S01BBZG8W20-3 Cylinder Petrol Engine (1 2 L)

Service
Workshop Manual
Ibiza 2008 ➤
Ibiza ST 2010 ➤
Toledo 2013 ➤
3 cylinder Petrol
permitted unless authorisedengine
by SEAT S.A. SEAT (1.2 l)not guarantee or accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
S.A does
CGP BZG CGP
Engine ID
CGP CJLB
respect to the correctness of information in this document. Copyright by SEAT S.A.
C A B
Edition 04.2016
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Seat S.A S01BBZG8W20

Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
3 cylinder Petrol engine (1.2 l) - Edition 04.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing and positioning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Detaching engine from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Attaching engine to repair stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Vehicles with air conditioning/heating: additional instructions and assembly information . . 13
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Engine assembly brackets: tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Engine: assembly and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
1.1 unless
permitted Partauthorised
I Timing beltS.A.
by SEAT system
SEAT S.A- does
Assembly overview
not guarantee or accept any .liability
. . . with
...
........................... 15
1.2 Part II Chain control - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.4 Removing and fitting the distribution casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Engine block, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Crankshaft oil seal- pulley side: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Crankshaft oil seal, flywheel side: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.2 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.3 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Checking distribution timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.5 Removing and fitting the distribution chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.6 Distribution timing: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2 Valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.4 Valve guides: verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5 Replacing valve shaft seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Oil filter - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.4 Oil filter element: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.5 Removing and replacing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.6 Oil pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.7 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Contents i
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.1 Cooling system components, bodywork side - Assembly overview . . . . . . . . . . . . . . . . . . 81
1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 83
1.3 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.4 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Thermostat housing, removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.6 Thermostat: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.7 Radiator fan V7 : removal and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1 Fuel supply system components . . permitted . . . . .unless
. . . .authorised
. . . . .by. SEAT
. . . .S.A.
. . SEAT
. . . S.A
. . does
. . .not
. .guarantee
. . . . . or. accept
. . . .any
. liability
98 with
1.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1.2 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.5 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.6 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.7 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.8 Fuel filter: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.9 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.10 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.11 Fuel delivery system: bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2 Electronic regulation of engine output, electronic accelerator . . . . . . . . . . . . . . . . . . . . . . 125
2.1 functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.2 Electronic power control (EPC) - Components overview . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.1 functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.2 Activated charcoal filter system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.3 Activated charcoal filter system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.5 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.1 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.5 Intake manifold - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.6 Remove and install the inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.7 Fuel rail with injection valves - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.8 Removing and installing fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.9 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.10 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.11 Replace the Teflon seal and support washer on the injection valve . . . . . . . . . . . . . . . . . . 145
1.12 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.13 Removing and replacing air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.14 Throttle valve control unit J338 : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.15 Throttle valve module J338 : clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
ii Contents
2.2 Vehicles with anti-theft secured engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.3 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.4 Interrogating and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . 158
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Exhaust manifold with catalytic converter, exhaust pipe with pre-silencer and accessories -
Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Silencers with suspension elements - Components overview . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Silencers with suspension elements - Components overview . . . . . . . . . . . . . . . . . . . . . . 162
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.1 General information about the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.2 Ignition system components - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.5 Spark plug test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2 Conversion table by relevance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.1 Graphical information on the use and VW units, Seat equivalents . . . . . . . . . . . . . . . . . . 170
2.2 Graphical information of equivalent tools and equipment at VW/Audi . . . . . . . . . . . . . . . . 178
Contents iii
iv Contents
00 – Technical data
1 Technical data
(ERL003052; Edition 04.2016)
⇒ “1.1 Engine number”, page 1 .
1.1 Engine number

The engine number “engine code” and “serial number” is en‐
graved on the front of the engine block, gearbox side, below the
thermostat housing.
The engine code is also on the vehicle data plate and on engine
block above the gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (3 identification letters max.) makes up the
“engine code”; and the second part (6 characters) the “serial
number”. If more than 999,999 engines with the same engine
identification letters are produced, the first of the six characters is
replaced with a letter.
Engine identification BZG CGPA CGPB CGPC CJLB

characters
Emissions fulfil EU4 EU5 EU5 EU5 EU4
Ca‐ cm 3 1198 1198 1198 1198 1198
pacity
Out‐ kW / rpm 51/5400 51/5400 44/5200 55/5400 51/5400
put
Tor‐ Nm / rpm 112/3000 112/3000 108/3000 112/3750 108/3000
que
Bore: ∅ mm 76,5 76,5 76,5
76,5 76,5
Stroke mm 86,9 86,9 86,9 86,9 86,9
Compression: 10,4 10,4 10,4 10,4 10
Valves per cylinder 4 4 4 4 4
RON min. 95 octane un‐ 95 octane un‐ 95 octane un‐ 95 octane un‐ 95 octane un‐
leaded (in ex‐ leaded (in ex‐ leaded (in ex‐ leaded (in ex‐ leaded (in ex‐
ceptional ca‐ ceptional ca‐ ceptional ca‐ ceptional ca‐ ceptional ca‐
ses, 91 octane ses, 91 octane ses, 91 octane ses, 91 octane ses, 91 octane
as a minimum, as a minimum, as a minimum, as a minimum, as a minimum,
but with a loss but with a loss but with a loss but with a loss but with a loss
of power) of power) of power) of power) of power)
Injection, ignition Simos Simos 3PG Simos 3PG Simos 3PG Simos
system
Order of starting 1-3-2 1-3-2 1-3-2 1-3-2 1-3-2
Exhaust gas recircu‐ No No No No No
lation
1. Technical data 1
10 – Removing and installing engine

1 Engine
⇒ “1.1 Removing and positioning the engine”, page 2 .
⇒ “1.2 Detaching engine from gearbox”, page 10
⇒ “1.3 Attaching engine to repair stand”, page 11
⇒ “1.4 Vehicles with air conditioning/heating: additional instruc‐
tions and assembly information”, page 13 .
⇒ “1.5 Tightening torques”, page 13 .
⇒ “1.6 Engine assembly brackets: tightening torques”,
page 14
1.1 Removing and positioning the engine

♦ Removing ⇒ page 3
♦ Installing ⇒ page 9
Consult the equivalence table for tools and equipment according
to applicability among Seat / VW / Audi / Skoda ⇒ page 168 .
Special tools and workshop

equipment required
♦ Lifting tackle - 2024 A- , see
equivalent ⇒ page 168
♦ Installation device -
T10038-
♦ Guide pins - T10093-
♦ Workshop crane - VAS
6100- , see equivalent
⇒ page 168
♦ Collector tray for workshop
crane - VAS 6208- , see
♦ Base - VAS 6340- , see
2 Rep. gr.10 - Removing and installing engine

Removing
Note
♦ The engine is removed upwards together with the gearbox.

♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing

and installing battery .
– Remove air filter ⇒ page 149 .
– Remove nuts -1- and the bolt -2- and remove the support from
the battery lifting upwards.
– Disconnect the engine cable harness connector -1- from the

engine control unit - J623- .
– Open the cable guide catches on the sill.
– Disconnect connection -3- from the engine wiring harness.
– Remove the engine cable harness from the cable guide and
place it on the engine.
Vehicles with anti-theft engine control unit
– Remove engine control unit ⇒ page 153 .
All vehicles (continued)
– Remove the gear selection mechanism: ⇒ 5-speed manual
gearbox 02T; Rep. gr. 34 ; Gear selection mechanism: Re‐
pairing
– Unscrew the bolts -arrows- and remove the slave cylinder; do

not open the pipe system.
WARNING
Do not depress clutch pedal after removing slave cylinder.
1. Engine 3
– Separate the pressure hose -arrow- in the servo-brake ampli‐

fier.
– Open and close expansion tank cap to release pressure in
cooling system.
WARNING
The fuel feed line is pressurized! Wear eye protection and

gloves to avoid injuries and skin contact. Before loosening
hose connections, wrap a cloth around the connection. Then
eliminate the pressure by carefully separating the pipe.
– Remove the fuel supply line and venting tube -arrows-.

– Cover the disconnected fuel lines immediately to avoid the
penetration of dirt into the fuel system.
– Observe rules for cleanliness ⇒ page 105 .
– Unscrew earth connection -1-.

– Separate the wires-2- and -3- at the control pedal.
– Remove the securing bolts -arrows- and remove the engine

anti-splash cover.
– Drain coolant ⇒ page 85
– Pull coolant hoses off radiator ⇒ Item 2 (page 82) and
⇒ Item 3 (page 82) .

– Disconnect the coolant hoses -2- and -3- to the heating heat
exchanger by releasing the spring type clips.
– Screw out bolts -arrows-.
Note
Disregard item -1-.
– Remove the expansion tank and place it on the engine.
– Disconnect the DF cable connector -1- and remove the pro‐

tection -2-.
– Unbolt the battery positive cable -arrow- of the alternator.

– Remove the front bumper ⇒ Trim on front bumper: remove
and install; Rep. gr. 63 ; General body repairs, exterior .
– Bring lock plate carrier into service position: ⇒ Lock carrier in
service position; Rep. gr. 50 ; Bodywork, exterior fitting work .
Vehicles with air conditioning/heating
– Follow the additional instructions and assembly work
⇒ page 13 .
– Removing poly V-belt ⇒ page 19 .
1. Engine 5
– Unplug the connector -1- and move the cable to one side.
– Unscrew the attachment bolts -arrows- (25 Nm).
Note
♦ Do not open the air conditioning pipes.

♦ Check that the conducts have not been bent.
– Fasten the compressor to the lock carrier using the counter‐

hold - T10038- .
– Disconnect the connector from the thermo-switch and the
coolant fan - V7- .
– Unscrew nuts -arrows- and remove support together with ca‐

ble harness.
– Unscrew bolt -1- and nut -3- and remove support -2-.
– Remove the front exhaust tube from the exhaust manifold %
page
– Disconnect electrical connection of the lambda probe - G39- .
– Disconnect electrical connection of the lambda probe after
catalytic converter - G130- .

– Unscrew nut -arrows-.
– Remove the electric connector -1- from the reverse gear

switch of the gearbox.
– Remove theunless
permitted support -2-byand
authorised SEATmove the
S.A. SEAT S.Acable
does notto one side.
guarantee or accept any liability with
– Unbolt left and right half shafts from gearbox flange or the in‐
termediate bearing.
– Tie the left half-shaft leaving it suspended.
– Turn the steering toward the right.
– Tilt the right-half shaft forwards and strap it to the sill -arrow-,
as shown in the image.
– Unscrew bolts -arrows- and remove pendulum arm support.
Caution
Bolt -1- must not be loosened.
1. Engine 7
– Hook the counterhold - 2024 A- as described below and lift

slightly with the workshop crane.
Pulley side: First hole of the perforated flange in position 2.
Flywheel side: 2nd hole in hook rail at position 6.
Caution
Insert safety pins into the hooks and bolts to prevent damage
to the engine and vehicle.
Note
♦ The positions numbered 1... 4 of the hoisting bar face the pul‐
ley.
♦ The holes in the perforated flanges are counted starting from
the hook. respect to the correctness of information in this document. Copyright by SEAT S.A.
Caution
Nut -2- must not be loosened.
– Unscrew the bolts -arrows- that fix the spring mount of the en‐
gine.

– Unscrew bolts -B-.

– Lower the engine until it is released from the gearbox mount‐
ing.
– Undo the bolts -A- and remove the gearbox support unit.
– Remove the assembly upwards. It may be necessary to turn
the unit for this purpose.
Note
When the assembly is lifted out, it must be carefully guided to

prevent damage to bodywork.
When performing assembly work, secure the engine to the engine

and gearbox support - VAS 6095- ⇒ page 11 .
Installing
Install in reverse order to dismantling, noting the following:
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
All conduits (for example for fuel, hydraulics, carbon filter, liquid
cooler and cooling agent, brake fluid, low pressure) and the
electric cables must be placed in such a way that they return
to their original position.
Ensure that there is adequate free access to all moving or hot
components.
– Check clutch release bearing for wear and renew if necessary.

– Lightly grease with lubricant grease ⇒ Parts catalogue the
clutch release bearing, release bearing guide sleeve and the
input shaft teeth.
– Check whether dowel sleeves for centring the engine/gearbox
assembly are fitted in the cylinder block; install if necessary.
– Fit intermediate plate onto sealing flange and slide onto dowel
sleeves.
– When inserting the engine, ensure that enough clearance ex‐
ists with the drive shafts.
– Align the engine using a shaking movement so that the sup‐
ports are not under any tension.
Note
Tightening torques of the engine assembly ⇒ page 13

⇒ page 14
Vehicles with air conditioner Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fitting the air conditioning compressor: ⇒ to
respect Heating, Air ofcondi‐
the correctness information in this document. Copyright by SEAT S.A.
tioning; Rep. gr. 87
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
1. Engine 9
– Install poly V-belt ⇒ page 19 .

– Install the gear selection mechanism: ⇒ 5-speed manual
gearbox 02T; Rep. gr. 34 ; Gear selection mechanism: re‐
pairing
– Observe the safety measures after connecting and discon‐
necting the battery ⇒ Electrical system; Rep. gr. 27 ; Battery:
connecting and disconnecting
– Fill up coolant ⇒ page 85 .
– Fit the air filter ⇒ page 149 .
– Connecting the central diagnosis - VAS 505X-
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
tions”.
– Carry out the vehicle system test “Guided fault finding”.
– Finish the vehicle system test so that any fault entries stored
during assembly can be erased automatically.
Observe applicable safety precautions during road test.
– Take vehicle for a test drive.
– A check of the vehicle system test should be carried out im‐
mediately afterwards. Possible error messages must be de‐
leted.
1.2 Detaching engine from gearbox

Special tools and workshop equipment required
♦ counterhold - T20186- , see equivalent
♦ Workshop crane - VAS 6100- , see equivalent ⇒ page 168

Air conditioner / heater setting

• Engine/gearbox assembly removed and fixed on engine
bracket - T20205- .
Work sequence
– Unscrew bolt -1- with gearbox fitted.
– Pull the cover plate -2- off upwards.
Note
This is shown in the figure with the gearbox removed.
– Unscrew the bolts -1 … 8- on the flange between the engine

and the gearbox.
– Take out starter motor.
Note
The gearbox is shown in illustration with engine removed.
– Place the support tool - T20186-
respect on the
to the correctness gearbox,
of information asdocument.
in this shown Copyright
in by SEAT S.A.
the illustration.
– Carefully separate the gearbox from the engine, using the
workshop crane.
1.3 Attaching engine to repair stand

1. Engine 11

equipment required
♦ Lifting tackle - 2024 A- , see
♦ Workshop crane - VAS
⇒ page 168
♦ Engine and gearbox sup‐
port - VAS 6095- , see
♦ counterhold - VW 540- , see equivalent ⇒ page 169

• Gearbox isunless
permitted separated
authorised from engine
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Work sequence
Note
When work is carried out on the crankshaft or on the sealing

flange, the flywheel and the intermediate plate must be disman‐
tled before mounting on the engine and gearbox mounting - VAS
6095- .

– Secure the engine using the lifting tackle - VW 540- on the

engine and gearbox support - VAS 6095- .
1.4 Vehicles with air conditioning/heating:

additional instructions and assembly in‐
formation
Note
♦ Do not open the refrigerant circuit of the air conditioning sys‐

tem.
♦ In order to avoid damage to the condenser as well as to the
refrigerant lines and hoses, ensure that the lines and hoses
are not over-tensioned, kinked or bent.
To facilitate removing and installing the engine without opening

the refrigerant circuit:
– Unbolt retaining clamps for refrigerant lines.
– Remove the air conditioning compressor with the connected
refrigerant pipes from its bracket: ⇒ Heater, air conditioner;
Rep. gr. 87
– Fasten the compressor to the lock carrier using the counter‐
hold - T10038- .
1.5 Tightening torques

Bolt union Tightening
permitted unless authorised by SEAT tor‐
S.A. SEAT S.A does not guarantee or accept any liability with
que in this document. Copyright by SEAT S.A.
respect to the correctness of information
Bolts, nuts M6 10 Nm
M8 20 Nm
M 10 45 Nm
M 12 60 Nm
1. Engine 13
Bolt union Tightening tor‐

que
Exhaust pipe to manifold 40 Nm
1.6 Engine assembly brackets: tightening

torques
Note
The fastening bolts of the engine assembly brackets are expand‐

able bolts and must be replaced.
Caution
Do not loosen the securing nut -arrow-.
Engine brackets, engine side

A = 20 Nm +90° (1/4 turn) further
B = 30 Nm +90° (1/4 turn) further
Engine assembly brackets, gearbox side

C = 50 Nm +90° (1/4 turn) further
Pendulum support
Caution
Do not unscrew the screw connection -Arrow- in the process.

13 – Crankshaft group
1 Engine: assembly and dismantling
Caution
The crankshaft must not be removed. Just loosening the main

bearing caps will cause deformation of the crankshaft bear‐
ings. This deformation reduces the bearing clearance. Even if
the half-bearings are not replaced, changes in the bearing
clearance may cause damage.
If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
Measuring the main bearing clearance is not possible with nor‐
mal workshop equipment.
Do not remove the piston.
⇒ “1.1 Part I Timing belt system - Assembly overview”,

page 15 .
⇒ “1.2 Part II Chain control - Assembly overview”, page 16 .
⇒ “1.3 Removing and installing poly V-belts ”, page 19 .
⇒ “1.4 Removing and fitting the distribution casing”, page 20 .
1.1 Part I Timing belt system - Assembly overview
1. Engine: assembly and dismantling 15

1 - Plug
❑ 3 off
❑ 20 Nm
2 - Pulley
❑ For coolant pump
❑ removing and fitting
⇒ page 95
3 - Cover
4 - Tensioner
5 - Plug
❑ 20 Nm + turn +90° fur‐
ther
6 - Alternator
7 - Idler roller
8 - Washer
9 - Pulley
❑ For crankshaft
❑ Do not tilt during assem‐
bly
10 - Plug
❑ 150 Nm + turn +180°
further
11 - Guide bushing
12 - Plug
❑ 5 off
❑ 25 Nm
13 - Guide bushing
14 - Spacer bush
15 - Poly V-belt
❑ Mark direction of rotation before removing
❑ removing and fitting ⇒ page 19
1.2 Part II Chain control - Assembly over‐

view
Caution
The crankshaft must not be removed. Just loosening the main

bearing caps will cause deformation of the crankshaft bear‐
ings. This deformation reduces the bearing clearance. Even if
the half-bearings are not replaced, changes in the bearing
clearance may cause damage.
If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
Measuring the main bearing clearance is not possible with nor‐
mal workshop equipment.
16 Rep. gr.13 - Crankshaft group

1 - Camshaft housing
❑ Sealing surface must
not be reworked.
❑ With integrated cam‐
shaft bearings
⇒ page 42
❑ Remove any sealant re‐
mains.
❑ Before mounting, apply
D 154,103 A1
❑ To fit, place vertically
with the adjustment
bolts in the cylinder
head holes
2 - Cylinder block
❑ 2-part
❑ The bolts must not be
loosened
Note
3 - Balancing shaft
4 - Sprocket
❑ Do not remove
❑ for balance shaft
❑ Installation position for
the crankshaft pinion
with regard to the bal‐
ance shaft pinion
⇒ page 19
5 - Oil pump
❑ must be replaced completely
6 - Guide pin, 20 Nm
7 - Guide rail
❑ For distribution chain ⇒ Item 35 (page 18)
8 - Sprocket
❑ For crankshaft
9 - Sprocket
❑ for oil pump drive
10 - Chain for oil pump
❑ Mark D.O.R. before dismounting (installation position)
11 - Sprocket
❑ For oil pump
❑ Adjust distribution timing ⇒ page 58 .
12 - Oil sump
❑ Remove and install on engines with liquid gasket ⇒ page 73 .
❑ Clean sealing surface before installing
❑ Install with silicone sealant D 176,404 A2

13 - Bolt, 9 Nm
14 - Cover
❑ Chain sprockets for operating the oil pump
15 - 20 Nm +90°
16 - O-ring
Note
Always replace the O-ring after dis‐

mounting
17 - Bush
18 - Oil seal
19 - Pulley
❑ Do not tilt during assembly
❑ Poly-V belt: removing and installing ⇒ page 19
20 - 150 Nm + turn +180° further
❑ replace
❑ Lubricate
❑ Secure pulley with retaining tool - 3415-
❑ When tightening, lock the crankshaft with the crankshaft stop - T10121- .
❑ The turning further angle can be checked using a commercial protractor e.g. Hazet 6690.
21 - 25 Nm
22 - 50 Nm
23 - 10 Nm
24 - Leads to intake manifold
25 - 10 Nm
26 - Baffle plate
❑ With heated vacuum valve
27 - O-ring
❑ Replace if damaged
28 - Distribution housing
❑ Install with sealant D 174.003 A2
❑ Screw two stud -M6x75- into cylinder head and cylinder block to improve guidance.
❑ Fix the oil sump with two bolts to ease the fitting of the distribution casing.
29 - Filler cap
30 - O-ring
❑ Replace
Protected if damaged
by copyright. Copying for private or commercial purposes, in part or in whole, is not
31 - 50 Nmto +90°
respect the correctness of information in this document. Copyright by SEAT S.A.
32 - Tensioning plate
33 - Chain tensioner
34 - 9 Nm
35 - Timing chain
❑ A roller chain is installed for engines with identification letters BZG.
❑ A toothed chain will be fitted in engines with engine code CGPA and CGPB.


