D3E804E4966-4 Cyl Petrol Engine (1 4 L Direct Injection 4V Turbocharger)

Service
Workshop Manual
Toledo 2013 ➤
4 cyl. petrol engine (1.4 l direct injection, 4V,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
turbocharger)
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Engine ID
CAX
A
Edition 05.2015
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
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information
Protected by copyright. Copying forshould alwayspurposes,
private or commercial be available to isthe
in part or in whole, not foremen and mechanics, because their
careful and
permitted unless constant
authorised adherence
by SEAT S.A. SEAT S.Ato doesthe instructions
not guarantee is
or accept any essential
liability with 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 © 2015 Seat S.A D3E804E4966

Toledo 2013 ➤
4 cyl. petrol engine (1.4 l direct injection, 4V, turbocharger) - Edition 05.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and positioning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Engine: dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Attaching engine to repair stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Engine: fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Vehicles with air conditioning/heating: additional instructions and assembly information . . 16
13 - Crankshaft group . . . . . . . . . permitted
. . . .respect
.unless
. . to.authorised
. .correctness
the . . by
. .SEAT
.of. information
. . . . . in. this
. .document.
. . . . .Copyright
. . . . by. SEAT
. . . S.A.
. . . . 17
S.A. SEAT S.A does not guarantee or accept any liability with
1 Engine: assembly and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.1 Parts I and II - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Part I Timing belt system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Part II Engine block - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Distribution housing: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.6 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Removing and installing sealing flange and flywheel/drive plate . . . . . . . . . . . . . . . . . . . . 30
2.1 Assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5 Sealing flange for crankshaft, flywheel side: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4 Pistons and conrods: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 Checking pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.5 Pistons: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.2 Checking distribution timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3 Distribution timing: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.4 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.5 Removing and installing the distribution chain of the control pump . . . . . . . . . . . . . . . . . . 74
1.6 Camshaft housing:removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.7 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.8 Test compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Contents i
Toledo 2013 ➤
2.2 Checking camshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2.3 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.4 Valve guides: verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.5 Replacing valve shaft seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Engine oil, quantities, specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Removing and replacing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4 Oil pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.5 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 115
1.3 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.4 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.7 Check the cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.10 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 High pressure system pressure reduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2 Separating push-fit couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.1 Fuel tank - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.2 Fuel tank: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4 Repairing fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.2 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 145
4.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.5 Fuel level gauge sender G : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.6 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5 Repairing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.1 Accelerator pedal module - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.2 Accelerator pedal module: functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
6 Fuel filter: . .Protected
. . . . . by. .copyright.
. . . . .Copying
. . . . for
. . private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. .in .whole,
. . . is. not
............... 162
6.1 Fuel filter - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 162
6.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7 Activated charcoal filter system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.1 Cleaning rules for working on the fuel supply system, fuel injection system and on the exhaust
gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.2 Activated charcoal filter system - Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.3 Activated charcoal filter system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.4 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ii Contents
Toledo 2013 ➤
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Exhaust gas turbocharger – Assembly overview (Part I ) . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.3 Exhaust gas turbocharger – Assembly overview (Part II) . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.4 Turbo compressor: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.5 Removing and installing compressor housing and turbine housing . . . . . . . . . . . . . . . . . . 177
1.6 Turbocharger pressure capsule: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.7 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.8 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2 Supercharger air system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.1 Supercharger air system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.2 Charged air cooler: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.3 Removing and installing radiator and charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.1 Parts I and II intake pipe - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.2 Assembly overview - part I, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.3 Assembly overview - part II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.4 Fuel rail with injection valves - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.5 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.6 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.7 Throttle valve control unit J338
Protected : removing
by copyright. Copyingand fitting
for private . . . . .purposes,
or commercial . . . . .in. part
. . or. .in .whole,
. . . is. not
........ 206
1.8 Throttle valve controlpermitted
unit J338
unless:authorised
cleaning . . S.A.
by SEAT . . .SEAT
. . .S.A
. .does
. . .not. .guarantee
. . . . .or. accept
. . . .any . .liability
. . . .with
....... 209
1.9 Remove and install the inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.10 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.11 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.12 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.13 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.14 Replace the Teflon seal and support washer on the injection valve . . . . . . . . . . . . . . . . . . 222
1.15 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.16 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.17 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.2 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 229
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.1 Catalytic converter and attaching parts - Assembly overview . . . . . . . . . . . . . . . . . . . . . . 232
1.2 Silencers with suspension elements - Components overview . . . . . . . . . . . . . . . . . . . . . . 235
1.3 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.4 Installation position and tightening torque of the clamping sleeve . . . . . . . . . . . . . . . . . . . . 237
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.1 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.2 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.4 Spark plug test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Contents iii
Toledo 2013 ➤
iv Contents
Toledo 2013 ➤
00 – Technical data
1 Technical data
(ERL002754; Edition 05.2015)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine characteristics”, page 1
1.1 Engine number

– Detach hose from activated charcoal filter at hose clip
-arrow-.
Engine code and engine number can be found on the sticker

-arrow- on the control 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 were produced with the
same code letters, the first of the six digits is replaced by a letter.
Vehicles with four digit engine codes
Starting with the letter “C”, new four digit engine codes have been
introduced. The first 3 digits denote the mechanical design of the
engine and are stamped on the engine as before. The fourth po‐
sition digit describes the engine power and torque and depends
on the engine control unit - J623- . The four-digit engine codes
are given on the model plate, the vehicle data plate and the engine
control unit.
Note
Position of the vehicle data sheet ⇒ Maintenance ; Booklet KG1 ;

vehicle data sheet
1.2 Engine characteristics

Engine identification characters CAXA
Emissions fulfil EU5
Capacity cm3 1390
Output kW / rpm 90/5000
Torque Nm / rpm 200/1500-4000
Bore: ∅ mm 76.5
Stroke mm 75.6
1. Technical data 1
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Compression: 10
RON min. 95 unleaded
Ignition system, fuel injection Motronic MED 17
Order of starting 1-3-4-2
Mixing system homogeneous
Supercharging Exhaust turbocharger
2 Rep. gr.00 - Technical data

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10 – Removing and installing engine

1 Removing and positioning the engine
⇒ “1.1 Engine: dismounting”, page 3
⇒ “1.2 Attaching engine to repair stand”, page 12
⇒ “1.3 Engine: fitting”, page 12
⇒ “1.4 Tightening torques”, page 15
⇒ “1.5 Assembly mountings”, page 15
⇒ “1.6 Vehicles with air conditioning/heating: additional instruc‐
tions and assembly information”, page 16
1.1 Engine: dismounting
Note
The engine is removed from underneath together with the gear‐

box.
Special tools and workshop

equipment required
♦ Engine support - T40075 A-
with adapters /4, /5, /6
♦ Torque wrench - V.A.G
1331-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Engine and gearbox sup‐
port - VAS 6095-
♦ Drip tray for workshop hoist
- VAS 6208-
1. Removing and positioning the engine 3

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♦ Pliers - VAS 6340-

♦ Step ladder - VAS 5085-
♦ Torque wrench - VAG
1332-
♦ Guide pins - T10093-
Note
Before carrying out further work, disconnect battery earth strap.

Therefore check whether a coded radio is fitted. Obtain anti-theft
coding first if necessary.
4 Rep. gr.10 - Removing and installing engine

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– Undo the fixing screws -1- from engine cover panel.

– Remove air filter ⇒ page 205 .
– Open and close the lid of the expansion tank again for releas‐
ing the pressure in the cooling system.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
– Drain coolant ⇒ page 116
– Observe rules for cleanliness ⇒ page 144 .
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
release pressure by carefully pulling hose off connection.
– Pull off fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing release tabs.
– Opening the quick-release coupling ⇒ page 131 .
– Remove the spring-type hose and the coolant hoses -1- and
-2-.
– Press the retainer -3- beneath the coolant hoses and pull the
hose upwards.
– Move the coolant hoses to the rear.
– Release the coolant hoses on the heat exchanger -arrow- and

remove.

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– Release the coolant hoses -arrow- on the gearbox ends and

disconnect.
– Remove the Lambda probe - G39- -1-.

– Unscrew the upper securing screw for the alternator -2- and
press the alternator slightly downwards.
– Unscrew the fastening bolts -arrows- and remove the heat
protection plate from the turbocharger.
– Unscrew the securing bolts on the exhaust gas turbocharger

-arrows-.
– Unscrew the securing bolts -arrows- of the splash guard cover

of the engine.
– Remove inner front right and left wheel housing Protected
moulding ⇒
by copyright. Copying for private or commercial purposes, in part or in whole, is not
Bodywork, exterior fitting work; Rep. gr. 66 ; Front wheel
housing moulding: removing and fitting respect to the correctness of information in this document. Copyright by SEAT S.A.

Toledo 2013 ➤
– Separate the coolant hose -1- from the coolant for the super‐
charger system and remove the coolant pipe -2-.
– Open the spring-type hose and remove the coolant hose -1-.
– Unplug the connector -2- from the coolant circulation - V50- .

– Detach the connector -3- of the knock sensor 1 - G61- y -4- of
the engine speed sender - G28- .
– Remove bracket for coolant circulation pump - V50- from

crankcase -arrows-.
– Disconnect the connector -1- of the oil level and temperature

sender - G266- .
– If an auxiliary heater is set, the coolant hoses -2- must be re‐
moved.
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .

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– Unclip lines -1- at catalytic converter.

– Release and unplug connectors -2-.
– Unscrew the securing nut -3- and remove the seal.
– Remove catalytic converter downwards.
Caution
Risk of damage to the vibration damper section!

♦ Do not bend decoupling element more than 10°.
♦ Install decoupling element so that it is not under tension.
♦ Take care not to damage wire mesh on decoupling ele‐
ment.
– Unscrew the exhaust pipe with the decoupling element

-arrow-.
– Unscrew the securing bolts of the double clamp -arrows- and

pull the exhaust pipe to the back.
– Pull connector off thermo-switch and radiator fan.
Vehicles with manual gearboxes
– Remove the drive shaft on the right and left from the gearbox
and tie up ⇒ Running gear, shafts, steering; Rep. gr. 40 ; Drive
shaft: repair; Drive shaft: removing and fitting
Vehicles with automatic gearbox
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shafts .

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All vehicles (continued)

– Unscrew the fixing bolts -arrows- of the pendulum support.
Caution
Bolt -1- must not be loosened.
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
– Pull vacuum and breather flexible hoses off the engine.
– Remove engine control unit ⇒ page 228 .
– Open cable guide fasteners -arrows-.

– Remove wiring from engine control unit.
– Secure lines/wiring to engine with a cable tie.
– Unscrew earth connection -1-.

– Unscrew bolts -arrows- on engine mounting approx. 2 turns.

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– Unscrew securing bolts -arrows- on gearbox mounting by ap‐

prox. 2 turns.
Vehicles with manual gearboxes
– Remove the gear mechanism from the gearbox: ⇒ Rep. gr.
34 ; Gear mechanism: repairs .
– Remove slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ;
Repairing clutch mechanism
Note
Do not depress the clutch pedal.
Vehicles with automatic gearbox

– Remove selector lever cable: ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable
– Remove the poly V-belt ⇒ page 22 .
Vehicles with air conditioner

– Unplug the electrical connector -1- from the air conditioner
compressor regulating valve - N280- .
– Unscrew the bolts -arrow- for air conditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do not expand the refrigerant lines and hoses
Protected by excessively.
copyright. Copying for private or commercial purposes, in part or in whole, is not
– Secure AC compressor to lock carrier.
Note
Do not open the air conditioning pipes.

To be able to lower the engine with gearbox, you will require the
engine support - T40075A- with adapters -/4-, -/5- and -/6-.

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– Tighten the adapters - T40075/4- until they make contact with

the crank case.
– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.
– Insert two M10 nuts between crankcase and engine support -
T40075A- .
– Secure engine support - T40075A- hand-tight to crankcase

using an M8x35 bolt -1-.
– Tighten bolts attached to engine support - T40075A- to 20 Nm.

– Lift the engine and gearbox slightly with the engine and gear‐
box crane - V.A.G 1383 A- .
Note
To loosen the mounting bolts, use the stepladder - VAS 5085- .
– Remove bolts -arrows- for engine mounting.


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– Unscrew securing bolts -arrows- from gearbox mounting.
Caution
Danger of damage to vacuum lines or electrical wiring and to

engine compartment.
♦ Check that all vacuum lines and electrical wiring between
engine, gearbox, subframe and body have been detach‐
ed.
♦ Carefully guide out engine/gearbox assembly with sub‐
frame from engine compartment when lowering.
Note
Carefully guide the unit when lowering to avoid damage.
– Carefully lower the engine with gearbox.

– Pull engine/gearbox assembly as far as possible forwards and
lower it slowly downwards.
Note
Engine and gearbox must be guided carefully when lowering to

prevent damage to the bodywork.
Caution
When it looks like the engine should remain removed for a lon‐
ger period, align the lines of the air conditioning system tension
free.
1.2 Attaching engine to repair stand

When carrying out repair work, secure the engine to the engine
and gearbox support - VAS 6095- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Work sequence respect to the correctness of information in this document. Copyright by SEAT S.A.
– Unbolt gearbox.
– Secure the engine to the engine and gearbox support - VAS
6095- .
1.3 Engine: fitting

The remaining installation is carried out in the reverse order; note
the following:

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WARNING
Important information for using an engine with one of the des‐

ignated spare parts (replacement engine):
♦ Take note that the roller tappet ⇒ Item 21 (page 57) is
not included in the scope of supply of the new replacement
engine.
♦ When exchanging the replacement engine, the roller tap‐
pet ⇒ Item 21 (page 57) has to be used, as long as this
is possible.
♦ The following parts will be influenced if the roller tappet is
not installed: Camshaft, high-pressure pump and cylinder
head cover.
♦ The cylinder head may also be influenced as a result of
damage to the bolt of the high-pressure pump.
♦ The engine will be damaged permanently if the valves
make contact with the piston.
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ All the various lines (e.g. fuel, coolant, refrigerant, vacuum
and electrical wiring) must be installed so that their original
positions are reproduced.
♦ To prevent damaging the hoses, ensure that all mobile or
hot components are easily accessible.
– Check the clutch release bearing for wear and replace (vehi‐
cles with manual gearbox), if necessary.
– Lubricate the clutch release bearing, the guide sleeve for re‐
lease bearing and input shaft splines withS.A. a small quantity of or accept any liability with
permitted unless authorised by SEAT SEAT S.A does not guarantee
G 000 100 (vehiclesrespect
with tomanual gearbox).
the correctness of information in this document. Copyright by SEAT S.A.
– Check whether dowel sleeves for centring the engine/gearbox

assembly are fitted in the cylinder block; install if necessary.

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– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
– Flange on the gearbox.
Tightening torques, gearbox: ⇒ Rep. gr. 34 ; Gearbox: removing
and installing .
– Align the engine using a shaking movement so that the sup‐
ports are not under any tension.
Note
Specified torques for assembly mountings ⇒ page 15
– Install pendulum support.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Specified torques for assembly mountings ⇒ page 15 respect to the correctness of information in this document. Copyright by SEAT S.A.
– Install slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ; Re‐

pairing clutch mechanism .
– Mount the gear-operating mechanism to the gearbox: ⇒ Rep.
gr. 34 ; Gear mechanism: Repairing .
– Install drive shafts: ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
– Install air conditioner compressor: ⇒ Heating, air conditioning
system; Rep. gr. 87 .
– Poly V-belt: installing ⇒ page 22 .
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
– Fit the engine anti-splash cover.
– Fill up coolant ⇒ page 116 .
– Fit the air filter ⇒ page 205 .
– Remove and install the bracket ⇒ Electrical system; Rep. gr.
27 ; Battery: Removing and installing .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and connecting battery .
– Install noise insulation.
– Connect the central diagnosis - VAS 505X- .
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided functions”.
– Carry out the vehicle system test ⇒ Vehicle diagnostic tester
“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.

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1.4 Tightening torques

Bolt union Tightening tor‐
que
Bolts, nuts M6 10 Nm
M8 20 Nm
M 10 45 Nm
M 12 60 Nm
Note
Specified torques for assembly mountings ⇒ page 15 .
1.5 Assembly mountings

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-.
Unit mounting for engine

A = 20 Nm + turn 90° further
B = 30 Nm + turn 90° further
Unit mounting for gearbox

C = 50 Nm + turn 90° further
Caution
Do not unscrew the screw connection -Arrow- in the process.

