Seat Leon 2013 Workshop Manual Download Page 233 | Manualshive

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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.

3.3

Removing and installing resonator for

intake air

Removing
– Open hose clips -1- and -2-.
– Remove resonator for intake air.
Installation
Reassembly is carried out in the reverse order; note the following:

Note

Reinstall hose clips in their original positions.

León 2013 ➤ , León ST 2013 ➤

4-cylinder petrol engine (1.2 l direct injection, 4 V, turbocharger, EA211) - Edition 02.2017

3. Air filter

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Summary of Contents for Leon 2013

Page 1: ...A does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by SEAT S A Workshop Manual Le n 2013 Le n ST 2013 4 cylinder petrol engine 1 2...

Page 2: ...15 Cylinder head valve gear 17 Lubrication 19 Cooling 21 Turbocharging supercharging 24 Mixture preparation injection 26 Exhaust system 28 Ignition system Technical information should always be avail...

Page 3: ...ounting 7 1 2 Separating engine and gearbox 18 1 3 Securing engine to engine and gearbox support 19 1 4 Engine fitting 21 2 Assembly mountings 25 2 1 Exploded view assembly mountings 25 2 2 Supporting...

Page 4: ...g and installing camshaft oil seal 111 3 6 Valve 1 for variable distribution N205 removing and fitting 116 3 7 Removing and installing valve stem seals 117 4 Inlet and exhaust valves 124 4 1 Checking...

Page 5: ...charger 189 1 2 Turbo compressor removing and fitting 191 1 3 Removing and installing charge pressure positioner V465 195 2 Supercharger air system 197 2 1 Assembly overview charge air system 197 2 2...

Page 6: ...haust system 253 1 Exhaust pipes silencers 253 1 1 Exploded view silencers 253 1 2 Disconnecting exhaust pipes silencers 257 1 3 Removing and installing silencers 259 1 4 Align exhaust system to be fr...

Page 7: ...C new four digit engine codes have been introduced The first 3 digits denote the mechanical design of the engine and are stamped on the engine as before The fourth po sition digit describes the engine...

Page 8: ...due to highly pressurised fuel The fuel system is pressurised Injury possible due to fuel which may spurt out Before opening the fuel system Use safety goggles Wear protection gloves Release pressure...

Page 9: ...lant The cooling system is under pressure when the engine is hot Hot steam hot coolant can escape risk of scalding Wear protection gloves Use safety goggles Reduce pressure by covering the cap of the...

Page 10: ...packaging immediately before installation Do not use parts that have been previously unpacked and stored away loose e g in toolboxes etc When the system is open Do not work with compressed air Do not...

Page 11: ...es in the intake and exhaust systems must always be sealed with suitable plugs to prevent foreign particles from en tering the engine Use engine bung set VAS 6122 In the event of mechanical damage to...

Page 12: ...e on the fins of these components This does not mean that the components are damaged Neither radiator nor condensers are to be replaced on account of such minor pressure marks 3 8 Vacuum system checki...

Page 13: ...g page 7 1 2 Separating engine and gearbox page 18 1 3 Securing engine to engine and gearbox support page 19 1 4 Engine fitting page 21 1 1 Engine dismounting Special tools and workshop equipment requ...

Page 14: ...lant or fuel from running out The cable clamps must be installed in their same place again All cable ties which were opened or cut when the engine was removed must be replaced with new cable ties in t...

Page 15: ...n the lock carrier and remove in the direction of the arrow Remove battery and battery tray Electrical system Rep gr 27 Battery Removing and installing battery tray Unplug electrical connector 1 for r...

Page 16: ...poly V belt runs in the opposite direction when it is refitted this can cause breakage Before removing the Poly V belt mark the direction of rotation with chalk or felt tipped pen for re installation...

Page 17: ...ix on the lock carrier and suspend Proceed with great care in order not to damage the system Continued for all vehicles Lift the retaining clip arrow remove the coolant hose at the top left from the r...

Page 18: ...om the heat exchanger on the heating unit Move clear vacuum hose at air intake pipe 2 Unscrew bolt 2 and remove screw type clip Remove bolt 1 and nuts arrows and tie up catalytic con verter Note Do no...

Page 19: ...place clean cloth around connection and carefully open connection Observe rules for cleanliness when working on the fuel supply system 2 1 Safety precautions when working on fuel supply sys tem page 2...

Page 20: ...from the bracket and separate Open the cable duct 2 upward in the direction of the arrow Note Item 1 can be disregarded Move electrical wiring clear Unplug the electrical connector 2 Note Item 1 can b...

Page 21: ...arrows and detach cover 1 for electronics box in engine compartment Release catch using a screwdriver arrow and detach cover 1 for electronics box in engine compartment upwards Remove nut 2 and screw...

Page 22: ...tuation Removing the clutch slave cylinder Rep gr 30 Clutch actuation Clutch slave cylinder removing and installing Dual clutch gearbox Remove selector lever cable pull connector of mechatronic off an...

Page 23: ...should be ordered and secured with flanges Make sure that all lines of the exhaust temperature sender are not exposed to tension and that hey are not damaged when removing the engine assembly Check t...

Page 24: ...Carefully guide out engine gearbox assembly with subframe from engine compartment when raising Make sure that air conditioner compressor and refrigerant pipes and hoses are not damaged Do not stretch...

Page 25: ...Rep gr 27 Starter Removing and installing starter Hook lifting device 10 222 A 12 onto gearbox and screw in the bolt as far as possible Attach workshop crane VAS 6100 with hooks 10 222 A 2 to lifting...

Page 26: ...rane VAS 6100 Work sequence Gearbox detached from engine page 18 Attach lifting tackle 2024 A to engine and workshop hoist VAS 6100 as shown in illustration Note To adjust to the centre of gravity of...

Page 27: ...quence Attach power unit with the aid of the lifting device 2024 A and the workshop crane VAS 6100 Note Renew bolts that are tightened with specified further tightening angle Renew self locking nuts a...

Page 28: ...mbled engine and gearbox supports Using the lifting tackle 2024 A and the workshop crane VAS 6100 insert the engine gearbox unit Note Make sure that air conditioner compressor and refrigerant pipes an...

Page 29: ...e fit connector of mechatronic and install all retainers on gearbox Rep gr 34 Removing and installing gearbox Continued procedure for all vehicles Install radiator cowl page 187 Install catalytic conv...

Page 30: ...an cause irreparable damage to control units Do not use charger for boost starting Filling cooling system page 151 Note Soiled coolant must not be reused Specified torques Assembly mountings 2 1 Explo...

Page 31: ...ort page 31 2 6 Checking adjustment of assembly mountings page 32 2 7 Adjusting assembly mounting page 32 2 1 Exploded view assembly mountings 1 Bolt renew Tightening sequence page 26 2 Engine support...

Page 32: ...ew bolts that are tightened with specified further tightening angle Tighten bolts in stages in the sequence shown stage Bolts Tightening torque angle specification 1 1 3 7 Nm 2 1 3 40 Nm 3 1 3 turn 90...

Page 33: ...oes not guarantee or accept any liability with respect to the correctness of information in this document Copyright by SEAT S A Support tool 10 222 A Adapter 10 222A 13 Spindle 10 222 A 10 Shackle 10...