36 - Sprocket
❑ For camshaft
Installation position for the crankshaft pinion with regard to the

balance shaft pinion
The marks must coincide -arrows-.
1.3 Removing and installing poly V-belts

♦ Counterholder - T20167-
Removing
Note
Insert the changed tensioning element in stages. Consider the

various work sequences.
– Now, mark direction of rotation of poly V-belt.

– Turn the tensioning element in the -direction of the arrow- until

the drill hole is visible. Lock tensioner with retention tool -
T20167- .
– Remove the Poly V-belt.
Installing
Note
When fitting the Poly-V belt, make sure that it is correctly seated
on the pulleys.
Routing of poly V-belt
Belt routing without air conditioning compressor

1 - Coolant pump - pulley
2 - Tensioning roller
3 - Pulley/alternator
4 - Poly V-belt
5 - Crankshaft toothed belt wheel
Belt routing with air conditioning

1 - Coolant pumppermitted
-Protected
pulley by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
2 - Tensioning roller
3 - Pulley/alternator
4 - Idler roller
5 - Air conditioner compressor pulley
6 - Poly V-belt
7 - Crankshaft toothed belt wheel
Install in the reverse order to removal.
1.4 Removing and fitting the distribution

casing


equipment required
♦ Hose clamp - 3415- , see
♦ Interlocking mandril -
3415/1- , see equivalent
⇒ page 168
♦ Socket - 10 222A- , see
♦ Additional part for the en‐
gine mounting - 10 222A/
⇒ page 169
♦ Fastening bolt - T10121- ,
see equivalent
⇒ page 169
♦ Basic engine mounting set
- T40091- , see equivalent
⇒ page 169

♦ Torque wrench (5... 50 Nm) - V.A.G 1331- , see equivalent

⇒ page 168
⇒ page 168
Preparation of the tool for Toledo

– Remove the two fastening bolts -1- of the additional part for
the engine mounting - 10 222A/31-4- .
Removing
– Remove the plate of the front right-hand side wheel housing
⇒ Remove and fit the front wheel housing; Rep. gr. 66 ;
Bodywork, exterior fitting work .
– Mark direction of rotation of poly V-belt and remove it
⇒ page 19 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the engine speed sender - G28- ⇒ page 28 .
– Turn the crankshaft with the securing bolt of the pulley in en‐
gine rotation direction -arrow- until the securing bolt - T10121-
can be fitted into the flywheel .
– Remove the air conditioning compressor with the connected
refrigerant pipes from its bracket: ⇒ Heater, air conditioner;
Rep. gr. 87

– Unscrew the bolts -arrows- and place the alternator to one

side.
Ibiza
– Pull the filler piece -1- up as far as it will go until the lever - 80
200- can be inserted.
– Place the suspension device - 10-222 A- as shown with the

frame - 10 - 222 A /1- and hang from the ring -arrow-.
Toledo
– Remove windscreen wiper arms and plenum chamber cover
⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system;
Removing and installing windscreen wiper system .
– Fit the support bracket - 10 222A- with the adapters -1- to -6-
beforehand and Protected
outsidebythe vehicle.
copyright. Copying for private or commercial purposes, in part or in whole, is not
1- Adapter - 10-222 A/31-2-

2- Adapter - T40091 /3-

3- Adapter - 10-222 A/31-1-
4- Support bracket - T40091 /1- .
5- Adapter - 10-222 A/31-4-
6- Adapter - 10-222 A/31-3-
– Fit support bracket - 10-222 A- with the necessary adapters
as shown and take up weight of engine in installation position.

Note
♦ It is not necessary to remove the upper cover of the lock car‐

rier.
♦ Position the adapter - 10-222 A /31-4- -1- centrally on the
bracket of the lock -2-.

– Fit the hooks in the retainer on the control side.
Caution
Nut -2- must not be loosened.


– Take up weight of engine and remove securing bolts
-arrows-.
– Remove the oil pan ⇒ page 73 .
– Immobilise the crankshaft with the counterhold - 3415- and

-3415/1- and remove the pulley.

– Remove Allen keys from the distribution casing and the bolts
marked with -arrows-.
– Remove valve timing housing.
Note
Note that crankshaft bearing bush remains in sealing flange.
Installing
– Clean sealing surfaces carefully. They must be free of oil and
grease.
– Screw two stud -M6x80- into cylinder head and cylinder block
to improve guidance.
– Apply a thin even coat of sealant D 174 003 A2 onto the clean
sealing surface.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
– Tighten valve timing housing securing bolts evenly and diag‐
onally.
Ensure that timing housing is not canted.
Tightening torque:
Bolt M6 - 10 Nm
Bolt M10, 50 Nm
– Fit the belt pulley with a new fastening bolt.
– Tighten the fastening bolt as far as possible by hand.
Note
Ensure that the pulley is not tilted during fitting.
– Hold the pulley tight using the counterhold - 3415- and

-3415/1- .
Tightening torque: 150 Nm +180° further
– Remove the fixing bolts - T10121- from

Protected by theCopying
copyright. borehole of the
for private or commercial purposes, in part or in whole, is not
flywheel. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Install the engine speed sender - G28- -arrow-.

Specified torque for securing bolt: 8 Nm.
– Installing the oil pan ⇒ page 73 .
– Fit the poly V-belt ⇒ page 19 .

2 Engine block, seals

⇒ “2.1 Assembly diagram”, page 27 .
⇒ “2.2 Removing and installing engine speed sender G28 ”, page
28
⇒ “2.3 Crankshaft oil seal- pulley side: replace”, page 28 .
⇒ “2.4 Crankshaft oil seal, flywheel side: replace”, page 31 .
2.1 Assembly diagram

❑ replace
❑ Lubricate
❑ Secure pulley with re‐
taining tool - 3415-
❑ When tightening, lock
the crankshaft with the
crankshaft stop -
T10121- .
❑ The retightening angle
can be measured with a
standard protractor
2 - Washer
3 - Pulley
❑ Do not tilt during assem‐
bly
❑ Poly V-belt: removing
and installing
⇒ page 19
4 - Bush
❑ With O-ring
Note

mounting
5 - Crankshaft oil seal, pulley

side
❑ replace ⇒ page 28
6 - Cylinder block
❑ 2-part
❑ Do not loosen the bolts
7 -permitted
60 Nm + turn
unless +90°
authorised further
❑ replace
8 - Flywheel
9 - Intermediate plate
❑ Must sit on dowel sleeves
❑ do not damage/bend during assembly work
10 - Crankshaft oil seal, flywheel side:
2. Engine block, seals 27

2.2 Removing and installing engine speed

sender - G28-
⇒ page 168
♦ 4 mm wrench - T10370-
Removing
– Separate the connector -1- of the engine speed sender - G28- .
– Remove the gasket -2- from the engine block and remove the
engine speed sender - G28- using the AF 4 mm wrench -
T10370- .
Installing
2.3 Crankshaft oil seal- pulley side: replace



equipment required
♦ Hose clamp - 3415/1- , see
♦ Tappet - T10117- , see
♦ Extractor kit - T20143- , see
♦ Torque wrench (40... 200
Nm) - V.A.G 1332- , see
Fastening bolt - T10121- , see equivalent ⇒ page 169

Removing
– Remove the plate of the front right-hand side wheel housing
⇒ Remove and fit the front wheel housing; Rep. gr. 66 ;
Bodywork, exterior fitting work .

gine rotation direction -arrow- until the securing bolt - T10121-
can be fitted into the flywheel .
– Loosen the pulley securing bolt. Immobilise the pulley with the
retaining tool - 3415- and engage 3415/1.
– Remove centre bolt and remove crankshaft pulley.
– Remove the bushing . ⇒ Item 4 (page 27)
– Remove the seal -1- using the extractor
respect - T20143/2-
to the correctness of information in this document. Copyright by SEAT S.A.
– Clean contact surface and sealing surface of seal.

Installing
Note
Make sure that the contact surfaces of the pulley, the attachment
bolt, the sleeve and the crankshaft sprocket are free of grease
and oil.
– Slide bushing onto crankshaft journal.

– Place the sleeve -T10117/2- on the bushing and slide the seal
along the bushing
– Remove the bushing sleeve -T10117/2- from the bushing.
– Insert the seal using the assembly tool -T10117- as far as

possible in the distribution housing by tapping it evenly
– Fit the belt pulley with a new fastening bolt.
– Tighten the fastening bolt as far as possible by hand.
Note
Ensure that the pulley is not tilted during fitting.
– Hold the pulley tight using the counterhold - 3415- and

-3415/1- .
Tightening torque: 150 Nm +180° further
– Remove the fixing bolts - T10121- from the borehole of the

flywheel.
– Install the engine speed sender - G28- -arrow-.

Specified torque for securing bolt: 8 Nm.
Continue installation following reverse order for removing.
2.4 Crankshaft oil seal, flywheel side: re‐

place



equipment required
♦ Extractor kit - T20143- , see
♦ Tappet - T20158- , see
♦ Hose clamp - T20176- , see
Nm) - V.A.G 1332- , see
♦ Guide pins - U 10050-10-

♦ Tightening torque - VAG 1331- , see equivalent
Removing
Note
♦ For clarity, the process is described with the engine removed.

♦ The sequence of operations is identical with the engine moun‐
ted and the gearbox removed.
– Remove the gearbox ⇒ Gearbox - remove and install; Rep.

gr. 34 ; 5-speed manual gearbox O2T .
– Apply counterhold - T20176- to slacken bolts of pressure plate.
– Slightly slacken bolts diagonally at each stage.
– Remove pressure
by SEAT disk andS.Aclutch
does notplate.
permitted unless authorised S.A. SEAT guarantee or accept any liability with
Note
When removing pressure disk, use the appropriate centre guide

- U 10050-10- , so that clutch plate does not fall.
WARNING
When removing pressure disk from engine assembly, take

care that clutch plate does not fall. This can cause damage.
– Unscrew the flywheel bolts and remove it.
– Extract the seal -1- with the extractor kit - T20143- .

Installing
Note
The seal should not be removed from the packaging until imme‐
diately before fitting.

– Position the new seal -1- in the installation tool - T20158- .

– Fit seal as far as it goes in its housing, using the installation
tool - T20158- to push in the direction of the -arrow-.
– Remove the installation tool - T20158-
Install in reverse order.

3 Pistons and conrods
Note
Oil the support and slide surfaces before carrying out assembly
work.

⇒ Fig. ““Checking piston ring gap”“ , page 36
⇒ Fig. ““Checking ring-to-groove clearance”“ , page 37
⇒ Fig. ““Checking pistons”“ , page 37
⇒ Fig. ““Inspecting cylinder bore”“ , page 37
⇒ “3.1.1 Piston and cylinder dimensions”, page 38 .
1 - Securing ring
2 - Piston pin
❑ if stiff, heat piston to 60°
C
❑ Remove and install with
the awl - 10 - 14- , see
3 - Piston
❑ check ⇒ page 37
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Arrow on piston crown
points to pulley end respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Install using piston ring
clamp
4 - Compression rings
❑ Offset gaps by 120°
❑ Remove and fit com‐
pression rings using pli‐
ers adapted for piston
rings
❑ The mark “TOP” must
face towards piston
crown
❑ Inspect gap clearance
⇒ page 36
❑ Checking piston ring
side clearance
⇒ page 37
5 - Oil scraper rings
❑ Carefully remove and
install by hand the oil
scraper rings made up
of 3 parts
❑ Inspect gap clearance ⇒ page 36
❑ The play between the rings and the grooves cannot be measured
3. Pistons and conrods 35

6 - Conrod
❑ replace as a set only
❑ Mark cylinder allocation -A-
❑ Fitting position: The marks -B- should point in the direction of the pulley
❑ Guided axially by piston.
7 - Conrod bearing cap
❑ When using conrods with centering by cracking, the bearing caps can only be fitted in one position and
fitted to the corresponding conrod
8 - Conrod bolt
❑ 20 Nm + 1/4 turn (90º)
❑ replace
❑ Oil threads and contact surface.
❑ To measure radial play, tighten to 20 Nm, without retightening
9 - Cylinder block
❑ Checking cylinder bore ⇒ page 37
❑ Piston and cylinder dimensions ⇒ page 38
10 - Bearing cap
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
Check radial clearance with Plastigage
Note respect to the correctness of information in this document. Copyright by SEAT S.A.
Do not rotate crankshaft when

checking radial clearance.
❑ New: 0.020…0.061 mm
❑ Wear limit: 0.091 mm
Checking piston ring gap

♦ Feeler gauge
– Push ring squarely from above down to approx. 15 mm from
bottom end of cylinder into the bottom cylinder opening.
Piston ring When new Wear limit
Dimensions in mm
1. nd compression ring 0,20...0,50 1,0
Oil scraping ring 0,25...0,50 ---1)

1) It is not possible to give an indication of the wear limit
Checking ring-to-groove clearance

♦ Feeler gauge
– Clean ring groove before checking.
Piston ring When new Wear limit
Dimensions in mm
Oil scraping ring Cannot be measured
Checking pistons

♦ External micrometer 75...100 mm
– Measure
Protected by copyright. pistons
Copying forapprox. 10 mmpurposes,
private or commercial from the lower
in part edge
or in whole, is notof skirt,
at 90authorised
permitted unless ° to the piston
by SEAT S.A. pin
SEATaxis.
S.A doesDifference inaccept
not guarantee or relation to max.
any liability with
specified measurement 0.04 mm. Nominal measurement

⇒ page 38
Inspecting cylinder bore
3. Pistons and conrods 37

♦ Internal precision measuring instrument 50...100 mm

– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
Difference between measured value and nominal value: max.
0.08 mm.
Nominal measurement ⇒ page 38
Note
The measurement of the interior diameter of the cylinders cannot

be done while the engine block is attached to the engine and
gearbox support - VAS 6095- , as doing so may result in errone‐
ous measurements.
3.1.1 Piston and cylinder dimensions

Honing dimen‐ ∅ of the pis‐ ∅ of the cylinder
sion tons
Basic dimen‐ mm 76,470 76,51
sion
Stage I mm 76,720 76,76
Stage I mm 76,970 77,01

15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When fitting a new cylinder head, before fitting the cylinder

head cover, the contact surfaces of the support elements must
be oiled, as well as the roller rocker fingers and the cam tracks
of the camshafts.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ After replacing the cylinder head, all coolant must be changed.
⇒ “1.1 Cylinder head - exploded view”, page 39 .

⇒ “1.2 Removing and installing camshaft housing”, page 42 .
⇒ “1.3 Removing and installing the cylinder head”, page 46 .
⇒ “1.4 Checking distribution timing”, page 52 .
⇒ “1.5 Removing and fitting the distribution chain”, page 54 .
⇒ “1.6 Distribution timing: adjustment”, page 58 .
⇒ “1.7 Checking compression”, page 59 .
1.1 Cylinder head - exploded view

1. Cylinder head 39
1 - 10 Nm +1/4 turn further

(90º)
❑ replace
❑ Tighten from centre out‐
wards
(90º)
❑ replace
wards
3 - O-ring
4 - Hall sender - G40-
5 - 8 Nm
6 - 10 Nm
7 - Support plate
❑ For the cable harness
8 - 10 Nm
9 - Filler cap
10 - Exhaust camshaft
11 - Camshaft bearing caps
12 - Roller rocker arm
❑ Check roller bearings
for ease of movement
❑ Oil contact surface.
❑ ?When installing, se‐
cure to support element
using securing clip.
13 - Supporting element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ Before installing,
permitted checkbycamshaft
unless authorised SEAT S.A. SEATaxial clearance
S.A does ⇒ page
not guarantee or accept64
any.liability with
14 - Woodruff keys
15 - Valve spring retainer
16 - Valve spring
❑ While the cylinder head is dismounted use the valve spring compressor - 3362- , see equivalent
⇒ page 168 .
❑ (with cylinder head installed) ⇒ page 67
17 - Valve stem oil seal
18 - Oil pressure switch - F1- 0.3 bar -0.7 Nm, 25 Nm
19 - Valves:
❑ Not to be reworked, only grinding in is permissible
❑ Valve dimensions ⇒ page 65
40 Rep. gr.15 - Cylinder head, valve gear

20 - Cylinder head
❑ Reworking valve seat ⇒ page 65 .
❑ Reworking sealing surface ⇒ page 64
❑ Check that the cylinder head is not deformed ⇒ page 42
21 - Oil seal
❑ Clean strainer if dirty
22 - Plug
❑ 4 off
❑ 20 Nm
23 - Attachment rings
24 - Sprocket
❑ For camshaft
❑ Immobilise the sprocket by using the retention tool - T10172- .
❑ replace
❑ Lock chain sprockets using counterhold - T10172- .
26 - Washer
❑ Depending on version
27 - Supply camshaft
28 - Plug
❑ 15 Nm
29 - Guide rail
Caution
Screw in two head studs
(M6 x 80) on the cam‐
shaft casing
Protected before
by copyright. Copyingfitting
therespect
camshaft housing.
The head bolts are used

to guide the camshaft
casing and prevent that
the roller rocker fingers
loosen from the support
elements.

❑ Remove any sealant remains.
❑ When installing fit vertically from above onto studs and dowel pins
1. Cylinder head 41
Check whether the cylinder head is deformed

Check using the 500 mm straight edged ruler - VAS 6075- and
the feeler gauge.
Max. permissible distortion: 0.05 mm.
1.2 Removing and installing camshaft hous‐

ing
♦ Remove camshafts ⇒ page 44
♦ Install camshafts ⇒ page 44 .

equipment required
Nm) - V.A.G 1332- , see
♦ Torque wrench (5... 50 Nm) permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
- V.A.G 1331- , see equiva‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
lent ⇒ page 168

♦ Interlocking mandril -

⇒ page 168
♦ Camshaft clamp - T10123- , see equivalent ⇒ page 169 .
♦ Fastening bolt - T10121- , see equivalent ⇒ page 169
♦ Two studs (M 6 x 80)

Removing
Note
♦ In this engine the camshafts are housed in a casing. There‐

fore, the camshaft housing can only be removed after remov‐
ing the distribution casing.
♦ The camshaft housing sealing surface must not be reworked.
– Disconnect battery earth cable -arrow- with ignition switched

off.
1. Cylinder head 43
– Unplug connector -1- from Hall sender - G40- .

– Unlock the engine cover -arrows- and pull upwards.
– Unscrew earth cable from camshaft housing.
– Remove the ignition coils with output stages ⇒ page 164 .

