Seat 4-cylinder diesel engine 1.6L and 2.0L 4V, TDI Common Rail, EA288 Workshop Manual

Leon 2013- Leon ST 2013-. Edition 02.2017. Engine ID: CLHA,  CLHB,  CKFC,  CUPA,  CRVA,  CRVC,  CRMB,  CKFB,  CUNA,  CRKB,  CRLB,  CRBC,  CXXB,  CXXA,  DBKA,  CRGA,  CRLD,  DDYA,  DDYB,  DCYA. 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.

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
21 – Turbocharging/supercharging
23 – Mixture preparation – injection
26 – Exhaust system
28 – Glow plug system

CONTENTS

  • 00 – Technical data
    • 1 Safety instructions
      • 1.1 Safety precautions when working on fuel supply system
      • 1.2 Safety precautions for working on vehicles with start-stop system
      • 1.3 Safety precautions during road tests in which testing and measuring equipment is used
      • 1.4 Safety precautions when working on the cooling system
    • 2 Identification
      • 2.1 Engine identification number / engine data
    • 3 Repair notes
      • 3.1 Cleaning rules
      • 3.2 Foreign particles in engine
      • 3.3 Contact corrosion
      • 3.4 Routing and attaching pipes and wiring
      • 3.5 Installing radiators and condensers
  • 10 – Removing and installing engine
    • 1 Removing and installing the engine
      • 1.1 Engine removal
      • 1.2 Separating engine and gearbox
      • 1.3 Securing engine to engine and gearbox support
      • 1.4 Installing engine
    • 2 Engine/gearbox mountings
      • 2.1 Exploded view – assembly mountings
      • 2.2 Removing and installing engine mountings
      • 2.3 Removing and installing gearbox mounting
      • 2.4 Removing and installing pendulum support
      • 2.5 Supporting engine in installation position
      • 2.6 Adjusting assembly mounting
      • 2.7 Checking adjustment of assembly mountings
    • 3 Engine cover
      • 3.1 Removing and installing engine cover panel
  • 13 – Crankshaft group
    • 1 Cylinder block (pulley end)
      • 1.1 Exploded view – cylinder block (pulley end)
      • 1.4 Removing and installing tensioner for poly V-belt
      • 1.5 Removing and installing vibration damper
      • 1.6 Removing and installing ancillary bracket
      • 1.7 Removing and installing engine support
      • 1.8 Removing and installing sealing flange – pulley end
    • 2 Cylinder block, gearbox end
      • 2.1 Exploded view – cylinder block, gearbox end
      • 2.2 Removing and installing flywheel
      • 2.3 Removing and installing sealing flange (gearbox end)
    • 3 Crankshaft
      • 3.1 Assembly overview – crankshaft
      • 3.2 Crankshaft dimensions
      • 3.3 Renewing needle bearing in crankshaft
      • 3.4 Measure axial play of crankshaft
    • 4 Pistons and conrods
      • 4.1 Exploded view – pistons and conrods
      • 4.2 Removing and installing pistons
      • 4.3 Measuring piston projection at TDC
      • 4.4 Checking pistons and cylinder bores
      • 4.5 Checking radial clearance of conrod bearings
  • 15 – Cylinder head, valve gear
    • 1 Cylinder head
      • 1.1 Exploded view – cylinder head
      • 1.2 Assembly overview – cylinder head cover
      • 1.3 Removing and installing cylinder head
      • 1.4 Cylinder head cover: removing and installing
      • 1.5 Removing and installing seals for injectors
      • 1.6 Removing and installing camshaft housing
      • 1.7 Check compression pressure
    • 2 Toothed belt drive
      • 2.1 Exploded view – toothed belt cover
      • 2.2 Exploded view – toothed belt
      • 2.3 Removing and installing toothed belt cover
      • 2.4 Timing belt: removing, fitting, tensioning
      • 2.5 Detaching toothed belt from camshaft
    • 3 Valve gear
      • 3.1 Assembly overview – valve gear
      • 3.2 Measuring axial play of camshaft
      • 3.3 Removing and installing camshaft oil seal
      • 3.4 Removing and installing camshaft adjuster
      • 3.5 Valve 1 for variable distribution N205 : removing and fitting
      • 3.6 Checking hydraulic valve compensation elements
      • 3.7 Removing and installing valve stem seals
    • 4 Inlet and exhaust valves
      • 4.1 Valve guides: verification
      • 4.2 Valves: checking
      • 4.3 Valve dimensions
  • 17 – Lubrication
    • 1 Sump, oil pump
      • 1.1 Exploded view – sump/oil pump
      • 1.2 Engine oil
      • 1.3 Removing and replacing oil sump
      • 1.4 Oil pump: removing and installing
      • 1.5 Removing and installing oil level and oil temperature sender G266
    • 2 Engine oil radiator
    • 3 Oil filter, oil pressure switch
      • 3.1 Exploded view – oil filter housing/oil pressure switches
      • 3.2 Removing and installing oil pressure switch F1
      • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
      • 3.4 Checking oil pressure
      • 3.5 Removing and installing oil filter
      • 3.6 Removing and installing valve for oil pressure control N428
  • 19 – Cooling
    • 1 Cooling system/coolant
      • 1.1 Connection diagram – coolant hoses
      • 1.2 Checking cooling system for leaks
      • 1.3 Draining and filling coolant
    • 2 Coolant pump/coolant thermostat
      • 2.1 Exploded view – coolant pump and thermostat
      • 2.2 Exploded view – electric coolant pump
      • 2.3 Exploded view – coolant temperature sensors
      • 2.4 Removing and installing electric coolant pump
      • 2.5 Removing and replacing coolant pump
      • 2.6 Cooling system thermostat: removing and installing
      • 2.7 Testing coolant thermostat
      • 2.8 Removing and installing coolant valve for cylinder head N489