Page 34: ...e air hose 2 from the air filter housing Carefully remove the air filter housing 1 from the retaining bolts in an upward motion sequentially Loosen the brackets arrow for the air duct hose Disconnect...

Page 35: ...but without raising it 2 3 Removing and installing engine mount ings Removing Loosen hose 2 for activated carbon filter Disconnect connector 1 Release detent using a screwdriver arrow and place coola...

Page 36: ...e control unit J623 and place to one side Remove engine control unit page 239 Remove nuts arrows and detach bracket 1 Note Different types of brackets are fitted depending on version Remove line guide...

Page 37: ...mounting have been tightened to specified torque Pull gearbox up with spindle on support bracket until gearbox support contacts support arm of gearbox mounting Check adjustment of assembly mountings...

Page 38: ...stment of assembly mountings Work sequence The following dimensions must be reached There must be a distance of a 10 mm between engine support 2 and engine mounting 1 The side surface of the engine su...

Page 39: ...ne and renew if they were not renewed when installing engine First screw bolts in loosely Using assembly lever adjust engine gearbox assembly so that specifications listed below are attained There mus...

Page 40: ...Tighten bolts for gearbox mounting Installation is in the reverse sequence of removal Specified torques 2 1 Exploded view assembly mountings page 25 2 1 Assembly overview charge air system page 197 El...

Page 41: ...lling tensioner for poly V belt page 40 1 4 Removing and installing vibration damper page 41 1 5 Removing and installing engine support page 42 1 6 Crankshaft oil seal pulley side replace page 46 1 1...

Page 42: ...tation with chalk or felt tipped pen Do not kink Routing of poly V belt page 38 Removing and installing page 38 When installing make sure it is properly seated on pulleys 4 Bolt 20 Nm 90 5 Tensioner f...

Page 43: ...V belt Pivot with socket to slacken poly V belt Lock with locking pin T10060 A Removing and installing page 40 5 Bolt 20 Nm 90 6 Bolt Tightening torque Electrical system Rep gr 27 Alternator Ex ploded...

Page 44: ...ssor Special tools and workshop equipment required Locking pin T10060 A Removing To slacken poly V belt turn tensioner in anti clockwise direc tion arrow Lock tensioner with locking pin T10060 A Note...

Page 45: ...nt required Locking pin T10060 A Removing To slacken poly V belt turn tensioner in anti clockwise direc tion arrow Lock tensioner with locking pin T10060 A Note If a used poly V belt runs in the oppos...

Page 46: ...ompressor page 40 1 3 1 Clamping fixture for V belt removing and installing vehicles without air con ditioner compressor Removing Detach poly V belt from tensioner 1 2 1 Poly V belt Removing and insta...

Page 47: ...op equipment required Counter hold tool T10475 Removing Remove noise insulation General body repairs exterior Rep gr 50 Noise insulation Removing and installing noise insulation Remove poly V belt pag...

Page 48: ...nstallation sequence carried out in reverse sequence note the following Fit poly V belt page 38 Specified torques 1 1 Exploded view poly V belt drive page 35 1 5 Removing and installing engine support...

Page 49: ...o one side Remove tensioner for poly V belt 1 3 Removing and installing tensioner for poly V belt page 40 Loosen bolt 1 but do not remove Unscrew bolt 2 Swivel alternator 3 in direction of arrow towar...

Page 50: ...n bolt arrow of the vibration damper using the coun terhold tool T10475 to do so Remove bolt and take off vibration damper Unscrew bolts arrows and remove lower toothed belt guard Remove bolts 1 2 3 a...

Page 51: ...ing the spindle of the support bracket 10 222 A Pull out engine support downwards Installation Installation is carried out in the reverse order Please note the following Fit the engine support and han...

Page 52: ...Exploded view assembly mountings page 25 1 1 Exploded view poly V belt drive page 35 2 1 Exploded view toothed belt cover page 82 1 1 2 Exploded view poly V belt drive vehicles with air conditioner co...

Page 53: ...aused by incorrect valve timing Do not turn crankshaft out of TDC position Pry out seal arrow with the extractor hook T20143 2 Clean contact surface and sealing surface Note Do not lubricate new seal...

Page 54: ...t Draw in seal 2 to stop using thrust piece T10485 1 and bolt 1 for pulley Fit crankshaft sprocket onto crankshaft The contact surface between vibration damper and crankshaft toothed belt pulley must...

Page 55: ...gearbox end Note For assembly work secure engine to engine and gearbox support page 19 1 Bolt renew 60 Nm 90 2 Flywheel Removing and installing page 50 Fitting possible in one position only 3 Engine s...

Page 56: ...in stages as follows stage Bolts Tightening torque 1 1 6 Screw in by hand until they make con tact 2 1 6 in diagonal sequence and in stages final torque 10 Nm Installing intermediate plate Engage int...

Page 57: ...n the reverse order Please note the following Note Renew bolts that are tightened with specified further tightening angle Flywheel with sender wheel can only be fitted in one position Insert counter h...

Page 58: ...dure is shown with the engine removed Remove the flywheel page 50 Remove intermediate plate 1 from dowel sleeves arrows A Guide intermediate plate 1 upwards While doing so pull retaining lug arrow B o...

Page 59: ...tion of an assembly sleeve and cannot be removed before fitting Sealing flange and sensor wheel 1 must not be separated or turned after removal from packaging The sender wheel 1 is held in its install...

Page 60: ...34 in a vice 1 on tightening flats A of threaded spindle Press assembly housing C downward so that it rests against nut B Inner part of assembly device and installation socket must be level with each...

Page 61: ...s sealing flange 1 and sealing lip sup port ring 2 against surface of assembly tool T10134 This prevents the locating pin from slipping out of the sensor wheel hole When installing sealing flange ensu...

Page 62: ...d in the direction of the arrow until the sealing lip support ring 1 lies on the surface of the crankshaft flange 2 Check that the guide pin for petrol engines red handle F is seated correctly in the...

Page 63: ...en crankshaft flange 2 and sender wheel 1 Measure distance a between crankshaft flange 2 and sen sor wheel 1 Specification Distance a 0 5 mm Press sensor wheel in further if distance is too small page...

Page 64: ...ighten bolts for sealing flange vehicles with manual gearbox page 50 Install oil pan 1 3 Removing and installing sump page 130 Install intermediate plate vehicles with manual gearbox page 50 Install f...

Page 65: ...aft bearing cap are loosened the bearing pedestals of the cylinder block will be deformed and damage to the bearings will result Never remove the crankshaft Honing dimension Crankshaft bearing journal...

Page 66: ...t VW 387 to cylinder block as shown in illustration Position dial gauge against crankshaft web Press crankshaft against dial gauge by hand and set gauge to 0 Push the crankshaft away from the gauge an...

Page 67: ...installing gearbox Prerequisites Always replace needle bearing arrow if the engine and trans mission are being separated The front edges of the inner puller must not be broken Driving out needle bear...

Page 68: ...in crankshaft and apply as thin coating of grease Drive needle bearing into crankshaft to installation depth using drift VW 207 C Installation depth Dimension a 2 0 mm Note If the needle bearing has...

Page 69: ...bearing cap from the conrod in man ufacture the caps only fit in one position and only on the appropriate conrod Mark cylinder and con rod allocation in colour B Installation position Tab A in the co...