– Remove cable guide with wiring harness from camshaft hous‐
ing.
– Remove the coolant bleeding tube from the camshaft housing.
– Remove the cable harness support ⇒ Item 7 (page 40) .
– Remove valve timing housing ⇒ page 20 .
– Remove distribution chain ⇒ page 54 .
– Loosen camshaft housing bolts from outside to inside, alter‐

nately and diagonally and remove.
– Carefully lift camshaft housing off.
Remove camshafts
– Loosen the bolts on the camshaft casing in the order shown
and remove.
– Carefully lift camshaft housing off.
Fit the camshafts
Note
The projection of the intake camshaft should be above the drill

hole for the Hall sensor.

– Manually tighten the camshaft bearing bolts in the sequence

indicated.
Take care not to tilt the camshaft bearing caps. Tightening torque:
10 Nm + 1/4 turn (90º)
Installing
Caution
Screw in two head studs (M6 x 80) on the camshaft casing

before fitting the camshaft housing.
The head bolts are used to guide the camshaft casing and
prevent that the roller rocker fingers loosen from the support
elements.
Install in reverse order to dismantling, noting
respect to the theoffollowing:
correctness information in this document. Copyright by SEAT S.A.

• Pistons must not be at TDC.
Note
On turning the camshafts, the valves may hit the pistons if they
are at TDC.
– Remove sealant remnants on cylinder head and camshaft

housing with a commercially available sealant remover.
– Prevent dirt and sealant remains from entering the cylinder
block.
– Clean sealing surfaces. They must be free of oil and grease.
– Apply thin, even coat of sealant on clean camshaft housing

sealing surface. See hatched area in illustration.
Note
The sealant must not be applied too thickly otherwise excess

sealant could enter the oil channels and cause damage to the
engine.
– Ensure that all roller rocker fingers contact valve stem ends
-1- correctly and that they are clipped into their respective
support elements -2-.
– Bolt two studs (M6 x 80) on the cylinder head before fitting the
camshaft housing.
1. Cylinder head 45
– Carefully fit the camshaft housing vertically onto the cylinder

head studs and dowel pins -arrows-.
– Evenly tighten new camshaft housing securing bolts from in‐

side to outside alternately and diagonally.
Ensure that camshaft housing is not canted. Tightening torque:
10 Nm + 1/4 turn (90°).
Note
After installing the camshaft housing, wait about 30 minutes for

the sealant to dry.
1.3 Removing and installing the cylinder

head


equipment required
♦ Guide pins - 3450- , see
♦ Socket - T10358- , see
♦ Socket - 10 222A- , see
♦ Additional part for the en‐
gine mounting - 10 222A/
⇒ page 169
Nm) - V.A.G 1332- , see
♦ Basic engine mountingProtected
set by copyright. Copying for private or commercial purposes, in part or in whole, is not
- T40091- , see equivalent
⇒ page 169 respect to the correctness of information in this document. Copyright by SEAT S.A.
1. Cylinder head 47
♦ Adapter - 10 222A/18- , see equivalent ⇒ page 169

⇒ page 168
Preparation of the tool for Toledo

– Remove the two fastening bolts -1- of the additional part for
the engine mounting - 10 222A/31-4- .
Removing
Note
Engine at tepid temperature at most.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing

and installing battery .
WARNING
Steam may be released when opening the expansion tank.

Wear safety goggles and appropriate clothing to avoid injury to
eyes and burns. Cover the cap with a cloth and open carefully.
– Open and close expansion tank cap to release pressure in

cooling system.
– Loosen hose clips and pull coolant hoses off the thermostat
cover.
– Remove thermostat cover ⇒ page 89 .
WARNING
The fuel feed line is pressurized! Wear

Protected by copyright. eye
Copying protection
for private andpurposes, in part or in whole, is not
or commercial
gloves to avoid injuries and
permitted skin
unless contact.
authorised by SEATBefore
S.A. SEATloosening
S.A does not guarantee or accept any liability with
hose connections, wrap arespect
clothtoaround theofconnection.
the correctness information in thisThen
document. Copyright by SEAT S.A.

– Remove the fuel supply tube -2-. Also press the release tabs.
– Cover the disconnected fuel lines immediately to avoid the
penetration of dirt into the fuel system.
Ibiza
– Pull the filler piece -1- up as far as it will go until the lever - 80
200- can be inserted.
– Attach two spindles with hooks to the support bracket - 10
222A- .
– Place the suspension device - 10-222 A- as shown with the

frame - 10 - 222 A /1- and hang from the ring -arrow-.
– Unscrew the front attachment bolt of the gearbox and screw

on the bracket - T10358- as shown in the figure.
– Fit the hooks of the support device - 10 222A- to the bracket -
T10358- as shown in the figure.
1. Cylinder head 49
Toledo
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Plenum chamber cover; removing and
installing plenum chamber cover .
– Insert the support bracket - 10 - 222 A- and hold the engine
with gearbox tight.
1- Adapter - T40091/3-
2- Support equipment - 10-222 A /31-1-
3- Adapter - 10 222A/18-
4- Support equipment - 10 222A/2-
5- Engine gearbox upper front bolt
6- Adapter - 10-222 A /31-4-
7- Adapter - 10-222 A /31-3-
8- Rod - T40091/1- .
9- Adapter - 10 222A/3-
10 - Support equipment - 10-222 A /31-2-
– Remove the upper front bolt of the engine gearbox -5-.
– Screw in the bracket - T10358- with the bolt, as shown in the
illustration.
Note
♦ It is not necessary to remove the upper cover of the

to thelock car‐ of information in this document. Copyright by SEAT S.A.
respect correctness
rier.
♦ Position the adapter - 10-222 A /31-4- -1- centrally on the
bracket of the lock -2-.
All vehicles
– Rotate the spindle until the hooks are slightly tensed.
– Remove distribution chain ⇒ page 54 .
– Remove camshaft housing ⇒ page 42 .
– Remove roller rocker fingers together with support elements
and lay aside on clean surface.
– Ensure that the roller rocker fingers and the support elements
are not mixed up.
– Unscrew the spark plugs using spark plug socket and exten‐
sion - 3122 B- .

Ibiza
– Release the hook -1- from the left eye and move the spindle
to the left-hand side of the support tool - 10 222A- .
Toledo
– Remove the right spindle -A-.
– Push the adapter - 10-222 A /3- -9- backwards.
All vehicles
– Remove the rings ⇒ Item 23 (page 41) .
– Remove intake manifold ⇒ page 135 .
– Remove the exhaust manifold with catalytic converter
⇒ page 159 .
– Remove oil pressure switch - F1- ⇒ Item 18 (page 40) .
– Loosen socket head studs in the sequence given and then re‐
move completely from the cylinder head.
– Carefully remove the cylinder head.
Installing
Note
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Handle new gasket with extreme care. Any damage will result
in leaks.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Also prevent dirt and particles from getting into the coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure no long grooves or scratches are pro‐
duced (if using sandpaper. it must be at least 100 grain).
– Carefully remove any abrasive metal particles and then the
cloths. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Position the cylinder number 1 into TDC and then rotate the
crankshaft a little backwards.
1. Cylinder head 51
– Place the new cylinder head gasket over the centralising pins
-A-. The inscription (part no.) -B- should be legible.
– Fit cylinder head, insert the 8 cylinder head studs and hand
tighten.
– Tighten the cylinder head studs in the sequence shown in the

following:
– Tighten all bolts to 30 Nm.
– Then tighten all bolts 1/4 turn (90°) using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90°).
Note
When turning camshaft, crankshaft should not be at TDC. The

piston head/valves might be damaged.
– Install camshaft housing ⇒ page 42 .

– Install timing chain and drive chain of oil pump ⇒ page 54 .
– Adjust valve timing ⇒ page 58 .
– Install the timing housing ⇒ page 20 .
1.4 Checking distribution timing

♦ Test sequence ⇒ page 53
to applicability among Seat / VW / Audi / Skoda ⇒permitted
pageunless
168authorised
.


Test sequence
– Remove the camshaft housing cover -arrows-.
gine rotation direction until the grooves on both camshafts are
horizontal.
1. Cylinder head 53
– The camshaft fasteners - T10123- must enter the camshafts

easily.
– Fit both tools tightening the hexagonal bolts by hand -M6- .
– Now lock the crankshaft by inserting the fastening bolt -

T10121- in the flywheel drill hole.
Note
If it is not possible to insert the fastening bolt -T10121- remove

the camshaft fastening pins - T10123- from the camshafts. Turn
the crankshaft in the direction of engine rotation (360º) and repeat
the operation.
If it is not possible to insert both locking tools:

– Adjust valve timing ⇒ page 58 .
If it is possible to insert both locking tools:
– Remove the locking tools from their housing in the drill holes
and remount the sensor and cover.
– Fit the air filter ⇒ page 149 .
– Fit theProtected
camshaft housing
by copyright. cover
Copying -arrows-.
1.5 Removing and fitting the distribution

chain
A roller chain is installed for engines with identification letters
BZG.
A toothed chain will be fitted in engines with engine code CGPA
and CGPB.

♦ Hose clamp - T10172- , see equivalent ⇒ page 168
Removing
– Lock camshafts and crankshaft ⇒ page 52 .
– Use a screwdriver to lever the elastic brace -1- off the stud.
– Unscrew securing bolt -2- and remove chain tensioner.
– Unscrew securing bolt -3-. Use the counterhold - T10172- to
hold the wheel.
– Remove the sprocket for the oil pump, distribution chain and
drive wheel.
Note
♦ As an original, the chain tensioning device is fitted with locking

borehole.
♦ To reduce noise, a modified chain tensioner has been intro‐
duced. In the event of complaint, this chain tensioner, without
locking drill hole, should be mounted.
♦ Please observe the different procedures for repair.
Chain tensioner with locking drill hole

– Push the tensioning guide rail -in the direction of the arrow-
and lock the chain tensioner using a 3 mm hexagonal socket
wrench -1-
Chain tensioner without locking drill hole
Caution
Hold down the chain tensioner rod until removal, to prevent
damage to the unit.
1. Cylinder head 55
– Remove the fastening bolts -1- and release the bolt -2-.
– Hold the chain tensioner rod pressed down in
-the direction of the arrow A-.
– Turn the chain tensioner in the -direction of arrow B- until the
rod is below the tensioning plate.
– Loosen fastening bolt -2- and remove the chain tensioner.
– Disconnect the guide rail -1-.
– Unscrew securing bolt -1-. Use counterhold - T10172- to do

this.
– Remove the tensioning plate -3- and the guide rail -2- from the
front guide bolts.
– Remove the distribution chain from its mount on the sprockets.
Installing
– Place the distribution chain on the crankshaft gear and the
camshaft pinion.
– Fit the tensioning plate -3- and the guide rail -2- placing them
in front of the guide bolts.
– Fit the second camshaft sprocket with a new fastening bolt
-1-.
Tightening torque of the sprocket fastening bolt: 50 Nm + 1/4 turn
(90º)
– Use counterhold - T10172- to do this.
– Install the distribution chain for the oil pump with both sprock‐
ets.
– Fasten the oil pump sprocket with a new fastening bolt.

Tightening torque of sprocket -3-for the oil pump: 20 Nm + 1/4turn

(90º)
– Fit the chain tensioner for the pump activation.
Chain tension device fastening bolt -2- tightening torque: 15 Nm
– Use counterhold - T10172- to do this.
– Use a screwdriver to lever the elastic brace -1- onto the stud.
Note
♦ In the original, the chain tensioner is mounted with the locking

drill hole.
♦ To reduce noise, a modified chain tensioner has been intro‐
duced. In the event of complaint, this chain tensioner, without
locking drill hole, should be mounted.
♦ Please observe the different procedures for repair.
Chain tensioner with locking drill hole

– Tighten the roller chain of the camshaft by moving the 3 mm
hexagonal socket wrench from the chain tensioner.
Chain tensioner without locking drill hole
– Assemble chain tightener as described below
permitted and
unless keepbyrod
authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
pressed down. respect to the correctness of information in this document. Copyright by SEAT S.A.
Assembly diagram
1 - Chain tensioner casing
2 - Compression spring
3 - Mandrel
4 - Piston
Caution
Hold down the chain tensioner rod until removal, to prevent

damage to the unit.
– Tighten the securing bolt by hand -2-.

– Hold the chain tensioner rod pressed down in
-the direction of the arrow A-.
– Turn the chain tensioner in the -direction of arrow B- until the
rod is below the tensioning plate.
– Fasten the chain tensioner by manually tightening the two fas‐
tening bolts -1-.
– Tighten securing bolts -1- and -2-.
Tightening torque of fastening bolts of the chain tensioner: 9 Nm
– Checking valve timing ⇒ page 52 .
– Install the timing housing ⇒ page 20 .
1. Cylinder head 57
1.6 Distribution timing: adjustment

♦ Adjust convergence ⇒ page 58
Work sequence
gine rotation direction until the grooves on both camshafts are
horizontal.

– The camshaft fasteners - T10123- must enter the camshafts

easily.
– Fit both tools tightening the hexagonal bolts by hand -M6- .
– Release both fastening bolts from the camshaft pinion, using
the counterhold - T10172- .
– Turn the crankshaft in the direction of engine rotation, using

the pulley locking bolt, until it is possible to fit the retaining tool
- T10121- on the fly wheel .
– Tighten the fastening bolt-2- for the camshaft pinion -1- to 50
Nm, using the counterhold - T10172- .
– Then tighten all bolts 1/4 turn (90°) using a rigid wrench.
– Remove the camshaft and flywheel counterholds.

– Turn
Protected crankshaft
by copyright. two
Copying for fullorturns
private in engine
commercial purposes, D.O.R.
in part or inand
whole,check
is not
permitted valve timingbyagain
unless authorised SEAT S.A.⇒ SEAT
pageS.A52 does. not guarantee or accept any liability with
1.7 Checking compression

♦ Checking ⇒ page 60
1. Cylinder head 59

equipment required
♦ Spanner - 3122 B- , see
♦ Torque wrench (5... 50 Nm)
- V.A.G 1331- , see equiva‐
lent ⇒ page 168
♦ Check compression -
V.A.G 1763-
♦ Extractor - T10094 A-
Test condition
• Engine oil temperature at least. 30 ℃.
Test sequence

– Remove the 4-pin connector from the ignition coils -arrows-.

– Extract all the ignition coils from their spark plugs using the
extractor - T10094 A- .
sion - 3122 B- .
– Remove fuse for the injectors. Fuse installation ⇒ Current flow

diagrams, Electrical fault finding and Fitting locations
– Check compression using compression tester - V.A.G 1763- .
Note
How to use the test unit is described in the respective operating

instructions.
– Operate starter until tester shows no further pressure in‐

crease.
Compression values:
new: 10 ... 15 bar has been generated.
Wear limit: 7 bar
Maximum permissible difference between all cylinders: 3 bar
– Insert spark plugs using spark plug socket and extension -
3122 B- and tighten to 30 Nm.
– Read fault memory,permitted
repairunless
faults if necessary
by SEAT S.A.andSEATthen clear
authorised S.A does not guarantee or accept any liability with
fault memory ⇒ Vehicle diagnostic tester “Guided
respect to the correctness fault
of information finding”.
in this document. Copyright by SEAT S.A.
– If the fault memory has been erased, you must generate the
readiness code again
1. Cylinder head 61
2 Valve control
⇒ “2.2 Checking camshaft axial clearance”, page 64 .
⇒ “2.3 Machining valve seats”, page 65 .
⇒ “2.4 Valve guides: verification”, page 66 .
⇒ “2.5 Replacing valve shaft seals.”, page 67 .

(90º)
❑ replace
wards
2 - O-ring
4 - 8 Nm
5 - 10 Nm
6 - Support plate permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ For the cable harness
7 - Filler cap
8 - Exhaust camshaft
9 - Camshaft bearing caps
10 - Roller rocker arm
❑ Check roller bearings
for ease of movement
❑ ?When installing, se‐
cure to support element
using securing clip.
11 - Supporting element
❑ do not interchange
❑ with hydraulic valve
clearance compensa‐
tion
❑ Before installing, check
camshaft axial clear‐
ance ⇒ page 64 .
12 - Woodruff keys
13 - Valve spring retainer
14 - Valve spring
❑ While the cylinder head is dismounted use the valve spring compressor - 3362- .
❑ (with cylinder head installed) ⇒ page 67
15 - Valve stem oil seal

16 - Oil pressure switch - F1- 0.3 bar -0.7 Nm, 25 Nm

17 - Valves:
❑ Not to be reworked, only grinding in is permissible
❑ Valve dimensions ⇒ page 65
18 - Cylinder head bolt
❑ replace
❑ Follow installation instructions and sequence when loosening ⇒ page 51 and tightening ⇒ page 52
19 - Cylinder head
removing and fitting ⇒ page 46
❑ Reworking valve seat ⇒ page 65 .
❑ Reworking sealing surface ⇒ page 64
20 - Oil seal
21 - 20 Nm
22 - Attachment rings
23 - Sprocket
❑ For camshaft
❑ Immobilise the sprocket by using the retention tool - T10172- .
24 - 50 Nm +1/4 turn further (90º)
❑ replace
❑ Lock chain sprockets using counterhold - T10172- .
25 - Supply camshaft
Caution
Screw in two head studs
(M6 x 80) on the cam‐
shaft casing before fitting
the camshaft housing.
The head bolts are used
to guide the camshaft
casing and prevent that
the roller rocker fingers
loosen from the support
elements.

❑ Remove any sealant remains.
❑ Before mounting, apply D 154,103 A1
❑ When installing fit vertically from above onto studs and dowel pins
2. Valve control 63
Reworking cylinder head sealing surface on engine block side

Reworking dimensions for cylinder head: a = min. 108.25 mm
2.2 Checking camshaft axial clearance

♦ Checking ⇒ page 64
Special tools and work‐
shop equipment re‐
quired
♦ Universal dial gauge
support - VW 387- ,
see equivalent
⇒ page 169
♦ Dial gauge
inspect camshaft, axial
play
Perform test with the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
support elements and permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the cylinder head cover respect to the correctness of information in this document. Copyright by SEAT S.A.
removed.
– Press the camshaft
with thumb onto the
central bearing of the
camshaft -arrow-,
and check the axial
play of the camshaft
by moving back and
forth.
Wear limit: max. 0.20
mm

Valve dimensions
Note
Valves are not to be machined. Only grinding in is permissible.
Measurement Inlet valve Outlet valve

∅a mm 29,5 26,0
∅b mm 5,973 5,953
c mm 100,9 100,5
α ∠° 45 45
2.3 Machining valve seats

♦ Reworking ⇒ page 65
♦ Gauge
♦ Valve seat re-facing tool
Work sequence
Note
♦ When carrying out repairs on engines with leaking valves, it is

not sufficient to machine or replace the valve seats and valves.
Particularly on high mileage engines, it is necessary also to
check valve guides for wear ⇒ page 66 .
♦ Rework valve seats only sufficiently in order to obtain a proper
contact pattern. Calculate the maximum permissible rework‐
ing dimension before commencing. If the reworking dimension
is exceeded, proper operation of the hydraulic valve clearance
compensation is no longer assured and the cylinder head must
be replaced.
Calculate the maximum permissible reworking level as follows:

– Insert valve and press firmly against the valve seat.
Note
If the valve is replaced when carrying out repair work, use a new
valve for the measurement.
2. Valve control 65
– Measure the distance -a- between the end of the stem and the
upper edge of the cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance and minimum dimension.
Minimum dimension: inlet valve 7.6 mm, exhaust valve 7.6 mm.
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
Distance measured 8,0 mm
Minimum distance 7,6 mm
Max. permissible reworking dim. 0,4 mm
2) The max. permissible reworking dimension is shown in the figures for reworking
the valve seats as dimension “b”.
Reworking the intake valve seat

a = ∅ 28.7 mm
b = maximum permitted reworking dimension 1
c = 1.5 - 1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
γ = 60° lower correction angle permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1Calculation of the maximum permissible reworking dimension
⇒ page 65
Reworking the exhaust valve seat
a = ∅ 25.0 mm
b = maximum permitted reworking dimension 1
c = approx. 1.8 mm
Z = cylinder head lower edge
α = 45 ° valve seat angle
β = 30 ° upper correction angle
γ = 60 ° lower correction angle
1Calculation of the maximum permissible reworking dimension
⇒ page 65
2.4 Valve guides: verification

♦ check ⇒ page 67
♦ Universal dial gauge support - VW 387- , see equivalent
⇒ page 168

♦ Dial gauge
Test sequence
– Insert new valve into guide. The end of the valve stem should
be flush with the guide. Due to the slight difference in stem
dimensions, ensure that only an inlet valve is used in the inlet
guide and an exhaust valve in the exhaust guide.
– To test the tilting play, move the valve in the direction of the
-arrow- .
Wear limit: 0.8 mm
If wear limit is exceeded:
– Repeat measurement with a new valve.
If wear limit is exceeded again:
– Replace the cylinder head.
2.5 Replacing valve shaft seals.


equipment required
♦ Spanner - 3122 B- , see
♦ counterhold - 2036- , see
♦ Valve stem seal extractor -
⇒ page 168
♦ Hose clamp - VW 541/1A-
permitted,unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
see equivalent respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ page 169
♦ Pressure hose - VW
⇒ page 169
♦ Tool for inserting seals onto
the valve stems - 3365- ,
see equivalent
2. Valve control 67
⇒ page 168
Removing
• When cylinder head is installed
– Remove camshaft housing ⇒ page 42 .
– Remove roller rocker arms and place on a clean surface. En‐
sure that roller rocker arms are not mixed up.
sion - 3122 B- .
– Set piston of appropriate cylinder to “bottom dead centre”.
– Insert the valve fitting tool - 2036- and adjust the bearing to the
stud height.
– Screw pressure hose -VW 653/3- into the spark plug thread.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Remove valve springs using valve lever - VW 541/1 A- and
press tool - VW 541/6- .
Note
Tight valve cotters can be loosened by tapping lightly on assem‐

bly lever.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
Installing
– Place plasticpermitted
sleeve supplied on respective valve stem. This
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
will prevent the new valve
respect to the stem seal
correctness from being
of information in this damaged.
– Fit the new valve stem seal onto the installation tool - 3365- .
– Lubricate the sealing lip of valve stem seal and carefully slide
the seal onto the valve guide.
– Install camshaft housing ⇒ page 42 .