      • 2.9 Removing and installing coolant temperature sender G62
    • 3 Coolant pipes
      • 3.1 Exploded view – coolant pipes
      • 3.2 Removing and installing coolant pipes
    • 4 Radiator/radiator fans
      • 4.1 Exploded view – radiator/radiator fans
      • 4.2 Exploded view – radiator cowl and radiator fans
      • 4.3 Assembly overview – radiator blind
      • 4.4 Removing and positioning radiator
      • 4.5 Removing and installing cooler for charge air cooling circuit
      • 4.6 Removing and installing radiator cowling with radiator fan
      • 4.7 Removing and installing radiator fans
      • 4.8 Removing and installing radiator blind
      • 4.9 Removing and installing radiator blind control motor V544
    • 21 – Turbocharging/supercharging
      • 1 Exhaust turbocharger
        • 1.1 Exploded view – turbocharger
        • 1.2 Turbo compressor: removing and fitting
        • 1.3 Renewing vacuum unit for turbocharger
      • 2.1 Assembly overview – charge air system
      • 2.2 Removing and installing charge pressure sender G31
      • 2.3 Checking charge air system for leaks
      • 2.4 Checking charge air cooler for leaks
  • 23 – Mixture preparation – injection
    • 1 Injection system
      • 1.1 Schematic overview – fuel system
      • 1.2 Overview of fitting locations – injection system
      • 1.3 Filling and bleeding fuel system
      • 1.4 Checking fuel system for leaks
    • 2 Vacuum system
      • 2.1 Connection diagram – vacuum system
      • 2.2 Vacuum system: checking
    • 3 Injectors/high-pressure accumulator (rail)
      • 3.1 Assembly overview – injectors
      • 3.2 Exploded view – high-pressure reservoir (rail)
      • 3.3 Performing adaption of correction values for injectors
      • 3.4 Checking injectors
      • 3.5 Checking return flow rate of injectors with engine running
      • 3.6 Checking return flow rate of injectors at starter cranking speed
      • 3.7 Check the open nozzle units
      • 3.8 Removing and installing injectors
      • 3.9 Removing and installing high-pressure pipes
      • 3.10 Removing and installing high-pressure reservoir (rail)
    • 4 Air cleaner
      • 4.1 Exploded view – air cleaner housing
      • 4.2 Air filter housing: removing and fitting
    • 5 Suction pipe
      • 5.1 Exploded view – intake manifold
      • 5.2 Removing and installing intake manifold
      • 5.3 Throttle valve control unit J338 : removing and fitting
    • 6 Sensors
      • 6.1 Remove and install fuel pressure regulating valve N276
      • 6.2 Checking fuel pressure regulating valve N276
      • 6.3 Removing and installing fuel pressure sensor G247
      • 6.4 Air mass meter G70 / intake air temperature sender G42 : Removal and installation . .
      • 6.5 Removing and installing differential pressure sensor G505
      • 6.6 Removing and installing exhaust gas pressure sensor 1 G450
      • 6.7 Removing and installing charge air temperature sender ahead of charge air cooler G810
      • 6.8 Removing and installing charge air temperature sender after charge air cooler G811
      • 6.9 Removing and installing fuel temperature sender G81
    • 7 Engine control unit
      • 7.1 Removing and installing engine control unit J623
      • 7.2 Removing and installing engine control unit J623 (with protective housing)
    • 8 High-pressure pump
      • 8.1 Exploded view – high-pressure pump
      • 8.2 High-pressure pump: removing and fitting
    • 9 Lambda sensor
      • 9.1 Exploded view – Lambda probe
      • 9.2 Removing and installing Lambda probe
  • 26 – Exhaust system
      • 1.2 Removing and installing front exhaust pipe with catalytic converter
      • 1.3 Disconnecting exhaust pipes/silencers
      • 1.4 Removing and installing rear silencer
      • 1.5 Align exhaust system to be free of stress
      • 1.6 Check exhaust system for leaks
    • 2 Emission control
      • 2.1 Assembly overview – emission control
      • 2.2 Removing and installing catalytic converter
      • 2.3 Removing and installing particulate filter
      • 2.4 Removing and installing emission control module
      • 2.5 Removing and installing exhaust flap control unit J883
    • 3 Exhaust gas temperature control
      • 3.1 Assembly overview – exhaust gas temperature regulation
      • 3.2 Removing and installing exhaust gas temperature sensor 1 G235
      • 3.3 Removing and installing exhaust gas temperature sender 2 G448
      • 3.4 Removing and installing exhaust gas temperature sensor 3 G495
      • 3.5 Removing and installing exhaust gas temperature sender 4 G648
    • 4 Exhaust gas recirculation
      • 4.1 Assembly overview – exhaust gas recirculation
      • 4.2 Assembly overview – Control motor for exhaust gas recirculation V338
      • 4.3 Removing and installing exhaust gas recirculation cooler
      • 4.4 Removing and installing exhaust gas recirculation control motor V338
      • 4.5 Removing and installing exhaust gas recirculation control motor 2 V339
      • 4.6 Check seal integrity of exhaust recirculation cooler
  • 28 – Glow plug system
    • 1 Glow plug system
      • 1.1 Assembly overview – glow plug system
      • 1.2 Removing and installing glow plug
      • 1.3 Removing and installing automatic glow period control unit J179
      • 1.4 Removing and installing Hall sensor G40
      • 1.5 Removing and installing engine speed sensor G28

Language: English
Format: PDF
Pages: 456

Seat 4-cylinder diesel engine 1.6L and 2.0L 4V, TDI Common Rail, EA288 Workshop Manual

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