Page 70: ...o remove and install Installation position marking TOP or side with lettering faces towards piston crown Offset gaps by 120 9 Segment ring Oil scraping ring Measuring piston ring gap page 66 Measuring...

Page 71: ...position below the dotted line Unscrew bolts arrows approx 5 turns Using a plastic hammer carefully knock conrod bearing cap loose arrow 4 2 Removing and installing pistons Special tools and workshop...

Page 72: ...Install cylinder head page 72 Install oil pan page 130 Specified torques 4 1 Assembly overview pistons and conrods page 63 4 3 Checking pistons and cylinder bores Checking pistons Using a micrometer...

Page 73: ...ylinder gauge VAS 6078 to take measurements at 3 points criss cross in transverse direction A and in longitu dinal direction B Maximum deviation from nominal dimension 0 08 mm Inside diameter of cylin...

Page 74: ...p page 130 Turn crankshaft via vibration damper securing bolt in direction of engine rotation until the respective bolt is accessible Unscrew pressure relief valve 1 using bit T10545 Remove oil spray...

Page 75: ...view cylinder head Note The camshafts must not be removed individually In the event of repair the camshaft housing must be renewed completely 1 Cylinder head gasket Replace page 72 Observe installati...

Page 76: ...r tightening angle Tighten bolts in stages in the sequence shown stage Bolts Tightening torque angle specification 1 1 10 40 Nm 2 1 10 turn 90 further 3 1 10 turn 90 further 4th 1 10 turn 90 further C...

Page 77: ...amshaft housing Removing and installing 1 4 Removing and in stalling camshaft hous ing page 76 5 Hall sender G40 Removing and installing 1 5 Removing and in stalling Hall sender page 271 6 Bolt 8 Nm 7...

Page 78: ...nlet camshaft Replace 3 5 1 Removing and installing camshaft oil seal for inlet camshaft belt pulley end page 111 17 Oil seal For exhaust camshaft pulley end Replace 3 5 2 Removing and installing exha...

Page 79: ...nstal ling Remove camshaft housing page 76 Remove intake manifold page 229 Unplug electrical connectors 1 At oil pressure switch for reduced oil pressure F378 2 at fuel pressure sender G247 3 On injec...

Page 80: ...ess of information in this document Copyright by SEAT S A Unscrew bolts arrows and detach oil supply pipe 1 and oil return pipe 2 Unplug electrical connectors 1 for coolant temperature sender G62 2 Fo...

Page 81: ...cylinder head gasket Carefully remove any remaining emery and abrasive material Do not remove new cylinder head gasket from packaging until it is ready to be fitted Handle the cylinder head gasket ve...

Page 82: ...Remaining installation sequence carried out in reverse sequence note the following Install camshaft housing page 76 Remove intake manifold page 229 Change engine oil Maintenance Booklet 501 Fill cooli...

Page 83: ...t by SEAT S A Unplug the electrical connector 1 Release hose clip 2 and disconnect hose Unplug the electrical connector 2 Remove bolts arrows and detach connection 1 Loosen the hose clip 2 remove the...

Page 84: ...and de tach Mark original positions of roller rocker fingers and compensa tion elements for reinstallation Remove roller rocker fingers together with compensation ele ments and put down on a clean sur...

Page 85: ...se se quence note the following points Install high pressure pipe page 248 Install notched belt adjusting valve timing page 89 Install ignition coils page 269 Fit the coolant pump page 162 Electrical...

Page 86: ...l temperature at least 30 C Battery voltage at least 12 5 V Remove fuse for fuel pump control unit from fuse holder Fuse installation Current flow diagrams Electrical fault finding and Fitting locatio...

Page 87: ...letely and simultaneously operate the starter until the pres sure no longer increases on the tester display Repeat procedure on each cylinder Compression pressure bar new 10 0 15 0 Wear limits 7 0 Max...

Page 88: ...loded view toothed belt page 83 2 3 Checking distribution timing page 84 2 4 Detaching toothed belt from camshaft page 89 2 5 Timing belt removing fitting tensioning page 95 2 1 Exploded view toothed...

Page 89: ...page 95 2 Bolt 25 Nm When setting the speci fied torque on the torque wrench VAS 6583 the length indicated on the insert tool T10500 must be entered in the torque wrench 3 Tensioning roller Removal a...

Page 90: ...Crankshaft pulley Contact surface between sprocket and crankshaft must be free of oil Fitting possible in one position only Bend radius of toothed belt Plug for TDC drilling in cylinder block tighteni...

Page 91: ...haft length of 250 mm not illus trated Work sequence Remove resonator for intake air 3 3 Removing and installing resonator for intake air page 227 Free air hose from air pipe Open hose clips arrows an...

Page 92: ...ress release tabs and disconnect hose 1 for activated char coal filter Remove bolts arrows and detach crankcase breather hose Remove bolts arrows and detach connection 1 Move clear electrical wiring h...

Page 93: ...insulation Rotate crankshaft to TDC as follows Remove ignition coil 1 with output stage N70 and the spark plug cylinder 1 page 269 Note Risk of damage to engine The fixing bolt T10340 has 2 stop posit...

Page 94: ...te The locking pin T10340 locks the crankshaft only in the direction of engine rotation On both camshafts asymmetrically positioned grooves top arrows on gearbox end must face upwards as shown in illu...

Page 95: ...an be fitted Valve timing is OK Note Risk of damage to engine After completing work check that locking pin T10340 and camshaft clamp T10494 have been removed Perform remaining installation steps in re...

Page 96: ...information in this document Copyright by SEAT S A Special tools and workshop equipment required Torque wrench VAS 6583 counter hold tool T10172 with adapter T10172 1 Securing bolts T10340 Counter ho...

Page 97: ...no 1 to TDC position 2 3 Checking distribution timing page 84 Remove plug and loosen securing bolt of camshaft adjuster on inlet side by approx one turn 3 3 Removing and installing camshaft adjuster...

Page 98: ...should never be below 25 mm approx half the diameter of gear 1 on crank shaft page 92 Note Renew bolts that are tightened with specified further tightening angle Renew O ring of plug if damaged Renew...

Page 99: ...indow Note Torque wrench VAS 6583 must be used for tightening When setting the specified torque on the torque wrench VAS 6583 the length indicated on the insert tool T10500 must be entered in the torq...

Page 100: ...belt page 83 using counter hold tool T10172 with adapter T10172 1 and T10172 2 Use counter hold tool T10554 1 and counter hold tool T10172 to lock camshaft in position push in clockwise direction Tig...

Page 101: ...this document Copyright by SEAT S A 2 5 Timing belt removing fitting tensioning Special tools and workshop equipment required Torque wrench VAS 6583 counter hold tool T10172 with adapter T10172 1 Sec...

Page 102: ...per 1 4 Removing and installing vibration damper page 41 Unscrew bolts arrows and remove lower toothed belt guard Note If a used toothed belt runs in the opposite direction when it is refitted this ca...

Page 103: ...er at eccentric 2 using span ner T10499 Removing notched belt Detach crankshaft sprocket 1 arrow Installing adjusting the valve timing Bend radius of toothed belt NOTICE If the radius diameter is not...

Page 104: ...nkshaft sprocket must be free of oil and grease Note Renew bolts that are tightened with specified further tightening angle Renew O ring of plug if damaged Renew bolt 2 for camshaft adjuster on inlet...