17 – Lubrication
1 Parts of lubrication system
⇒ “1.1 Engine oil”, page 69 .
⇒ “1.3 Oil filter - Assembly overview”, page 72
⇒ “1.4 Oil filter element: removing and installing”, page 72
⇒ “1.5 Removing and replacing oil sump”, page 73 .
⇒ “1.6 Oil pump: removing and installing”, page 76 .
⇒ “1.7 Testing oil pressure and oil pressure switch”, page 79 .
Note
♦ During engine repairs if significant amounts of metal shavings

or particles created by damage or abrasion are found in the
oil, this could be due to damage to the piston or bedplate
bearings. To avoid subsequent damage, carry out the follow‐
ing operations following the initial repairs:
♦ Clean minutely, the oil conduits
♦ Replace the oil filter.
♦ The oil level must not be above the max. mark - danger of
damaging catalytic converter! Marks ⇒ page 71
1.1 Protected byEngine oil for private or commercial purposes, in part or in whole, is not
copyright. Copying
Oil capacity
Ibiza: ⇒ Maintenance ; Booklet 601 , Toledo ⇒ Maintenance ;

Booklet KG1
Engine oil specifications
Ibiza: ⇒ Maintenance ; Booklet 601 , Toledo ⇒ Maintenance ;
Booklet KG1
Change engine oil: Ibiza: ⇒ Maintenance ; Booklet 601 , Toledo
⇒ Maintenance ; Booklet KG1 “”
1. Parts of lubrication system 69

1 - Oil pressure switch - F1-

0.3 bar -0.7 Nm, 25 Nm
2 - Guide bushing
3 - Oil pump
❑ must be replaced com‐
pletely
⇒ page 76
4 - 25 Nm
5 - Oil sump
⇒ page 73
❑ Clean sealing surface
before fitting.
❑ Install with silicone seal‐
ant D 176 600 A1
6 - 9 Nm
7 - Oil seal
❑ replace
8 - Oil drain plug, 30 Nm
❑ with captive seal
❑ replace
9 - 8 Nm
10 - Cover
(90º)
12 - Sprocket
❑ For the oil pump
⇒ Item 13 (page 70)
❑ Adjust timing after assembly ⇒ page 58
13 - Drive chain for oil pump
❑ Mark D.O.R. before dismounting (installation position)
14 - Chain tensioner with tensioning plate
❑ Drive chain for operating the oil pump ⇒ Item 13 (page 70)
15 - 15 Nm
16 - Sprocket
❑ Drive chain for operating the oil pump ⇒ Item 13 (page 70)
17 - Bush
❑ With O-ring
Note

mounting
18 - Pulley
❑ Do not tilt during assembly
❑ Poly-V belt: removing and installing ⇒ page 19
70 Rep. gr.17 - Lubrication


❑ replace
❑ Lubricate
❑ Secure pulley with retaining tool - 3415- see equivalent ⇒ page 168 .
❑ The turning further angle can be checked using a commercial protractor e.g. Hazet 6690.
20 - Oil level/oil temperature sender - G266-
21 - Guide pipe
22 - Dipstick
❑ Oil level must not be above max. mark on dipstick!
❑ Marks ⇒ page 71
23 - 10 Nm
24 - Baffle plate
❑ With heated vacuum valve
25 - O-ring
26 - Oil filter, 25 Nm
❑ Oil filter - Assembly overview ⇒ page 72
❑ Oil filter element: removing and fitting ⇒ page 72
27 -by24
Protected Nm Copying for private or commercial purposes, in part or in whole, is not
copyright.
Markings on oil dipstick

1 - max. mark
2 - min. mark
a - Zone between upper ridge of printed area and max. mark: do
not add oil
b - If the level is within the printed area, oil may be added
c - Zone between min. mark and upper edge of printed area: add
at most 0.5 ltr. of oil

1.3 Oil filter - Assembly overview
1 - Screw plug with holder for

the oil filter cartridge, 25 Nm
2 - Oil seal
❑ replace
❑ This is supplied together
with the oil filter car‐
tridge.
3 - Oil filter element
4 - Seal
5 - 24 Nm
6 - Oil filter housing:
7 - O-ring
1.4 Oil filter element: removing and instal‐

ling
Removing
– Unscrew the screw plug using a spanner - T20160- to the edge
-arrow- or about 3 rotations -a-.
Caution
If the screw is taken out completely without waiting a little, oil

will run out and may damage the generator.

– Leave the screw plug in this position for about 1 minute.

– Pull the screw plug with holder for the oil filter cartridge out.
– Lightly knock the screw plug with the oil filter bracket -1- on a
solid base -3- in the direction of the -arrow-.
In this way, the oil filter cartridge is loosened -2-.
– Carefully release the sealing ring from the groove -arrow- us‐
ing a screwdriver.
Installation respect to the correctness of information in this document. Copyright by SEAT S.A.
– Insert the new sealing ring into the groove.

– Fit a new oil filter cartridge and tighten the screw to 25 Nm.
1.5 Removing and replacing oil sump



equipment required
♦ Extractor - SAT 1100- , see
♦ Measuring container -
T10058- , see equivalent
⇒ page 168
lent ⇒ page 168
♦ Electric drill with plastic brush attachment

♦ Flat scraper
♦ Protective glasses
♦ Silicone sealant ⇒ Spare parts catalogue

Removing
anti-splash cover.
– Place the oil extractor - SAT 1100- underneath the engine and
drain the engine oil.
Note
Please observe requirements for disposal.
– Remove the exhaust manifold with front silencer

⇒ page 159 .
– Extract the gearbox and oil sump attachment bolts.
– Unbolt sump sealed with liquid gasket.
– Detach sump. It may be necessary to release sump by tapping
lightly with a rubber head hammer.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove the sealant residues at the oil sump using a rotating

brush, e.g. a hand drill machine with plastic brush (wear pro‐
tective goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe use-by date of sealant.

♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant.
♦ To help when fitting the oil sump, threaded pins M6 may be
inserted in two points in the cylinder block flange.

– Cut off nozzle of tube at front marking (nozzle ∅ approx. 3

mm).
– Apply the silicone-based sealant to the clean contact surface
of the oil sump, proceeding as shown. The strip of sealant
must:
♦ 2...3 mm thick.
♦ Apply along the inner edge of the bolt holes -arrows-.
Note
The sealant bead must not be thicker. Otherwise the excess seal‐
ant may enter the oil sump, and obstruct the strainer in the oil
intake pipe.
– Install sump immediately and tighten all sump bolts lightly.

– Tighten oil sump bolts to 9 Nm.
Note
Starting must be carried out 30 minutes after applying the sealant

to the oil sump. Only then should the engine be refilled with oil.
1.6 Oil pump: removing and installing



equipment required
♦ Extractor - SAT 1100- , see
lent ⇒ page 168
Removing
– Place the oil extractor - SAT 1100- underneath the engine and
drain the engine oil.
Note
– Remove the oil pan ⇒ page 73 .

– Hold oil pump chain sprocket with counterhold - T10172- .
– Loosen chain sprocket securing bolt.
Note
Do not remove bolt completely.

– Push the chain tensioner in the -direction of the arrow- using

a screwdriver.
– Unscrew securing bolt for chain sprocket.
– Take chain sprocket off oil pump and out of chain.
– Loosen oil pump securing bolts -arrows- and remove them.

– Remove oil pump from cylinder
Protected block.
Installing respect to the correctness of information in this document. Copyright by SEAT S.A.
– Push the chain tensioner in the -direction of the arrow- using

a screwdriver.
– Seat chain sprocket in chain and fit chain sprocket onto oil
pump shaft.
– Observe installation position of chain sprocket on oil pump

shaft -arrow-.
– Screw in chain sprocket securing bolt.
– Hold chain sprocket with counterhold - T10172- .

– Place the torque wrench (5...50 Nm) - V.A.G. 1331- as shown.

– Tighten fastening bolt to 20 Nm + 1/4 revolution. (90°) using a
spanner.
– Installing the oil pan ⇒ page 73 .
– Fill with engine oil.
1.7 Testing oil pressure and oil pressure

switch
♦ check ⇒ page 80

equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Pressure tester - V.A.G
1527 B-
♦ Auxiliary cable kit - V.A.G
1594C-

Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test sequence
– Remove oil pressure switch - F1- and screw into oil pressure
tester - V.A.G 1342- .
– Screw tester into cylinder head in place of oil pressure switch.
– Connect the brown wire of the tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- .
– If the LED lights up, replace oil pressure switch Copying
Protected by copyright. -F1- . for private or commercial purposes, in part or in whole, is not
If the LED does not light up: respect to the correctness of information in this document. Copyright by SEAT S.A.
– Start engine and slowly increase engine speed. At 0.3 ... 0.7
bar, the LED must light up; otherwise renew oil pressure
switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.

19 – Cooling
1 Parts of cooling system
Caution
♦ When doing any repair work, especially in the engine com‐

partment, pay attention to the following due to the cram‐
ped conditions:
♦ All the various lines (e.g. fuel, hydraulic system, active
carbon filter system, coolant, refrigerant, brake fluid and
vacuum pipes and hoses) and electrical wiring must be
installed in their original positions.
♦ To prevent damaging the hoses, ensure that all mobile or
hot components are easily accessible.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. Therefore, this pressure must de reduced before repair‐
ing.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Use pliers for spring strap clamps - VAS 5024A- to fit the spring
strap clips.
♦ Coolant hoses should be free from tension when installing, so
that they do not come into contact with other components (ob‐
serve markings on coolant connection and hose).
Perform cooling system leakage check with cooling system tester

- V.A.G 1274- and the adaptors -V.A.G 1274/8- and -
V.A.G 1274/9- .
⇒ “1.1 Cooling system components, bodywork side - Assembly
overview ”, page 81 .
⇒ “1.2 Assembly overview - parts of cooling system, engine side”,
page 83 .
⇒ “1.3 Diagram of coolant hose connections”, page 85 .
⇒ “1.4 Draining and filling cooling system”, page 85 .
⇒ “1.5 Thermostat housing, removing and installing”, page 89 .
⇒ “1.6 Thermostat: removing and installing”, page 90 .
⇒ “1.7 Radiator fan V7 : removal and fitting”, page 91 .
⇒ “1.8 Removing and installing radiator”, page 93 .
⇒ “1.9 Removing and installing coolant pump”, page 95 .
1.1 Cooling system components, bodywork side - Assembly overview
1. Parts of cooling system 81

1 - Spring-type clip
2 - Top coolant hose
❑ Note installation posi‐
tion:
❑ Coolant hose schematic
diagram ⇒ page 85 .
3 - Coolant hose
tion:
4 - Plug
❑ 2 off
❑ 10 Nm
5 - Sealing plug
❑ Check using the cooling
system tester - V.A.G
1274- and the -
V.A.G 1274/9- adapter
❑ Test pressure 1.4...1.6
bar
6 - Expansion reservoir
❑ Perform cooling system
leakage check with
cooling system tester -
V.A.G 1274- and the
adapters -
V.A.G 1274/9- .
7 - To thermostat housing
82 Rep. gr.19 - Cooling

8 - Support plate
❑ 2 off
❑ Bolt: 10 Nm
❑ For radiator
❑ Note installation position:
9 - Air duct with coolant fan - V7-
❑ Air duct fastening screw with radiator fan - V7- : 10 Nm
10 - Plug
❑ 3 off
❑ 10 Nm
11 - Bottom coolant hose
❑ Note installation position:
❑ Coolant hose schematic diagram ⇒ page 85 .
12 - Spring-type clip
13 - Rubber reception
14 - Refrigerant fan - V7-
15 - Electrical connector
16 - Radiator fan thermo-switch - F18-
❑ 35 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For coolant fan - V7-
Switching temperatures
– 1st gear: Turn on: 92 ... 97 ℃, Turn off: 84 ... 91 ℃
– 2nd gear: Turn on: 99 ... 105 ℃, Turn off: 91 ... 98 ℃
17 - Radiator
❑ Renew coolant after replacing.
1.2 Assembly overview - parts of cooling

system, engine side
Thermostat side

1 - Plug
❑ 3 off
❑ 9 Nm
2 - Thermostat cover
3 - From the lower section of
the radiator
4 - Coolant temperature send‐
er - G62-
❑ green
❑ Before removing, possi‐
bly reduce cooling sys‐
tem pressure
5 - O-ring
❑ replace
6 - Retaining clip
❑ 2 off
❑ Check that it is seated
securely
7 - Plug
❑ 4 off
❑ 10 Nm
8 - To upper part of radiator
and expansion tank
9 - Thermostat housing
⇒ page 89
10 - From the engine block
11 - Pipe for coolant
12 - From expansion tank
13 - To the coolant Protected
pump by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Coolant hose schematic correctness ⇒
respect to thediagram page 85in this
of information . document. Copyright by SEAT S.A.
14 - to heat exchanger
15 - From heat exchanger for heater unit.
16 - Coolant regulator
❑ Checking working: Heat the thermostat in water. The tip of the thermocouple must start the opening at
approx. 87 °C and complete it at approx. 102 ℃)
♦ minimum run: 8 mm.
17 - Valve
18 - Spring

1.3 Diagram of coolant hose connections
1 - Expansion reservoir
❑ Perform cooling system
leakage check with
cooling system tester -
V.A.G 1274- and the
adapters -
V.A.G 1274/9- .
2 - Heat exchanger for heater
3 - Thermostat housing
⇒ page 89
4 - Coolant temperature send‐
er - G62-
❑ green
❑ Before removing, possi‐
bly reduce cooling sys‐
tem pressure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Bottom coolant hose
6 - Top coolant hose
7 - Radiator
⇒ page 93
❑ Renew coolant after re‐
placing ⇒ page 85
8 - Cylinder block
9 - Coolant pump
⇒ page 95
1.4 Draining and filling cooling system

♦ Empty ⇒ page 86
♦ Filling ⇒ page 87


equipment required
♦ Measuring instrument -
T10007-
♦ Charger - VAS 6096-
♦ Collecting tray - VAS 6208- , see equivalent

Draining
WARNING



anti-splash cover.
– Open and close the compensation tank to release pressure in
cooling system.
– Place under the collecting tray - VAS 6208- .
– Release the hose clips -Arrow- and remove the hose.
Note
Filling
Note respect to the correctness of information in this document. Copyright by SEAT S.A.
The amount of water used in the coolant mixture has a great in‐
fluence on its effectiveness. Because the water quality differs
from country to country and even region to region, Volkswagen
has decided to define the quality of the water to be used in the
coolant system. Distilled water fulfils all requirements. It is there‐
fore recommended that purified water is mixed with the coolant
whenever an older model's coolant is toped up or replaced. On
newer vehicle models (model year 2010 ►), the use of purified
water is absolutely essential.

Note
♦ Only use antifreeze additive G 12 plus-plus according to spec‐

ification “TL VW 774 G”.
♦ It is only permissible to use distilled water for mixing.
♦ Coolant additives marked “in accordance with TL VW 774 G”
prevent lime accretion, frost damage and corrosion. Moreover,
the boiling temperature is raised. For this reason, the cooling
system must be filled with coolant additive all year round.
♦ Thanks to this rise in the boiling point, the coolant guarantees
good running, even when the engine undergoes heavy strain,
especially in countries with tropical climates.
♦ The antifreeze protection must be guaranteed to approx. - 25
ºC (down to approx. -35 ℃ in countries with arctic climate).
♦ The concentration of the coolant must not be reduced by add‐
ing water in summer or in countries with hot climates. The
amount of anti-freeze in the coolant must be at least 40 %.
♦ If a stronger anti-freeze mixture is necessary due to harsher
weather conditions, it can be increased using G 12 Plusplus.
It may only be strengthened, however, to 60% (antifreeze pro‐
tection to about -40 ℃). If the proportion is greater, the cooling
and anti-freeze protection capacity is reduced.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket has been replaced, do not reuse old coolant.
♦ The refractometer -T10007- is recommended for determining
the current anti-freeze density.
Recommended mixture ratios:

Frost Anti-freeze G 12 plus1) Water 1)
protection to proportion G 12 plus permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
plus1) respect to the correctness of information in this document. Copyright by SEAT S.A.
-25 ℃ 40 % 2.25 l 3.35 l

-35 ℃ 50 % 2.8 l 2.8 l
1)The quantity of coolant can vary depending upon the vehicle
equipment.
– Put the coolant hose on the connecting hose and fix using the
hose clips -arrow-.

– Fit the engine anti-splash cover.

Using cooling system charge unit - VAS 6096- :
– Fill the coolant circuit using the -VAS 6096- cooling system
filling equipment⇒ Instructions for operation the cooling sys‐
tem filler equipment VAS 6096, instructions .
Without cooling system filler - VAS 6096- :
– Fill with coolant up to max. mark on expansion tank.

With or without cooling system filler - VAS 6096-
– Seal expansion reservoir.
– Turn off heater controls.
– Start the engine and keep the engine speed at approx. 2000
rpm for approx. 3 minutes.
– Let the engine run until coolant fan - V7- cuts in.
WARNING

– Check coolant level and top up any missing coolant, if neces‐

sary. If the engine is warm, coolant level must be at max. mark;
if cold, between min. and max. marks.
1.5 Thermostat housing, removing and in‐

stalling
♦ Base - VAS 6340- , see equivalent ⇒ page 168


⇒ page 168
Removing
– Switch off ignition.
– Remove hoses from connection sleeves ⇒ Item 3 (page 84) ,
⇒ Item 8 (page 84) , ⇒ Item 14 (page 84) and
⇒ Item 15 (page 84) using the pliers for spring type clips - VAS
5024A- .
– Unplug the terminal connector on the coolant temperature
sender - G62- ⇒ Item 4 (page 84) .
– Press the tab ⇒ Item 6 (page 84) .
– Remove the bolts ⇒ Item 7 (page 84) and pull the thermostat
casing outwards.
Installing
1.6 Thermostat: removing and installing

Special tools
permitted unless and workshop
authorised equipment
by SEAT S.A. SEAT required
S.A does not guarantee or accept any liability with
♦ Pliers for spring-loaded band-type clamps - VAS 5024 A- , see


⇒ page 168
Removing
– Remove hoses from connection sleeve ⇒ Item 3 (page 84)
using the pliers for spring type clips - VAS 5024A- .
– Unplug the terminal connector on the coolant temperature
sender - G62- ⇒ Item 4 (page 84) .
– Remove bolts ⇒ Item 1 (page 84) .
– Remove the thermostat ⇒ Item 16 (page 84) .
Installing
– Fill up coolant
permitted⇒ page 85 . by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
1.7 Radiator fan - V7- : removal and fitting
⇒ page 168
Removing
– Remove front bumper lining ⇒ Bodywork, exterior installation
work; Rep. gr. 63 ; Front bumper lining: removing and instal‐
ling .
– Remove the front cross-member ⇒ Lock carrier - exploded
view; Rep. gr. 50 ; General body repairs, exterior .


anti-splash cover.
– Disconnect the connector from the coolant fan - V7- .
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Note
In order to avoid damage to the condenser as well as to the re‐

frigerant lines and hoses, ensure that the lines and hoses are not
over-tensioned, kinked or bent.