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Pendulum support
1.6 Vehicles with air conditioning/heating:

additional instructions and assembly in‐
formation
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.
To facilitate removing and installing the engine without opening

the refrigerant circuit:
– Remove the clip/s from the cooling agent hose/s.
– Bring lock carrier into service position: ⇒ Bodywork, exterior
fitting work; Rep. gr. 50 ; Body, front; Lock carrier in service
position .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87

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13 – Crankshaft group
1 Engine: assembly and dismantling
Note
♦ If during repairs to the engine, large quantities of metal shav‐

ings and particles produced by wear and abrasion, for exam‐
ple from the bed plate bearings, to avoid further damage
derived from this problem, apart from thoroughly cleaning the
oil pipes, the oil filter must be replaced.
♦ Oil the support and slide surfaces before carrying out assem‐
bly work.
⇒ “1.1 Parts I and II - assembly overview”, page 17

⇒ “1.2 Part I Timing belt system - Assembly overview”,
page 19
⇒ “1.3 Part II Engine block - Assembly overview”, page 20
⇒ “1.4 Removing and installing poly V-belts”, page 22
⇒ “1.5 Distribution housing: removing and fitting”, page 23
⇒ “1.6 Removing and installing ancillary bracket”, page 28
Note
When carrying out repair work, secure the engine to the engine
and gearbox support - VAS 6095- .
1.1 Parts I and II - assembly overview
1. Engine: assembly and dismantling 17

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18 Rep. gr.13 - Crankshaft group

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1.2 Part I Timing belt system - Assembly overview
1 - 20 Nm
2 - Pulley
❑ For coolant pump
❑ Use water pump wrench
- V.A.G 1590- to loosen
and tighten.
3 - 40 Nm +1/4 turn further
(90º)
❑ replace
❑ Removing and installing
with vehicle raised.
4 - 40 Nm
5 - Washer
6 - Idler roller
7 - Washer
8 - Spacer bush
9 - Alternator
10 - 25 Nm
11 - Centring sleeve
12 - Tensioner
13 - Pulley
❑ For crankshaft
❑ The contact surfaces
must be free of oil and
grease.
14 - 150 Nm + 1/2 turn (180º)
❑ Observe tightening se‐
quence ⇒ page 34 .
❑ replace
❑ The contact surface of the fastening bolt must be free of oil and grease
❑ Apply oil before fitting it (thread)
❑ Secure the pulley with the counterhold - 3415- to prevent it from turning
❑ Turning further can be done in several stages.
❑ The retightening angle can be measured with a standard protractor

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1.3 Part II Engine block - Assembly overview
1 - Cylinder head with cam‐

shaft housing
❑ removing and fitting
⇒ page 88
❑ The seal surface should
not be reworked
❑ With integrated cam‐
shaft bearings
❑ Remove any sealant re‐
mains.
❑ Coat with
AMV 188 001 02 before
installing.
❑ When installing, insert
vertically from above so
that dowel pins fit into
holes in cylinder head.
2 - Cylinder block
❑ Dismantling and assem‐
bling cylinder block
⇒ page 30 .
❑ Disassembling and as‐
sembling pistons and
conrods ⇒ page 49
3 - Bracket for ancillary me‐
chanical units
❑ For tensioning element
and air conditioner com‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
pressor.
⇒ page 28
4 - Filler cap
5 - Sprocket
❑ To drive oil pump and
distribution chain
❑ The contact surfaces must be free of oil and grease.
6 - 20 Nm +1/4 turn further (90º)
❑ replace
7 - Sprocket
❑ Immobilise the sprocket using the retention tool -T10172- .
8 - Drive chain
❑ Mark D.O.R. before dismounting (installation position)
9 - 25 Nm
10 - Locating pin for chain tensioner
❑ Tightening torque: 8 Nm
11 - Chain tensioner with tensioning plate
❑ for oil pump drive

Toledo 2013 ➤
12 - Tensioning spring
13 - Oil sump
❑ removing and fitting ⇒ page 104
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant D 176,404 A2
14 - 13 Nm
15 - Piston
❑ For control chain tensioner
16 - Compression spring
17 - Chain tensioner
18 - 9 Nm
19 - Distribution housing
❑ Install with sealant D 176 501 A1.
❑ For ease of assembly, tighten 2 studs -M6x80- on the camshaft casing and the engine block
❑ To improve timing case guidance, secure sump in position with two bolts.
20 - 10 Nm
21 - Pulley
❑ Observe tightening sequence ⇒ page 34 .
❑ Protected
The contact surfaces
by copyright. Copying for must be
private or free ofpurposes,
commercial oil andin grease.
part or in whole, is not
❑permitted
Secure the pulley with the counterhold - 3415- to prevent it from turning
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Poly-V belt: removing and installing ⇒ page 22
22 - 150 Nm + 1/2 turn (180º)
❑ Removing and installing crankshaft pulley ⇒ page 34 .
❑ replace
23 - Bush
24 - O-ring
❑ replace
25 - 50 Nm
26 - Seal
❑ Lock chain sprockets using counterhold - T10172- .
❑ Bolt with left-hand thread.
❑ replace
❑ replace
29 - Sliding / tensioning shoe
30 - Controller
❑ Must not be dismantled

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31 - Timing chain
32 - Sprocket
❑ For exhaust camshaft.
❑ Lock chain sprockets using counterhold -T10172- .
33 - Runner
❑ For timing chain
34 - Guide pin
35 - Bush
1.4 Removing and installing poly V-belts

Special tools respect
and workshop equipment
to the correctness of informationrequired
in this document. Copyright by SEAT S.A.
♦ 16 mm spanner
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Removing and installing noise insulation or un‐
derride guard .
– Mark running direction of poly V-belt.
– To loosen the Poly-V belt, turn the tension device using an e/
c 16 spanner in the -direction of the arrow-.
– Lock tensioning element with a 4 mm Allen key -1-.
– Take off poly V-belt.
Installation
– Initially install the poly V-belt over the vibration protection. The
belt is placed last on the tension pulley.
Continue installation following reverse order for removing.
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
♦ When fitting the Poly-V belt, ensure that it is fitted with the
correct direction of rotation and that it is correctly seated on
the pulleys.
After completing repair:

– Start engine and check that belt runs properly.

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1.4.1 Routing of poly V-belt

Belt routing with air conditioning
1 - Coolant pump - pulley
2 - Idler roller
3 - Alternator pulley
4 - Tensioning roller
5 - Air conditioner compressor pulley
6 - Pulley - crankshaft
Belt routing without air conditioning compressor

1 - Coolant pump - pulley
2 - Tensioning roller
3 - Alternator pulley
4 - Poly V-belt
5 - Pulley - crankshaft
1.5 Distribution housing: removing and fitting

Toledo 2013 ➤

equipment required
♦ Counterholder - 3415-
♦ Mandrel - 3415/1-
♦ Support tool - 10-222A-
♦ Additional part for the en‐
gine mounting - 10 222A/
31-
♦ Basic engine mounting set
- T40091-
♦ Torque wrench (5 … 50
Nm) - V.A.G. 1331-
♦ Torque wrench (40 … 200 Nm) - V.A.G. 1332-

♦ D 176,501 A1 Sealing compound

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Preparing the bracket

– Remove the two fastening bolts -1- of the additional part for
the engine mounting - 10 222A/31-4- .
1.5.1 Removing
– Unhook the coolant hoses -2- on the engine cover and pull
from the engine cover upwards.
– Remove engine splash guard.
– Remove front right hand side wheel housing protection: ⇒
Bodywork, exterior fitting work; Rep. gr. 66 ; Wheel housing
protection: removing and fitting .
– Mark direction of rotation of Poly-V belt and remove
⇒ page 22 .
– Turn crankshaft in direction of engine rotation to TDC
permitted unless No.by1SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
cylinder ⇒ page 58 . respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove belt pulley for coolant pump ⇒ page 125 .

– Remove banjo bolt from oil supply pipe to turbocharger.
– Remove the air conditioning compressor with the connected
refrigerant pipes from its bracket: ⇒ Heater, air conditioner;
Rep. gr. 87
– Remove bracket for ancillaries .
– Remove alternator.
– 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 outside the vehicle.
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.

Toledo 2013 ➤
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.
– Unscrew the nut and remove earth wire -1-.

– Take up weight of engine and remove securing bolts
-arrows-.
– Remove the oil pan ⇒ page 104 .
– Loosen the pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .
– Remove holder -1-, unscrew screws -arrows- for this purpose.

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– Remove Allen head bolts for timing housing and hexagon bolts
indicated by -arrows-.
– Remove valve timing housing.
Note
Note that crankshaft bearing bush remains in sealing flange.
1.5.2 Installation
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.
– Clean sealing surfaces carefully. They must be free of oil and

grease.
Note
♦ The valve timing housing is still sealed to the engine with a

seal and also sealant D 176 501 A1.
♦ The sealant D 176 501 A1 is used to prevent leaks between
the valve timing housing and the joints -1- and -2-.
♦ The sealant point must have a diameter of 10 mm and a thick‐
ness of approx. 1 mm.
♦ Apply the sealant immediately before fitting the distribution
housing.

Toledo 2013 ➤
– Apply sealant D 176 501 A1 to the joints camshaft housing/

cylinder head -1- and cylinder head/cylinder block -2-.
– Fit the new gasket on the adjustment pins.
– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– 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:
M6 bolt to 10 Nm.
M8 bolt to 20 Nm
M10 bolt to 50 Nm.
– Align the engine using a shaking movement so that the sup‐
ports are not under any tension.
Note
Specified torques for assembly mountings ⇒ page 15
– Install crankshaft pulley ⇒ page 34 .

– Continue installation following reverse order for removing.
1.6 Removing and installing ancillary brack‐

et
Special tools and workshop equipment required
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
Removing
derride guard .
– Remove the alternator ⇒ Electrical system; Rep. gr. 27 ; Re‐
moving and installing alternator .
– Removing air conditioning compressor ⇒ Heating, Air condi‐
tioning; Rep. gr. 87 .

Toledo 2013 ➤
Note

– Check that the conducts have not been bent.
– Remove bolts -1- and remove bracket.
Installation
– Fit the bracket for the ancillary units to the cylinder block.
– Tighten securing bolts -1- to 25 Nm.

Specified torque for tensioning element ⇒ Item 3 (page 19)

Toledo 2013 ➤
2 Removing and installing sealing

flange and flywheel/drive plate
⇒ “2.1 Assembly diagram”, page 30
⇒ “2.2 Removing and installing engine speed sender G28 ”, page
31
⇒ “2.3 Renewing crankshaft oil seal - belt pulley end”,
page 32
⇒ “2.4 Removing and installing crankshaft pulley”, page 34
⇒ “2.5 Sealing flange for crankshaft, flywheel side: replacing”,
page 37
2.1 Assembly diagram
Note
Repairing the clutch ⇒ Repairing the clutch ; Rep. gr. 30 ; Re‐

moving and fitting the clutch .
1 - 150 Nm + 1/2 turn (180º)
❑ replace
crankshaft pulley
⇒ page 34 .
❑ The contact surface of
the fastening bolt must
be free of oil and grease
❑ Apply oil before fitting it
(thread)
❑ Secure the belt pulley
against turning with
counterhold 3415.
❑ The retightening angle
can be measured with a
standard protractor
2 - Pulley
grease.
❑ Secure against turning
with counterhold - 3415-
when removing and in‐
stalling
❑ Poly-V belt: removing
and installing
⇒ page 22
3 - Oil seal
❑ replace
4 - Bush
grease.
5 - O-ring
❑ replace

Toledo 2013 ➤
6 - Cylinder block
❑ replace
8 - Flywheel/drive plate
❑ To remove and fit the engine flywheel, immobilise it with the retention tool - T10044-
9 - Intermediate plate
❑ Must sit on dowel sleeves
❑ do not damage/bend during assembly work
10 - 10 Nm
❑ replace
11 - Sealing flange with sender wheel and oil seal
❑ Removing and installing engine speed sender - G28- (not shown) ⇒ page 31 .
❑ Specified torque for the engine speed sender - G28- : 5 Nm
❑ Always replace the sealing flange together with the seal and the sender crown
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 37 .
2.2 Removing and installing engine speed

sender - G28-
♦ Socket
Protected and key
by copyright. - T10370-
Copying for private or commercial purposes, in part or in whole, is not
Removing
Note
The engine speed sender is located on the seal flange of the

crankshaft on the flywheel side.
2. Removing and installing sealing flange and flywheel/drive plate 31

Toledo 2013 ➤
– Pull off connector -1- from engine speed sender - G28- .

– Remove gasket -2- from cylinder block and remove engine
speed sender - G28- with socket - T10370- .
Installation
– Install engine speed sender - G28- and tighten securing bolt
to 5 Nm.
2.3 Renewing crankshaft oil seal - belt pulley end

equipment required
♦ Gasket ring extractor -
3203-
1332-
♦ Slider - T10117/2-
♦ Assembly tool - T10053-
Removing
– Remove front right wheel housing liner: ⇒ }General body re‐
pairs; Rep. gr. 66 ; Wheel housing liner: removing and instal‐
ling; front wheel housing liner .

Toledo 2013 ➤
– Turn crankshaft in direction of engine rotation to TDC No. 1

cylinder ⇒ page 58 .
– Loosen the pulley securing bolt. To do this hold the pulley with
counter-hold tool -3415- and -3415/1- .
– Unscrew the inner part of the compression ring extractor -

3203- by three turns (approx. 5 mm) from the outside part and
lock with the knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Remove bearing bush from crankshaft journal and clean con‐
tact surfaces of crankshaft chain sprocket and bearing bush.
Installation
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.

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– Insert the seal using the assembly tool -T10053- as far as

possible in the distribution housing by tapping it evenly
2.4 Removing and installing crankshaft pulley

equipment required
1601-
♦ Pin - 3415/1- (not illustra‐
ted)
♦ Securing bolts - T10340-
Nm) - V.A.G 1331-

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♦ Dial gauge - VAS 6079-
♦ Dial gauge adapter -

T10170-
Removing

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– Loosen the pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .
Installation
– Tighten by hand the belt pulley with a new fastening bolt.
– Turn crankshaft in direction of engine rotation to TDC No. 1

cylinder ⇒ page 58 .
– Unscrew plug from crankcase.

– Screw locking pin - T10340- to stop into crankcase.
– Tighten locking pin - T10340- to 30 Nm.
Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
Note
♦ Note that all contact surfaces from the securing bolt to the
crankshaft chain sprocket must be free of oil and grease.
♦ Always use a new bolt.
Tightening torque: 150 Nm + 1/2 turn (180º)

– Hold pulley with counterhold - 3415- and -3415/1- .

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– Undo the fastening bolt - T10340- of the crankshaft sump.

– Screw the locking bolt in the crankshaft sump.
Tightening torque: 30 Nm
– Fit the poly V-belt ⇒ page 22 .
2.5 Sealing flange for crankshaft, flywheel side: replacing

Toledo 2013 ➤

equipment required
Nm) - V.A.G 1331-
♦ Tool insert 24 mm - V.A.G
1332/11-
♦ 3 hexagon bolts M6×35 mm
♦ Feeler gauge
♦ Dial calliper
2.5.1 Pressing sealing flange with sender

wheel off crankshaft
Note
♦ For clarity, the process is described with the engine removed.

♦ The sequence of operations
Protected byis identical
copyright. with
Copying the engine
for private moun‐
or commercial purposes, in part or in whole, is not
ted and the gearbox removed.
Work sequence
– Remove the flywheel and the drive plate.
– Put the engine in TDC cylinder 1 ⇒ page 58 .

Toledo 2013 ➤
– Remove the engine speed sender - G28- -arrow-.

– Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using three M6×35 mm bolts.
– Screw 3 M6 x 35 mm bolts into threaded holes of sealing flange

-arrows-.
– Screw in the bolts alternatively by max. 1/2 turn (180°) per bolt,
on the sealing flange and remove it from the crankshaft to‐
gether with the sender crown.
2.5.2 Pressing sealing flange with sender

wheel onto crankshaft
Note
♦ The sealing flange with the PTFE seal is fitted with a pressure
ring on the sealing lip. This support ring acts as an assembly
sleeve and must not be removed before installation.
♦ Sealing flange and sender wheel must not be separated or
rotated out of position after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
Assembly tool - T10134-

A - Tightening flats
B - Hexagonal nut
C - Assembly housing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
D - Locating pin respect to the correctness of information in this document. Copyright by SEAT S.A.
E - Hexagon socket-head bolt

F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red handle)

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2.5.3 A - Assembling seal with sender wheel

on assembly tool - T10134-
– Tighten the hexagonal nut -B- to just before the threaded spin‐
dle attachment surface -A-.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on hexa‐
gon nut -B- -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.
– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
rotated out of position.
– The locating hole -A- on the sender wheel -C- must align with
the marking -B- on the sealing flange.
– Secure the sealing flange by the front on a flat, clean surface.