Page 105: ...in adjustment window Note Torque wrench VAS 6583 must be used for tightening When setting the specified torque on the torque wrench VAS 6583 the length indicated on the insert tool T10500 must be ente...

Page 106: ...urned to TDC position Rotate crankshaft to TDC as follows Set piston in cylinder no 1 to TDC position 2 3 Checking distribution timing page 84 Tighten bolt 1 to final specified torque 2 2 Exploded vie...

Page 107: ...torques 1 1 Exploded view poly V belt drive page 35 2 1 Exploded view toothed belt cover page 82 2 2 Exploded view toothed belt page 83 Fig Plug for TDC drilling in cylinder block tightening tor que...

Page 108: ...rview valve gear 1 Inlet valve Not to be reworked only grinding in permissible Valve dimensions page 125 Valve guides check page 124 2 Outlet valve Not to be reworked only grinding in permissible Valv...

Page 109: ...cept any liability with respect to the correctness of information in this document Copyright by SEAT S A Lubricate contact surface Position of valve spring The smaller a faces the valve spring plate T...

Page 110: ...9 Checking camshaft axial play Remove camshaft housing page 76 Secure dial gauge VAS 6079 to cam shaft housing with universal dial gauge bracket VW 387 as shown in illustration Press camshaft against...

Page 111: ...SEAT S A Torque wrench VAS 6583 Counter hold tool T10554 1 Knurled screws T10554 2 not illustrated Counter hold tool T10172A Prepare tool Bolt on counter hold tool T10172 and counter hold tool T10554...

Page 112: ...tour of the bolt circle in the cam shaft adjuster Note During opening of the plug on the inlet camshaft sprocket slight oil leakage can occur The contact points between the toothed belt and components...

Page 113: ...Risk of damage to crankshaft group Camshafts are located in TDC position The camshaft pulleys are properly aligned with each other Crankshaft is in TDC position Note Renew bolts that are tightened wit...

Page 114: ...ide to final specified torque 2 2 Exploded view toothed belt page 83 Further assembly is performed in the reverse sequence Specified torques 2 1 Exploded view toothed belt cover page 82 2 2 Exploded v...

Page 115: ...installing camshaft adjuster page 104 Loosen bolts 1 approx 1 turn using counter hold tool T10172 with adapter T10172 2 and T10172 1 Detach toothed belts from the camshafts 2 4 Detaching toothed belt...

Page 116: ...rection Tighten bolt 1 initially to 50 Nm Tighten bolt 1 initially to 50 Nm using counter hold tool T10172 with adapter T10172 2 and T10172 1 Tighten bolt 1 for camshaft adjuster to final specified to...

Page 117: ...haft oil seal pulley end page 113 3 5 3 Sealing ring on exhaust camshaft transmission side removing and installing page 114 3 5 1 Removing and installing camshaft oil seal for inlet camshaft belt pull...

Page 118: ...the guide sleeve T10478 2 this is done using the fitting sleeve T10478 3 Installation position The closed side of the oil seal points to ward the assembly sleeve Separate fitting sleeve from guide sl...

Page 119: ...A 3 5 2 Removing and installing exhaust cam shaft oil seal pulley end Special tools and workshop equipment required Assembly tool T10478 B Puller hooks T20143 Removing Remove toothed belt pulley 3 4 R...

Page 120: ...ation position The closed side of the oil seal points to ward the assembly sleeve Separate fitting sleeve from guide sleeve Fit guide sleeve T10478 2 with oil seal 1 to camshaft Pull in thrust piece T...

Page 121: ...s of information in this document Copyright by SEAT S A Assembly tool T10479 A Puller hooks T20143 Removing Remove toothed belt pulley for coolant pump page 166 Carefully fit extractor hook T20143 1 b...

Page 122: ...sleeve from guide sleeve Fit guide sleeve T10479 2 with oil seal 2 centrally to cam shaft Secure guide sleeve onto camshaft using bolt 1 for coolant pump drive sprocket Push seal onto camshaft and un...

Page 123: ...ve 1 N205 The O ring cannot be renewed individually Specified torques 1 2 Exploded view camshaft housing page 70 3 7 Removing and installing valve stem seals 3 7 1 Removing and installing valve stem o...

Page 124: ...t 3122 B Set piston of respective cylinder to bottom dead centre Fit guide plate VAS 5161A 32 onto cylinder head and secure with knurled screws VAS 5161 12 Screw adapter T40012 with seal hand tight in...

Page 125: ...Move knurled screw back and forth to press apart valve cotters and capture them in assembly cartridge Release the pressure prong Remove assembly cartridge Detach guide plate and turn to one side The...

Page 126: ...onto cylinder head Insert assembly cartridge VAS 5161A 32 1 with sleeve VAS 5161A 32 2 into guide plate Press down pressure fork and pull the knurled screw upwards while turning screw in both directi...

Page 127: ...ept any liability with respect to the correctness of information in this document Copyright by SEAT S A Engine gearbox support VAS 6095 Cylinder head tensioning device VAS 6419 Valve stem pliers VAS 6...

Page 128: ...guide plate VAS 5161A 32 onto cylinder head and secure with knurled screws VAS 5161 12 Apply drift VAS 5161 3A to guide plate and use plastic head ed hammer to release sticking valve cotter pins Scre...

Page 129: ...lve cotters have been removed from the assembly car tridge they must first be inserted into the insert tool VAS 5161A 32 3 Larger diameter of valve cotters faces upwards Press assembly cartridge VAS 5...

Page 130: ...079 Test procedure Insert a new valve in the guide The end of the valve stem should be flush with the guide On account of differing stem diameters only use inlet valve in inlet valve guide and exhaust...

Page 131: ...o the correctness of information in this document Copyright by SEAT S A 4 3 Valve dimensions Note Inlet and exhaust valves must not be reworked Only lapping in is permitted Dim Inlet valve Outlet valv...

Page 132: ...stalling oil level and oil temperature send er G266 page 137 1 1 Exploded view sump oil pump Note If large quantities of metal chips and abraded material are found during engine repair this may indica...

Page 133: ...in by hand by ap prox 3 full turns 20 Nm Checking page 144 Removing and installing page 143 7 Oil sump Removing and installing page 130 8 Oil filter 20 Nm See note page 126 If outer circumference of o...

Page 134: ...Nm 15 Suction pipe 16 Bolt 8 Nm 17 Bolt For tensioning assembly renew 20 Nm 90 18 Oil seal Replace page 46 For oil pump drive 19 Bolt renew Specified torques page 136 20 Oil pump Removing and installi...

Page 135: ...thin the printed area oil may be added c Area min marking up to screened field refill with max 0 5 l engine oil Oil drain plug with lock seal factory fitting Discard the oil drain plug with lock seal...

Page 136: ...em Tighten threaded connection 2 by tightening nut 3 Loosen and unscrew both nuts taking care not to loosen threaded connection Specified torques Threaded connection Tightening torque 2 50 Nm 1 2 Engi...

Page 137: ...with oil filter tool 3417 Remove poly V belt page 38 Only vehicles with air conditioner Note The air conditioning system lines must not be opened Prevent damage to condenser and refrigerant lines and...