– Unscrew the bolts -1- that fasten the radiator to the lock carrier
plate.
– Move radiator-air duct forwards.
– Press upper locking elements on both sides -1- and remove

air duct upwards -arrow-.

– Remove clips -3- using a screwdriver.

– Separate tabs -4- from fastenings and remove protector -5-.
– Undo bolts -1- and remove coolant fan - V7- -2- from air
duct-6-.
Installing
– Observe correct procedure for assembly of locking elements
of the radiator unit - air duct.
Specified torques:
Component Nm
Coolant fan - V7- to air duct 10
1.8 Removing and installing radiator



equipment required
♦ Refractometer - T10007-
lent ⇒ page 168
♦ Collecting tray - VAS 6208- , see equivalent ⇒ page 168

Removing
anti-splash cover.
– Pull connector off thermo-switch and radiator fan.
– Pull coolant hoses off radiator.
Vehicles with air conditioning/heating: additional instructions and
assembly information
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Note
In order to avoid damage to the condenser as well as to the re‐

frigerant lines and hoses, ensure that the lines and hoses are not
over-tensioned, kinked or bent.
– Unscrew the bolts -1- that fasten the radiator to the lock carrier
plate. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Move radiator-air duct forwards.
– Unscrew the bolts -2- attaching the catalytic converter to the
sump.
– Remove radiator-air duct upwards.
– Press upper locking elements on both sides -1- and remove

air duct upwards -arrow-.
Installing
– Observe correct procedure for assembly of locking elements
of the radiator unit - air duct.
Note
Secure all hose connections with the correct hose clips (same as
original equipment) ⇒ Parts catalogue .

– Electrical connections and routing: ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
1.9 Removing and installing coolant pump




equipment required
♦ Refractometer - T10007-
lent ⇒ page 168
♦ Coolant pump wrench - V.A.G 1590- , see equivalent

⇒ page 168 .
Modifying water pump wrench - V.A.G 1590-

– Due to changes to the securing bolts of the coolant pump pul‐
ley, file the rounded ends in a = 1 mm at minimum.

Removing
Note
♦ The integrated coolant pump seal must not be separated from

the coolant pump.
♦ Damaged or leaking coolant pumps must be completely re‐
placed with seal.

– To lock the pulley, use the coolant pump wrench - V.A.G
1590- .
– Unscrew fastening bolts -arrows- for the
permitted coolant
unless authorisedpump
by SEAT pulley
S.A. SEAT S.A does not guarantee or accept any liability with
and remove pulley. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Unscrew securing bolts -arrows- of the coolant pump -1- and

remove pump from engine block.
Installing
– Place the coolant pump onto the engine block.
– Tighten securing bolts to 25 Nm
– Tighten the coolant pump pulley to 20 Nm.
– Fill up with coolant ⇒ page 85 .

20 – Fuel supply system

1 Fuel supply system components
Note
♦ The connections for the flexible tubes are secured using spring
type clips or screw clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ Fuel hoses at the engine must only be secured with spring-
type clips. The use of clamp or screw-type clips is not permis‐
sible.
♦ Hose clip pliers - VAS 5024A- are recommended for fitting
spring-type hose clips.
♦ After removing the filter, the pump or the fuel distributor, the
fuel supply system must be bled ⇒ page 121 .
⇒ “1.1 Fuel tank with attached components - exploded view”, page

98 .
⇒ “1.2 Fuel tank with attached components - exploded view”, page
101
⇒ “1.3 Safety precautions when working on the fuel supply sys‐
tem”, page 104 .
⇒ “1.4 Rules for cleanliness”, page 105 .
⇒ “1.5 Removing and installing fuel delivery unit”, page 105 .
⇒ “1.6 Removing and installing fuel gauge sender G ”,
page 107 .
⇒ “1.7 Removing and installing fuel tank”, page 109 .
⇒ “1.8 Fuel filter: replace”, page 112 .
⇒ “1.9 Crash fuel shut-off”, page 114 .
⇒ “1.10 Testing fuel pump”, page 114 .
⇒ “1.11 Fuel delivery system: bleeding”, page 121 .
1.1 Fuel tank with attached components - exploded view

98 Rep. gr.20 - Fuel supply system

1 - Retaining clip
2 - Sealing plug
3 - Oil seal
4 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
5 - Gravity valve
❑ For removal, remove
the fuel tank cap
⇒ Item 4 (page 99) , un‐
do the securing tab and
push the inlet valve out,
upwards.
Check valve for through-flow.
❑ Perpendicular valve:
open Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Valve inclined ± 45°:
closed.
6 - Earth connection
securely
7 - 10 Nm
8 - Vent line
❑ Between active carbon
filter
and vent pipe ⇒ Item 15 (page 99)
❑ Check that it is seated securely
9 - Active carbon filter
❑ Location: in right rear wheel housing
❑ Activated charcoal filter system ⇒ page 127
10 - 10 Nm
11 - Vent line
❑ Clipped onto fuel tank
12 - 25 Nm
❑ 5 off
13 - Fuel tank
❑ When removing, support with the engine and gearbox crane - V.A.G 1383 A-
❑ If the fuel tank has been replaced, the fuel supply system must be bled ⇒ page 121
14 - tension belt
15 - Vent line
❑ For the Solenoid valve 1 for the active carbon filter system (pulsed) - N80- , in the engine compartment
1. Fuel supply system components 99

16 - Fuel filter:
❑ With pressure regulator
❑ Fitting position: The arrow indicates the direction of flow
❑ The fuel pressure regulator can be found in the fuel filter.
❑ If the fuel filter has been replaced, the fuel supply system must be bled ⇒ page 121
17 - Fuel supply line
❑ Black
❑ To the fuel distributor in the intake manifold
18 - 5 Nm
❑ for the clamping bracket for the fuel filter
19 - Fuel delivery unit
❑ Note fitting position on fuel tank ⇒ page 101
❑ Checking fuel pump ⇒ page 114 .
❑ With fuel level indicator sender - G-
❑ Separating and fitting the fuel level sender ⇒ page 107
20 - Oil seal
❑ Moisten with fuel for installation
21 - Hood nut, 80 Nm
❑ Remove and install using wrench - 3217- .
22 - Delivery line
❑ To fuel filter ⇒ Item 16 (page 100)
❑ Clipped to the fuel tankProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Check for secure seating respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Black
❑ To pull off flange, press release button on connecting piece.
23 - Return-flow line
❑ Blue colour or blue mark
❑ Clipped to the fuel tank
❑ Check for secure seating
24 - Vent valve
❑ To remove pull locking latch lightly to inside and pull valve out
❑ To get access to the breather valve, remove the fuel tank cover unit ⇒ Bodywork, exterior fitting work;
Rep. gr. 55 ; Bonnet, tailgate or boot, covers Fuel tank cover unit; General overview
❑ Before fitting, unscrew the cap

Fitting position of fuel delivery unit flange

The marking on the sender must align with the marking on the
fuel tank -arrows-.
Return pipe -2- (blue or with blue marking) to connection marked
-R-.
Black supply pipe -3- to connection with -V- .
Note
After installing fuel delivery unit flange, check that the supply, re‐
turn and breather pipes are still clipped onto the fuel tank.
Inspect vent valve

Lever in rest position: closed
Lever pushed in direction of arrow: open.
Note
Before installing vent valve remove fuel tank cap.
1.2 Fuel tank with attached components - exploded view

1 - Fuel tank
❑ When removing, sup‐
port with the engine and
gearbox crane - V.A.G
1383 A-
⇒ page 109
❑ If the fuel tank has been
replaced, the fuel supply
system must be bled
⇒ page 121
2 - Oil seal
❑ Moisten with fuel for in‐
stallation
3 - Fuel delivery unit
❑ Note fitting position on
fuel tank ⇒ page 104
⇒ page 105
❑ Checking fuel pump
⇒ page 114 .
❑ With fuel level indicator
sender - G-
❑ Separating and fitting
the fuel level sender
⇒ page 107
4 - Hood nut, 80 Nm
❑ Remove and install us‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ing wrench - 3217- . respect to the correctness of information in this document. Copyright by SEAT S.A.
5 - Return-flow line
❑ Blue colour or blue mark
❑ Between the fuel pump unit and the fuel filter
6 - Delivery line
❑ To fuel filter ⇒ Item 23 (page 103)
❑ Black
7 - Overflow hose
8 - Sealing plug
9 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
10 - Earth connection

11 - O-ring
12 - Vent valve
❑ To remove pull locking latch lightly to inside and pull valve out
❑ To get access to the breather valve, remove the fuel tank cover unit ⇒ Bodywork, exterior fitting work;
Rep. gr. 55 ; Bonnet, tailgate or boot, covers Fuel tank cover unit; General overview
❑ Before fitting, unscrew the cap
13 - Gravity valve
❑ For removal, remove the fuel tank cap ⇒ Item 9 (page 102) , undo the securing tab and push the inlet
valve out, upwards.
Check valve for through-flow.
❑ Perpendicular valve: open
❑ Valve inclined ± 45°: closed.
❑ Activated charcoal filter system ⇒ page 129
15 - Vent line
❑ Clipped onto fuel tank
16 - O-ring
17 - Plug
❑ 10 Nm
18 - Retainer
19 - Heat shield
❑ For fuel tank
20 - 25 Nm
❑ 5 off
21 - tension belt
❑ Note the different measurements
22 - Fuel supply line
❑ Black
❑ To the fuel distributor in the intake manifold
23 - Fuel filter:
❑ With pressure regulator
❑ Fitting position: The arrow indicates the direction of flow
❑ The fuel pressure regulator can be found in the fuel filter.
❑ If the fuel filter has been replaced, the fuel supply system must be bled ⇒ page 121
24 - Fuel filter holder
❑ 3 Nm
25 - Activated charcoal filter solenoid valvepermitted
1 - N80- unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
26 - Vent line
❑ For the Solenoid valve 1 for the active carbon filter system (pulsed) - N80- , in the engine compartment

Fitting position of fuel delivery unit flange

The marking on the sender must align with the marking on the
fuel tank -arrows-.
Return pipe -2- (blue or with blue marking) to connection marked
-R-.
Black supply pipe -3- to connection with -V- .
Note
After installing fuel delivery unit flange, check that the supply, re‐
turn and breather pipes are still clipped onto the fuel tank.
Inspect vent valve

Lever in rest position: closed
Lever pushed in direction of arrow: open.
Note
Before installing vent valve remove fuel tank cap.
1.3 Safety precautions when working on the
fuel supply system
Caution

tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, active
vacuum pipes and hoses) and electrical wiring so that the
original positions are restored.
♦ To prevent damaging the hoses, ensure that all mobile or
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
WARNING

♦ Before beginning work, place an extraction hose close to

sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust extraction

system is available, a radial fan (as long as motor is not in air

flow) with a displacement greater than 15 m3/h may be used.
♦ Avoid skin contact with fuel. Use fuel resistant gloves!
♦ For safety reasons, the fuel pump fuse must be removed be‐
fore the fuel system is opened, seeing as the fuel pump can
be activated by the door contact switch in the driver's door.
Fuse installation ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations
1.4 Rules for cleanliness

When carrying out work on the fuel supply and injection system,
the following cleanliness rules must be observed:
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use lenty rags!
♦ Carefully cover or seal open components if repairs cannot be
completed immediately.
♦ Only fit clean parts: Only remove replacement parts from
packaging immediately before assembly. Do not use parts that
have been stored loose (e.g. in toolboxes etc.).
♦ If the system is open, do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.5 Removing and installing fuel delivery

unit
♦ Spanner - 3217- , see equivalent ⇒ page 169


⇒ page 168
Removing
– Note safety precautions before starting work ⇒ page 104
• To remove the fuel supply unit, the tank should be at a maxi‐
mum of 1/2 of full capacity. Drain the tank if necessary.
– With the ignition switched off, disconnect battery earth strap
Ibiza
– Fold down the rear seat forwards.
– Unclip fastening notches -arrows- and remove the protector
from the fuel supply unit.
Toledo
– Remove the rear bench ⇒ Bodywork, interior fitting work; Rep.
gr. 72 .
– Remove the cover -1- of the fuel delivery unit together with the
fuel pump control unit - J538- -2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
All vehicles (continued) permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
WARNING
The fuel and the fuel lines may become excessively hot (burn
risk).
The fuel supply system is also under pressure. Before opening
the system, place a cloth over the junction and depressurise
the system by gently loosening.
For all assembly work carried out on the fuel supply system,
protective glasses and gloves must be worn!

– Remove the 5-pin connection terminal from the fuel pump,

-1- and the supply lines -3- and return lines -2-.
Note
To do this, press on the connection buttons for the hoses.
– Unscrew union nut using key - 3217- .

– Pull fuel delivery unit and seal out of their housing in fuel tank.
Note
If the fuel delivery unit is to be renewed thenProtected

drain the old unit
before disposal.
Installing
Note
♦ Take care not to bend the fuel level sender during fitting.
♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten the seal using fuel only for fitting of the flange or the
fuel delivery unit.
♦ Ensure that fuel hoses are securely seated.
♦ After installing the fuel supply unit, check that the fuel supply
-3- and fuel return line -2- lines are clipped onto fuel tank.
♦ Note the fitting position of the fuel delivery unit flange: The
mark on the flange should coincide with the mark made on the
fuel tank -arrows- .
1.6 Removing and installing fuel gauge

sender - G-

♦ Spanner - 3217- , see equivalent ⇒ page 169

⇒ page 168
Removing
– Remove fuel delivery unit ⇒ page 105 .
– Push the fuel level sender - G- slightly inwards in the
-direction of the arrow- and at the same time remove upwards
in the -direction of the arrow-.
– Unlock the connector tabs -1 … 3-, inserting a fine screwdriver

through the holes -arrows- and disconnect the connectors.
Installing

Fitting position for fuel level indicator sender - G- cables

I - Brown Cable
II - Blue Cable
III - Black Cable
Note
When mounting the fuel level sender - G- on the supply unit, make
sure that the cables are correctly positioned.
– Insert the fuel gauge sender - G- into the guides on fuel deliv‐
ery unit and press upwards until it clicks into place.
1.7 Removing and installing fuel tank

⇒ page 168
♦ Engine/gearbox jack - V.A.G 1383 A-
Removing
– Note safety precautions before starting installation work
⇒ page 104 .
– Remove the plenum chamber cap ⇒ Bodywork,
permitted unless exterior fitting
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
work; Rep. gr. 55 ; Plenum chamber cap:removing and fitting .
– Drain fuel tank and clean fuel filler neck and surrounding area.

Ibiza
Toledo
gr. 72 .
fuel pump control unit - J538- -2-.
– Pull 5-pin connector -1- off flange.

– Remove rear right wheel.
– Remove the rear right-hand wheel housing moulding ⇒ Body‐
work, exterior fitting work; Rep. gr. 66 ; Rear wheel house
moulding:removing and fitting .
Ibiza
– Pull off the pressure holding valve -1- and the breather line
-2- (press in safety ring).

– Unscrew the securing bolt -arrow-.
Toledo
– Unscrew fixing screws at tank filler neck -arrows-.
– Detach both vent lines from the activated charcoal container,
if they are installed in the wheelhouse at the rear, by pressing
the locking buttons ⇒ page 129 .
– Remove the rear axle ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Rear axle: removing and fitting
– Remove silencer ⇒ page 161 .
– Undo clips -arrows- and remove exhaust pipe protector.
WARNING

– Disconnect the supply hose -1- (black) and the breather hose
-2- (white) at the connecting point.

Ibiza
– Remove clamping strap and mounting screws -1 to 5-.
Toledo
– Remove the clamping screws and securing bolts -arrows-.
Note
During this operation, support the fuel tank with the engine and
gearbox crane - V.A.G 1383 A- .
– Lower fuel tank.

Installing
♦ Breather and fuel hoses are to be installed kink-free.
♦ Secure hoses with spring-clips.
♦ Check the connections on the active carbon filter.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
Note
♦ After installing fuel tank, check that the supply, return

Protected and Copying for private or commercial purposes, in part or in whole, is not
by copyright.
breather lines are still clipped onto the fuelpermitted
tank. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ After replacing (fitting) the fuel tank, the fuel supply system
should be bled ⇒ page 121
1.8 Fuel filter: replace



⇒ page 168
Removing
Note
♦ Note safety precautions before starting installation work

⇒ page 104 .
♦ Observe rules for cleanliness ⇒ page 105 .
– Place container under fuel filter.
WARNING
Fuel system is under pressure! Before opening the system

place a cloth around the connection. Then release pressure by
carefully pulling fuel hose from connection. Wear eye protec‐
tion and gloves to avoid injuries and skin contact.
– Pull off fuel lines -1-, -2- and -3- by pressing release button.
– Unscrew the bolt -4-.
– Remove fuel filter.
Installing
installation position
Pin -2- on filter housing must engage in notch of guide -1- in filter
bracket.
Flow direction is marked on filter housing with arrows.
The tightening torque for the securing clip is 3 Nm.
Note
After replacing (fitting) the fuel filter, the fuel supply system should
be bled ⇒ page 121 .

1.9 Crash fuel shut-off

functioning
This system reduces the risk of a vehicle burning in the event of
a crash in that the fuel pump is switched off by the fuel pump relay.
It also achieves more comfort when starting the engine. When the
door is opened, the fuel pump is activated for 2 seconds in order
to build up pressure in the fuel system.
Observe safety measures when opening the fuel system
⇒ page 104
– Checking fuel pump relay: ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
1.10 Testing fuel pump

♦ Operation and voltage supply: verification ⇒ page 116
♦ Check the fuel pressure ⇒ page 117 .
♦ Retention pressure: check ⇒ page 119
♦ Fuel delivery rate: check ⇒ page 119
♦ Checking current draw ⇒ page 121 by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless authorised

equipment required
♦ Spanner - 3217- , see
♦ Pressure tester - VAG
1318-
♦ Adapter - VAG 1318/1-
Nm) - V.A.G 1332- , see

♦ Measurement device - VAG

1348/2B- Remote control -
VAG 1348/3 A-
♦ Pressure tester - VAG
1527B-
♦ Auxiliary cable kit - VAG
1594C-
♦ Digital multimeter - VAG
1715-
♦ Measurement device
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Step ladder
♦ Measuring container
♦ Current flow diagrams, electrical fault finding and fitting loca‐
tions

1.10.1 check operation and electricity supply

Test prerequisites
• The fuse for the fuel pump must be in perfect condition. Fuse
installation ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
• The battery voltage must be at least 11.5 V.
Note
♦ The operation of the fuel pump is checked with the actuator

diagnosis.
♦ Observe the functional description of the crash fuel shut-off
system ⇒ page 114 .
– Connect the Vehicle diagnostic, testing and information sys‐

tem - VAS 5051 A- as follows:
– Plug the connector 2 of the diagnosis cable into the diagnosis
socket in the footwell on the driver's side.
– Switch on the ignition.
– Press buttons on display one after the other for “Vehicle self-
diagnosis”, “01 - Engine electronics” and “Final control diag‐
nosis”.
– Press the right-hand side button until the fuel pump electronic
actuator diagnosis is selected.
The fuel pump should start running, first slowly and then gradually
up to full power.
Note
The fuel pump runs very quietly.
Switch off ignition.

