 405 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 414 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 416: Disconnecting Exhaust Pipes/Silencers
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Page 419: Align Exhaust System To Be Free Of Stress
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Page 420: Aligning Tailpipes
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Page 422: Emission Control
❑ Renew after removal 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 ❑ Installation position respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 423 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 424 ❑ with pressure differen‐ 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 tial sender for particu‐...
Page 425 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 428: Removing And Installing Catalytic Converter
❑ 9 Nm 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 10 - Bolt respect to the correctness of information in this document. Copyright by SEAT S.A.
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Page 432 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 434 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 435 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 436 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 437 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove pendulum support ⇒ page 50 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. 2. Emission control...
Page 438 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 439 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 440 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not CAUTION 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 441 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 ♦ Underbody trim; assembly overview - underbody trim⇒ Gen‐...
Page 442 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 443 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 444 Note 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 Risk of damage to flexible joint ♦...
Page 445 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 446 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Connect the engine support - T50015A- -2- as shown in the permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with diagram.
Page 447 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 448 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Insert new seal. 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 449 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 450 - underbody trim . 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 and installing holder of pres‐...
Page 451: Removing And Installing Exhaust Flap Control Unit J883 / J945
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 452 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 453: Exhaust Gas Temperature Regulation
- G506- 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 or installing respect to the correctness of information in this document.
Page 454: Removing And Installing Parts Of Exhaust Gas Temperature Regulation
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Page 455 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 – Unclip wires of the temperature sender in front of particulate respect to the correctness of information in this document.
Page 456 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Installation 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 457 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 458 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 459: Ignition System
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Page 460: Ignition Coils With Output Stage: Removing And Fitting
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Page 461 – Tighten ignition coils. 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 Specified torques respect to the correctness of information in this document. Copyright by SEAT S.A.
Page 462: Removing And Installing Knock Sensor 1 G61
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Page 463: Removing And Installing Hall Sender
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Page 464: Removing And Installing Engine Speed Sensor G28
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