Page 138: ...securing bolts arrows Unscrew sump securing bolts on gearbox side arrows using Allen key long reach T10058 Note The sump is sealed with liquid sealant Electronic parts catalogue When hardened the seal...

Page 139: ...tating brush e g an electric drill with plastic brush attachment wear eye pro tection Clean sealing surfaces They must be free of oil and grease Installation Note Observe use by date of sealant The su...

Page 140: ...aling compound dry for approx 30 minutes after installing oil sump Only then should the engine be refilled with oil Fill oil filter with engine oil and tighten it with oil filter tool 3417 Fill engine...

Page 141: ...d remove tensioning ele ment Remove alternator Electrical system Rep gr 27 Alter nator Removing and installing alternator Remove crankshaft oil seal on belt pulley end page 46 Unscrew oil pump securin...

Page 142: ...ins Specified torques Tighten new securing bolts 1 to 8 Nm 90 Tighten the bolts 2 to 20 Nm Install new crankshaft oil seal on belt pulley end page 46 Install oil pan page 130 Install alternator Electr...

Page 143: ...ng Removing Engine oil drained Maintenance Booklet 501 Unplug the electrical connector 3 Unscrew bolts 1 and remove oil level and oil temperature sender G266 item 4 Installation Installation is carrie...

Page 144: ...ne oil cooler page 138 2 2 Removing and installing engine oil cooler page 138 2 1 Assembly overview engine oil cooler 1 Engine oil radiator See note page 126 Removing and installing page 138 Renew coo...

Page 145: ...Unscrew bolts arrows and detach engine oil cooler 1 Installation Insert new O rings Installation is carried out in the reverse order Please note the following Install intake manifold page 229 Fill up...

Page 146: ...oil separator page 141 3 1 Exploded view crankcase breather system 1 Flexible pipe For crankcase breather 2 Cover For oil separator 3 Oil separator Removing and installing page 141 Replace if damaged...

Page 147: ...e insulation Unscrew bolts arrow and push charge air cooling pump V188 to one side Disconnect crankcase breather hose 3 Release fasteners 2 arrow on cover 1 for oil separator and detach cover Slacken...

Page 148: ...il separator as shown in illustration Width of the sealant line 2 mm The oil separator must be installed within 5 minutes after applying the sealant Place oil separator over studs and support on engin...

Page 149: ...sure switches 1 Oil filter See note page 126 Removing and installing Maintenance Book let 501 20 Nm If the connecting union for oil filter in sump be came loose page 130 2 Oil pressure switch for re d...

Page 150: ...aping engine oil Unscrew oil pressure switch for reduced oil pressure F378 1 Installation Installation is carried out in the reverse order Please note the following Note Insert the new oil pressure sw...

Page 151: ...ssure tester V A G 1342 to seal it off Start engine Oil pressure at idling speed at least 0 6 bar Oil pressure at 2 000 rpm at least 1 5 bar Oil pressure at 4500 rpm at least 2 8 bar Note Low oil pres...

Page 152: ...ngine oil Remove oil filter arrow with oil filter tool 3417 Installation Fill oil filter with engine oil and moisten seal with oil Tighten oil filter with oil filter tool 3417 If the connecting union...

Page 153: ...3 Check the cooling system for leaks page 155 1 1 Connection diagram coolant hoses 1 1 1 Circuit diagram coolant hoses vehicles June 2013 page 147 1 1 2 Circuit diagram coolant hoses vehicles June 201...

Page 154: ...re send er G62 8 Coolant pump With thermostat hous ing 9 Engine oil radiator 10 Radiator outlet coolant temperature sender G83 11 Radiator Renew coolant after re placing 12 Charge air cooling pump V18...

Page 155: ...urbocharger 5 Integrated exhaust manifold 6 Heat exchanger for heater Renew coolant after re placing 7 Coolant temperature send er G62 8 Coolant pump With thermostat hous ing 9 Engine oil radiator 10...

Page 156: ...SEAT S A 1 2 Draining and filling coolant Special tools and workshop equipment required Refractometer T10007 A Drip tray for workshop hoist VAS 6208 Hose clip pliers VAS 6340 Cooling system charge uni...

Page 157: ...rior Rep gr 66 Noise insulation Removing and installing noise insulation Set drip tray for workshop hoist VAS 6208 underneath Disconnect connector 2 from radiator outlet coolant temper ature sender G8...

Page 158: ...icularly in countries with tropical climates ONLY refractometer T10007A may be used for determining current anti freeze value The normal frost protection must be to at least 25 C in coun tries with Ar...

Page 159: ...of premixed coolant according to recommended ratio Screw down adapter for cooling system tester V A G 1274 8 to coolant expansion tank Connect cooling system charge unit VAS 6096 to adapter V A G 1274...

Page 160: ...equent filling Note If the needle does not reach the green zone repeat the proc ess If the vacuum drops the cooling system must be checked for leaks Pull off compressed air hose Open valve A The vacuu...

Page 161: ...essure on the cooling system With the engine running fill with coolant up to approx 5 mm above the Max mark When the engine is cold the coolant level must be between the Min mark and the Max mark When...

Page 162: ...ng hand pump on tester build up a positive pressure of approx 1 5 bar The pressure must not drop by more than 0 2 bar within 10 mi nutes If pressure drops by more than 0 2 bar locate leaks and rectify...

Page 163: ...and installing coolant temperature sender page 171 2 8 2 Removing and installing coolant temperature sender at radiator outlet G83 page 172 2 1 Exploded view coolant pump and thermostat 1 Thermostat...

Page 164: ...coolant pump For coolant pump drive Removing and installing page 162 10 Toothed belt sprocket For coolant pump drive Removing and installing page 166 Before removing the cylinder 1 must be moved to TD...

Page 165: ...large cooling circuit Must be positioned with centring pin in guide arrow in ther mostat housing Thermostat housing to coolant pump tightening torque and se quence Tighten bolts in the sequence A F t...

Page 166: ...or accept any liability with respect to the correctness of information in this document Copyright by SEAT S A 1 Charge air cooling pump V188 With holder Removing and installing page 166 2 Coolant hos...

Page 167: ...ht by SEAT S A 2 3 Exploded view coolant temperature sensors 1 O ring renew 2 Radiator outlet coolant tem perature sender G83 Removing and installing page 172 3 Support ring 4 O ring renew 5 Coolant t...

Page 168: ...equipment required Refractometer T10007 A Drip tray for workshop hoist VAS 6208 Hose clip pliers VAS 6340 Cooling system charge unit VAS 6096 Adapter for cooling system tester V A G 1274 8 Torque wren...

Page 169: ...breaking off Remove air intake pipe 2 2 Removing and installing the air intake pipe page 199 Press release buttons and disconnect hose 1 leading to ac tivated charcoal filter Seal all openings in cha...

Page 170: ...h the hose clips corresponding to original equipment Electronic parts catalogue Ensure proper seating of gaskets arrows Lubricate seal for coolant pump lightly with coolant Note Always adhere to the s...

Page 171: ...ave a second mechanic tighten securing bolts 2 1 and 5 to specified torque while your are keeping the torque wrench VAS 6583 pushed to that torque Pre load coolant pump While doing so have a second me...

Page 172: ...e toothed belt pulley 2 Installation Installation is carried out in the reverse order Please note the following Fitting toothed belt pulley The grooves 1 and 2 in the camshaft are arranged asym metric...