If the fuel pump does not run:
Ibiza

Toledo permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
gr. 72 .

fuel pump control unit - J538- -2-.
– By performing a pull check without actuating the lock, check if
the plug connector A has been connected correctly.
– Pull the connector from the fuel tank flange.

– Check theProtected
contact by on the Copying
copyright. plug connector and thepurposes,
for private or commercial fuel supply
in part or in whole, is not
unit for damage.
– Fit the adapter - VAS 5565- to the connection and to the fuel
delivery unit.
– Connect the voltage tester - VAG 1527B- to terminals -1- and
-5- of the adapter.
Switch on the ignition.
– LED must light up briefly.
If the LED does not light up:
– Locate and eliminate open circuit using current flow diagram
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
If LED lights up (voltage supply OK):
– Unscrew union nut using key - 3217- .

– Check that the electrical wires between flange and fuel pump
are connected.
If there is cable integrity:
– Renew fuel delivery unit.
1.10.2 Checking fuel pressure
Note
The fuel pressure regulator is installed on the fuel filter.

Checking sequence
WARNING
Fuel system is under pressure! Wear safety goggles and pro‐

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
– Separate the coupling from the fuel supply line -arrow- and
catch escaping fuel with a cloth.
Note
Press in safety ring to release fuel lines.
– Connect the K-Jetronic pressure tester - V.A.G 1318- using

the adapters - V.A.G 1318/9- and -VAG 1318/17A- as shown.
– Open pressure tester shut-off valve. Lever must Protected
point inbydi‐
rection of flow.
– Start engine and run at idling speed.
– Measure the fuel pressure.
Specification: 3.90 ... 4.20 bar
If readout does not match specification:
Caution
The shut-off valve must be closed slowly. As soon as a fuel

pressure of 4.2 bar is reached, the shut-off valve must be
opened immediately in order to avoid damaging the pressure
gauge.
– Close cut-off valve -arrow- on pressure tester. Pressure must

rise to min. 3.9 bar. When 4.2 bar is reached, open shut-off
tap again immediately.
If pressure has risen:
– Fuel filter is OK. Pressure limiting valve in the fuel filter faulty:
Replace the fuel filter.
If pressure does not rise:
– Fuel pump is defective, renew fuel delivery unit.
Note
Before removing pressure gauge place a cloth around the con‐

nections to be loosened

1.10.3 Checking residual pressure

Test condition
• Fuel pressure is correct and the K-Jetronic pressure tester -
V.A.G 1318- connected.
Checking sequence
– Remove cover from fuse holder.
– Remove the fuel pump fuse from the fuse holder. Fuse allo‐
cation ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
– Connect the remote control for the V.A.G 1348 - V.A.G
1348/3A- with adapter cable - V.A.G 1348/3-2- to the fuse ba‐
sis and battery positive (+).
WARNING

tion. Then release pressure by carefully pulling hose off con‐
nection. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull the supply line -1- from the fuel filter outlet.
Note
– Connect pressure tester - V.A.G 1318- with the double hose -

V.A.G 1318/23- and the adapter unit - V.A.G 1318/17A- as
shown in figure.
– Close pressure gauge shut-off tap (lever at right angles to the
flow direction - position -B-).
– Actuate the remote control for V.A.G 1348 - V.A.G 1348/3A-
for about 10 seconds for filling the fuel filter and to generate a
pressure equalisation in the system at 4 bar.
– Watch pressure drop on pressure gauge. After 10 minutes the
pressure must not drop below 3 bar.
If the pressure still drops:
– Check pipe connections for leaks.
If no fault in lines is detected:
– Replace fuel pressure regulator.
1.10.4 Checking delivery rate

Test prerequisites
• Voltage supply OK.
• Remote control for V.A.G 1348 - V.A.G 1348/3A- is connected.

Checking sequence
Note
The delivery rate of the fuel pump is measured at a pressure of 3

bar. This is why you have to check the fuel pressure before meas‐
uring the delivery rate.
– Remove filler cap from fuel tank filler neck.

– Disconnect the fuel return line -1-. Push the buttons on the fuel
hose coupling for this purpose.
– Connect the Adapter - V.A.G 1318/17A- to the fuel pressure
regulator and place the adapter end in a measuring container.
– Operate remote control -V.A.G 1348/3A- for approx. 5 sec‐
onds to fill fuel filter.
– Drain measuring container.
– The quantity of fuel delivered by the fuel pump is dependent
upon voltage. Therefore, connect the multimeter with auxiliary
line from the auxiliary measuring set - VAG 1594C- to both
external contacts (with connector attached) of the fuel pump.
– Operate remote control for 30 seconds and measure the volt‐
age.
– Compare the fuel flow measured with the specification.

3) Minimum delivery cm3/30 seconds
4) Voltage on the fuel pump when the engine is stationary and with running pump
(approx. 2 volt under battery voltage).
Readout example:
During the test a voltage of 10.5 volts is measured. At this voltage
the pump can produce a minimum delivery rate of 540
cm3/30 secs.
If the minimum delivery rate is not attained:
– Check the fuel supply pipes to the filter for possible restrictions
(kinks) or blockages.
If the fuel line is not damaged:
– Check the flow of fuel at the entry to the fuel filter.
WARNING

release pressure by carefully pulling hose off connection.

– Pull supply hose -1- off inlet to fuel filter.
Note
– Connect pressure tester - V.A.G 1318- using the adaptors -

V.A.G 1318/17- as shown.
– Connect the Adapter - V.A.G 1318/1- to the Adapter - V.A.G
1318/11- of the pressure gauge and hold it in the measure‐
ment container.
– Open pressure tester shut-off valve. The lever then points in
through flow direction -A-.
– Activate the V.A.G 1348 remote control - V.A.G 1348/3A- . In
doing so, slowly close the shut-off cock arrow until pressure
gauge indicates a pressure of 3 bar. From here on, do not
change position of shut-off tap.
– Drain measuring container.
– Activate remote control again for 30 seconds. Compare the
flow with the first value measured.
If the minimum flow rate is now reached:
– Replace fuel filter ⇒ page 112 .
If the minimum flow rate is again not reached:
– Remove the fuel delivery unit and check the strainer filter for
soiling ⇒ page 105 .
Only when up to now no fault has been detected:
– Replace fuel delivery unit ⇒ page 105 .
1.10.5 Checking current consumption

– Check the power consumption of the fuel pump as follows:
– Connect multi-metre - V.A.G 1715- with crocodile clip to wiring
to contact 1 -arrow- of 5-pin connector.
– Measure current draw
permitted ofauthorised
unless fuel pump.by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Specification: max. 8 amps.
Note
If there is a temporary fuel system fault, the check can also be

carried out during a test drive, with the help of a second person.
If the power consumption is exceeded:

– Replace fuel delivery unit ⇒ page 105 .
1.11 Fuel delivery system: bleeding

♦ Bleeding ⇒ page 123


equipment required
♦ Remote control - V.A.G
1348/3 A-
♦ Adaptor cable - V.A.G
1348/3-2- , see equivalent
⇒ page 169
♦ Diesel extraction system -
VAS 5226-


♦ Adapter - V.A.G 1318/20-1-
Fuel supply system: bleed
Test prerequisites
• The fuses must be in good condition. Fuse allocation ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
• Battery voltage min. 11.5 V
• Fuel pump relay OK.
To avoid damage to the catalytic converter, the fuel system must
be purged of air without return line after performing work on fuel
lines or on fuel filter. The vehicle must only be started after purging
the system of air.
Observe rules for cleanliness ⇒ page 105 .
Checking sequence
– Remove cover from fuse holder.
– Remove the fuel pump fuse from the fuse holder. Fuse instal‐
lation ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
– Connect remote control - V.A.G 1348/3A- with adapter cable
- V.A.G 1348/3-2- to lower contact to fuel pump and battery
positive (+).
WARNING
Fuel system is under pressure! Wear
permitted safety
unless goggles
authorised by SEATand ap‐S.A does not guarantee or accept any liability with
S.A. SEAT
propriate clothing to avoid injury and contact
respect with skin.
to the correctness Beforein this document. Copyright by SEAT S.A.
of information
tion. Then eliminate the pressure by carefully separating the
pipe.
– Unscrew and remove the bleeding valve cover from the fuel
distributor.
DANGER!
Bleeding should only be carried out when the engine is cold -

there is a risk of fire from the released fuel vapour.
As a small amount of fuel may spill out, the bleed valve should
be wrapped with a clean cloth

– Screw the adapter - VAG 1318/20-1- onto the adapter - VAG

1318/20- .
– Turn valve (on T piece) anti-clockwise until it is entirely open.
– Manually screw adapter - VAG 1318/20- to the fuel distributor

bleeding valve.
– Attach diesel fuel extractor hose - VAS 5226- as shown.
– Screw valve (onpermitted
T piece) clockwise
unless to stop
authorised by SEAT into S.A
S.A. SEAT bleed valve.
does not guarantee or accept any liability with
– Check the adapter and hose connectors for leaks.
– Operate remote control - VAG 1348/3A- until fuel flows free of
air bubbles from bleed valve.
– Turn valve (on T piece) anti-clockwise until it is entirely open.
– Clamp the diesel extractor hose - VAS 5226- (e.g. using hose
clamps of up to 25 mm in diameter) - 3094- and remove it from
adapter -V.A.G 1318/20-1- .
– Unscrew adapter -V.A.G 1318/20- from bleeder valve.
– Screw on the bleeding valve cover from the fuel distributor.

2 Electronic regulation of engine out‐

put, electronic accelerator
⇒ “2.1 functioning”, page 125 .
⇒ “2.2 Electronic power control (EPC) - Components overview”,
page 125 .
2.1 functioning
In the EPC, the throttle is not operated by a control cable from the
accelerator. There is no mechanical link between the accelerator
and the throttle valve.
The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in a housing) which are connected to the accelerator pedal
The position of the accelerator (driver's requirement) is the main
input value for the engine control unit
The throttle is operated over the complete revolution and load
range by an electric motor (throttle position device) in the throttle
control part.
The throttle valve position device actuates the throttle valve ac‐
cording to the commands it receives from the engine control unit.
With the engine off and the ignition connected, the engine control
unit operates the throttle positioner according to the data provided
by the accelerator position sender. For example, when the accel‐
erator is pressed down half way, the throttle valve position device
opens the throttle valve by an equivalent amount, i.e. about half
way.
When the engine is running (under load) the engine control unit
can open or close the throttle valve independently of the accel‐
erator pedal position sender.
For example, the throttle valve might already be fully open even
though the accelerator is only pressed down half way. The ad‐
vantage of this is that losses through bottlenecks caused by the
throttle are avoided
After evaluating the torque requirements of various components
(e.g. air conditioning, automatic gearbox, ABS/ESP and so on),
the engine control unit calculates the optimal throttle valve open‐
ing angle for the respective situation
This also gives vastly improved consumption and exhaust emis‐
sion levels at certain load conditions
It is incorrect to believe that the “E-Gas” is comprised of one or
two components
Protected byonly. The
copyright. EPC
Copying is a system,
for private which
or commercial is incomprised
purposes, part or in whole, is not
of all components
permitted unlesswhich have
authorised an
by SEAT influence,
S.A. SEAT S.A does control or monitor
not guarantee theliability with
or accept any
position of the throttle valve, e.g. the accelerator pedal position

sender, the throttle valve control unit, the EPC warning lamp, the
engine control unit.
2.2 Electronic power control (EPC) - Components overview
2. Electronic regulation of engine output, electronic accelerator 125

1 - Support plate
❑ Removing and fitting ⇒
Running gear; Rep. gr.
46
❑ Black, 6-pin
3 - Accelerator pedal position
sender - G79- and accelerator
pedal position sender 2 -
G185-
❑ When removing, re‐
move foot well protec‐
tion and pedal cluster.
4 - Bolt
❑ 3 off
❑ 10 Nm

3 Activated charcoal filter system

⇒ “3.1 functioning”, page 127 .
⇒ “3.2 Activated charcoal filter system - exploded view”,
page 127 .
⇒ “3.3 Activated charcoal filter system - exploded view”,
page 129
⇒ “3.4 Checking fuel tank breather”, page 129 .
⇒ “3.5 Checking fuel tank breather”, page 130
3.1 functioning
Depending upon the air pressure and ambient temperature, fuel
vapour will form above the level of fuel in the tank.
The active carbon filter system prevents these hydrocarbon emis‐
sions escaping to the atmosphere
Fuel vapours pass through a gravity valve (which closes at an
angle of 32°) located at the highest point in the tank and through
a pressure retention valve into the active carbon filter in limited
quantities.
The activated charcoal stores these gases in the same way as a
sponge.
When the car is being driven and the lambda
Protected by copyright.control isprivate
Copying for activeor commercial purposes, in part or in whole, is not
(engine warm), the activated carbon
permittedfilter
unless solenoid
authorised byvalve
SEAT S.A.1 -SEAT
N80- S.A,does not guarantee or accept any liability with
also known as regeneration valve, respect
is activated (pulsed) by the
engine control unit - J623- depending upon load and engine

speed. The opening time is dependent on the incoming signals.
Intake manifold vacuum draws fresh air through the vent opening
on the underside of the activated carbon filter during the purging
procedure (regenerating the activated carbon). The fuel vapours
and fresh air stored in the activated charcoal, are metered back
to the combustion process.
The pressure holding valve prevents fuel vapours being drawn
out of the fuel tank when the activated charcoal filter solenoid
valve 1 - N80- is opened and the intake manifold vacuum is
present. It thus ensures that priority is given to emptying the ac‐
tivated charcoal tank.
The activated carbon filter solenoid valve - N80- is closed and
without voltage supply (e.g. break in cable). The activated char‐
coal tank is not emptied.
Note
♦ The connections for the flexible tubes are secured using spring
type clips or screw clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ To fit the spring clips, use the assembly tool spring clip pliers
- VAS 5024A- .
Observe safety precautions ⇒ page 104

Observe rules for cleanliness ⇒ page 105 .
3.2 Activated charcoal filter system - exploded view
3. Activated charcoal filter system 127

1 - Vent line
❑ Towards the solenoid
valve 1 for the active
carbon filter (pulsed) -
N80- (in engine com‐
partment)
securely
2 - Pressure retention valve
with connection hose
❑ Check for secure seat‐
ing
❑ Coming from fuel tank
gravitational valve
3 - Breather connection
❑ Visible from below
4 - 10 Nm
5 - Throttle valve module -
J338-
⇒ page 151
❑ Cleaning ⇒ page 152
❑ If the throttle valve con‐
trol part is replaced, the
new control part must
without fail be adapted
to the engine control unit
⇒ page 157 .
❑ In vehicles fitted with an
automatic gearbox, it is
also necessary to adapt
the gearbox control unit
⇒ page 157
6 - Solenoid valve 1 for active
carbon filter (pulsed) - N80-
❑ In engine compartment, right front
❑ Valve closed with ignition switched off
❑ Valve is activated (pulsed) by engine control unit when engine is warm
8 - Active carbon filter permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Filled by the gravity valve ⇒ Item 5 (page 99) and the vent valve ⇒ Item 24 (page 100)
❑ To remove:
Remove the right back wheel.
Remove the plate of the front right-hand side wheel housing ⇒ Remove and fit the front wheel housing; Rep.
gr. 66 ; Bodywork, exterior fitting work .
Remove the line ⇒ Item 1 (page 128)
Remove bolt ⇒ Item 4 (page 128) and detach tank by bottom part

3.3 Activated charcoal filter system - exploded view
1 - Breather hose
2 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ Valve closed with igni‐
tion switched off
❑ The valve is controlled
(pulsed) by the engine
control unit - J623- when
the engine is at operat‐
ing temperature.
3 - Breather hose
4 - Intake manifold
❑ Location: in rear right
wheel housing.
6 - Vent line
ing
7 - Pressure retention valve
with connection hose
❑ Check for secure seat‐Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Coming from fuel tank
gravitational valve
8 - Gravity valve
❑ In the tank flap unit
3.4 Checking fuel tank breather

♦ Manual vacuum pump - VAS 6213- , see equivalent
⇒ page 168

Test condition
• Ignition must be switched off.
Checking sequence
– First remove the active carbon filter breather hose -1- from its
connection to the active carbon filter solenoid 1 - N80- -2-.
– Connect the manual vacuum pump -VAS 6213- to the hose
-1- as shown in the figure.
– Operate the vacuum pump a few more times -VAS 6213- . No
vacuum should build up.
If a vacuum builds up.
– Check breather connection -3- located on bottom of active
carbon filter -4- for soiling; clean if necessary.
If no vacuum builds up:
– Temporarily seal breather connection -3- and operate vacuum
pump again several times. A vacuum must build up.
– Renew active carbon filter.
3.5 Checking fuel tank breather

♦ Manual vacuum pump - VAS 6213- , see equivalency
⇒ page 168
Test condition
• Ignition must be switched off.

Checking sequence
– First remove the active carbon filter breather hose -1- from its
connection to the active carbon filter solenoid 1 - N80- -2-.
– Connect the manual vacuum pump -VAS 6213- to the hose
-1- as shown in the figure.
– Operate the vacuum pump a few more times -VAS 6213- . No
vacuum should build up.
If a vacuum builds up.
– Check the ventilation opening below the cover -4- on the ac‐
tivated charcoal filter -3- for dirt. Clean as required.
– Remove the cover -4- and shut off the ventilation opening on
the activated charcoal filter and once again operate the hand
vacuum pump several times. A vacuum must build up.
– Renew active carbon filter.

