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

Seat

Ateca 2017- Leon 2013- Leon ST 2013- Workshop Manual. Edition 06.2018. Engine ID: DDYA, DFFA, DFHA,  CRVA, CRVC, DFGA, DGTE, CLHA, CLHB, CKFC, CUPA, CRMB, CKFB, CUNA, CRKB, CRLB, CRBC, CXXB,  CXXA, DBKA, CRGA, CRLD, DDYB, DCYA, DJGA. 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 when working on vehicles with start/stop system
      • 1.3 Safety precautions during road tests in which test and measuring equipment is used .
      • 1.4 Safety precautions when working on the cooling system
      • 1.5 Safety precautions when working on the SCR system
      • 1.6 Safety precautions when working on exhaust system
    • 2 Identification
      • 2.1 Engine number, engine data
    • 3 Repair instructions
      • 3.1 Rules for cleanliness
      • 3.2 Foreign objects in engine
      • 3.3 Contact corrosion
      • 3.4 Routing and attachment of lines
      • 3.5 Installing radiators, coolers and condensers
    • 4 Technical data
      • 4.1 Coolant
  • 10 – Removing and installing engine
    • 1 Removing and installing engine
      • 1.1 Removing engine
      • 1.2 Separating engine and gearbox .A.
      • 1.3 Securing engine to engine
      • 1.4 Installing engine
    • 2 Assembly mountings
      • 2.1 Assembly overview – 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 (engine and gearbox mountings)
    • 3 Engine cover
      • 3.1 Removing and installing engine cover panel
  • 13 – Crankshaft group
    • 1 Cylinder block (pulley end)
      • 1.1 Assembly overview – cylinder block, pulley end
      • 1.2 Assembly overview – sealing flange, pulley end
      • 1.3 Removing and installing poly V-belt
      • 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 Assembly overview – cylinder block, gearbox end
      • 2.2 Removing and installing flywheel
      • 2.3 Removing and installing sealing flange, gearbox side
    • 3 Crankshaft
      • 3.1 Assembly overview – crankshaft
      • 3.2 Crankshaft dimensions
      • 3.3 Renewing needle bearing in crankshaft
      • 3.4 Measuring axial clearance of crankshaft
    • 4 Pistons and conrods
      • 4.1 Assembly overview – 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 conrods
  • 15 – Cylinder head, valve gear
    • 1 Cylinder head
      • 1.1 Assembly overview – cylinder head
      • 1.2 Assembly overview – cylinder head cover
      • 1.3 Removing and installing cylinder head
      • 1.4 Removing and installing cylinder head cover
      • 1.5 Removing and installing seals for injectors
      • 1.6 Removing and installing camshaft housing
      • 1.7 Checking compression
    • 2 loothed belt drive
      • 2.1 Assembly overview – toothed belt cover
      • 2.2 Assembly overview – toothed belt
      • 2.3 Removing and installing toothed belt cover
      • 2.4 Removing and installing toothed belt
      • 2.5 Removing 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 Removing and installing camshaft control valve 1 N205
      • 3.6 Checking hydraulic compensation elements
      • 3.7 Removing and installing valve stem seals
      • 3.8 Removing and installing control valve for the camshaft adjuster
    • 4 Inlet and exhaust valves
      • 4.1 Checking valve guides
      • 4.2 Checking valves
      • 4.3 Valve dimensions
  • 17 – Lubrication
    • 1 Sump, oil pump
      • 1.1 Assembly overview – sump, oil pump
      • 1.2 Engine oil
      • 1.3 Removing and installing sump
      • 1.4 Removing and installing lower part of sump
      • 1.5 Removing and installing upper part of sump
      • 1.6 Removing and installing oil pump
      • 1.7 Removing and installing oil level and oil temperature sender G266
    • 2 Engine oil cooler
    • 3 Oil filter, oil pressure switch
      • 3.1 Assembly overview – oil filter housing, oil pressure switch
      • 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 housing
      • 3.6 Removing and installing valve for oil pressure control N428
    • 4 Oil circuit
      • 4.1 Oil supply pipe: removing and fitting
      • 4.2 Removing and installing oil return line for turbocharger
  • 19 – Cooling
    • 1 Cooling system, coolant
      • 1.1 Schematic diagram – coolant hoses
      • 1.2 Checking cooling system for leaks
      • 1.3 Draining coolant
      • 1.4 Filling with coolant:
      • 1.5 Checking electric vacuum pump VAS 6096/2
      • 1.6 Flushing cooling system
      • 1.7 Flushing cooling system, quick reference guide
    • 2 Coolant pump, thermostat
      • 2.1 Assembly overview – coolant pump, thermostat
      • 2.2 Assembly overview – electric coolant pump
      • 2.3 Assembly overview – coolant temperature sender
      • 2.4 Removing and installing electric coolant pump
      • 2.5 Removing and replacing coolant pump
      • 2.6 Removing and installing thermostat
      • 2.7 Testing coolant thermostat
      • 2.8 Removing and installing the valve for the cylinder head coolant N489 . .
      • 2.9 Removing and installing coolant temperature sender G62
      • 2.10 Removing and installing radiator outlet coolant temperature sender G83
    • 3 Coolant pipes
      • 3.1 Assembly overview – coolant pipes
      • 3.2 Removing and installing coolant pipes
    • 4 Radiator, radiator fans
      • 4.1 Assembly overview – radiator, radiator fan
      • 4.2 Assembly overview – 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 cowl
      • 4.7 Removing and installing radiator fan
      • 4.8 Removing and installing radiator blind