Page 173: ...coolant expansion tank CAUTION The cooling system is under pressure when the engine is hot Hot steam hot coolant can escape risk of scalding Risk of scalding to skin and body parts Wear protection glo...

Page 174: ...lease note the following Note Secure all hose connections with the hose clips corresponding to original equipment Electronic parts catalogue Install front noise insulation General body repairs exterio...

Page 175: ...se 1 Pull connector off charge pressure sender GX26 Note Make sure to use the new tools to prevent the locking lugs of the air intake pipe from breaking off Remove air intake pipe 2 2 Removing and ins...

Page 176: ...special wrench T10508 and turn it to stop in direction of arrow while doing so Installation is carried out in the reverse order Please note the following Note Renew gasket Moisten gasket with coolant...

Page 177: ...page 162 Fill up with coolant page 150 Specified torques Fig Thermostat housing to coolant pump tightening tor que and sequence page 159 2 8 Removing and installing coolant temper ature sender 2 8 1...

Page 178: ...void loss of coolant Installation Installation is carried out in the reverse order Please note the following Note Replace the O ring Check the coolant level page 155 Specified torques 2 3 Exploded vie...

Page 179: ...radiator outlet coolant tem perature sender G83 out of connection 3 Installation Installation is carried out in the reverse order Please note the following Note Replace the O ring Insert new coolant t...

Page 180: ...ed view coolant pipes 1 Coolant hose 2 Coolant pipe Clipped onto intake manifold bottom Carefully lever it out of catches using a screw driver when removing 3 Bolt 8 Nm 4 Coolant hose 5 Coolant hose 6...

Page 181: ...p pliers VAS 6362 Removing CAUTION The cooling system is under pressure when the engine is hot Hot steam hot coolant can escape risk of scalding Risk of scalding to skin and body parts Wear protection...

Page 182: ...nch as shown Place e g a block of wood 2 under the intake manifold as an underlay Note To avoid damaging the intake manifold and coolant pipe this pro cedure must be carried out very carefully Insert...

Page 183: ...ages Check that the coolant pipe has properly engaged by pulling on it Installation is carried out in the reverse order Please note the following Note Renew gaskets and O rings Secure all hose connect...

Page 184: ...Removing and installing radiator fans page 187 4 1 Exploded view radiator radiator fans 1 Radiator Removing and installing page 180 Renew coolant after re placing 2 Coolant hose Lift the retaining cl...

Page 185: ...nditioning Rep gr 87 Refrigerant circuit Removing and installing condenser 15 Bonded rubber bush for radiator 16 O ring renew 17 Coolant hose Lift the retaining clip to remove Connecting page 179 18 O...

Page 186: ...ocument Copyright by SEAT S A 4 2 Exploded view radiator cowl and radiator fans 1 Bolt 5 Nm 2 Fan shroud Removing and installing page 187 3 Radiator fan V7 Removing and installing page 187 4 3 Removin...

Page 187: ...tor Use the removal wedge to press both sides of locking tab 1 away from the engine compartment 3409 and push the radiator in the direction of the arrow Pull radiator out of mountings at bottom Remove...

Page 188: ...sure proper engage ment by pulling Install radiator cowl page 187 Connect coolant hose with plug in connector page 179 Fill up with coolant page 151 Specified torques 4 1 Exploded view radiator radiat...

Page 189: ...09 and push the radiator in the direction of the arrow Pull radiator out of mountings at bottom Remove radiator from water radiator for charge air cooling cir cuit Remove coolant radiator upwards Remo...

Page 190: ...r from the lower supports and press back wards Press catches 1 on both sides in direction of arrow A to release them Pull condenser 3 in direction of arrow B and detach it from charge air cooler 2 Tie...

Page 191: ...the correctness of information in this document Copyright by SEAT S A Engage radiator in charge air cooler Ensure proper engage ment by pulling Insert radiator module 1 at bottom into radiator mounti...

Page 192: ...off to lock carrier Screws 2 ETKA elec tronic spare parts catalogue Tightening torque 5 Nm Continued procedure for all vehicles Install the front headlights Electrical System Rep gr 94 Headlights Ass...

Page 193: ...ress down release catch Press locking tabs on left and right sides of radiator cowl arrow B and at the same time lift radiator cowl off radiator For this purpose turn the fan guard upwards by approxim...

Page 194: ...document Copyright by SEAT S A Unplug the electrical connector Unscrew bolts arrows and remove radiator fan V7 Installation Installation is carried out in the reverse order Please note the following...

Page 195: ...pressor removing and fitting page 191 1 3 Removing and installing charge pressure positioner V465 page 195 1 1 Exploded view turbocharger 1 Turbocharger Removing and installing page 191 2 Bolt 8 Nm 3...

Page 196: ...new Note Bolts are provided with a coating They must be renewed after remov al 5 Nm 10 O ring If there is damage re place hose for crank case breather Item 11 page 190 Lubricate lightly with engine oi...

Page 197: ...ocument Copyright by SEAT S A 16 Coolant lines Supply and return 17 Bolt 8 Nm 18 O ring renew Lubricate lightly with engine oil 19 Bolt 9 Nm 1 2 Turbo compressor removing and fitting Special tools and...

Page 198: ...r The following work must be performed in order to avoid further damage Check air cleaner housing air filter element and air hoses for dirt and foreign particles Check the whole charge air path and ch...

Page 199: ...d installing resonator for intake air page 227 Free air hose from air pipe Open hose clips arrows and remove air hose 1 Pull connector off charge pressure sender GX26 Note Make sure to use the new too...

Page 200: ...ector 2 Remove bolts arrows and detach connection 1 Loosen the hose clip 2 remove the coolant hose Remove bolts arrows and swivel coolant lines 1 to right Unscrew bolts arrows and remove bracket with...

Page 201: ...ctronic parts catalogue After installing turbocharger run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger It is important not to operate the engine at higher s...

Page 202: ...g tool T40265 Remove bolts arrows and detach charge pressure positioner V465 Installation Installation is carried out in the reverse order Please note the following Renew securing bolts for charge pre...

Page 203: ...arge air system Note Check all air hoses and pipes for firm seating and leaks before carrying out tests or repairs Observe rules for cleanliness page 4 1 Coolant hose 2 Bolt Thread forming Fit and scr...

Page 204: ...installing lightly moisten O ring with clean engine oil 17 O ring renew Before installing lightly moisten O ring with clean engine oil 18 Bolt Thread forming Fit and screw in bolt by hand so that it i...

Page 205: ...orques 1 Hose clip a 13 mm wide 5 5 Nm 2 Hose clip b 9 mm wide 3 Nm 2 2 Removing and installing the air intake pipe Special tools and workshop equipment required Release tool T10527 Release tool T1052...

Page 206: ...sender GX26 comprises Charge air regulator G31 Intake air temperature sensor G42 Removing Unplug the electrical connector 1 Release fasteners arrows remove charge pressure sender GX26 Installation In...

Page 207: ...o 25 mm 3094 Drip tray for workshop hoist VAS 6208 Hose clip pliers VAS 6362 Removing Remove radiator cowl page 187 Remove from the air conditioner compressor arrow and tie up Rep gr 87 Air conditione...