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 General notes on the injection system”, page 132 .
⇒ “1.2 Safety precautions”, page 133 .
⇒ “1.3 Rules for cleanliness”, page 134 .
⇒ “1.4 Technical data”, page 134 .
⇒ “1.5 Intake manifold - Assembly overview”, page 134 .
⇒ “1.6 Remove and install the inlet manifold”, page 135 .
⇒ “1.7 Fuel rail with injection valves - Summary of components”,
page 137 .
⇒ “1.8 Removing and installing fuel rail with injectors”,
page 138 .
⇒ “1.9 Checking injectors”, page 140
⇒ “1.10 Removing and installing injectors”, page 144 .
⇒ “1.11 Replace the Teflon seal and support washer on the in‐
jection valve”, page 145 .
⇒ “1.12 Assembly overview - air filter”, page 149 .
⇒ “1.13 Removing and replacing air cleaner”, page 149 .
⇒ “1.14 Throttle valve control unit J338 : removing and fitting”,
page 151 .
⇒ “1.15 Throttle valve module J338 : clean”, page 152 .
1.1 General notes on the injection system

♦ If the fuel system has been opened it must be purged before
starting the engine .
♦ The engine control unit - J623- is equipped withS.A.self-diagnosis.
permitted unless authorised by SEAT SEAT S.A does not guarantee or accept any liability with
Before carrying out repairsrespect
and fault finding, the
to the correctness event inmemory
of information this document. Copyright by SEAT S.A.
must be interrogated. Also, the low pressure hoses and con‐
nections must be checked (infiltrated air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. The use of clamp or screw-type clips is not
permissible.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine, will not be burnt in the engine and dam‐
age the Lambda probe.
♦ If the engine starts, runs for a short period and then stops, after
fault finding, repairs or component tests, then the fault may lie
with the immobiliser blocking the engine control unit. In this
case the control unit must be adapted “Guided functions”.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore after completing all checks and re‐
pairs the fault memory must be read and if necessary cleared.
♦ If the fault memory has been erased, you must generate the
♦ The vehicles are equipped with a fuel shut-off system in the
event of collisions. It reduces the danger of a fire in a crash as
the fuel pump is switched off via the fuel pump relay. It also
132 Rep. gr.24 - Mixture preparation - injection

achieves more comfort when starting the engine. When the

door is opened, the fuel pump is activated for 2 seconds in
order to build up pressure in the fuel system.
1.2 Safety precautions
WARNING

tion. Then eliminate the pressure by carefully separating the
pipe.
To prevent injuries to persons and/or serious damage to the fuel

injection and ignition system, the following must be noted:
♦ Do not touch or remove the ignition cables with the engine
running or idling.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ For safety reasons, if the battery terminals are not disconnec‐
ted, fuse SC 34 on the left-hand side of the instrument panel
must be removed from fuse holder before the fuel system is
opened, seeing as the fuel pump can be activated by the door
contact switch in the driver door. Fuse installation ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations
Caution

tions:
♦ All the various lines (e.g. fuel, hydraulic system, active
vacuum pipes and hoses) and electrical wiring must be
installed in their original
Protectedpositions.
♦ To prevent damaging respect
the hoses, ensureof that
to the correctness all mobile
information or Copyright by SEAT S.A.
in this document.
Please note the following if test equipment has to be used during

a test drive:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person.
If test equipment is operated from the front passenger's seat, the
occupant could suffer injury in the event of an accident if the front
passenger's airbag is triggered.
If the engine is to be turned at starter speed without starting:
– Remove the fuses in order to cut off the power supply to the
injectors and the ignition coils. Fuse installation ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
Note
When removing the fuses, the power supply of the injectors and
the ignition coils is interrupted.
1. Injection system 133

– Consult fault memory; if necessary, repair any faults and then

erase fault memory “guided fault finding”
1.3 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following “5 rules” for cleanliness:
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use lenty rags!
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
♦ Only fit clean parts: Only remove replacement parts from
packaging immediately before assembly. Do not use parts that
have been stored loose (e.g. in toolboxes etc.).
♦ If the system is open, do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.4 Technical data

Engine identification characters BZG - CGPA - CGPB
Idling speed check
Idling speed 2) 1 rpm 650...870 1)
Engine control unit - J623-
System Simos 3PG
Part Number. ⇒ ETKA (Electronic parts catalogue)
Speed limitation: 1 rpm from approx. 6000
1) Up-to-date specifications: ⇒ Exhaust emissions test

2)Non-adjustable
1.5 Intake manifold - Assembly overview

1 - Intake manifold
⇒ page 135
2 - Plug
❑ 6 off
❑ 20 Nm
3 - Throttle valve module -
J338-
⇒ page 151
❑ Cleaning ⇒ page 152
❑ 6-pin plug connector
❑ contacts gold-plated
❑ Heated by coolant
❑ When replacing, adapt
the engine control unit -
J623- to the throttle con‐
trol unit“Guided func‐
tion”
4 - Plug
❑ 4 off
❑ 10 Nm
5 - Oil seal
6 - Oil seal
7 - Connecting nipple
8 - Plug
❑ 2 off
❑ 10 Nm
9 - Oil seal
10 - O-ring
❑ byReplace
Protected if damaged
11respect
- Intake
to the manifold
correctness ofpressure
information in gauge sensor
this document. - G71-
Copyright with
by SEAT S.A. air intake temperature sensor - G42-
❑ 4-pin plug connector
❑ contacts gold-plated
12 - Plug
❑ 2 off
❑ 3 Nm
1.6 Remove and install the inlet manifold


♦ Pliers for spring-loaded band-type clamps - VAS 5024 A- , see


⇒ page 168
Removing
– Disconnect battery earth cable -arrow- with ignition switched
off.
– Remove the intake hose ⇒ Item 13 (page 149) releasing the
spring type clips ⇒ Item 12 (page 149) with the spring type
clip pliers - VAS 5024A- .
– Remove throttle valve module - J338- ⇒ page 151 .
– Remove the servo brake pressure hose.

– Remove hoses from the fastenings -3-.

– Unscrew bolts -5-.
– Remove fuel rail with injectors -7- from housing on the intake
collector.
– Remove connection hose ⇒ Item 7 (page 135) by unscrewing
the bolts ⇒ Item 8 (page 135) .
– Remove connector from the intake manifold pressure gauge
sensor - G71- with air intake temperature sensor - G42-
– Extract the bolts ⇒ Item 2 (page 135) and remove the intake
manifold.
Installing
Note
Replace the O-ring if damaged ⇒ Item 9 (page 135) .
– Renew the O-rings at all opened connections.

– Moisten the O-rings with some clean engine oil.
– Fit the fuel distribution with the injectors secured to the intake
manifold and insert it evenly.
– Fit the fuel rail hose to the intake manifold. Tightening torque:
7 Nm
– Bolt on the intake manifold. Tightening torque: 20 Nm
– Purge the fuel system ⇒ page 121 .
1.7 Fuel rail with injection valves - Summary of components

1 - Breather connection
2 - Fuel rail with injection
valves
❑ Check injector flow and
seal ⇒ page 140
⇒ page 138
3 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
4 - Injector, cylinder 1 - N30-
❑ Injector, cylinder 2 -
N31-
❑ Injector, cylinder 3 -
N32-
❑ Check injector flow and
seal ⇒ page 140
5 - Retaining clip
❑ check tightness on the
injection valve and fuel
distributor
6 - Delivery line
❑ Black, with white mark
❑ secure with spring strap
clamps
ing
❑ From fuel filter
7 - Plug
❑ 2 off
❑ 10 Nm
1.8 Removing and installing fuel rail with in‐

jectors


⇒ page 168
Removing
WARNING
The fuel feed line is pressurized! Wear safety goggles and

protective clothing to avoid possible injury and skin contact.
Before loosening hose connections, wrap a cloth around the
connection. Then eliminate the pressure by carefully separat‐
ing the pipe.
– Disconnect fuel pipe -arrow-, and clean spills with a cloth.
Note
– Unplug connectors -6- from injectors.

– Open tabs and unclip injector cable harness.
– Open support -2- and unclip hoses.
– Detach hose from support -1-.
– Remove fuel rail with injectors -7- from housing on the intake
collector.
Installing
7 Nm

1.9 Checking injectors


equipment required
lent ⇒ page 168
♦ Remote control - V.A.G
1348/3A- , please see Cor‐
respondence ⇒ page 169
♦ Adapter cable - V.A.G
1348/3-2-
♦ Auxiliary cable kit - VAG
1594C-
♦ Injection rate tester - V.A.G
1602-
Check injection quantity and spray
respectpattern of injectors.
Test condition
• Fuel pressure OK ⇒ page 114 .
Checking sequence
– Disconnect the plug from the ignition coils ⇒ page 164 .
– Detach hose from support -1-.
– Open support -2- and unclip hoses.

– Remove the hose from the fastenings -3-.

– Disconnect connector -4-.
– Unplug connectors -6- from injectors.
– Remove the fuel rail together with the injectors -7- from the
intake manifold holder.
Note
Insert fuel rail loosely into intake manifold to prevent any dirt from
entering the intake manifold when the test equipment is being
connected.
• The fuel hoses remain connected.

• Injectors are not being removed from fuel rail.
• All connectors for the injectors must be disconnected.
– Connect one contact of injector to be checked to remote con‐
trol - V.A.G 1348/3-2- using test lead ( adapter cable - V.A.G
1348/3A- ).
– Connect other contact of injector to be checked to engine earth
using auxiliary measuring set - V.A.G 1594C- .
– Connect earth wire to measuring cables - V.A.G 1594/2- ,

measuring cables - V.A.G 1594/19- and pick-up clamp - V.A.G
1594/14- .
– Connect crocodile clip to battery (+) in engine compartment.
– For injection rate measurement, remove 3 measuring glasses
from injection rate tester - V.A.G 1602- .
– Use one measuring glass for each injector to be tested.

– Connect ⇒ Vehicle diagnostic tester as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
Note
♦ During final control diagnosis, the relay for electronic fuel

pump will be activated only for 30 seconds.
♦ The button on the remote control - V.A.G 1348/3A- must be
pressed at the same moment as the final control diagnosis
begins.
♦ The button of the remote control - V.A.G 1348/3A- must not
be released as long as fuel still drips from the valve.

– Press following buttons on display in succession:
♦ Self-diagnosis
♦ 01 - Engine electronics
♦ 005 - Final control diagnosis
♦ Fuel pump relay
♦ Start
Note
♦ After checking
permitted an injector,
unless authorised by SEATswitch
S.A. SEATthe ignition
S.A does off, on
not guarantee and any
or accept offliability with
again before beginning
respect to the
the correctness check of
of information the
in this next injector.
♦ If the ignition is not switched off, on and off again between

checks, it might not be possible to perform the final control
diagnosis repeatedly.
– Repeat check on other injectors.

– After all injectors have been activated, place measuring beak‐
ers on a level surface and compare the quantity injected.
Note
♦ When the final control diagnosis has been completed, there is

still fuel in the lines and in the valve, which continues to flow
after the final control diagnosis.
♦ This after-run quantity is approx. 6 ml. The after-run quantity
must be subtracted from the total quantity.
♦ A sample calculation is provided in the table below.
Total Continued flow (constant Actual

quan‐ value)
tity in
meas‐
uring
glass
after
check
e.g.: – 6 ml = 91 ml
97 ml

Rated value: 84 - 91 ml per injector

If the measured values of one or more injectors lie above or below
the prescribed specifications:
– Renew defective injector.
Checking for leaks
Test condition
• Fuel pressure OK.
• Engine and fuel temperature: approx. 20 °C.
• Fuel rail is removed.
• Connectors of all injectors are disconnected.
– As a precaution, place a measuring glass - V.A.G 1602/1- un‐
der each injector.
Note
♦ During the leakage test, pressure will build up in the fuel sys‐
tem.
♦ Valves will not be actuated.
♦ If fuel escapes from a valve, the valve is defective.

– Connect ⇒ Vehicle diagnostic tester as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Press following buttons on display in succession:
♦ Self-diagnosis
♦ 01 - Engine electronics
♦ 005 - Final control diagnosis
♦ Fuel pump relay
♦ Start
Specification: No more than 2 drops must escape during final
control diagnosis.
If the fuel loss is greater:
– Renew defective injector ⇒ page 144 .
Install injectors in reverse order. The following should be taken
into account:
– Renew O-rings on all injectors and lightly moisten with clean
engine oil.
Specified torques:
♦ Fit fuel rail with secured injectors onto intake manifold and
tighten evenly ⇒ page 137 .
Install injectors in reverse order. The following should be taken
into account:
♦ Fit fuel rail with secured injectors onto intake manifold and
press in evenly.
Tightening torque: 10 Nm
1.10 Removing and installing injectors

to applicability amongProtected
Seat / byVW / Audi
copyright. / Skoda
Copying ⇒ or
for private page 168purposes,
commercial . in part or in whole, is not
Special tools and workshop equipment
respect required

⇒ page 168

Removing
– Remove fuel rail with injectors ⇒ page 138 .
– Remove clamp -arrow - and remove the injector.
Installing
– Ensure that the injectors are fitted in the correct position.
– Ensure retaining clips are properly seated.
7 Nm
1.11 Replace the Teflon seal and support

washer on the injection valve

♦ Teflon seal: replace ⇒ page 145

♦ Support washer on the injector: replace ⇒ page 147
♦ Tool set - T10133-
Teflon seal: replace

– Remove fuel rail with injectors ⇒ page 138 .
– Remove injectors ⇒ page 144 .
– Clean the injector thoroughly.
– Carefully cut the seal with a knife. Always avoid contact be‐
tween the blade and the body of the valve.

– Remove used seal and clean seal throat in the corresponding

area -arrow-. Remove the sediments (cinders) with a brass
brush.
– Fit new oil seal -1- onto assembly cone - T10133/5- . Using
assembly sleeve - T10133/6- (knurling points to seal -1-), gen‐
tly slide seal onto assembly cone - T10133/5- as far as possi‐
ble.
– Turn the assembly sleeve - T10133/6- (the knurled part no

longer faces the seal ) and fit the seal -1- to the end in the
assembly cone - T10133/5- .
– Now place the assembly cone - T10133/5- with seal in front of
the injector. Slide seal further onto injector using assembly
sleeve - T10133/6- .
The seal is no longer on the throat of the casing.

– Remove assembly sleeve - T10133/6- and assembly cone -
T10133/5- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Slide the seal by hand until
respect to theitcorrectness
enters on the throat.
of information in this document. Copyright by SEAT S.A.

– Insert the spacer sleeve - T10133/11- on the body of the valve.

– Now press the calibration sleeve - T10133/7- onto the seal as
far as possible on the spacer sleeve - T10133/11- .
– Pull off calibration sleeve - T10133/7- again.
– Now press the calibration sleeve - T10133/8- onto the seal as

far as possible on the spacer sleeve - T10133/11- .
– Pull off calibration sleeve - T10133/8- again.
The Teflon seal now has the correct assembly measurement.
– Install injectors ⇒ page 144 .
– Fit fuel rail with injectors ⇒ page 138 .
– Bleed fuel system ⇒ page 121 .
Support washer on the injector: replace
– Remove fuel rail
Protected with injectors
by copyright. ⇒ page
Copying for private 138 . purposes, in part or in whole, is not
or commercial
– Remove injectors ⇒correctness
respect to the page 144 .
of information in this document. Copyright by SEAT S.A.
– Clean the injector thoroughly.
– Remove O-ring -3-.

– Open the support washer -2- using a small pair of pliers and
remove.
– Now remove the spring element -1- on the injector and replace
with the plate safety catch - T10133/12- .
– Insert the new support washer -1- on the assembly cone -

T10133/13- and fit on the injector as shown in the figure.
– Move the support washer -1- with the calibration sleeve -
T10133/14- (the knurled side facing towards the injector) until
it reaches the first throat -arrow- on the injector.
– Now turn calibration sleeve - T10133/14- around (knurled side
no longer points to injector). Move the calibration sleeve on
the support washer -1- in -the direction of the arrow- as far as
possible on the plate safety catch - T10133/12- .

– Lower the calibration sleeve - T10133/14- again.
The support washer now has the correct assembly measurement.
– Now position a new spring element -1- for retaining plate -

T10133/12- and position a new O-ring -3- in front of support
ring -2-.
Note
The Teflon
Protected seal mustCopying
by copyright. not be oiledor-arrow-
for private commercialfor the injector
purposes, in part or inassem‐
whole, is not
bly. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Install injectors ⇒ page 144 .

– Fit fuel rail with injectors ⇒ page 138 .
– Bleed fuel system ⇒ page 121 .

1.12 Assembly overview - air filter
Note
♦ Self-tapping bolts are the standard means of fastening the up‐

per part of the air filter housing to the lower part of the air filter
housing. When these screws are loosened or tightened using
a power tool, the threads in the intake manifold or the lower
part of air filter may be damaged.
♦ Therefore, the use of a power tool can only be allowed when:
♦ The power tool maximum speed is 200 rpm.
♦ A specified torque of max 1.6 Nm is set.
1 - Air cleaner (top section)

2 - Plug
❑ 4 off
❑ 1.6 Nm
3 - Filter element
4 - Air cleaner housing
5 - Securing bolts
❑ 8 Nm
6 - Rubber mounting
7 - Plug
8 - Rubber mounting
9 - Air intake hose
10 - Rubber mounting
11 - Flexible hose
❑ From cylinder head cov‐
er respect to the correctness of information in this document. Copyright by SEAT S.A.
12 - Spring type clip

❑ 2 off
13 - Air intake hose
❑ to throttle valve control
unit - J338-
1.13 Removing and replacing air cleaner



Removing
– Release the elastic clamp -1- with the pliers - VAS 6340- and
detach the hose from the air filter casing.
– Press the inserts -3- and remove the intake duct opening -4-
– Remove the fastening bolt -2- and remove the air filter casing
from its rubber housing -arrows- upwards.
Installing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Position the air filter casing with the rubber attachments

-arrows-on the pins.
– Press the air filter casing down onto the pins.
– Tighten securing bolt -2- to 8 Nm.
– Attach the hose with the elastic clamp -1- to the air filter casing.
– Press the intake opening -4- against the intake duct opening
until the inserts -3- clip in.

1.14 Throttle valve control unit - J338- : re‐

moving and fitting

⇒ page 168
Removing
– Remove the intake hose ⇒ Item 13 (page 149) from the throttle
valve control unit - J338- releasing the spring type clip
⇒ Item 12 (page 149) with the spring type clip pliers - VAS
5024A- .
– Disconnect electrical connection -1- on throttle valve control
unit - J338- -3-.
– Unscrew the fastening bolts -2- and remove the intake mani‐
fold from the throttle control unit - J338- -3-.
Installing
– Place a new seal on the throat of the intake manifold.

– Tighten securing bolts -2- to 7 Nm.

– Connect electrical connection -1- on throttle valve control unit
- J338- -3-.
– Fit the intake hose ⇒ Item 13 (page 149) on the throttle valve
control unit - J338- tightening the spring type clip
⇒ Item 12 (page 149) with the spring type clip pliers - VAS
5024A- .
If a new throttle control unit has been fitted:
– Erase adaptive values, and adapt the engine control unit -
J623- to the throttle control unit.
1.15 Throttle valve module - J338- : clean
Note
♦ If a new engine control unit - J623- has been fitted, the throttle
control unit must be adapted. Adapting is only carried out with
the new or previously cleaned throttle control unit, because if
there is dirt/carbon at the top limit of the throttle, the adapting
readings could be faulty.
♦ The throttle valve support must not be scratched when clean‐
ing.
– Remove engine control unit - J623- ⇒ page 151 .

– Open the throttle by handof and lockin the open position

Copyright bywith
SEATan
respect to the correctness information this document. S.A.
appropriate tool, such as a plastic or wooden wedge -arrow-.
WARNING
Acetone is highly inflammable. Respect the accident preven‐

tion regulations and the safety indications when working with
highly inflammable liquids. Do not use compressed air to clean
the throttle valve. Wear safety goggles and appropriate cloth‐
ing to avoid injury and contact with skin.
– Clean throttle valve housing, especially around the points

-arrows- where the throttle valve closes, using commercially
available acetone (DIN 53247) and a small brush.
– Clean the throat of the throttle valve with a lint free cloth.
– Allow acetone to fully ventilate and then fit clean throttle valve
control unit.
– Adapt engine control unit - J623- to the throttle valve control
unit “Guided function”.

2 Engine control unit - J623-

⇒ “2.1 Removing and installing engine control unit J623 ”,
page 153 .
⇒ “2.2 Vehicles with anti-theft secured engine control unit J623 ”,
page 153
⇒ “2.3 Adapting functions and components”, page 157 .
⇒ “2.4 Interrogating and erasing engine control unit fault memory”,
page 158 .
2.1 Removing and installing engine control

unit - J623-
Removing
– First print out or memorise the control unit identification and
also the previous control unit coding ⇒ page 158 .
– Remove the air filter housing ⇒ page 149 .
– Separate the bracket lugs -arrow A-.
– Disconnect and separate the control unit connectors and re‐

move the engine control unit.
Installation
– Place the new control unit into the retaining frame.
– Install control unit connector and lock.
– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit ⇒ Vehicle diagnostic tester “Gui‐
ded functions”.
– Install air cleaner housing ⇒ page 149 .
– Read fault memory, repair faults if necessary and then clear
fault memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
readiness code again.
– Read control unit fault memory again.
2.2 Vehicles with anti-theft secured engine

control unit - J623-
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
2. Engine control unit J623 153


♦ Pneumatic sabre saw - VAG 1523B-
Removing
– Remove the air filter housing ⇒ page 149 .
– Open the line guide -1- and lift the locking catch -2-.
– Remove the engine control unit from the bracket.