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– Press the sealing lip pressure ring -A- in the direction of the
arrow downwards until it rests on the flat surface.
– Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
– Place the front of the sealing flange onthethe
respect to fittingofdevice
correctness information- in this document. Copyright by SEAT S.A.
T10134- , so that the position pin -B- fits into the hole -A- in
the sender crown.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
Ensure that the sender wheel remains secured in the fitting device
when fitting the sealing flange.
2.5.4 B - Fit the installation device - T10134-

with the sealing flange on the crankshaft
flange
• The crankshaft flange must be free of oil and grease.
• The engine should be in TDC cylinder 1.

Toledo 2013 ➤
– Screw hexagon nuts -B- to end of threaded spindle.

– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing to crankcase's sealing sur‐
face on the oil sump side.
– Secure the fitting device - T10134- to the crankshaft flange; to

do so, tighten the Allen bolts -A- about
Note
Screw the Allen screws -A- by approx. 5 threads into the crank‐
shaft flange.
– Screw in the 2 bolts M6 × 35 -A- on the cylinder block to guide

the sealing flange.
2.5.5 C - Bolting assembly tool - T10134- onto

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- touches crankshaft flange -A-.
– Insert the guide pin for petrol engines (red handle) -F- into the
crankshaft hole. In this way, the final fitting position of the
sender wheel is established.
Note
Do not insert the guide pin for petrol engines (red handle) -F- into
the crankshaft hole.
– Hand-tighten both hexagon socket head bolts of assembly

tool.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.

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2.5.6 D - Pressing sender wheel onto crank‐

shaft flange using assembly tool -
T10134-
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐
ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
Note
A small air gap must be present between cylinder block housing

and sealing flange after tightening hexagon nut to 35 Nm.
2.5.7 E - Check the fitting position of the send‐

er wheel on the crankshaft.

♦ Ruler - T40100-
– permitted
Screw hexagon
unless authorised nut -E-S.A.
by SEAT toSEAT
endS.A
ofdoes
threaded spindle.
not guarantee or accept any liability with
– Unscrew 2 bolts -A- from cylinder block.
– Unscrew the three knurled screws -B- out of sealing flange.
– Loosen the two hexagon socket head bolts on assembly tool
again.
– Remove assembly tool - T10134- .
– Remove the pressure ring from the sealing lip.
– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.

Toledo 2013 ➤
– Set vernier gauge on crankshaft flange.

– Measure distance »a« between crankshaft flange and sender
wheel.
Note
If the engine and gearbox support - VAS 6095- does not allow for
sufficient space, the measuring ruler - T40100- has to be attached
to the crankshaft flange and the clearance should be measured
using a feeler gauge.
If distance »a« is too small:

– Readjust the sender wheel ⇒ page 44 .
If distance »A« is attained:
– Tighten new securing bolts for sealing flange to 10 Nm using
alternate and diagonal sequence.
– Install the engine speed sender - G28- - arrow- and tighten the
fixing bolt to 5 Nm.
– Installing the oil pan ⇒ page 104 .
– Install spacer plate.
– Install flywheel with new bolts. Tighten the fixing screws with
60 Nm + 1/4 turn (90°).
2.5.8 F - Re-pressing sender wheel

– Secure the fitting device - T10134- to the crankshaft flange; to
do so, tighten the Allen
Protected bolts -A-
by copyright. about
Copying for private or commercial purposes, in part or in whole, is not
– Hand tighten bothrespect
hexagon socket head
to the correctness bolts.
of information in this document. Copyright by SEAT S.A.
– Move the fitting device - T10134- by hand onto the sealing

flange.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.

Toledo 2013 ➤
– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐

ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again ⇒ page 43 .
If the distance »a« is too small:
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 43 .

Toledo 2013 ➤
3 Crankshaft
⇒ “3.2 Pulling needle bearing out of and driving into crankshaft”,
page 47
⇒ “3.3 Crankshaft dimensions”, page 48

(90º)
❑ replace
❑ Only tighten to 50 Nm
when measuring crank‐
shaft radial clearance.
Do not retighten
2 - Bearing caps
❑ Do not interchange
bearing caps (mark po‐
sitions).
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
3 - Crankshaft
❑ Axial play when new:
0,07…0.24 mm
❑ Wear limit: 0.26 mm
Check radial clearance with
Plastigage
❑ New: 0.03 … 0.05 mm
❑ Do not rotate the crank‐
shaft when checking the
radial clearance
❑ Pulling needle bearing
out of and driving into
crankshaft
⇒ page 47 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Crankshaft dimensions permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ page 48 .
4 - Sealing flange with sender wheel and oil seal
❑ With engine speed sender - G28- (not illustrated).
❑ Specified torque for the engine speed sender - G28- : 5 Nm
❑ Always replace the sealing flange together with the seal and the sender crown
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 37 .
5 - 10 Nm
❑ replace
6 - Thrust washers
❑ For bearing cap 3.

Toledo 2013 ➤
❑ Note attachment
7 - Bearing cap
❑ In cylinder block.
8 - Sprocket
❑ To drive oil pump and distribution chain
9 - Bearing cap
❑ In bearing cap.
❑ Do not interchange used bearing shells (mark positions)
3.2 Pulling needle bearing out of and driving

into crankshaft
Only for vehicles with DSG gearbox
♦ Adapter - 22/1- from Kukko
♦ Extractor - Kukko 21/2-
♦ Mandrel - VW 207 C-
3. Crankshaft 47
Toledo 2013 ➤
Removing
– Pull out needle bearing using commercially available puller,
e.g. Kukko - 21/2- or Adapter Kukko - 22/1- .
Installation
– Insert flush using the punch - VW 207 C- .
3.3 Crankshaft dimensions

Honing dimension Crankshaft bearing Conrod
in mm journal ∅ journal ∅
Basic dimension -0.022 -0.022
54.00 47.80
-0.037 -0.037
Stage I -0.022 -0.022
53.75 47.55
-0.037 -0.037
Stage II --- -0.022
47.30
-0.037

Toledo 2013 ➤
4 Pistons and conrods: dismantling

and assembling
⇒ “4.2 Checking pistons”, page 51
⇒ “4.3 Separating new conrod”, page 52
⇒ “4.4 Piston and cylinder dimensions”, page 52
⇒ “4.5 Pistons: removing and installing”, page 53
⇒ “4.6 Removing and installing oil spray jets”, page 54
Oil the support and slide surfaces before carrying out assembly
work.
1 - Securing ring
2 - Piston pin
❑ if stiff, heat piston to 60°
C
❑ Remove and install us‐
ing drift - 10 - 14-
3 - Piston
❑ Checking ⇒ page 51
❑ Mark installation posi‐
tion and cylinder num‐
ber.
Caution
Arrow on piston crown
points to belt pulley end.
❑ 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 51
❑ Checking piston ring
side clearance
⇒ page 51
5 - Oil scraper rings
❑ Carefully remove and install by hand the oil scraper rings made up of 3 parts
❑ Inspect gap clearance ⇒ page 51
4. Pistons and conrods: dismantling and assembling 49

Toledo 2013 ➤
❑ The play between the rings and the grooves cannot be measured
6 - Conrod bolt
❑ M7×0.75: 20 Nm + 1/4 turn (90°)
❑ M8×1: 30 Nm + 1/4 turn (90°)
❑ replace
❑ Lubricate threads and contact surface
❑ To measure radial play, tighten to the applicable torque, without retightening
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod
❑ Marks -A- Mark allocation on the cylinder.
❑ Marks -B-: Mark conrod and corresponding conrod bearing cap
8 - Bearing cap
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
Checking radial clearance with Plastigage:
❑ New: 0.020…0.060 mm
❑ Do not rotate the crankshaft when checking the radial clearance
9 - 27 Nm
❑ Opening pressure of pressure relief valve: 1.8…2.2 bar.
10 - Oil spray jet
❑ For cooling the piston
11 - Conrod
❑ replace as a set only
❑ Marks -A- Mark allocation on the cylinder.
❑ Marks -B-: Mark conrod and corresponding conrod bearing cap
❑ Separate new conrod ⇒ page 52 .
Caution
Install the conrod in the
same position as it was
before it was removed.
If new conrods are fitted,
then the choice of posi‐
tion is arbitrary.
❑ Guided axially by piston.

Toledo 2013 ➤
4.2 Checking pistons

♦ External micrometer 75…100 mm - VAS 6071-
Checking pistons
– Measure pistons approx. 12 mm from the lower edge of skirt,
at 90 ° to the piston pin axis. Difference in relation to max.
specified measurement 0.04 mm. Nominal dimension
⇒ page 52 .
Checking piston ring gap

– 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
1st compression ring 0.20 … 0.40 1.0
2nd compression ring 0.40 … 0.60 1.0
Oil scraping ring 0.20 … 0.80 ---1)
1) No wear limit details available
Checking ring-to-groove clearance

Before checking, clean the groove of the rings.
Piston ring When new Wear limit
Dimensions in mm
1st compression ring 0.04 … 0.08 0.15
2nd compression ring 0.02 … 0.06 0.15
Oil scraping ring Not measurable

Toledo 2013 ➤
4.2.1 Inspecting cylinder bore

♦ Cylinder gauge - VAS 6078-
Inspecting cylinder bore
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between meas‐
ured value and nominal value: max. 0.08 mm.
– Nominal dimension ⇒ page 52 .
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.
4.3 Separating new conrod

It is permitted
possible that the fracture point is not completely fractured in
new conrods. If the
respect to it is not possible
correctness to take
of information off the Copyright
in this document. conrodbybearing
SEAT S.A.
cap by hand, proceed as follows:
– Mark cylinder allocation of conrod ⇒ Item 11 (page 50)
– Secure the conrod, as shown in the figure, on a vice with pro‐
tecting aluminium clamps.
Note
♦ Secure the conrod slowly so that it does not break.

♦ The conrod is attached below the cutting line.
– Unscrew the two bolts -arrows-. approx. 5 turns.
– Using a plastic hammer, carefully knock conrod bearing cap

loose in direction of -arrow-.
4.4 Piston and cylinder dimensions

Honing dimen‐ Piston ∅2) Cylinder bore ∅
sion
Basic dimen‐ mm 76.475 76.51
sion

Toledo 2013 ➤
Honing dimen‐ Piston ∅2) Cylinder bore ∅

sion
Stage III mm 76.495 76.53
2) Measure at about 12 mm from the lower edge of the piston
4.5 Pistons: removing and installing

♦ Mandrel - VW 222 A-
♦ Commercially available tapered sleeve for mounting the piston

rings
Removing
– Removing the cylinder head ⇒ page 88 .
– Mark piston installation position and corresponding cylinder
number ⇒ Item 3 (page 49) .
– Mark conrod installation position and corresponding cylinder
and conrod bearing cap ⇒ Item 7 (page 50) .
– Remove the bearing cover of the conrod and remove upwards
with the piston and conrod.
Note
If the piston pin is difficult to move, heat the piston to approx. 60

℃.
– Remove circlip from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installation
Installation is carried out in the reverse order; noting the following
in the process:
Note
Renew the bolts tightened with specified tightening angle.

– Lubricate
permitted the friction
unless authorised surfaces
by SEAT S.A. SEAT S.Aof doesthe half bearings.
not guarantee or accept any liability with
– Install piston with commercially available piston ring clamp,
observing installation position ⇒ Item 3 (page 49) .
– Insert the conrod bearing cover considering the installation
position in the process ⇒ Item 7 (page 50) .

Toledo 2013 ➤
– Installing cylinder head ⇒ page 88 .

Tightening torques
♦ ⇒ “4.1 Assembly diagram”, page 49
4.6 Removing and installing oil spray jets

♦ Socket and key - T10545-
Removing
derride guard .
– Remove the fluid pump ⇒ page 106 .
– Turn crankshaft via vibration damper securing bolt in direction
of engine rotation until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using bit - T10545- .
– Remove oil spray jets -2-.
Installation
Caution
Avoid damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Check that oil spray jets adequate clearance after re-in‐
stalling pistons.
♦ Bent oil spray jets must be renewed.
1- Pressure relief valve, 27 Nm

2- Oil spray jet
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
– Fit the oil pump ⇒ page 106 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Removing and installing noise insulation or underride
guard . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Toledo 2013 ➤
15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head, all the contact

surfaces between the support elements, roller rocker fingers
and cams must be oiled before installing the camshaft hous‐
ing.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is replaced, all the coolant in the system
must also be changed.
♦ Oil the support and slide surfaces before carrying out assem‐
bly work.
♦ Removing and installing intake manifold ⇒ page 210

⇒ “1.2 Checking distribution timing”, page 58
⇒ “1.3 Distribution timing: adjustment”, page 61
⇒ “1.4 Checking timing chain”, page 69
⇒ “1.5 Removing and installing the distribution chain of the control
pump”, page 74
⇒ “1.6 Camshaft housing:removing and fitting”, page 82
⇒ “1.7 Removing and installing the cylinder head”, page 88
⇒ “1.8 Test compression pressure”, page 92

1. Cylinder head 55
Toledo 2013 ➤
1 - 20 Nm
2 - High-pressure pump
❑ For the fuel supply
❑ With fuel pressure regu‐
lating valve - N276-
⇒ page 211
3 - Wiring guide
❑ Bolt to camshaft hous‐
ing with 8 Nm torque.
4 - to air filter
5 - 10 Nm
6 - Hall sender - G40-
❑ With O-ring
❑ Renew O-ring if dam‐
aged.
(90º)
❑ replace
❑ Tighten from centre out‐
wards
8 - Camshaft housing
Caution
Screw in the studs (M6 x
80) on the camshaft cas‐
ing 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.
❑ Carefully clean the contact surfaces making sure that they are free of oil and grease
❑ Before mounting, apply D 154,103 A1
❑ When installing fit vertically from above onto studs and dowel pins
9 - 20 Nm
10 - Attachment rings
11 - Exhaust turbocharger
12 - Oil pressure switch - F1- , 20 Nm
❑ after removal the oil pressure switch must be replaced since the seal cannot be replaced separately
13 - Cylinder head gasket
❑ replace
❑ Metal gasket
❑ Renew coolant after replacing.
56 Rep. gr.15 - Cylinder head, valve gear

Toledo 2013 ➤
14 - Cylinder head
❑ check for distortion ⇒ page 57
❑ The sealing surfaces in contact with the camshaft housing must be free of oil and grease
❑ Renew coolant after replacing.
15 - Guide pin
16 - Locking pin
17 - Supporting element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ Oil contact surface.
18 - Roller rocker arm
❑ Check roller bearings for ease of movement
❑ ?When installing, secure to support element using securing clip.
19 - Cylinder head bolt
❑ replace
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 88 .
20 - Oil seal
Note
Note the different sealing types

when removing and installing the
camshaft housing ⇒ page 82 .
❑ replace
❑ 4 off
❑ Fitted on cylinder head
21 - Tappet with roller
❑ Apply a light coat of engine oil to the slide surface
22 - O-ring
❑ replace
❑ Lubricate with oil before fitting
Check whether the cylinder head is deformed

– Check using the 500 mm straight edged ruler - VAS 6075- and
the feeler gauge.
Maximum deformation: 0.05 mm
1. Cylinder head 57
Toledo 2013 ➤
1.2 Checking distribution timing

equipment required
♦ Spark plug socket and ex‐
tension - 3122 B-
Nm) - V.A.G 1331-
♦ Extractor - T10094 A-
T10170- or dial gauge
adapter - T10170 A-
♦ Camshaft fastener -
T10171 A-
Note
The fastening points for securing the fastener to the camshaft

have been modified. A new special tool has been introduced de‐
scribed as camshaft fastener - T10171 A- . The camshaft fastener
- T10171- may remain in use if modified as described below.

Toledo 2013 ➤
– Place the template -1- on the camshaft fastener - T10171- as

shown in the figure.
– Mark the camshaft fastener - T10171- with a notch at the mark
-2-.
– Drill the camshaft fastener - T10171- using a 7 mm drill bit.
– Deburr the drill on both sides.
– For tool number -T10171- , add an »A«.
Checking sequence
– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .

– Unhook
permitted the coolant
unless authorised by SEAThoses
S.A. SEAT-2-
S.Aondoesthe engineorcover
not guarantee and
accept any pull
liability with
– Disconnect the coolant hoses on the coolant pipe -1- and un‐
screw the pipe on the camshaft casing and on the engine block
from below.
– Release connector -2- and unplug.

– Remove oil pressure switch - F1- -1-.
1. Cylinder head 59
Toledo 2013 ➤
– Unscrew the screws on the both covers of the camshaft -3-.

– Unclip engine pre-wiring harness -1-.
– Pull coolant pipe -2- and engine pre-wiring harness -1- away
from cylinder head.
– Lever both camshaft covers -3- out of cylinder head.
– Remove the cylinder 1 spark plug. To do so, use the extractor
-T10094 A- and the spark plug spanner - 3122B-
⇒ page 240 .
– Screw the adapter for dial gauge -T10170- into spark plug hole
as far as the stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC No. 1
cylinder. Note position of small needle on dial gauge.
The openings -arrows- of the camshafts should be in the positions

shown. Turn crankshaft one turn (360°) if necessary.
Note
♦ If crankshaft is turned 0.01 mm passed TDC, turn crankshaft

two full turns in engine direction of rotation to set crankshaft at
TDC for No. 1 cylinder.
♦ Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.
Caution
Before using camshaft clamp - T10171 A- you must check that
the pins on the tool project by at least 7 mm.