Page 208: ...the reverse order Please note the following Fit sealing lip 1 in direction of arrow onto charge air cooler 2 Insert new gasket into groove on intake manifold Tighten bolts arrows alternately and diago...

Page 209: ...yright by SEAT S A Charge air system tester V A G 1687 Work sequence Remove resonator for intake air 3 3 Removing and installing resonator for intake air page 227 Connect the adapter V A G 1687 15 wit...

Page 210: ...0 5 bar Adjust pressure to 0 5 bar via pressure control valve 2 Open valve 4 and wait until test circuit is full If necessary adjust pressure to 0 5 bar again Check the charge air system for leaks by...

Page 211: ...ng locations engine intake side page 207 1 1 3 Overview of fitting locations engine exhaust side page 208 1 1 1 Fitting location overview injection system engine compartment 1 Camshaft control valve 1...

Page 212: ...ower control G187 Throttle valve drive angle sender 2 electric power control G188 Exploded view page 228 9 Charge air pressure sender GX26 comprising Charge air regulator G31 Intake air temperature se...

Page 213: ...Oil pressure switch for re duced oil pressure F378 Exploded view page 143 3 Fuel pressure sender G247 Exploded view page 210 4 Activated charcoal filter sol enoid valve 1 N80 5 Injectors Cylinder 1 i...

Page 214: ...ng page 171 1 2 Reducing fuel pressure in high pressure section CAUTION The fuel system is under high pressure Risk of injury due to fuel which may spurt out Release high pressure Special tools and wo...

Page 215: ...ssure area must immediately be opened To do this wrap a clean cloth around the connection Catch the escaping fuel Note The pressure will increase again due to the effect of residual heat if the high p...

Page 216: ...o not lubricate thread 22 Nm 2 Fuel rail Removing and installing page 211 3 High pressure pipe 1 2 Reducing fuel pressure in high pres sure section page 208 Connections must not be damaged Do not alte...

Page 217: ...and installing fuel rail Removing CAUTION The fuel system is under high pressure Risk of injury due to fuel which may spurt out Release high pressure 1 2 Reducing fuel pressure in high pressure sectio...

Page 218: ...sealing surfaces in the fuel rail must be free of scoring or scratches Otherwise renew the component Apply mountings on fuel rail onto injectors Press fuel rail onto injectors as far as stop first on...

Page 219: ...type production date and injection pressure injectors from different suppliers may be used Identify the part number or the relevant supplier as follows page 213 Allocation is done using Electronic par...

Page 220: ...s document Copyright by SEAT S A Removing fuel rail 2 2 Removing and installing fuel rail page 211 Remove O ring 3 from injector 1 Unplug electrical connector from corresponding injector Lever support...

Page 221: ...ll can t be pulled out remove the puller Use the impact sleeve again to loosen the injector Repeat procedure for each injector Note Observe correct torque to avoid irreparable damage to injec tor The...

Page 222: ...spacer ring if damaged When re installing an injector clean any combustion residue off groove for combustion chamber ring seal and injector stem with a clean cloth Fit assembly cone T10133 5 with new...

Page 223: ...spacer ring 2 onto injector 1 Before installing new injector 1 lubricate new O ring 3 light ly with clean engine oil Note The combustion chamber ring seal 8 must not be lubricated Push injectors by h...

Page 224: ...icle type production date and injection pressure injectors from different suppliers may be used Identify the part number or the relevant supplier as follows page 218 Allocation is done using Electroni...

Page 225: ...rmation in this document Copyright by SEAT S A Removing fuel rail 2 2 Removing and installing fuel rail page 211 Remove O ring 3 from injector 1 Unplug electrical connector from corresponding injector...

Page 226: ...d out remove the puller Use the impact sleeve again to loosen the injector Repeat procedure for each injector Note Observe correct torque to avoid irreparable damage to injec tor The combustion chambe...

Page 227: ...l and injector stem with a clean cloth Fit assembly cone T10133 5 with new combustion chamber ring seal 1 onto injector 2 Push combustion chamber ring seal onto assembly cone T10133 6 as far as it wil...

Page 228: ...ean engine oil Note The combustion chamber ring seal 8 must not be lubricated Push injectors by hand as far as they will go into the hole of the cylinder head must be free of oil and grease Ensure the...

Page 229: ...epending on the vehicle type production date and injection pressure injectors from different suppliers may be used Ultrasonic cleaning is only permissible for injectors from Con tinental Identify the...

Page 230: ...1 item 2 Immerse injectors together with mounting plate for injection modules VAS 6418 1 into cleaning fluid VAS 6418 2 Set rotary knob 4 to a temperature of 50 C Select a cleaning time of 30 minutes...

Page 231: ...On lock carrier 3 Cover for air duct 4 Bolt 2 Nm 5 Air cleaner bottom section Clean out dirt leaves and salt deposits 6 Air filter element Use only genuine air fil ter elements Elec tronic Parts Cata...

Page 232: ...ss of power as the calculated injection quantities will be too low Use original air filter The air filter housings must be clean Hose unions and air intake pipes hoses must be free of oil and grease w...

Page 233: ...rmation in this document Copyright by SEAT S A 3 3 Removing and installing resonator for intake air Removing Open hose clips 1 and 2 Remove resonator for intake air Installation Reassembly is carried...

Page 234: ...e manifold 2 Intake manifold Combined with charge air cooler Removing and installing page 229 3 Coolant pipe Clipped onto intake manifold 4 Bolt Tightening torque and sequence page 229 5 O ring renew...

Page 235: ...rottle valve drive electric power control G186 Throttle valve drive angle sender 1 electric power control G187 Throttle valve drive angle sender 2 electric power control G188 Removing and installing p...

Page 236: ...hose 1 CAUTION The fuel system is pressurised Risk of injury due to fuel which may spurt out Use safety goggles Wear protection gloves Release pressure place clean cloth around connection and carefull...

Page 237: ...ke pipe 2 2 Removing and installing the air intake pipe page 199 Release the fastener arrow remove the vacuum hose 1 Remove screw 1 release upper clips arrows a remove coolant hoses Unplug electrical...

Page 238: ...and O rings Install front noise insulation General body repairs exterior Rep gr 66 Noise insulation Removing and installing noise insulation Install air cleaner housing page 226 Fill up with coolant...

Page 239: ...ctrical connector 3 Unscrew bolts arrows and remove throttle valve module GX3 1 with adapter 2 Installation Installation is carried out in the reverse order Please note the following After throttle va...

Page 240: ...is highly flammable and may cause eye and skin irritation Use safety goggles Wear protection gloves Clean throttle valve housing thoroughly especially around the points arrows where the throttle valv...

Page 241: ...d pressure sender G71 Removing Remove air cleaner housing page 226 Disconnect electrical connector arrow Release fasteners and remove intake manifold sender GX9 Installation Installation is carried ou...

Page 242: ...2 using socket 27 mm T40218 Installation Installation is carried out in the reverse order Please note the following Note Do not lubricate thread of fuel pressure sender Specified torques 2 1 Assembly...

Page 243: ...08 Note Risk of functional impairment due to soiling Observe the 2 1 Safety precautions when working on fuel supply sys tem page 2 Remove fuel pressure sender G247 page 235 Lubricate taper seal of ada...

Page 244: ...ured values Select Fuel pressure from the list Compare pressure displayed on tester VAS 6394 1 with ac tual value displayed on vehicle diagnosis tester Observe fuel pressure displayed on vehicle diagn...