Using the body saw - VAG 1523B- make a groove on the heads
of the shear screws for inserting a screwdriver.
Note
♦ The slot must be wide enough in order to be able to screw out

the screws using an appropriate screwdriver.
♦ The thread on the shear screws can been treated with a threa‐
dlocker. For making sure that unscrewing is easier, you can
warm the shear screws using the Hot air blower - VAS
1978/14A- . In doing so, take care that no bordering cables,
connectors or components are damaged! .
WARNING
The threads of the two shear screws which are screwed into
the engine control unit are not secured with locking fluid. Do
not apply heat to the threads in the control unit housing; this is
not necessary and would cause overheating of the control unit.
The threads of the shear screws which are not screwed into
the engine control unit are not secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot-air blower.
To ensure that damage (burning) is not caused to the cables
and connectors as well as insulation and control units, the fol‐
lowing steps must be observed in all cases: Remember the
instructions for using the hot-air gun.
Carry out the adjustments

Protectedon
by the hotCopying
copyright. air blower -4-
for private as described
or commercial purposes, in part or in whole, is not
below: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Turn the temperature control button -2- to the maximum heat‐

ing power (600 °C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
The threads of the two shear screws which are screwed into
the engine control unit are not secured with locking fluid. Do
not apply heat to the threads in the control unit housing; this is
not necessary and would cause overheating of the control unit.
When breakaway bolts are heated, some parts of the protec‐
tive casing become very hot. Risk of burn injuries! Also, make
sure that, as far as possible, you only heat the breakaway bolt
and not adjoining parts. If necessary, cover these parts.
Note
Next, heat the breakaway bolts with the hot-air gun. This reduces
the strength of the threadlocker on the thread of the breakaway
bolts to make them easier to remove.

– Bring the nozzle of the hot-air gun up to the breakaway bolt on

the lock.
– Connect hot air gun and heat the head bolt approx. 20 to 25
seconds.
– Unscrew the shear screws using a screwdriver.
– Remove the bracket -1- and the protective casing -2- from the
engine control unit -3- in -the direction of the arrow-.
– Now release connector on engine control unit and pull off con‐
nector.
Installation
Installation is carried out in the reverse order; note the following:
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. Use a thread tap to clean.
– Fit connectors and lock in position.
– Slide the protective casing over the engine control unit.
– Separate the protective casing from the engine control unit.
– Use new breakaway bolts.
– Tighten the shear screws evenly, until the screw heads break
off.

– Insert engine control unit into mounting bracket on bulkhead

until it audibly engages in catches -2-.
– Press the cable in the cable guide -1- and seal.
– Install air cleaner housing ⇒ page 149 .
When replacing the engine control unit
– Adjust the new engine control unit.
– Read fault memory, repair faults if necessary and then clear
fault memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
readiness code again.
– Read control unit fault memory again.
– Read
Protected control
by copyright. unitforfault
Copying privatememory
or commercialagain.
purposes, in part or in whole, is not
2.3 Adapting functions and components
♦ adjust ⇒ page 157
♦ Central diagnosis - VAS 5051 B-
Work sequence
– Connecting the central diagnosis - VAS 5051B-
– Select the function “Guided fault finding” on the diagnosis cen‐
tre - VAS 5051B - system.
Once you have consulted all of the control units:
– “GoTo” button.
– Select “Function/component selection”.
– “Select drive”
– Select “Engine code”.
– Select “01- On Board Diagnostic (OBD) capable systems”.
– Select “engine control”.
– Select “Functions”.
– Select “Function or component”.

2.4 Interrogating and erasing engine control

unit fault memory
♦ Central diagnosis - VAS 5051 B -
Work sequence
– Connecting the central diagnosis - VAS 5051B-
Only when engine does not start:
– Press the “Vehicle self-diagnosis” key.
Indicated on the vehicle diagnostic, testing and information sys‐

tem - VAS 5051B- :
– Select vehicle system “01 - Engine electronics” in menu -1-.
– Wait until the following is displayed.
Indicated on the vehicle diagnostic, testing and information sys‐

tem - VAS 5051B- :
– Select function “02 - Interrogate fault memory”.
– If no fault is stored in engine control unit “0 fault(s) detected”
is displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press ← button.
– Select function “05 - Erase fault memory”.
– Press function “06-End output”.

26 – Exhaust system
1 Parts of the exhaust system
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the supports are evenly loa‐
ded.
♦ Always replace self-locking nuts.
⇒ “1.1 Exhaust manifold with catalytic converter, exhaust pipe

with pre-silencer and accessories - Assembly overview”,
page 159 .
⇒ “1.2unless
permitted Silencers
authorisedwith suspension
by SEAT S.A. SEAT S.Aelements - Components
does not guarantee over‐
or accept any liability with
view”, page
respect 161
to the .
correctness of information in this document. Copyright by SEAT S.A.
⇒ “1.3 Silencers with suspension elements - Components over‐

view”, page 162
1.1 Exhaust manifold with catalytic converter, exhaust pipe with pre-silencer
and accessories - Assembly overview
1. Parts of the exhaust system 159

1 - Warm air collector plate

❑ Assemble without ten‐
sion
2 - 10 Nm
3 - Exhaust manifold with cat‐
alytic converter
4 - Lambda probe - G39- , 52
Nm
❑ Fitting location: in the
exhaust manifold
❑ Removing and installing
with the wrench kit -
3337-
❑ Only grease the thread
with heat proof paste ⇒
Spare parts catalogue .
Heat proof paste ⇒
Spare parts catalogue
must not reach the
probe body grooves
❑ Renew seal if leaking
5 - Seal
❑ replace
6 - 10 Nm
7 - Protective plate
8 - Double pipe bracket
9 - Plug
10 - 25 Nm
11 - Exhaust pipe with silencer
12 - Holder
13 - Support plate Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - 20 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ replace
15 - 20 Nm
❑ M8 x 16
16 - Locking nut, 25 Nm
❑ replace
17 - Seal
❑ replace
18 - Lambda probe downstream of catalytic converter - G130- , 52 Nm
❑ Location: in principal catalytic converter
❑ Removing and installing with the wrench kit - 3337-
❑ Only grease the thread with heat proof paste ⇒ Spare parts catalogue . Heat proof paste ⇒ Spare parts
catalogue must not reach the probe body grooves
❑ Renew seal if leaking
19 - 20 Nm
20 - Locking nut, 25 Nm
❑ replace
160 Rep. gr.26 - Exhaust system

1.2 Silencers with suspension elements - Components overview
1 - 23 Nm
2 - Hanger
tion:
3 - Silencers
4 - Hanger
❑ For silencer
tion:
5 - Separating point
❑ Marked by impressions
on connecting pipe
❑ Cut the connecting pipe
at right angles at the
separation area using
the saw for bodywork -
V.A.G 1523A-
⇒ page 161
Separating point on exhaust pipe
WARNING
Wear safety goggles and appropriate clothing to avoid injury

caused by metal shavings.
– Separate the exhaust pipe at right angles in the cutting some

-arrow 2-.
– When installing double repair clamp-4- place between side
markings -arrows 1 and 3-. Tightening torque: 25 Nm
1. Parts of the exhaust system 161

1.3 Silencers with suspension elements - Components overview
1 - The middle silencer

❑ Factory Silencer execu‐
ted with center as a
component. In case of
repair individually re‐
placeable
❑ Align exhaust system to
be free of stress
V.A.G 1523A-
⇒ page 162
2 - Bracket with mounting
3 - 25 Nm
4 - Secondary silencer
❑ Factory Silencer execu‐
ted with center as a
component. In case of
repair individually re‐
placeable
❑ Align exhaust system to
be free of stress
V.A.G 1523A-
⇒ page 162
5 - Hanger
tion:
Separating point on exhaust pipe
WARNING
Wear safety goggles and appropriate clothing to avoid injury

caused by metal shavings.
– Separate the exhaust pipe at right angles in the cutting some

-arrow 2-.
– When installing double repair clamp-4- place between side
markings -arrows 1 and 3-. Tightening torque: 25 Nm
162 Rep. gr.26 - Exhaust system

28 – Ignition system
1 Ignition system
⇒ “1.1 General information about the ignition system”,
page 163 .
⇒ “1.2 Ignition system components - Assembly overview”,
page 163 .
⇒ “1.3 Removing and installing ignition coils with output stages”,
page 164 .
⇒ “1.4 Safety precautions”, page 166 .
⇒ “1.5 Spark plug test data”, page 167 .
1.1 General information about the ignition

system
♦ Only the components which specifically relate to the ignition
system are dealt with here. The other components are dealt
with in the injection system.
♦ The control unit for the fuel injection and ignition system is
equipped with self-diagnosis. Before carrying out repairs and
fault finding, the fault memory must be interrogated
⇒ page 158 . Also, the low pressure hoses and connections
must be checked (infiltrated air).
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the engine control unit.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ If the engine starts, runs for a short period and then stops, after
fault finding, repairs or component tests, then the fault may lie
with the immobilizer blocking the engine control unit. The fault
memory must be interrogated and, if necessary the control unit
matched ⇒ page 157 ; Functions and components: adapting
♦ Certain tests may lead to a fault being detected by the control
unit and stored. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ page 158 .
♦ Vehicles with an airbag are fitted with a crash/fuel shut-off.
This system reduces the risk of a vehicle burning in the event
of a crash in that the fuel pump is switched off by the fuel pump
relay. At the same time, this provides better starting perform‐
ance. When the door is opened, the fuel pump is activated for
2 seconds in order to build up pressure in the fuel system.
1.2 Ignition system components - Assembly overview

1. Ignition system 163

1 - Ignition coil 1 with output

stage - N70-
❑ Ignition coil 2 with output
stage - N127-
❑ Ignition coil 3 with output
stage - N291-
⇒ page 164
❑ 4-pin, black
❑ Black, 2-pin
❑ For knock sensor 1 -
G61- .
❑ connectors with gold
plated contacts
4 - 20 Nm
❑ Tightening torque influ‐
ences functions of
knock sensor
5 - Knock sensor 1 - G61-
❑ connectors with gold
plated contacts
6 - 10 Nm
❑ 3-pin, black
❑ for Hall sender - G40-
9 - O-ring
❑ 3-pin, black
❑ For engine speed sender - G28-
11 - Engine speed sender - G28-
12 - 8 Nm
13 - Spark plug, 30 Nm
❑ Remove and install with the wrench - 3122 B- , see equivalent ⇒ page 168
❑ Type and electrode spacing ⇒ page 167
1.3 Removing and installing ignition coils

with output stages

164 Rep. gr.28 - Ignition system

♦ Installation tool - T10118-
♦ Extractor - T10094 A-
Note
The housing for the ignition coils and final power stages has been
modified. As a result, the ignition coils can only be removed and
mounted using the extractor - T10094 A- . The former extractor -
T10094- may still be used if it is modified as follows.
– Reduce the marked zone -2- using suitable workshop meth‐

ods to reach a new nominal measurement -B- of 18 mm.
– Additionally identify the tool designation with the letter A -1-.
Removing

– Fit puller - T10094 A- on ignition coil with final output stage

-arrow-.
– Lightly extract the ignition coils with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully release the connector lock and remove the connec‐
tor.
Installing
– Fit puller - T10094 A- on ignition coil with final output stage.
– Push the plug into the ignition coil with output stage until it
audibly clicks in.
– Insert the ignition coil with output stage in the cylinder head in
the -direction of the arrow-.
– Fit engine cover clipping on tabs -arrows-.
1.4 Safety precautions
WARNING
Fuel system is under pressure! Wear eye protection and gloves

to avoid injuries and skin contact. Before opening the system
place a cloth around the connection. Then release pressure by
carefully pulling fuel hose from connection.
To prevent injuries to persons and/or damage to the fuel injection

and ignition system, the following must be noted:
♦ Do not touch or remove the ignition cables with the engine
running or idling.
♦ Always switch off the ignition before disconnecting or recon‐
necting injection or ignition system wiring or tester cables.

Caution

tions:
All conduits (for example for fuel, hydraulics, carbon filter, liquid
cooler and cooling agent, brake fluid, low pressure) and the
electric cables must be placed in such a way that they return
to their original position.
Ensure that there is adequate free access to all moving or hot
components.
Please note the following if test equipment has to be used during

a test drive:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test equipment is operated from the front passenger's seat, the
occupant could suffer injury in theProtected
eventbyofcopyright.
an accident if the
Copying for front
private or commercial purposes, in part or in whole, is not
passenger's airbag is triggered.permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If the engine is to be turned at starter speed without starting:
– Remove the 4-pin connectors -arrows- from the ignition trans‐
formers.
– Remove the fuse for the injector units from the fuse holder.
Fuse allocation ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations
1.5 Spark plug test data

Engine identification charac‐ BZG, CGPA, CGPB
ters
Order of starting 1-3-2
Spark plugs
VW Wrench 101,905,618 A 101 905 601 F
Electrode gap 1.0 ... 1.1 mm 1.0 ... 1.1 mm
Tightening torque 25 Nm 25 Nm
Change interval Ibiza: ⇒ Maintenance ; Booklet 601 , Toledo ⇒ Maintenance ; Booklet KG1

2 Conversion table by relevance

VW / AUDI tool SEAT tool
Mandrel - 10 - 14- Plunger - T20019- . See image of
the tool or equipment
⇒ page 170
Coupling tool - 2024 A- Support tool - T20127- . See im‐
age of the tool or equipment
⇒ page 170
Counterholder - T10172- Retention tool - T20018B- see
image for tool or unit
⇒ page 171
Spanner - 3122 B- Spanner - T20175- See image of
⇒ page 171
Compressor tool for valve Push rod - T20034D- See image
spring - 3362- of the tool or equipment
⇒ page 171
Valve stem seal puller - 3364- Extractor - T20058A- See image
of tool or equipment
⇒ page 172 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Valve stem seal insertion tool Plunger - T20039- .respect
See image of
- 3365- the tool or equipment
⇒ page 172
Counterholder - 3415- Retention tool - T20018B- see
⇒ page 171
Guide pin - 3450- Centring pin - T20049- See im‐
⇒ page 173
Plunger - T10117- Guide bush - T20081B- See im‐
⇒ page 173
Spanner - T10058- Spanner - T20203- See image of
⇒ page 174
Counterholder - T10172- Retention tool - T20018B- see
⇒ page 171
Torque wrench (5 … 50 Nm) Torque wrench socket set - SAT
- V.A.G 1331- 8010- See image of the tool or
equipment ⇒ page 174
Torque wrench (40 … 200 Torque wrench socket set - SAT
Nm) - V.A.G 1332- 8010- See image of the tool or
Coolant pump wrench - Retention tool - T20159- see im‐
V.A.G 1590- age for tool or unit ⇒ page 174
Engine and gearbox support Engine and gearbox support -
- VAS 6095- T20172-
Pliers - VAS 6340- Pliers - T20174- See image of
⇒ page 175
Workshop crane - VAS 6100- Workshop crane
Tray - VAS 6208- Drip tray - T20173- See image of
⇒ page 175
Manual vacuum pump - VAS Pressure / underpressure pump
6213- - SAT 1390- see image for tool or
unit ⇒ page 176

VW / AUDI tool SEAT tool

Universal dial gauge holder - Support - T20020- See image of
VW 387- the tool or equipment
⇒ page 176
Support tool - VW 540- Engine and gearbox support -
T20172-
Pressure hose - VW 653/3- Measuring tool - T20033- . See
image of the tool or equipment
⇒ page 177
Support plate - 10 222A- Support - U 30025E- See image
of the tool or equipment
⇒ page 177
Rack - 10 222A/8- Support - U 30025E- See image
⇒ page 177
Support plate - T10358- No equivalent
Basic engine mounting set - Support - U 30025E- See image
T40091- of the tool or equipment
⇒ page 177
Adapter - 10 222A/10- Support - U 30025E- See image
⇒ page 177
Additional part for the engine Support - U 30025E- See image
mounting - 10 222A/31- of the tool or equipment
⇒ page 177
Lever - 80 200- No equivalent
Adapter - 10 222A/18- Support - U 30025E- See image
⇒ page 177
Fastening bolt - T10121- No equivalent
Camshaft fastener - T10123- No equivalent
pressure tool - VW 541/1A- No equivalent
SEAT tool VW / AUDI tool

Oil extraction unit - SAT Oil extraction equipment - V.A.G
1100- 1782- . See image of the tool or
Adapter cable - SAT Adapter cable - V.A.G
1348/3-3- 1348/3-2- . See image of the tool
or equipment
Extractor - T20143- Extractor - 3203- See image of
tool or equipment ⇒ page 178
Sealing ring extractor - 3240- .
See image of the tool or equip‐
ment ⇒ page 179
Plunger - T20158- Push rod - T10122- See image of
⇒ page 179
Counterhold
permitted unless authorisedtool - T20176-
by SEAT S.A. SEAT S.A doesRetention tool
not guarantee - 3067-
or accept see with
any liability image
respect to the correctness of information in thisfor tool or
document. unit ⇒
Copyright pageS.A.
by SEAT 180
Wrench - T20207- Union nut tool - 3217- . See im‐
⇒ page 178
2. Conversion table by relevance 169

2.1 Graphical information on the use and

VW units, Seat equivalents
2.1.1 Plunger - T20019-
Application
2.1.2 Support equipment - T20127-
Application

2.1.3 Counterholder - T20018B-
Application
2.1.4 Spanner - T20175-
2.1.5 pressure tool - T20034D-

Application
2.1.6 Extractor - T20058A-
Application
2.1.7 Plunger - T20039-

Application
2.1.8 Guide bushing - T20081B-
Application
2.1.9 Guide pins - T20049-


Application
2.1.10 Special wrench - T20203-
2.1.11 Torque wrench kit - SAT 8010-
2.1.12 Counterholder - T20159-

Application
2.1.13 Pliers - T20174-
Application
2.1.14 Tray - T20173-

Application
2.1.15 Pressure pump - SAT 1390-
2.1.16 Support plate - T20020-
Application

2.1.17 Measuring instrument - T20033-
Application
2.1.18 Support plate - U 30025E-
Application

2.2 Graphical information of equivalent tools

and equipment at VW/Audi
2.2.1 Wrench for union nut - 3217-
2.2.2 Used oil collection and extraction unit -

V.A.G 1782-
2.2.3 Extractor - 3203-
Application

2.2.4 Gasket ring extractor - 3240-
Application
2.2.5 pressure tool - T10122-
Application

2.2.6 Engine support - VAS 6095-
2.2.7 Counterholder - 3067-
2.2.8 Adapter cable - V.A.G 1348/3-2-

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Service

Service Department. Technical Information

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Copyright © 2016 Seat S.A S01BBZG8W20

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1.2 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.1 Engine number

Engine identification BZG CGPA CGPB CGPC CJLB

10 – Removing and installing engine

1.1 Removing and positioning the engine

Special tools and workshop

2 Rep. gr.10 - Removing and installing engine

♦ The engine is removed upwards together with the gearbox.

– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing

– Disconnect the engine cable harness connector -1- from the

– Unscrew the bolts -arrows- and remove the slave cylinder; do

Do not depress clutch pedal after removing slave cylinder.

– Separate the pressure hose -arrow- in the servo-brake ampli‐

The fuel feed line is pressurized! Wear eye protection and

– Remove the fuel supply line and venting tube -arrows-.

– Unscrew earth connection -1-.

– Remove the securing bolts -arrows- and remove the engine

4 Rep. gr.10 - Removing and installing engine

– Screw out bolts -arrows-.

Disregard item -1-.

– Remove the expansion tank and place it on the engine.

– Disconnect the DF cable connector -1- and remove the pro‐

– Unbolt the battery positive cable -arrow- of the alternator.

♦ Do not open the air conditioning pipes.

– Fasten the compressor to the lock carrier using the counter‐

– Unscrew nuts -arrows- and remove support together with ca‐

6 Rep. gr.10 - Removing and installing engine

– Unscrew nut -arrows-.

– Remove the electric connector -1- from the reverse gear

– Unscrew bolts -arrows- and remove pendulum arm support.

Bolt -1- must not be loosened.

– Hook the counterhold - 2024 A- as described below and lift

– Unscrew earth connection -1-.

Nut -2- must not be loosened.

8 Rep. gr.10 - Removing and installing engine

– Unscrew bolts -B-.

When the assembly is lifted out, it must be carefully guided to

When performing assembly work, secure the engine to the engine

When doing any repair work, especially in the engine compart‐

– Check clutch release bearing for wear and renew if necessary.

Tightening torques of the engine assembly ⇒ page 13

– Install poly V-belt ⇒ page 19 .

1.2 Detaching engine from gearbox

♦ Workshop crane - VAS 6100- , see equivalent ⇒ page 168

10 Rep. gr.10 - Removing and installing engine

Air conditioner / heater setting