If this is not the case, the camshaft clamp is defective and must
be renewed.
The camshaft clamp must not be positioned using any kind of
hammer.

Toledo 2013 ➤
– Fit the camshaft fastener -T10171- as far as possible into the

openings in the camshaft.
The locking pins -arrow 1- should fit in the openings -arrow 2-.
The word “TOP” -arrow 3- should be legible from above.
If camshaft clamp -T10171 A- cannot be inserted into camshaft
openings to stop, then timing is incorrect and must be readjusted
⇒ page 61 .
Timing is OK if the camshaft clamp -T10171 A- can be fitted into
camshaft openings to stop.
– Continue installation following reverse order for removing. The
following should be taken into account:
♦ Replace the seals of the camshaft covers and lubricate with
oil before assembly.
♦ After removal the oil pressure switch must be replaced since
the seal cannot be replaced separately.
♦ Tightening torque for oil pressure switch - F1- : 20 Nm
– Fill coolant system with coolant ⇒ page 116 .
1.3 Distribution timing: adjustment

equipment required
♦ Dial gauge adapter
Protected- by copyright. Copying for private or commercial purposes, in part or in whole, is not
adapter - T10170respect
A- to the correctness of information in this document. Copyright by SEAT S.A.
T10171 A-
♦ Counterholder - T10172-
♦ Locking pin - T40011-
1. Cylinder head 61
Toledo 2013 ➤

1601-
♦ Securing bolts - T10340-
Nm) - V.A.G 1331-

Toledo 2013 ➤

tension - 3122 B-
Work sequence
from below.
1. Cylinder head 63
Toledo 2013 ➤


from cylinder head.
– Remove valve timing housing ⇒ page 23 .
– To turn the crankshaft, place the bushing, the crankshaft pul‐

ley -2- and the crankshaft bolt -3- in position and tighten the
crankshaft bolt (use retention tool - 3415- ).
-T10094 A- and the spark plug spanner - 3122B-
⇒ page 240 .
– Tighten the dial gauge adapter - T10170- as far as possible

on the thread of the spark plug.
– Fit the dial gauge -VAS 6079- with the extension -T10170/1-
as far as possible and fasten using the retainer nut -arrow-.
– Then turn crankshaft 2 revolutions in engine direction of rota‐
tion.

Toledo 2013 ➤
– Push the tensioning rail -1- in the direction of the arrow and
lock the piston with the bolt -T40011- .
– Mark the direction of rotation of the distribution chain -3- using

a felt tip pen.
Caution
The central bolt of the variator -2- is left-threaded.
– Remove bolts -2- and -4- and take out the variator -1- together
with the distribution chain -3-. To lock, use the retention tool -
T10172- .
– Replace the variator in its position -1-.
– Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt
-4- to 50 Nm (use counterhold - T10172- ).
Caution

be renewed.
hammer. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be inserted into holes in camshaft to stop.
Note
The camshafts must not be moved in an axial direction when ro‐

tating.
1. Cylinder head 65
Toledo 2013 ➤
– For securing the camshaft clamp - T10171 A- , screw an M6

screw -arrows- in the respective hole by hand (do not tighten).
Note
Remember that there are different securing points for the cam‐
shaft fastener - T10171 A- .
– Loosen the bolts of the camshaft wheels. To do this, use the

camshaft clamp - T10171 A- .
Note
The camshaft fastener - T10171 A- must not be used as a reten‐

tion tool.
– Remove a camshaft sprocket.

– Fit the distribution chain on the camshaft sprockets observing
the direction of rotation and replace the camshaft sprocket re‐
moved earlier.
– Tighten the camshaft bolts so that the camshaft sprockets are
still able to turn on the cam.
– Tension timing chain by removing locking pin - T40011- .
– Turn the crankshaft in the direction of engine rotation to TDC

cylinder
Protected by1copyright.
. Permissible deviation
Copying for private from purposes,
or commercial TDC No. 1 orcylinder:
in part ±
in whole, is not
0.01 mm.
Note
If crankshaft is turned 0.01 mm passed TDC, turn crankshaft two

full turns in engine direction of rotation to set crankshaft at TDC
for No. 1 cylinder.

– Unscrew the fastening bolt -3- and remove the coolant pump
- V50- .

Toledo 2013 ➤
– Remove locking bolt -arrow- on the crankshaft sump.

Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
– Using the retention tool -T10172- , hold the camshaft sprock‐

ets -1- and -5- in this position and tighten the bolts -2- (left-
threaded) to 40 Nm and -4- to 50 Nm.
Note
When tightening the camshaft bolts, the crankshaft must not turn
and both sides of the distribution chain -3- must be tight.
– Remove camshaft clamp - T10171 A- .
– Undo the fastening bolt - T10340- of the crankshaft sump.

– Turn the crankshaft in the direction of engine by 2 rotations to
TDC cylinder 1 . Permissible deviation from TDC No. 1 cylin‐
der: ± 0.01 mm.
Caution

be renewed.
hammer.
1. Cylinder head 67
Toledo 2013 ➤
– Insert camshaft clamp - T10171 A- as far as stop in camshaft

openings.
If the camshaft clamp - T10171 A- does not fit in properly:
– adjust again.
If the camshaft clamp - T10171 A- can be fit properly:


Toledo 2013 ➤
– Remove the camshaft clamp - T10171 A- , lock the camshaft

sprockets using the counter holder - T10172- and tighten the
screws -2- (left hand thread) and -4- using a spanner by 1/4
(90°) of a rotation
Note
The central bolt of the variator -2- is left-threaded.
Note
The camshaft sprockets must not turn when tightening them onto
the camshaft.
Continue installation following reverse order for removing. The

Note
The locking pin - T10340- remains in the crankcase until the

crankshaft pulley is installed.
♦ Valve timing housing: installing ⇒ page 17 .

♦ Insert the crankshaft pulley
permitted unless⇒authorised
page 34 by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Poly V-belt: installing ⇒ page 22 .
♦ Replace the seals of the camshaft covers and lubricate with
♦ Tightening torque for the coolant circulation pump - V50- , 10
Nm.
♦ After removal the oil pressure switch must be replaced since
the seal cannot be replaced separately.
♦ Fill coolant system with coolant ⇒ page 116 .
1.4 Checking timing chain

♦ Torque wrench - VAS 6583-
1. Cylinder head 69
Toledo 2013 ➤
♦ Test tool - T10550-
♦ Camshaft fastener - T10550/1-

♦ Sender - T10550/2-
♦ Scale sleeve - T10550/3-
• The temperature of the engine oil must be at least 40 ℃ ⇒ Ve‐
hicle diagnostic tester.
• The engine must necessarily not be at »TDC« position.
– Carry out function Timing chain elongation ⇒ Vehicle di‐
agnostic tester.
– Remove right front wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres .
– Remove noise insulation ⇒ Body, front; Rep. gr. 50 ; Noise
insulation; Assembly overview - noise insulation .
– Remove front right hand side wheel housing protection ⇒
Bodywork, exterior fitting work ; Rep. gr. 66 ; Front wheel
housing protection: removing and fitting .
– Removing poly V-belt ⇒ page 22 .
from below.

Toledo 2013 ➤
Note
Disregard item -1-.
– Then remove bolts for both camshaft covers -3-.

– Unclip wiring harness -1-.
– Pull coolant pipe -2- and wiring harness -1- away from cylinder
head.
– The hole in the exhaust camshaft -left arrow- must be posi‐

tioned as shown in the illustration.
– If necessary, turn crankshaft in direction of engine rotation.
– Insert camshaft clamp - T10550/1- as far as stop in camshaft

openings. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– The locking pinrespect
-arrow A-correctness
to the must engage in inhole
of information -arrow Copyright
this document. B- in by SEAT S.A.
exhaust camshaft.
– Inscription “TOP” must be readable from above.
1. Cylinder head 71
Toledo 2013 ➤
– Bolt on camshaft clamp - T10550/1- hand-tight.

– Use one bolt of the camshaft covers for this purpose -arrow-.
– Screw indicator - T10550/2- into hole in sump.

– Align centring point vertically so that the tip faces upwards.
– Tighten centring point with knurled nut.
– Position scale sleeve - T10550/3- on belt pulley.
Caution
There is a risk of injury caused by trapping fingers.

The scale sleeve - T10550/3- is equipped with magnets.
Proceed with great care when joining the components.
Note that the components are joined quickly by the magnetic
force.
– Align scale sleeve - T10550/3- with indicator - T10550/2- as

shown in illustration.
– Fit torque wrench - VAS 6583- with a suitable socket to crank‐

shaft bolt.
– Push torque wrench - VAS 6583- clockwise and keep it pushed
with a torque of 40 Nm.
– Set scale sleeve - T10550/3-
permitted unless authorisedand indicator
by SEAT S.A. SEAT- S.A
T10550/2- to »0«.
does not guarantee or accept any liability with

Toledo 2013 ➤
– Switch setting of torque wrench - VAS 6583- , and push it

slowly anti-clockwise.
– Keep torque wrench - VAS 6583- pushed with a torque of
40 Nm.
– Read value on the scale.
– If the chain skips during the test, renew timing chain
⇒ page 74 .
– If the chain skips, it can be heard and felt clearly.
Conclusions after the test
– If a chain elongation of up to 28° has been determined during
the test, the timing chain is OK.
– If a chain elongation of 29° and more has been determined,
the timing chain is not OK and must be renewed
⇒ page 74 .
Install in reverse order: The following should be taken into ac‐
count:
Note
♦ The scale sleeve - T10550/3- is equipped with magnets.

♦ Do not use any levers for removing the scale sleeve -
T10550/3- from the belt pulley!
– Rotate the scale - T10550/3- around 45° to the right so that

the edge of the scale does not remain above the display -
T10550/2- .
– Grasp behind scale sleeve - T10550/3- with both hands.
– Push your thumbs onto the bolt of the belt pulley, and pull off
scale sleeve - T10550/3- .
– Replace the seals of the camshaft covers and lubricate with
– Fill up with coolant ⇒ page 116 .
Tightening torques
♦ ⇒ “2.1 Assembly diagram”, page 94
♦ ⇒ “1.4 Removing and installing poly V-belts”, page 22
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Removing and
installing noise insulation
♦ ⇒ Bodywork, exterior fitting work ; Rep. gr. 66 ; Wheel housing
liner; Removing and installing front wheel housing liner
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
1. Cylinder head 73
Toledo 2013 ➤
– Place the engine cover on the camshaft housing and hang the
coolant hoses -2- into the holder.
1.5 Removing and installing the distribution chain of the control pump

equipment required
adapter - T10170 A-
T10171 A-

Toledo 2013 ➤
♦ Spark plug socket and extension - 3122 B-

Removing
– Undo theProtected
fixingbyscrews
copyright. -1- from
Copying engine
for private cover panel.
or commercial purposes, in part or in whole, is not
– Unhook therespect
coolant
to thehoses -2-of on
correctness the engine
information coverCopyright
in this document. and pullby SEAT S.A.
– Disconnect the connector -1- from the turbocharger air recir‐

culation valve - N249- .
– Unhook the hoses -2- on the pressure hose and open the cable
guide -3-.
1. Cylinder head 75
Toledo 2013 ➤
from below.


from cylinder head.

- T10094 A- and the spark plug spanner - 3122 B-

⇒ page 240 .
– Tighten the dial gauge adapter - T10170- as far as possible

on the thread of the spark plug.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.

Toledo 2013 ➤
The openings -arrows- of the camshafts should be in the positions

shown. Turn crankshaft one turn (360°) if necessary.
Note
♦ If crankshaft is turned 0.01 mm past TDC, turn crankshaft two

full turns in direction of engine rotation to set crankshaft in di‐
rection of engine rotation at TDC for No. 1 cylinder.
♦ Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.
Caution

be renewed.
hammer.
– Insert camshaft clamp - T10171 A- as far as stop in camshaft

openings.
– Forrespect
securing the camshaft
to the correctness clamp
of information in this-document.
T10171 A- , screw
Copyright by SEATanS.A.M6
screw -arrows- in the respective hole by hand (do not tighten).
Note
Remember that there are different securing points for the cam‐
shaft fastener - T10171 A- .
1. Cylinder head 77
Toledo 2013 ➤
– Remove the cover -1- of the oil pump sprocket.
– Press tensioning rail in -direction of arrow- by hand and lock

piston of chain tensioner with locking pin - T40011- .
– Mark the direction of rotation of the distribution chain -3- using

a felt tip pen.
Caution
The securing bolt of the variator -2- is left-threaded.
– Remove bolts -2- and -4- and take out the variator -1- together
with the distribution chain -3-. To lock, use the retention tool -
T10172- .
– Lock the oil pump sprocket using the retention tool - T10172-
and undo the fastening bolt -1-.

Toledo 2013 ➤
– Using a screwdriver, lever the tensioning spring -1- at the bolt

-2- and remove the tensioning spring -1-.
– Unscrew securing bolt -3- and remove chain tensioner.
– Mark the direction of rotation of the oil pump control chain
-2- using a felt tip pen.
– Remove securing bolt for chain sprocket -1- and remove chain
sprockets -1- and -3- together with drive chain for oil pump
-2-.
Installation
• The crankshaft must be located at TDC cyl. 1.
– Move the sprocket -1- in the -direction of the arrow - as far as

possible along the crankshaft journal.
Caution
The cast-iron projection -2- on the sprocket -1- should fit into
the groove -3- of the crankshaft journal.
– Mark position of chain sprocket and crankshaft to cylinder

block using a felt-tip marker.
1. Cylinder head 79
Toledo 2013 ➤
– Place the oil pump control chain -3- on the sprocket -1- and at
the same time fit the sprocket -2- on the oil pump drive shaft.
Note
♦ Observe the mark showing the direction of rotation of the oil

pump control chain.
♦ The oil pump drive wheel only fits in one position on the oil
pump drive shaft -arrow-.
– Lock the oil pump drive wheel using the retention tool -
T10172- .
– Tighten the new fixing screw -1- with 20 Nm + 1/4 turn (90°)
further.
– Place the chain tensioner on the oil pump control chain and
tighten the securing bolt -3- to 8 Nm.
– Lever the tensioning spring -1- using a screwdriver at bolt
-2-.
Note
♦ Observe the marks -arrows-.

The crankshaft
♦ Protected can not
by copyright. Copying turn.or commercial purposes, in part or in whole, is not
for private
– Bolt the sprocket -3- by hand using a new fastening bolt.
– Fit the distribution chain -1- on the crankshaft sprocket -4-, the
exhaust camshaft sprocket -3- and hand tighten the variator
-2- with a new fastening screw.
Note
♦ Note running direction mark on timing chain -1-.

♦ Check that the guide hose is fitted between the intake cam‐
shaft and the variator.
♦ The securing bolt of the variator -2- is left-threaded.

Toledo 2013 ➤
Timing chain must lie on guide rail -1- and crankshaft chain
sprocket -arrow-.
– Install chain tensioner -1- and tighten securing bolts -2- to

9 Nm.
– Tension the distribution chain by removing the retention tool -
T40011- from the tensioning device.
– Check that the marks on the crankshaft sprocket and the en‐
gine block match.
– Tighten securing bolt -2- to 40 Nm and bolt -4- to 50 Nm (use

counterhold -T10172- ).
Note
♦ The fastening bolts -2- and -4- are tightened with a retightening
angle of 90°, after checking the distribution timing
♦ The securing bolt of the variator -2- is left-threaded.
– Undo bolt -arrow- and remove the retention
respect tool - ofT10171
to the correctness informationA-in this document. Copyright by SEAT S.A.
from the camshaft casing.

– Check distribution timing ⇒ page 58
If timing is OK:
1. Cylinder head 81
Toledo 2013 ➤
– Lock the camshaft sprockets using the retainer tool - T10172-

and tighten the fixing screws -2- (left-threaded) and -4- 1/4 turn
(90°) using a spanner.
Note
The securing bolt of the variator -2- is left-threaded.
Note
The camshaft sprockets must not turn when tightening them onto
the camshaft.
– Fit the cover of the oil pump wheel -1-.

– Install the timing housing ⇒ page 17 .
– Fit the poly V-belt ⇒ page 22 .
– Fill coolant system with coolant ⇒ page 116 .
After removal the oil pressure switch must be replaced since the
seal cannot be replaced separately.
Tightening torque for oil pressure switch - F1- : 20 Nm
1.6 Camshaft housing:removing and fitting

Toledo 2013 ➤

equipment required
adapter - T10170 A-
T10171 A-
1. Cylinder head 83
Toledo 2013 ➤
♦ Spark plug socket and extension - 3122 B-

♦ Two studs (M6x80)
♦ D 154,103 A1 Sealing compound
1.6.1 Removing
♦ In this engine the camshafts are housed in a casing. Before
removing the camshaft housing, the timing case must be re‐

moved ⇒ page 17 .
♦ The camshaft housing sealing surface must not be reworked.
– First check whether a coded radio is fitted. If so, obtain anti-

theft coding:
– With the ignition switched off, disconnect battery earth strap.