Page 245: ...ing engine control unit J623 with protective housing page 241 6 1 1 Removing and installing engine control unit J623 with metal locking plate Special tools and workshop equipment required Repair set f...

Page 246: ...g battery Release retaining clip arrow and take out engine control unit J623 Make groove for a screwdriver in head of shear bolt 1 using a small grinder 2 Note The threads of the shear bolts are secur...

Page 247: ...er Please note the following The metal locking plate must always be re fitted on the engine control unit J623 Clean threaded holes for shear bolts to remove any residue from locking fluid This can be...

Page 248: ...iagnosis tester in Guided functions mode Switch off ignition and remove key Note If the engine control unit comes into contact with the positive battery terminal permanent damage to the engine control...

Page 249: ...fore be heated with the hot air blower Set the hot air blower as shown in illustration Meaning poten tiometer for temperature regulation 2 set to maximum heat ing power and 2 stage switch for air volu...

Page 250: ...order Please note the following Make sure you fit protective housing back on engine control unit J623 Clean threaded holes for shear bolts to remove any residue from locking fluid This can be done us...

Page 251: ...er tappet When installing lubri cate lightly with clean engine oil 2 O ring renew When installing lubri cate lightly with clean engine oil 3 High pressure pump With fuel metering valve N290 Do not dis...

Page 252: ...8 Check for damage be fore re installing Do not alter shape Connections must not be damaged Lubricate threads of un ion nuts with clean en gine oil 16 Nm 45 5 Bolt renew Tightening torque and sequence...

Page 253: ...sure pipe page 248 Unplug the electrical connector 1 Note Use cloth to catch escaping fuel Release hose clip 2 and detach fuel supply hose Unscrew bolts 3 and detach high pressure pump with roller tap...

Page 254: ...rkshop equipment required Torque wrench VAS 6854 Tool set T10395 A Removing Remove throttle valve control unit GX3 page 232 CAUTION The fuel system is under high pressure Risk of injury due to fuel wh...

Page 255: ...ote the following Lubricate threads of union nuts with clean engine oil Initially tighten union nuts for high pressure pipe by hand on high pressure pump make sure that pipe is not under ten sion Note...

Page 256: ...rature paste Electronic parts catalogue ETKA When re installing the electric wire of the lambda sensor it is important that these are connected to the same locations Contact of the electric wires with...

Page 257: ...Lambda sensor G39 Lambda probe heater Z19 Lambda probe 1 after catalytic converter GX7 comprises Lambda probes after the catalytic converter G130 Lambda probe heater 1 after catalytic converter Z29 S...

Page 258: ...ing Note New Lambda sensors are coated with an assembly paste The paste must not get into the slots on the Lambda probe body In the case of a used Lambda probe grease only the thread with high tempera...

Page 259: ...del page 253 1 1 2 Assembly overview silencer Leon ST page 255 1 1 1 Assembly overview silencers Leon SC 5 door model 1 Holder Replace if damaged 2 Bolt 20 Nm 3 Mounting A Replace if damaged Only for...

Page 260: ...free of stress page 261 Aligning mounting A Pre tighten bolt Arrange hanger over the long hole bore Using blunt side of commercially available 8 mm drill bit align holes of mounting A centrally and pe...

Page 261: ...nit with rear silencer as original equipment Can be renewed individually for repair purposes Removing and installing page 259 Disconnecting exhaust pipes silencers page 257 Aligning exhaust sys tem fr...

Page 262: ...Aligning page 257 11 Holder Replace if damaged 12 Bolt M8 x 25 20 Nm Aligning mounting A Pre tighten bolt Using blunt side of commercially available 8 mm drill bit align holes arrows of mounting A ce...

Page 263: ...position shown Angle approx 20 Bolt connections face to rear Nuts facing upwards 1 2 Disconnecting exhaust pipes silencers 1 2 1 Separating exhaust pipe silencer Leon SC 5 door mod el page 257 1 2 2...

Page 264: ...ition clamp centrally at side marks arrows when instal ling Fit rear clamp page 257 Align exhaust system without tension page 261 1 2 2 Disconnecting exhaust pipes silencers Leon ST The connecting pip...

Page 265: ...haust system to be free of stress page 261 1 3 Removing and installing silencers 1 3 1 Removing and installing front silencer page 259 1 3 2 Removing and installing rear silencer page 260 1 3 1 Removi...

Page 266: ...terior Rep gr 50 Underbody trim Assembly overview underbody trim panels 1 3 2 Removing and installing rear silencer Removing CAUTION Risk of accident caused by high weight of silencers Seek help from...

Page 267: ...Align exhaust system to be free of stress page 261 Specified torques 1 1 Exploded view silencers page 253 2 1 Assembly overview emission control page 263 General body repairs exterior Rep gr 66 Underb...

Page 268: ...ncers page 253 Specified torques 2 1 Assembly overview emission control page 263 1 4 2 Aligning tailpipes Work sequence Align rear silencer so that there is an equal distance a and b between bumper cu...

Page 269: ...ue and sequence page 264 9 Bolt Tightening torque and sequence page 264 10 Front exhaust pipe with catalytic converter Do not bend decoupling element more than 10 It may be damaged Install decoupling...

Page 270: ...acing towards right Nuts facing upwards Installing catalytic converter tightening torque and sequence 1 Fit catalytic converter to tur bocharger attach screw type clip arrow without tightening 2 Loose...

Page 271: ...rical wiring clear Note Prior to loosening the connection between the catalytic con verter and the turbocharger mark position of the clamp page 265 According to the part which is to be replaced the pa...

Page 272: ...Unscrew right nut arrow of bracket Unscrew left nut arrow of bracket Remove heat shield General body repairs exterior Rep gr 66 Underbody cover Assembly overview underbody panels Remove bolts arrows D...

Page 273: ...n the exhaust turbocharger and remove ring seal 1 Installation Installation is carried out in the reverse order Please note the following Note Renew seal and self locking nuts Coat studs and bolts on...

Page 274: ...stalling engine speed sensor G28 page 272 1 1 Assembly overview ignition system 1 Bolt Tightening torque influ ences functions of knock sensor 20 Nm 2 Knock sensor 1 G61 Removing and installing page 2...

Page 275: ...eed sender G28 Removing and installing page 272 12 Bolt 4 5 Nm 1 2 Spark plug test data Engine codes CJZA CJZB CYVA CYVB Order of starting 1 3 4 2 Spark plugs Part number 1 04E 905 601 Electrode gap 0...

Page 276: ...nables the plugs to be released easily when the engine is hot Ignition coils with output stage and spark plug connectors are available individually for repairs ETKA Electronic Parts Catalogue Removing...

Page 277: ...ock sensor Removing Remove from the air conditioner compressor from the bracket and tie it up Heating air conditioner Rep gr 87 Air con ditioner compressor Removing the air conditioner from the bracke...

Page 278: ...ation is in the reverse sequence of removal Specified torques 1 1 Assembly overview ignition system page 268 1 6 Removing and installing engine speed sensor G28 Special tools and workshop equipment re...

Page 279: ...Note Carefully insert engine speed sender G28 in bore This will prevent the engine speed sender G28 from falling between engine and gearbox Installation is in the reverse sequence of removal Install...

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