  • 21 – Turbocharging/supercharging
    • 1 Turbocharger
      • 1.1 Assembly overview – turbocharger
      • 1.2 Removing and installing turbocharger
      • 1.3 Renewing vacuum unit for turbocharger
      • 1.4 Removing and installing connection for turbocharger
    • 2 Charge air system
      • 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 Removing and installing air intake pipe
      • 2.5 Checking charge air cooler for leaks
  • 23 – Mixture preparation – injection
    • 1 Injection system
      • 1.1 Schematic overview – fuel system
      • 1.2 Fitting location overview – injection system
      • 1.3 Filling and bleeding fuel system
      • 1.4 Checking fuel system for leaks
    • 2 Vacuum system
      • 2.1 Schematic diagram – vacuum system
      • 2.2 Removing and installing vacuum line
      • 2.3 Checking vacuum system
    • 3 Injectors and high-pressure accumulator (fuel rail)
      • 3.1 Assembly overview – injectors
      • 3.2 Assembly overview – high-pressure accumulator (fuel rail)
      • 3.3 Adapting correction values for injectors
      • 3.4 Testing injectors
      • 3.5 Checking return flow rate of injectors with engine running
      • 3.6 Checking return flow rate of injectors at starter speed
      • 3.7 Testing jammed-open injectors
      • 3.8 Removing and installing injectors
      • 3.9 Removing and installing high-pressure pipes
      • 3.10 Removing and installing fuel rail (rail)
    • 4 Air filter
      • 4.1 Assembly overview – air filter housing
      • 4.2 Removing and installing air filter housing
    • 5 Intake manifold
      • 5.1 Assembly overview – intake manifold
      • 5.2 Removing and installing intake manifold
      • 5.3 Removing and installing throttle valve module J338
    • 6 Senders and sensors
      • 6.1 Removingrandd installing N276
      • 6.2 Checking regulating valve N276
      • 6.3 Removing and installing fuel pressure sender G247
      • 6.4 Removing and installing air mass meter G70
      • 6.5 Removing and installing pressure differential sender G505
      • 6.6 Removing and installing exhaust pressure sensor 1 G450
      • 6.7 Removing and installing NOx sender 2 G687
      • 6.8 Removing and installing charge air temperature sender before charge air cooler G810
      • 6.9 Removing and installing charge air temperature sender after charge air cooler G811
      • 6.10 Removing and installing fuel temperature sender G81
      • 6.11 Removing and installing control unit for NOx sender GX30
      • 6.12 Removing and installing temperature and pressure sender for low-pressure fuel system GX20
    • 7 Engine (motor) 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 Assembly overview – high-pressure pump
      • 8.2 Removing and installing high-pressure pump
    • 9 Lambda probe
      • 9.1 Assembly overview – Lambda probe
      • 9.2 Removing and installing Lambda probe
  • 26 – Exhaust system
    • 1 Exhaust pipes/silencers
      • 1.1 Assembly overview – silencers
      • 1.2 Assembly overview – front exhaust pipe
      • 1.3 Removing and installing front exhaust pipe
      • 1.4 Separating exhaust pipes, silencers
      • 1.5 Removing and installing central exhaust pipe
      • 1.6 Removing and installing rear silencer
      • 1.7 Aligning exhaust system free of stress
      • 1.8 Check exhaust system for leaks
      • 1.9 Installation position of clamp
      • 1.10 Aligning tailpipes
    • 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 SCR system (selective catalytic reduction)
      • 3.1 Assembly overview – reducing-agent tank
      • 3.2 Assembly overview – delivery line for reducing agent
      • 3.3 Assembly overview – delivery module for reducing agent
      • 3.4 Removing and installing reducing agent tank
      • 3.5 Removing and installing reducing agent supply line
      • 3.6 Removing and installing delivery module for reducing agent
      • 3.7 Removing and installing injector for reduction agent N474
      • 3.8 Removing and installing control unit for reducing-agent heater J891
      • 3.9 Assembly overview – injector for reducing agent N474
      • 3.10 Drain the reducing agent tank
      • 3.11 Removing and installing filler pipe for tank for reducing agent
      • 3.12 Disconnecting reducing agent supply line
      • 3.13 Resetting SCR learnt values
    • 4 Exhaust gas temperature regulation
      • 4.1 Assembly overview – exhaust gas temperature regulation
      • 4.2 Removing and installing exhaust gas temperature sender 1 G235
      • 4.3 Removing and installingi sender 2G448
      • 4.4 Remove an co installingsexhaustigast temperaturesenderA3 G495
      • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    • 5 Exhaust gas recirculation
      • 5.1 Assembly overview – exhaust gas recirculation
      • 5.2 Assembly overview – exhaust gas recirculation valve 1 GX5
      • 5.3 Removing and installing exhaust gas recirculation cooler
      • 5.4 Removing and installing exhaust gas recirculation valve 1 GX5
      • 5.5 Removing and installing exhaust gas recirculation valve 2 GX6
      • 5.6 Removing and installing exhaust gas recirculation temperature sensor G98 .
      • 5.7 Checking exhaust gas recirculation cooler for leaks
  • 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 sender G40
      • 1.5 Removing and installing engine speed sender G28

Language: English
Format: PDF
Pages: 594

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