Toledo 2013 ➤

guide -3-.
– Remove turbocharger ⇒ page 172 .
– Turn crankshaft to TDC for No. 1 cylinder. Then turn crank‐
shaft 45° in engine direction and remove camshaft timing
chain sprockets with timing chain ⇒ page 61 .
– Unbolt camshaft sealing covers.
– Pull connectors off fuel pressure sender for low-pressure -
G410- and off high-pressure pump.
– Unscrew earth cable from camshaft housing.
– Removing ignition coils. To do so, use the socket - T10094A-
⇒ page 240 .
– Remove cable guide with wiring harness from camshaft hous‐
ing.
WARNING

release pressure by carefully pulling hose off connection.
– Pull connector and fuel supply line -arrows- off high-pressure

pump.
– Remove wiring guide -2- and take clip -4- off high-pressure
line.
1. Cylinder head 85
Toledo 2013 ➤

Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
– Loosen union nuts -3- and -1- of high-pressure line.

– Disconnect the connector from the Hall sender - G40- .
– Remove the dip stick.
– Remove intake manifold lower section
⇒ Item 17 (page 203) .
– Unbolt left lifting eye.
– Loosen camshaft housing bolts from outside
Protectedto inside, Copying
by copyright. alter‐ for private or commercial purposes, in part or in whole, is not
nately and diagonally and remove. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Carefully lift camshaft housing off.
1.6.2 Installation
Caution
The studs (M6 x 80) have to be screwed into the cylinder head
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.
Air conditioner / heater setting

• Pistons must not be at TDC.
– Remove the sealant residues from the camshaft casing and
the cylinder head using a rotating brush, e.g. a hand drill ma‐
chine with plastic brush (wear protective goggles).
– Clean sealing surfaces carefully. They must be free of oil and
grease.
– Prevent dirt and sealant remains from entering the cylinder
block.
Caution

be renewed.
hammer.

Toledo 2013 ➤
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be inserted into holes in camshaft to stop.
– Hand thread (without tightening ) an M6 bolt to secure the the
camshaft fastener - T10171 A- .
Sealing on cylinder head with no sealing ring in area of spark plug

recess
– Apply thin, even coat of sealant on clean camshaft housing
sealing surface. See yellow 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.
Sealing on cylinder head with sealing ring in area of spark plug

recess
– Place 4 new seals in the cylinder head grooves.
– Apply thin, even coat of sealant on clean camshaft housing

sealing surface. See yellow area in illustration.
– Do not apply sealant in area of -arrows-.
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-.
– Screw in 2 head studs (M6 x 80) on the camshaft casing before
fitting the camshaft housing.
1. Cylinder head 87
Toledo 2013 ➤
– Carefully fit camshaft housing vertically onto studs -arrows-

and dowel pins from above.
Note
Ensure that no oil residue can drip onto sealing surfaces.
– 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 (90º)
Note
After installing the camshaft housing, wait about 30 minutes for

the sealant to dry.
– Adjust valve timing ⇒ page 61 .

After removal the oil pressure switch must be replaced since the
seal cannot be replaced separately.
♦ Install turbocharger ⇒ page 172 .
♦ Insert the crankshaft pulley ⇒ page 34 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Attaching fuel lines ⇒ page 211 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1.7 Removing and installing the cylinder head

Toledo 2013 ➤

equipment required
♦ Support plate - 10 222A-
♦ Adapter - 10 222A/10-
♦ Adapter - 10 222A/18-
♦ Additional part for the en‐
gine mounting - 10 222A/
31-
♦ Support plate - T10358-
♦ Basic engine mounting set
- T40091-
1. Cylinder head 89
Toledo 2013 ➤

Preparing the bracket

– Remove the two fastening bolts -1- of the additional part for
the engine mounting - 10 222A/31-4- .
Removing
Remove the following components:
♦ Remove the thermostat housing from the cylinder head.
♦ Remove variator ⇒ page 61 .
♦ Turbocharger:
permittedremoving and
unless authorised fitting
by SEAT ⇒SEAT
S.A. pageS.A 172 . guarantee or accept any liability with
does not
♦ Intake manifold: removing and installing ⇒ page 210 .
– 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.

Toledo 2013 ➤
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-.
– Rotate the spindle until the hooks are slightly tensed.
– Remove the right spindle -A-.

– Push the adapter - 10-222 A /3- -9- backwards.
– Removing and fitting the distribution casing ⇒ page 17
– Remove the guide shoe and tensioner of the distribution chain.
– Removing and installing camshaft housing ⇒ page 82 .
– Remove roller rocker fingers together with support elements
and lay aside on clean surface.
– Ensure that the roller rocker fingers and the support elements
arepermitted
not mixed up.
– Loosen socket head bolts in the sequence given and then re‐
move completely.
– Carefully remove the cylinder head.
Installation
• Pistons must not be at TDC.
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.
– Carefully clean the sealing surfaces on the cylinder head and
cylinder 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.
– Set No. 1 cylinder piston to top dead centre and then turn
crankshaft approx. 45° in engine direction of rotation.
– Fit a new cylinder head gasket. The inscription (spare part no.)
must be legible.
– Fit cylinder head. Note the centering pins of the engine block.
– Fit new cylinder head bolts and tighten by hand.
1. Cylinder head 91
Toledo 2013 ➤
– Tighten cylinder head bolts in tightening sequence as follows:

Tightening torque/angle specification
stage: Tightening torque
1 30 Nm
2 Use rigid wrench to turn 90° fur‐
ther.
ther.
ther.
– Install support elements in cylinder head and fit respective
roller rocker fingers onto respective valve stem end and sup‐
port elements.
– Install camshaft housing.
– Removing and installing camshaft housing ⇒ page 82 .
1.8 Test compression pressure

equipment required
tension - 3122 B-
Nm) - V.A.G 1331-
♦ Check compression -
V.A.G 1763-

Toledo 2013 ➤
Test condition
• Engine oil temperature at least. 30 ℃.
Work sequence
– Removing ignition coils. Use puller -T10094 A- for this pur‐
pose.
– Unscrew spark plugs with spark plug socket and extension -
3122 B- ⇒ page 240 .
– Remove the fuse for the fuel pump control unit from the fuse
holder. Fuse allocation ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
– Check compression using compression tester - V.A.G 1763- ,

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .
Note
Using compression tester: ⇒ Operating instructions .
– Operate starter
Protected until tester
by copyright. Copying shows
for private no furtherpurposes,
or commercial pressure in‐
in part or in whole, is not
crease.
Compression values:
New, pressure in Wear limit in bar Permissible differ‐
bar overpressure ence between cylin‐
ders in bar over‐
pressure
10.0 … 15.0 7.0 3.0 (maximum)
– Insert spark plugs using spark plug socket and extension -
3122 B- and tighten to 30 Nm.
– Read event memory, rectify any faults and then clear fault
memory: ⇒ Vehicle diagnostic tester “Guided Fault Finding”.
The readiness code must be generated if the event memory has
been cleared.
1. Cylinder head 93
Toledo 2013 ➤
2 Servicing valve gear

⇒ “2.2 Checking camshaft axial play”, page 96
⇒ “2.3 Machining valve seats”, page 96
⇒ “2.4 Valve guides: verification”, page 98
⇒ “2.5 Replacing valve shaft seals.”, page 98

(90º)
❑ Left-hand thread
❑ replace
2 - Controller
❑ Must not be dismantled
⇒ page 61
3 - Camshaft wheels Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Check the position on permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
fitting the distribution
chain
4 - O-ring
❑ Replace if damaged
❑ Before mounting, lightly
grease with engine oil
5 - Camshaft control valve 1 -
N205-
6 - 10 Nm
(90º)
❑ replace
❑ Tighten from centre out‐
wards
8 - Camshaft housing
Caution
The studs (M6 x 80) have
to be screwed into the
cylinder head before fit‐
ting the camshaft hous‐
ing.
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

Toledo 2013 ➤
❑ When installing fit vertically from above onto studs and dowel pins
9 - 10 Nm
10 - Filler cap
❑ For inlet camshaft.
❑ For exhaust camshaft.
11 - Roller rocker arm
❑ Check roller bearing.
❑ ?When installing, secure to support element using securing clip.
12 - Woodruff keys
13 - Valve stem oil seal
❑ replace
14 - Supporting element
❑ Check oil spray holes.
❑ with hydraulic valve clearance compensation
❑ do not interchange
❑ Before installing, check camshaft axial clearance ⇒ page 96 .
15 - Valve guide
16 - Valve spring
❑ To remove and install with cylinder head removed, use valve spring tool - 3362- .
❑ (with cylinder head installed) ⇒ page 98
17 - Cylinder head
❑ Reworking valve seat ⇒ page 96 .
❑ Reworking sealing surface ⇒ page 96
18 - Valves:
❑ Not to be reworked, only grinding in is permissible
❑ Valve dimensions ⇒ page 96
19 - Exhaust camshaft
❑ Do not interchange with inlet camshaft.
❑ Inspecting axial play ⇒ page 96
❑ Apply oil before fitting (also axial bearing collar)
20 - Guide bushing
21 - Supply camshaft
❑ With cam for high-pressure pump -arrow-
❑ Before removing, remove and renew bucket tappet for high-pressure pump.
❑ Do not interchange with exhaust camshaft.
❑ Inspecting axial play ⇒ page 96
❑ Apply oil before fitting (also axial bearing collar)
❑ Always renew after removing
2. Servicing valve gear 95

Toledo 2013 ➤
Reworking cylinder head sealing surface

Reworking dimensions for cylinder head: a = min. 108.25 mm
Note
When the sealing surface is reworked, the valves must be low‐

ered by the same amount (rework the valve seat inserts), if not
the pistons will collide with the valves. When doing so, ensure that
the minimum permissible dimension is maintained ⇒ page 96 .
2.2 Checking camshaft axial play

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Perform measurements with camshaft housing removed and
sealing cover fitted.
Checking camshaft axial play
Wear limit: max. 0.40 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

♦ Gauge
♦ Valve seat re-facing tool

Toledo 2013 ➤
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 98 .
♦ 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 respect to the correctness of information in this document. Copyright by SEAT S.A.
If the valve is replaced when carrying out repair work, use a new
valve for the measurement.
– Measure distance between end of valve stem and upper edge

of 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 dimension 3) 0.4 mm
3) 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 dimension1
c = 1.5 - 1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
4) Calculating max. permissible reworking dimension ⇒ page 96 .
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
5) Calculating max. permissible reworking dimension ⇒ page 96 .

Toledo 2013 ➤
2.4 Valve guides: verification

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Checking sequence permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– 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 rock tolerance is exceeded:
– Replace the cylinder head.
2.5 Replacing valve shaft seals.

Toledo 2013 ➤

equipment required
tension - 3122B-
♦ Valve spring tool - 3362-
with thrust piece - 3362/1-
♦ Valve stem seal puller -
3364-
♦ Valve stem seal insertion
tool - 3365-
♦ Pressure hose - VW 653/3-
Removing
(With cylinder head installed)
– Remove camshaft housing ⇒ page 82 .
– Remove roller rocker arms and place on a clean surface. En‐
sure that roller rocker arms are not mixed up.
– Remove spark plugs with spark plug spanner -3122B- .
– Set piston of appropriate cylinder to “bottom dead centre”.

Toledo 2013 ➤
– Attach valve spring tool - 3362- with thrust piece - 3362/1- .

– 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.
– Pull off valve stem seals with extractor - 3364- .
Installation
– Place plastic sleeve supplied on respective valve stem. This

will prevent the new valve stem seal from being damaged.
– Place new valve stem seal in valve stem seal fitting tool -
3365- .
– Lubricate the sealing lip of valve stem seal and carefully slide
the seal onto the valve guide.
– Install camshaft housing ⇒ page 82 .
♦ Fit the fuel lines ⇒ page 215 .

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17 – Lubrication
1 Removing and installing parts of lu‐
brication system
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:
♦ Thoroughly clean oil channels.
♦ Replace the oil filter.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! Marks ⇒ page 104
⇒ “1.1 Engine oil, quantities, specification”, page 101

⇒ “1.2 assembly overview”, page 101
⇒ “1.3 Removing and replacing oil sump”, page 104
⇒ “1.4 Oil pump: removing and installing”, page 106
⇒ “1.5 Testing oil pressure and oil pressure switch”, page 108
1.1 Engine oil, quantities, specification

Oil capacity
⇒ Maintenance ; Booklet KG1 ; Service table
Engine oil specifications
Change engine oil: “Engine oil: Draining or extraction”
1.2 assembly overview
1. Removing and installing parts of lubrication system 101

Toledo 2013 ➤
1 - Dipstick
❑ Oil level must not be
above max. mark on
dipstick!
❑ Marks ⇒ page 104
2 - Engine oil radiator
3 - O-ring
❑ replace
4 - Pipe for coolant
❑ For the engine cooler
❑ Tightening torque of
bracket on crankcase:
20 Nm
5 - Bolts
❑ Engine oil cooler torque
setting: 8 Nm + 90°.
❑ Renew engine oil cooler
bolts.
6 - Filler cap
❑ Replace gasket if it
shows signs of damage.
7 - Oil seal
8 - Oil filter, 20 Nm
❑ Use the oil filter wrench
- 3417- to unfasten Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Observe the installation respect to the correctness of information in this document. Copyright by SEAT S.A.
instructions printed on
the filter
❑ With non-return valve.
9 - Distribution housing
❑ Fit with an additional silicon sealant - D 176 501 A1-
❑ Removing and fitting the distribution casing ⇒ page 17
❑ For ease of assembly, tighten 2 studs -M6x80- on the camshaft casing and the engine block
❑ To guide valve timing housing, secure sump in position with two bolts.
10 - 10 Nm
11 - 150 Nm + 1/2 turn (180º)
❑ replace
❑ Removing and installing crankshaft pulley ⇒ page 34 .
12 - Pulley
❑ The contact surfaces of the pulley must be free of oil and grease.
❑ Poly-V belt: removing and installing ⇒ page 22
13 - Oil seal
❑ replace
102 Rep. gr.17 - Lubrication

Toledo 2013 ➤
14 - Bush
❑ The contact surfaces of the sleeve must be free of oil and grease.
15 - Seal
16 - Sprocket
❑ for oil pump drive
❑ replace
18 - Sprocket
❑ For oil pump
❑ Lock with counterhold - T10172- .
19 - Drive chain
❑ For oil pump
❑ Mark D.O.R. before dismounting (installation position)
20 - 10 Nm
21 - Oil level/oil temperature sender - G266-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
22 - Oil drain plug, 30 Nm
❑ with captive seal
❑ replace
23 - 13 Nm
❑ replace
❑ Loosen and fasten the bolts only on the side of the flywheel using the socket - T10058- .
24 - 40 Nm
25 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 600 A1- .
27 - Oil pump
❑ must be replaced completely
28 - 5 Nm
29 - Baffle plate

Toledo 2013 ➤
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 - Area between marker MIN and lower edge of the gridded area:
fill with max. 0.5 l of oil
1.3 Removing and replacing oil sump

♦ Socket and key - T10058-
♦ Electric drill with plastic brush attachment

♦ Flat scraper
♦ Protective glasses
♦ Silicone sealant D 176,600 A1 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing
– Remove noise insulation.

– Disconnect front exhaust pipe from catalytic converter
⇒ page 232 .

Toledo 2013 ➤
– Disconnect the 3-pin connector from the oil level and temper‐
ature sender - G266- -1-.
– Drain engine oil.
– Unbolt sump sealed with liquid gasket.

– Two screws may be fitted on the gear side that cannot be ac‐
cessed directly. If the screw heads cannot be reached with a
bit - T10058- , turn the crankshaft in the engine direction until
the screws are accessible. The flywheel has been provided
with two recesses.
– 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 atpermitted
the oilunless
sump using
authorised a rotating
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
brush, e.g. a hand drill machine withrespect
plastic brush
to the (wear
correctness pro‐ in this document. Copyright by SEAT S.A.
of information
tective goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installation
Note
♦ Observe use-by date of sealant.

♦ The sump must be installed within 5 minutes after applying the
silicone sealant.
♦ The oil sump is attached more gently and securely if M6 threa‐
ded pins are inserted in two points in the cylinder block flange.

Toledo 2013 ➤
– 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.
♦ Pass next to the bolt holes, through the inner side -arrows-.
Note
♦ The sealant bead must not be thicker. Otherwise the excess

sealant may enter the oil sump, and obstruct the strainer in the
oil intake pipe.
♦ Use new bolts for the oil sump.
– Install sump immediately and tighten all sump bolts lightly.

– Tighten oil sump bolts to 13 Nm.
– Tighten the fastening screws of the oil sump on the gearbox
to a tightening torque of 40 Nm.
Note
Starting can be carried out 30 minutes after applying the sealant

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

Removing

Toledo 2013 ➤
– Remove the cover -1- of the oil pump sprocket.

– 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 block.
Installation

Toledo 2013 ➤
– 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 -arrows-.
– Screw in chain sprocket securing bolt.
– Hold chain sprocket with counterhold - T10172- .
– Fit torque wrench (5 - 50 Nm) - V.A.G. 1331- in position as

shown.
– Tighten the fixing screw with 20 Nm + 1/4 turn (90°).
1.5 Testing oil pressure and oil pressure switch

Toledo 2013 ➤

equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Pressure tester - V.A.G
1527B-
♦ Auxiliary cable kit - V.A.G
1594C-
♦ Articulated wrench, 24 mm
- T40175-
Note
Checking operation of and servicing visual and acoustic oil pres‐
sure gauge: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Checking sequence
The oil pressure switch is located on the gearbox side beneath
the two camshaft covers.
– Unscrew the bolt -1- from the coolant pipe holder.
– Detach the connector of the oil pressure switch -arrow-.

Toledo 2013 ➤
– Remove oil pressure switch - F1- using 24 mm jointed spanner

- T40175- and screw into oil pressure tester - V.A.G 1342- .
– Screw tester into cylinder head in place of oil pressure switch.
– Connect brown wire of 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 LED lights up, renew oil pressure switch -F1- .
If the LED does not light up:
– 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 2,000 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.
Tightening torque, oil pressure switch: 20 Nm

Toledo 2013 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing 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 avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
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.Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
♦ To fit spring-type clips,
respect to the hose clipofpliers
correctness - VAS
information 6340- or
in this document. spring-
Copyright by SEAT S.A.
type clip pliers - VAS 5024A- are recommended
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Perform cooling system leakage check with cooling system tester

- V.A.G 1274 B- and the adaptors -V.A.G 1274/8- and -
V.A.G 1274/9- .
⇒ “1.1 Assembly overview - parts of cooling system, body side”,
page 112
⇒ “1.2 Assembly overview - parts of cooling system, engine side”,
page 115
⇒ “1.3 Diagram of coolant hose connections”, page 116
⇒ “1.4 Draining and filling cooling system”, page 116
⇒ “1.5 Removing and installing radiator fan V7 ”, page 120
⇒ “1.6 Removing and installing radiator fan V7 ”, page 121
⇒ “1.7 Check the cooling system for leaks”, page 122
⇒ “1.8 Removing and installing radiator”, page 123
⇒ “1.9 Removing and installing coolant pump”, page 125
⇒ “1.10 Removing and installing coolant circulation pump V50 ”,
page 126
1. Removing and installing parts of cooling system 111

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1.1 Assembly overview - parts of cooling

system, body side
Note
♦ This engine is equipped with a combination of engine cooler

and low-temperature cooler for the supercharger system
⇒ page 192 .
♦ The engine cooler and low-temperature cooler are combined
in one unit.
♦ Coolant hose schematic diagram ⇒ page 116
♦ Remove and install the spring-type hose using hose clip pliers
- VAS 6340- .
Version 1
1 - Radiator
⇒ page 123
❑ Renew coolant after re‐
placing.
2 - Coolant hose
❑ To turbocharger
3 - Coolant hose
❑ In charge air cooler at
the top
4 - Coolant hose
❑ To turbocharger
5 - Coolant hose
❑ To the charge-air cooler
in the intake manifold
6 - Radiator cowl
7 - Coolant hose
❑ Coolant pipe below the
intake manifold
8 - Coolant hose
❑ To fuel radiator
9 - Expansion reservoir
❑ Check the cooling sys‐
tem for leaks using the
cooling system tester -
V.A.G 1274 B- and the
cooling system tester
adaptor - V.A.G 1274/8-
10 - Electrical connector
11 - Filler cap
❑ Check using cooling system tester - V.A.G 1274
Protected B- andCopying
by copyright. adapter for cooling
for private system
or commercial tester
purposes, in part-or
V.A.G
in whole,1274/9-
is not
.
❑ At a pressure of 1.4 ... 1.6 bars pressure release valve should open.
112 Rep. gr.19 - Cooling

Toledo 2013 ➤
12 - 5 Nm
13 - Plastic inserts
❑ For securing bolts.
14 - Support plate
15 - Coolant hose
❑ At the coolant circulation pump - V50-
16 - Refrigerant fan - V7-
❑ With coolant fan control unit - J293-
17 - Air deflector
18 - 2 Nm
❑ Depending on version
19 - Heat shield
❑ Depending on version
20 - 8 Nm
21 - Radiator mounting
22 - Intercooler system
23 - Coolant hoses Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Housing for the thermostat
24 - Radiator fan thermo-switch - F18-

25 - O-ring
26 - Radiator mounting
27 - 5 Nm
28 - Coolant hose
❑ to the expansion reservoir
Version 2

Toledo 2013 ➤
1 - Coolant hose
❑ Coolant hose schematic
diagram ⇒ page 116 .
❑ Check the cooling sys‐
tem for tightness
⇒ page 122
❑ With coolant shortage
indicator sender - G32-
3 - Filler cap
❑ With pressure relief
valve
❑ Test
permitted unless pressure: 0.14
authorised by SEAT …SEAT S.A does not guarantee or accept any liability with
S.A.
0.16toMPa
respect (1.4 ....
the correctness 1.6
bar)
❑ Checking pressure re‐
lief valve in filler cap
⇒ page 122 .
4 - Clip
5 - Connector
6 - Retaining clip
7 - Support plate
8 - Top coolant hose
9 - Bottom coolant hose
10 - Intermediate plate for fan
11 - Refrigerant fan - V7-
12 - Radiator cowl
13 - 10 Nm
14 - Support plate
❑ To connect to fan terminal
15 - Connector
❑ On radiator fan thermo-switch - F18-
16 - Bottom radiator bearing
17 - Radiator fan thermo-switch - F18-
❑ 35 Nm
❑ Three-pin connector
❑ Switching temperatures:
1. stage:
♦ on: 92...97°C
♦ off: 84...91°C
2. stage:
♦ on: 99...105°C
♦ off: 91...98°C

Toledo 2013 ➤
18 - 10 Nm
19 - Top radiator bearing
20 - Radiator
❑ Renew coolant after replacing cylinder head gasket
21 - Coolant hose
❑ To the expansion tank
1.2 Assembly overview - parts of cooling system, engine side

Thermostat side
1 - Connecting nipple
2 - O-ring
❑ replace
3 - Compression spring
4 - Plunger
❑ Do not tilt during assem‐
bly
5 - Coolant regulator
Note
Do not confuse thermal elements.
Start of opening
❑ Thermal element (as il‐
lustrated below): 83 °C
❑ Thermal element (as il‐
lustrated above): 105 °C
6 - Coolant temperature send‐
er - G62-
❑ Before removing, re‐
duce cooling system
pressure if necessary
7 - Retaining clip Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Check for secure seat‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
ing.
8 - Thermostat housing
9 - Oil seal
❑ replace
10 - 11 Nm
11 - to the expansion reservoir
❑ Coolant hose schematic diagram ⇒ page 116 .

Toledo 2013 ➤
15 - 5 Nm
16 - Comes from the bottom of radiator
17 - To top of radiator
1.3 Diagram of coolant hose connections
2 - Coolant pump - V50-
⇒ page 126
3 - Intake manifold
4 - Retaining valve
5 - Heat exchanger for heater
6 - Thermostat housing
7 - Restrictor
8 - Engine oil radiator
9 - Radiator
10 - Additional radiator for the
supercharging system
⇒ page 123
⇒ page 172
12 - Cylinder head/cylinder
block
❑ Fill new coolant after the
replacement
13 - Coolant pump
⇒ page 125
14 - Auxiliary heater
❑ Optional equipment.
1.4 Draining and filling cooling system

♦ Empty ⇒ page 117
♦ Filling ⇒ page 118

Toledo 2013 ➤

equipment required
♦ Refractometer - T10007A-
♦ Coolant charger - VAS
6096-
Empty
WARNING
Steam may be released when opening the expansion tank.

Wear eye protection and protective clothing to avoid eye inju‐
ries and scalding. Cover the cap with a cloth and open care‐
fully.
– Open the cap of the coolant expansion tank.

– Separate the under body protection.

Toledo 2013 ➤
Drain the coolant from the engine cooling system.

– Loosen the spring-type clip -arrow- and remove the coolant
hose.
Note
Please observe requirements for disposal.
Drain the coolant from the cooling system of the supercharging

air cooling.
hose.
Note
Please observe requirements for disposal.
Filling
Caution
Only distilled water may be used to mix coolant additives . The

use of distilled water ensures optimum protection against cor‐
rosion.

Toledo 2013 ➤
Note
♦ The water used for the mixture has a significant influence on

the affectivity of the cooling agent. The quality of water to be
used is specified since the ingredients can vary from one land
or region to another. Purified water fulfils all requirements. For
this reason, we recommend using distilled water when mixing
coolant for topping up or replacing coolant.
♦ Use only coolant additives in accordance with the ⇒ Electronic
parts catalogue (ETKA) . Other coolant additives may partic‐
ularly have a detrimental effect on corrosion protection. The
damage caused may lead to a loss of coolant and hence to
severe engine damage.
♦ The correct coolant solution ratio helps prevent damage from
freezing and corrosion as well as scaling. These also raise the
boiling temperature. Therefore, the cooling system must be
filled all year round with coolant additive.
♦ 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.
♦ ONLY refractometer - T10007A- may be used for determining
current anti-freeze value.
♦ The anti-freeze must be effective down to at least -25ºC; in
cold countries down to approx. -36ºC . The effect of the anti-
freeze may only be increased if a higher level of frost protec‐
tion is required due to climatic conditions. But only to -48 °C.
Otherwise, the cooling effect of the coolant will be impaired.
♦ The concentration of the coolant must not be reduced by add‐
ing water in summer or in countries with hot climates. The frost
protection must be at least -25 ℃.
♦ Read off anti-freeze figures for respective replenished anti-
freeze.
♦ The temperature read off the refractometer - T10007A- equa‐
tes to the »ice flocculation point«. Ice flocculation can start
forming in the coolant below this temperature.
♦ Do not reuse the used coolant.
♦ Use only a water/anti-freeze mixture as a slip agent for coolant
hoses.
Recommended mixing ratios (use only distilled water for mixing):

Anti-freeze pro‐ Anti-freeze con‐ Coolant ad‐ Distilled wa‐
tection centration ditive 6) ter 6)
up to permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
-25 ℃ 40 % 2.25 l 3.35 l
-36 ℃ 50 % 2.8 l 2.8 l
6) The coolant quantity may deviate depending on the vehicle equipment

Toledo 2013 ➤
– Push the coolant hose on the connecting hose and fix using
the spring-type clips -arrow-.
– Fit the engine anti-splash cover.
With cooling system charge unit - VAS 6096-
– Top up the coolant circulation using the cooling system filler -
VAS 6096- ⇒ Instruction manual for the filling equipment for
the coolant circulation VAS 6096 .
Without cooling system filler - VAS 6096- :
– Switch off air conditioner and heating.
– Fill with coolant up to max. mark on expansion tank.

– Carry out the ⇒ Vehicle diagnostic tester connection and the
guided function “Fill the cooling system and bleed the air”.
WARNING

Wear eye protection and protective clothing to avoid eye inju‐
ries and scalding. Cover the cap with a cloth and open care‐
fully.
– Check coolant level and top up any missing coolant, if neces‐

sary. When the engine is at normal operating temperature, the
coolant level should be at the max. mark and, when the engine
is cool, the level must be between the MIN and MAX marks.
1.5 Removing andpermitted
installing radiator fan -
V7-
Removing
– Unplug connector -arrow-.
– Open the hose guides in the cowling using the -2- and remove
the coolant hose -1-.

Toledo 2013 ➤
– Disengage cowling with radiator fan - V7- from locking hook

using a suitable tool.
– Push cowling together with radiator fan - V7- upwards out of
the mountings and remove downwards.
– Clip out the radiator cowl and remove towards the back.
– Take out the electric wiring -1- from wiring guide.

– Unscrew attachment nuts -arrows- and take out the radiator
fans - V7- .
Installation
the following:
Specified torques:
Component Nm
Radiator fan to air vent 8
Heat guard on the cowling 2
1.6 Removing and installing radiator fan -

V7-
♦ Removing ⇒ page 121
♦ Installing ⇒ page 122
♦ Tightening torques ⇒ page 122
Removing
– Unplug connector -1-. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Extract the attachment bolts of the air duct -arrows-.

– Remove the air conduit with the radiator fan to the bottom.

Toledo 2013 ➤
– Unscrew the securing screws -arrows- and remove the radia‐

tor fan.
Installing
the following:
Tightening torques
Component Nm
Radiator fan to air vent 5
Air vent to radiator 5
1.7 Check the cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-
Test condition
• Engine warm.
Checking sequence
WARNING

Cover the cap with a cloth and open carefully.
– Open the Sealing plug of the coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.

Toledo 2013 ➤
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling

system tester - V.A.G 1274/8- .
– Connect the connecting piece - V.A.G 1274 B/1- together with
the connecting hose of the device to the cooling system tester
- V.A.G 1274 B-
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
WARNING
Risk of scalding! Before removing the cooling system tester -

V.A.G 1274 B- from the connecting hose or from the connect‐
ing element - V.A.G 1274 B/1- , the pressure must be released.
To do this, press pressure relief valve on cooling system tester
- V.A.G 1274 B- until pressure gauge displays value of »0«.
If the pressure drops:

– Search position of the leak and repair fault.
Checking pressure relief valve in filler cap
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Connect the connecting piece - V.A.G 1274 B/1- together with
the connecting hose of the device to the cooling system tester
- V.A.G 1274 B-
– Generate a pressure of 1.6 bar max using the manual pump
of the cooling system tester.
The pressure relief valve must not open.
If the pressure relief valve opens prematurely:
– Renew cap.
– Increase pressure to over 1.6 bar.
The pressure relief valve must open.
If the pressure relief valve does not open:
– Renew cap.
1.8 Removing and installing radiator

Toledo 2013 ➤

equipment required
♦ Refractometer - T10007-
♦ Hose clip pliers - VAS
6340-
Nm) - V.A.G 1331-
Removing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Pull coolant hoses off radiator.
– Pull connector off thermo-switch and radiator fan.
– Screw out radiator bolts and take out radiator downwards.
Removal of the supplementary radiator.
– Bring lock carrier into service position: ⇒ Bodywork, exterior
fitting work; Rep. gr. 50 ; Body, front; Lock carrier in service
position .
Note

– Remove the clip/s from the cooling agent hose/s.

– Unbolt condenser from radiator and secure to lock carrier.

Toledo 2013 ➤
Installation
the following:
Method for filling fresh coolant ⇒ page 116 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Tightening torque
Component Nm
Cooler to supplementary radiator 5
Air vent to radiator 5
1.9 Removing and installing coolant pump

equipment required
6340-
Nm) - V.A.G 1331-
♦ Coolant pump wrench -
V.A.G 1590-

Toledo 2013 ➤
– Due to changes to the securing bolts of the coolant pump pul‐

ley, file the three rounded ends to a = 1 mm at minimum.
Change V.A.G 1590 gripping wrench
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.
Removing
– Drain coolant ⇒ page 116 .
– Remove holder -1-.
Note
The support is only required during the vehicle manufacture and

it is not necessary to mount it.
– Hold belt pulley with water pump wrench - V.A.G 1590- .

– Unscrew fastening bolts -arrows- for the coolant pump pulley
and remove pulley.
– Unscrew securing bolts -arrows- of the coolant pump -1- and
remove pump from engine block.

Installation
the following:
– Place the coolant pump onto the engine block.
– Tighten securing bolts to 9 Nm
– Tighten the coolant pump pulley to 20 Nm.
– Poly V-belt: installing ⇒ page 22 .
– Fill up coolant ⇒ page 116 .
1.10 Removing and installing coolant circulation pump - V50-

Toledo 2013 ➤

equipment required
6340-
Nm) - V.A.G 1331-
♦ Hose clamps, up to 40 mm - 3093-

Toledo 2013 ➤
Removing
WARNING
When the engine is warm, the cooling system is under pres‐

sure.
Hot steam/hot coolant can escape - risk of scalding.
To allow pressure to dissipate, cover filler cap on coolant ex‐
pansion tank with cloth and open carefully.
The installation location for the coolant circulation pump - V50- is

located beneath the intake manifold.
Rep. gr. 50 ; Removing and installing noise permitted
insulationunlessor un‐ by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
derride guard . respect to the correctness of information in this document. Copyright by SEAT S.A.

– Detach coolant hoses with clamps up to 40 mm - 3093- .
– Open the clamp and remove the coolant hose -2-.
– Unscrew the fastening bolt -3- and remove the pump from the
holder.
Installation
the following:
– Check coolant level and top up with coolant if necessary
⇒ page 116 .
Tightening torque
Component Tightening torque
Securing bolts 10 Nm

Toledo 2013 ➤
20 – Fuel supply system

1 Safety precautions
⇒ “1.1 Safety precautions when working on the fuel supply sys‐
tem”, page 129
⇒ “1.2 High pressure system pressure reduction.”, page 130
1.1 Safety precautions when working on the

fuel supply system
Caution

tions:
When removing and installing the fuel level sender - G- or fuel

pump (fuel delivery unit) from a full or partly full fuel tank, the fol‐
lowing must be observed:
Remove the fuse of the fuel pump. Fuse allocation ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
WARNING
Fuel system is under pressure! Wear eye protection and gloves

to avoid injuries and skin contact. Before loosening hose con‐
nections, wrap a cloth around the connection. Then release
pressure by carefully pulling hose off connection.
♦ 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!
1. Safety precautions 129

Toledo 2013 ➤
1.2 High pressure system pressure reduc‐

tion.
WARNING
The injection system is sub-divided into a high-pressure sys‐

tem (max. approx. 120 bar) and a low-pressure system (ap‐
prox. 6 bar).
Before opening the high-pressure system, e.g. to remove the
high-pressure pump, the fuel rail, the injectors, the fuel hoses
or the fuel pressure sender - G247- , the fuel pressure in the
high-pressure system must be reduced to approx. 6 bar. The
procedure to do so is described below.
– Carry out the ⇒ Vehicle diagnostic tester connection and the

guided function “reduce the high pressure of the fuel”.
– Switch off ignition.
WARNING
The fuel piping is exposed to fuel pressure. Wear safety gog‐

gles and protective clothing to avoid possible injury and skin
contact. Before opening the high-pressure system, place a
cloth around the connection.
– Place a clean cloth around the connection, and open it care‐

fully to eliminate the residual pressure of approx. 6 bar. Any
spilt fuel must be cleaned up.
– After completing Protected
work, read event
by copyright. memory
Copying oforengine
for private commercialcontrol
purposes, in part or in whole, is not
unit and clear allpermitted
event entries that may have been created as
a result of pulling off the connector.

Note
If the fault memory was cleared, the readiness code must be gen‐
erated ⇒ Vehicle diagnostic tester “Guided functions”.
130 Rep. gr.20 - Fuel supply system

Toledo 2013 ➤
2 Separating push-fit couplings

♦ -T10468-
Assignment of push-fit couplings
Note
The push-fit couplings for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the push-fit cou‐
pling or the release button is coloured.
Plug-in connector Colour code on push-fit cou‐

pling
Fuel supply Black
Fuel return line Blue colour
Breather White, beige
Vacuum green
WARNING
The fuel feed line is pressurized! Use protective goggles and

clothing to prevent injuries and contact with the skin. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
Version 1
Push-fit connector with release buttons -arrows- on right and left
2. Separating push-fit couplings 131

Toledo 2013 ➤
Opening
Counterhold on the decoupling point -1- intended for the fuel.
– Insert -T10468- between heat shield and stop -arrow- of fuel
line -2- and counterhold.
Continuation for all separating points of the fuel system

– Push push-fit coupling -1- in -direction of arrow A-.
– Press release buttons and pull push-fit coupling -1- off fuel line
-2- in -direction of arrow B-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Take note of colour assignment during installation
⇒ page 131 .
– Ensure push-fit couplings are secured properly by pulling.
Version 2
Push-fit coupling with pull-release mechanism -arrow-

Toledo 2013 ➤
Opening
– Push push-fit coupling -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull push-fit coupling -1- off fuel line -3- in
-direction of arrow B-.
Take note of colour assignment during installation ⇒ page 131
Version 3
Push-fit coupling with front button -arrow-
Opening
– Press release button -arrow- and pull push-fit couplings off.
⇒ page 131 .
Version 4
Opening
– Push push-fit coupling in -direction of arrow A-.
– Press release buttons -arrows- and pull push-fit coupling off.
⇒ page 131 .
Version 5
Opening
⇒ page 131 .
– Press release buttons -arrows- and pull push-fit coupling off.
⇒ page 131 .
2. Separating push-fit couplings 133

Toledo 2013 ➤
3 Fuel tank
tem”, page 129
⇒ “4.1 Rules for cleanliness”, page 144
⇒ “3.1 Fuel tank - assembly overview”, page 134
⇒ “3.2 Fuel tank: draining”, page 136
⇒ “3.3 Removing and installing fuel tank”, page 141
3.1 Fuel tank - assembly overview
1 - Fuel tank
⇒ page 141
2 - Oil seal
❑ Moisten with fuel for in‐
stallation
3 - Fuel delivery unit
⇒ page 145
❑ Fuel pump and fuel sys‐
tem: checking
⇒ page 148
❑ Note fitting positionProtected
on by copyright. Copying for private or commercial purposes, in part or in whole, is not
fuel tank ⇒ page 136
fuel gauge sender - G-
⇒ page 147
❑ Clean strainer if dirty
4 - Hood nut, 80 Nm
ing wrench - 3217- .
5 - Return-flow line
❑ Blue colour
❑ Between the fuel pump
unit and the fuel filter
❑ Check that it is seated
securely
6 - Delivery line
❑ Black
❑ Between the fuel pump
unit and the fuel filter
❑ Check that it is seated securely
7 - Overflow hose
8 - Sealing plug
9 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and fitting ⇒ Bodywork, exterior fitting work; Rep. gr. 55
10 - Earth connection

Toledo 2013 ➤
11 - O-ring
12 - Vent valve
❑ To remove pull locking latch lightly to inside and pull valve out
13 - Gravity valve
❑ For removal, remove the fuel tank cap ⇒ Item 9 (page 134) , undo the securing tab and push the inlet
valve out, upwards.
❑ Check valve for through-flow.
♦ Perpendicular valve: open
♦ Valve tilted 45 °: closed
14 - Active carbon filter
❑ Location: in rear right wheel housing.
❑ Active carbon filter system - Components overview ⇒ page 165
15 - Vent line
❑ Clipped onto fuel tank
16 - O-ring
17 - Plug
❑ 10 Nm
18 - Retainer
19 - Heat shield
❑ For fuel tank
20 - Plug
❑ 25 Nm
21 - tension belt
❑ Note the different measurements
22 - Fuel supply line
❑ Black
❑ To the fuel distributor in the intake manifold
23 - Fuel filter:
❑ Fitting position: The arrow indicates the direction of flow
❑ The fuel pressure regulator is installed on the fuel filter.
24 - Fuel filter holder
❑ 3 Nm
25 - Activated charcoal filter solenoid valve 1 - N80-
26 - Vent line
❑permitted
Towards the solenoid
unless authorised valve
by SEAT S.A. SEAT1S.Afordoes
thenotactive carbon
guarantee filter
or accept any - N80-
liability with (pulsed) in engine compartment
3. Fuel tank 135

Toledo 2013 ➤
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 breather valve, unscrew filler cap from fuel tank.
3.2 Fuel tank: draining

⇒ “3.2.1 Fuel tank: draining (fuel pump is okay)”, page 137
⇒ “3.2.2 Emptying fuel tank if it is more than 3/4Protected
full”, page 139 Copying for private or commercial purposes, in part or in whole, is not
by copyright.
⇒ “3.2.3 Emptying fuel tank if it is less than 3/4 full”,respect
pageto the
140 correctness of information in this document. Copyright by SEAT S.A.

♦ Fuel pump unit - VAS 5190-

Toledo 2013 ➤
♦ Wrench for union nut - 3217-

– Note safety precautions before starting installation work
⇒ page 129 .
3.2.1 Fuel tank: draining (fuel pump is okay)

♦ Adapter for fuel extraction - VAS 5190 /2-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-

♦ Remote control - V.A.G 1348/3A-
3. Fuel tank 137

Toledo 2013 ➤
Note
If the fuel extraction unit - VAS 5190- is still fitted with the extrac‐
tion hose with a solid tip, the extraction hose must be replaced
with the version with a screwed tip.
WARNING
♦ The fuel feed line is pressurized! Wear safety goggles and

protective clothing to avoid possible injury and skin con‐
tact. Before releasing the connections on the hoses, place
absorbent cloths round the connection. Then release
♦ Secure the earth cable of the fuel extractor - VAS 5190-
to an earthing point on the vehicle.
– Pull off supply line (metal coupling) -1- and catch escaping fuel
with a cloth. Opening the quick-release coupling
⇒ page 131 .
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Remove the rear bench ⇒ Bodywork, interior fitting work; Rep.
gr. 72 .
– Lift floor covering to the right in area of the fuel supply unit.
– Remove cover -1-.

Toledo 2013 ➤
– Pull off connector -arrow-.
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
Note
The following operation is to make the fuel pump run when the
engine is stopped.
– Remove filler cap from fuel tank filler neck.

– Press the remote control - V.A.G 1348/3A- and the shut-off
cock of the fuel drainage equipment - VAS 5190- until the fuel
tank is empty.
Caution
Fuel pump must not run »dry«.
3.2.2 Emptying fuel tank if it is more than 3/4

full
Caution
Secure earth wire of fuel extractor unit - VAS 5190- to a bare

metal part on the body.
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At distance -a- = 1,180 mm from end, mark extraction hose
with insulating tape -arrow-.
3. Fuel tank 139

Toledo 2013 ➤
– Remove the filler cap from fuel filler neck.

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
At the lower end of the filling mouth, there is a ball valve -2- on
the fuel tank -1-. Avoid damage to this with the suction hose -3-.
Therefore, only push the hose in as far as the tape marking
-arrow-.
– Drain fuel tank as much as possible through fuel filler neck.

– Carefully pull out extraction hose.
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
The fuel tank can be removed with the remaining fuel.
♦ If it is necessary to carry out work on the fuel pump or the fuel
gauge, proceed as follows:
3.2.3 Emptying fuel tank if it is less than 3/4 full

gr. 72 .
– Remove cover from fuel delivery unit.
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 release pressure by carefully pulling hose off
connection.
– Pull connector and fuel lines off flange.
Note
To do this, press on the connection buttons for the hoses.

Toledo 2013 ➤
– Open locking ring using union nut tool - 3217- .

– Lift the fuel delivery unit.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needs only to be emptied, install fuel delivery unit
again. ⇒ page 145
3.3 Removing and installing fuel tank

♦ Removing
permitted ⇒ page
unless authorised by SEAT141S.A. SEAT S.A does not guarantee or accept any liability with
♦ Tightening torques ⇒ page 143
♦ Torque wrench - VAG 1331-
♦ Engine/gearbox jack - VAG 1383A-
Removing
– Note safety precautions before starting work ⇒ page 129
– Remove the earth wire of the battery when the ignition is
turned off and lay to the side.
– Extract the securing bolt of the fuel tank cap unit and remove
the unit.
– Drain fuel tank, clean fuel filler and surrounding area.
⇒ page 136
gr. 72 .
– Remove cover from fuel delivery unit.
3. Fuel tank 141

Toledo 2013 ➤
– Pull out the plug -1-.

– Remove rear right wheel.
– Remove the rear right-hand side wheel housing liner: ⇒ Gen‐

eral body repairs, exterior; Rep. gr. 66 ; Rear wheel housing
liner; Wheel housing liner:
Protected by removing
copyright. Copying forand
privateinstalling . purposes, in part or in whole, is not
or commercial
– 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 165 .
– Separate the fuel inlet funnel from the bodywork.
– Remove from body all fixings from rear part of exhaust system.
Then support lowered exhaust system on body with wire.
– Remove the lower heat protection plate of the fuel tank.
– Remove rear shaft: ⇒ Running gear, axle, steering; Rep. gr.
42 .
WARNING

eliminate the pressure by carefully separating the pipe.
– Disconnect the breather pipe -1- (white) and the fuel pipe -2-
(black) at their connections.
Note
Press in safety wedge to release fuel lines.

Toledo 2013 ➤
– Unscrew the securing screws of the tank -arrows- and the ten‐
sioning belt of the tank. In doing so, support the fuel tank using
the engine and gearbox jack - VAG 1383A- .
– Lower fuel tank.
Installing
Install in reverse order to dismantling, noting the following:
♦ Breather and fuel hoses are to be installed kink-free.
♦ Secure hoses with spring-clips.
♦ Do nor swap the supply line with the venting line.
♦ Check the connections on the active carbon filter
⇒ page 165 .
♦ Fit rear axle⇒ Running gear; Rep. gr. 42
Note
After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.
Tightening torques
Components: Nm
Filling hole securing screws 10
Active carbon tank securing screws 10
Fuel tank securing screws 25
3. Fuel tank 143

Toledo 2013 ➤
4 Repairing fuel supply
Note
♦ The connections for the flexible tubes are secured using spring
type clips or screw clips.
♦ Renew 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 6340- are recommended for fitting
spring-type hose clips.

tem”, page 129
⇒ “4.2 Crash fuel shut-off”, page 144
⇒ “4.3 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 145
⇒ “4.4 Removing and installing fuel gauge sender G ”,
page 147
⇒ “4.5 Fuel level gauge sender G : removing and fitting”,
page 147
⇒ “4.6 Testing fuel pump”, page 148
4.1 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 free
of lint and cover them over. Use lint-free cloths.
♦ 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.).
♦ When the system is open: Do not work with compressed
permitted air. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
Do not move vehicle. respect to the correctness of information in this document. Copyright by SEAT S.A.
4.2 Crash fuel shut-off

functioning
This system reduces the risk of fire in the case of accidents, as
the fuel pump is disconnected. 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.
When opening the fuel system:
– Always follow safety precautions ⇒ page 129 .

Toledo 2013 ➤
4.3 Removing and installing fuel delivery

unit, fuel gauge sender
♦ Spanner - 3217-
♦ Torque wrench - VAG1332-
Removing
• The fuel tank should be at half capacity at the most.
Note
Drain fuel tank if necessary ⇒ page 136 .
– Note safety precautions before starting work ⇒ page 129

– First check whether a coded radio is fitted. Check the anti-theft
code in this case.
– Remove the earth wire of the battery when the ignition is
turned off and lay to the side.
gr. 72 .
4. Repairing fuel supply 145

Toledo 2013 ➤
– Remove the cover -1- of the fuel delivery unit together with the
fuel pump control unit - J538- -2-.
WARNING
Fuel system is under pressure! Wear eye protection and gloves

to avoid injuries and skin contact. Before loosening hose con‐
nections, wrap a cloth around the connection. Then release
– Separate the plug connection -1- and the fuel lines -2- and
-3-.
Note
Press in safety wedge to release fuel lines.
WARNING permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
The fuel pump unit may be removed only with the tank at max‐
imum 3/4 full. Otherwise a large amount of fuel will escape.
– Unscrew union nut with wrench - 3217- .

– Pull fuel delivery unit and seal out of their housing in fuel tank.
Note
If the fuel delivery unit is to be renewed then drain the old unit
before disposal.
Installing
Install in reverse order to dismantling, noting the following:
Note
♦ When inserting the fuel delivery unit ensure that the fuel gauge
sender is not bent - G- .
♦ Insert dry seal for fuel delivery unit into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ The marking on the sender must align with the marking on the
fuel tank -arrows-.
♦ Tighten the union nut to 80 Nm.
♦ Do not interchange supply and return lines.
♦ Ensure that line connections are tight.
♦ After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.

Toledo 2013 ➤
4.4 Removing and installing fuel gauge

sender - G-
Removing
– Remove fuel delivery unit.
– Release connector lugs on lines -3- and -4- and pull off.
– Lever off the retaining lugs -1- and -2- using a screwdriver and
remove the Fuel gauge sender G - G- by pulling downwards
-arrow-.
Installation
– Insert the fuel gauge sender - G- into the guides on fuel deliv‐
ery unit and press upwards until it clicks into place.
4.5 Fuel level gauge sender - G- : removing

and fitting
♦ Installing ⇒ by
Protected page 147Copying for private or commercial purposes, in part or in whole, is not
copyright.
Removing respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove fuel delivery unit ⇒ page 145 .

– 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
Installation is carried out in the reverse order; note the following:

Toledo 2013 ➤
Assembly position for fuel level indicator sensor - 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.
– Insert connector and check they have engaged properly.
– Install fuel delivery unit ⇒ page 145 .
4.6 Testing fuel pump

⇒ “4.6.1 check operation and electricity supply”, page 149
⇒ “4.6.2 Checking fuel pressure”, page 151
⇒ “4.6.3 Checking residual pressure”, page 153
⇒ “4.6.4 Checking delivery rate”, page 155
⇒ “4.6.5 Checking current consumption”, page 158
Note
After removing the Protected

fuel delivery unit,
by copyright. check
Copying whether
for private the fuel
or commercial tankin part or in whole, is not
purposes,
contains dirt and clean if required.

Toledo 2013 ➤

equipment required
♦ Pressure tester - VAS
6550-
♦ Remote control - VAG
1348/3A-
♦ Adapter - VAS 5565-
♦ Digital multimeter - VAG
1715-
♦ Wrench for union nut -
3217-
1332-
♦ Measuring container, ca‐
pacity: 2 litre
4.6.1 check operation and electricity supply

Test prerequisites
• Battery voltage at least 11.5 V
• Fuse for the fuel pump control unit - J538- in good condition.
• Fuel pump control unit - J538- OK.
Checking process:
Note
The operation of the fuel pump is checked with the actuator di‐
agnosis.

Toledo 2013 ➤
– Connect the vehicle diagnosis system 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.
– On the display, press the pushbuttons Vehicle self-diag-
nosis , Engine electronics and Actuator diagnosis
one after another.
– 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.

If the fuel pump does not run:
gr. 72 .
– Disconnect the connector of the fuel pump control unit - J538- .
– Using the multimeter - V.A.G 1715- , check the supply voltage

between contacts -1- and -6-.
• Specification: approx. battery voltage
Power supply is not okay:
– Locate and rectify open circuit using current flow diagram
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.

Toledo 2013 ➤
Power supply is okay:

– First check that connector -1- is fitted securely by pulling con‐

nector without pressing catch. If the plug connector had not
been connected properly, the functional inspection of the fuel
pump must be repeated.
– Now pull off connector.
– Check the contact on the plug connector and the fuel supply
unit for damage.
WARNING permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

connection.
– Disconnect the fuel lines -1- and -2- from the flange.
Note
Press in safety ring to release fuel lines.
– Open locking ring using union nut tool - 3217- .

– Check that the electrical wires between flange and fuel pump
are connected.
If there is cable integrity:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 145 .
4.6.2 Checking fuel pressure
WARNING

connection.

Toledo 2013 ➤
– Disconnect the supply line (metal connection) -arrow- and

clean escaping fuel with a cloth.
Note
– Connect the fuel supply pipe to pressure tester - VAS 6550- ,

using the adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that the drain cock is closed and that the flow valves
are open.
– Control and build up the pressure of the fuel pump using the
actuator diagnostic function.
– Take the fuel pressure reading on the pressure gauge.
• Specification: 4.0 - 7.0 bar.
If the fuel pressure is correct, check the retention pressure
⇒ page 151 .
If the specification is exceeded:
– Check that the return pipe between the filter and the fuel pump
is not kinked or blocked.
If no fault is found:
– Pressure limiting valve in the fuel filter faulty: Replace the fuel
filter.
If readout does not match specification:
– Check the fuel pressure before the filter as follows:
– Separate the fuel supply hose -arrow- from the fuel filter.

Toledo 2013 ➤
– Connect fuel supply line pressure gauge - VAS 6550- using

the adapter - VAS 6550/1- and -VAS 6550/2- between the fuel
filter and the fuel supply line.
are open.
– Start the engine and run at idling speed.
– Slowly close the shut-off valve on the pressure gauge -A-.
Pressure must rise to min. 7.0 bar. When 7.0 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:
4.6.3 Checking residual pressure

• Fuel pressure correct and pressure gauge - VAS 6550- con‐
nected. Check fuel pressure ⇒ page 151 .
Checking process:
• Specification: 4.0…7.0 bar
– Watch pressure drop on pressure gauge. After 10 minutes the
pressure must not drop below 3.0 bar.
If the pressure still drops:

Toledo 2013 ➤
– After reaching the desired pressure, the stop cock -B- on the
pressure gauge must be closed. The lever must point hori‐
zontally in the flow direction.
If the pressure does not drop any more:
Note
Search for the leak on the engine side. Repeat pressure retention
test. This time, close the shut-off cock -A- to check if there is ac‐
tually a leak on the engine side.
– Check fuel pipe leading to high-pressure pump for leaks.

– Replace the high-pressure pump ⇒ Mixture preparation - in‐
jection; Rep. gr. 24 .
If the pressure drops again:
The leak must be detected from the side of the fuel tank. Proceed
as follows:
– Check the fuel pipe leading to fuel filter for leaks.
If no fault in fuel piping is detected:
– Check the non-return valve of the fuel delivery unit. Proceed
as follows:
– Connect fuel supply line pressure gauge - VASProtected

6550-byusingcopyright. Copying for private or commercial purposes, in part or in whole, is not
the adapter - VAS 6550/1- and -VAS 6550/2- between theauthorised
permitted unless fuel by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
filter and the fuel supply line. respect to the correctness of information in this document. Copyright by SEAT S.A.
are open.
• Specification: 4.0…7.0 bar

Toledo 2013 ➤
– After pressure has been built up, close the shut-off cock -A-.
– Watch pressure drop on pressure gauge. After 10 minutes the
pressure must not drop below 3.0 bar.
If the pressure drops:
– Pressure retention valve in fuel pump defective; renew fuel
delivery unit ⇒ page 145 .
If the pressure does not drop:
– The pressure retention valve on the fuel pump is okay. Pres‐
sure limiting valve in the fuel filter faulty: Replace the fuel filter.
4.6.4 Checking delivery rate
Note
When malfunctions occur in the dynamic behaviour of the vehicle

with a fuel tank filled to max. 1/4, the fuel supply quantity must be
tested at a fuelpermitted
tank filling level ofby 1SEAT
/4foror
Protected by copyright. Copying
unless authorised less.
private or commercial purposes, in part or in whole, is not
S.A. SEAT S.A does not guarantee or accept any liability with

nector without pressing catch. The connector can cause a fault
if it has not been fitted correctly.
unit for damage.

Toledo 2013 ➤

– Connect the remote control - V.A.G 1348/3A- to the adapter -
VAS 5565- and to the battery positive (+) end in the engine
compartment.
Note
The following operation is to make the fuel pump run when the
engine is stopped.
WARNING

connection.
– Disconnect the supply line (metal connection) -arrow- and

clean escaping fuel with a cloth.
Note
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/2- . Hold adapter - VAS 6550/1- in a
measuring container.
are open.
WARNING
Danger of spraying! Wear safety goggles and protective cloth‐

ing to avoid possible injury and skin contact. Place a container
under the free coupling of the pressure gauge.
– Operate the remote control - V.A.G 1348/3A- . Then slowly

close shut-off tap -arrow- until
respect to theacorrectness
pressure of 4 barinisthisdisplayed
of information document. Copyright by SEAT S.A.
on pressure gauge. From here on, do not change position of
shut-off tap.
– Drain fuel tank.

Toledo 2013 ➤
– The quantity of fuel delivered by the fuel pump is dependent

upon battery voltage. For this purpose, connect multimetre -
V.A.G 1715- to outputs -1 and 5- on adapter for measuring
equipment / DSO (5 pin) - VAS 5565- .
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.
– Compare the fuel flow measured with the specification.

*) Minimum delivery rate cm3/60 s
**) Voltage in fuel pump with engine off and the pump working.
Readout example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 1,200 cm3/60 s.
If readout does not match specification:
– Check to ensure that there are no narrowings (kinks) or block‐
ages in the fuel pipes.
– Remove
Protected theCopying
by copyright. filler cap on orthe
for private fuel filler
commercial neck
purposes, and
in part repeat
or in whole, isthe
not
inspection. If the specified delivery quantity is not reached,
check the purging of the fuel tank.
If reading again does not match specification:
– Check the fuel filter as follows:
WARNING

connection.

Toledo 2013 ➤
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- . Hold adapter - VAS 6550/2- in a
measuring container.
are open.
– Operate the remote control - V.A.G 1348/3A- . Then slowly
close shut-off tap -arrow- until a pressure of 4 bar is displayed
on pressure gauge. From here on, do not change position of
shut-off tap.
– Drain fuel tank.
– Checking delivery rate again.
If the minimum flow rate is now reached:
– Renew fuel filter.
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and check filter strainer for soiling.
Only if no fault has yet been detected:
– Renew fuel delivery unit.
If delivery quantity has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Measure current draw of fuel pump ⇒ page 158 .
4.6.5 Checking current consumption

gr. 72 .

nector without pressing catch. The connector can cause a fault
if it has not been fitted correctly.
unit for damage.

Toledo 2013 ➤

– Connect the ammeter clip -A-to the red cable marked “Strom‐
zange (ammeter clip)” on the DSO (5 contact) adapter for the
measuring/oscilloscope module - VAS 5565- .
– Start engine and run at idling speed.
– Measure current draw of fuel pump.
• Specification: max. 9 amps.
Note
♦ The starting current of the fuel pump can be more than the
specification for a short period when starting the motor.
♦ When an irregular fault of the fuel system occurs sporadically,
the inspectionpermitted
can alsounless be carried
authorised outS.A.
by SEAT forSEAT
a test drive.
S.A does To do or accept any liability with
not guarantee
this a second person istonecessary.
respect the correctness of information in this document. Copyright by SEAT S.A.
If the current draw is exceeded:


Toledo 2013 ➤
5 Repairing electronic power control

(EPC)
⇒ “5.1 Accelerator pedal module - exploded view”, page 160
⇒ “5.2 Accelerator pedal module: functioning”, page 160
5.1 Accelerator pedal module - exploded view
1 - Mounting bracket
3 - 10 Nm
4 - Accelerator pedal position
sender - G79- and accelerator
pedal position sender 2 -
G185-
❑ To remove, remove
dash panel cover and
pedal cluster cover.
5.2 Accelerator pedal module: 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
permitted (driver's requirement)
unless authorised is the
by SEAT S.A. SEAT main
S.A does not guarantee or accept any liability with
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.

Toledo 2013 ➤
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. This means that if the accel‐
erator is pressed half way, the throttle positioner opens the throttle
valve proportionately; the throttle valve is then half open.
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.
This means that the throttle valve can already be completely open
even though the accelerator pedal is only pressed half way. The
advantage 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), the engine
control unit calculates the optimal throttle valve opening 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 only. The E-Gas is a system that contains all
components that are used to determine the position of the throttle
valve, to regulate it and to monitor it. These are, e.g. the sender
for the accelerator, the throttle valve control unit, the EPC warning
lamp and the engine control unit.
5. Repairing electronic power control (EPC) 161

Toledo 2013 ➤
6 Fuel filter:
tem”, page 129
⇒ “6.1 Fuel filter - assembly overview”, page 162
⇒ “6.2 Removing and installing fuel filter”, page 162
6.1 Fuel filter - assembly overview

If fuel system does not have a return line, there is a pressure
limiting valve in fuel filter. With this kind of system, only the supply
line is routed forwards into the engine compartment.
1 - Fuel filter:
❑ With pressure limiting
valve
❑ Direction of flow is
marked with arrows.
❑ Do not interchange the
connections
⇒ page 162
❑ Note the pressure spec‐
ifications on the pres‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
sure regulator. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Observe the equivalent
2 - Fuel supply
❑ Black
❑ From the fuel tank
3 - Fuel return line
❑ Blue colour
❑ To fuel tank
4 - Fuel line
❑ Black
❑ To engine
5 - 3 Nm
6 - Fuel filter holder
❑ Secured to fuel tank.
6.2 Removing and installing fuel filter

♦ Tray

Toledo 2013 ➤
Removing
Observe the safety precautions when working on fuel supply sys‐
tem
Follow rules for cleanliness
– Place drip tray under fuel filter.
WARNING

Before releasing the connections on the hoses, place absorb‐
ent cloths round the connection. Then release pressure by
carefully pulling hose off connection.
– DisconnectProtected
fuel lines -1-, -2-
by copyright. andfor-3-.
Copying Opening
private the
or commercial quick-re‐
lease coupling.
– Unscrew the bolt -4-.

– Remove fuel filter.
Installation
the following:
Installation position:
• Tightening torque ⇒ page 162 .
• Flow direction is marked on filter housing with arrows.
• Pin -2- on filter housing must engage in notch of guide -1- in
filter bracket.
6. Fuel filter: 163

Toledo 2013 ➤
7 Activated charcoal filter system:

⇒ “1 Safety precautions”, page 129
⇒ “7.1 Cleaning rules for working on the fuel supply system, fuel
injection system and on the exhaust gas turbocharger”,
page 164
⇒ “7.2 Activated charcoal filter system - Mode of operation”, page
164
⇒ “7.3 Activated charcoal filter system - exploded view”,
page 165
⇒ “7.4 Checking the fuel tank venting”, page 166
Note
♦ Clamp-type clips are to be renewed with spring-type clips.
7.1 Cleaning rules for working on the fuel

supply system, fuel injection system and
on the exhaust gas turbocharger
Even small amounts of dirt can cause malfunctions. For this rea‐
son, when working on the turbocharger, fuel injection and supply
systems, meticulously respect the following cleaning rules:
♦ Before opening them, carefully clean all the joints and its sur‐
roundings with adequate engine or brake cleaning products
and let them dry completely.
♦ Immediately plug the joints and conduits that are open with
adequate safety caps.
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use lenty rags!
♦ Fit only clean parts; remove new parts from their packaging
only immediately prior to fitting. Do not use parts that have
been stored loose (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle if avoidable.
♦ Protect the unplugged connectors against dirt and humidity. If
they are to be reconnected, they have to dry.
7.2 Activated charcoal filter system - Mode

of operation

♦ Always replace clamp-type clips with spring-type clips.

Toledo 2013 ➤
The quick-release connectors of the fuel, vacuum and venting

lines are colour coded. There is either a coloured dot on the push-
fit coupling or the release button is coloured.
Plug-in connector Colour code on push-fit cou‐
pling
Fuel supply Black
Fuel return line Blue colour
Breather white, beige
Vacuum green
Functioning of the activated carbon filter system
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 HC emissions es‐
caping to the atmosphere
Fuel vapours pass through a gravity valve (which closes at an
angle of 45°) located at the highest point in the tank and through
a vent 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 control is active
(engine warm), the Solenoid valve 1 for active carbon filter
(pulsed) - N80- , (also known as regeneration valve), is activated
by the engine control unit 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 active carbon filter during the purging
procedure (regenerating the active 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 unless
permitted emptying the
authorised by ac‐
SEAT S.A. SEAT S.A does not guarantee or accept any liability with
tivated charcoal tank. respect to the correctness of information in this document. Copyright by SEAT S.A.
The solenoid valve 1 for the active carbon filter (pulsed) - N80- is
closed without power supply (for example there is a break in the
power supply). The activated charcoal tank is not emptied.
7.3 Activated charcoal filter system - exploded view
7. Activated charcoal filter system: 165

Toledo 2013 ➤
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
5 - Active carbon filter
❑ Location: in rear right
wheel housing.
6 - Vent line
❑ Check for secure seat‐
ing
7 - Pressure retention valve
with connection hose
❑ Check for secure seat‐
ing
❑ Coming from fuel tank
gravitational valve
8 - Gravity valve
❑ In the tank flap unit
7.4 Checking the fuel tank venting

♦ Vacuum pump - VAS 6213-
Test condition
• Ignition must be switched off.

Toledo 2013 ➤
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.
If no vacuum builds up:
– 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.
If no vacuum builds up:
– Renew active carbon filter.
7. Activated charcoal filter system: 167

Toledo 2013 ➤
21 – Turbocharging/supercharging
1 Exhaust turbocharger
Note
♦ Secure the hose connections with original clamps.

♦ The couplings and air hoses of the supercharging system must
be free from oil and grease before assembling.
♦ Charge air system must be free of leaks.
♦ Always replace self-locking nuts.
♦ We recommend using spring-type clip pliers - VAS 5024A- or
spring-type clip pliers - VAS 6340- for installation of spring-
type clips.
♦ Fill the turbocharger at the coupling of the oil supply pipe with
engine oil.
♦ After fitting the turbocharger, allow the engine to idle for 1 mi‐
nute without accelerating to ensure turbocharger oil supply.
⇒ “1.1 Turbocharger - exploded view”, page 168

⇒ “1.2 Exhaust gas turbocharger – Assembly overview (Part I )”,
page 170 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.3 Exhaust gas turbocharger – Assembly overview (Part
respect to theII)”,
correctness of information in this document. Copyright by SEAT S.A.
page 171
⇒ “1.4 Turbo compressor: removing and fitting”, page 172
⇒ “1.5 Removing and installing compressor housing and turbine
housing”, page 177
⇒ “1.6 Turbocharger pressure capsule: checking”, page 181
⇒ “1.7 Removing and installing vacuum unit for turbocharger”,
page 183
⇒ “1.8 Adjusting vacuum unit for turbocharger”, page 185
1.1 Turbocharger - exploded view

Part I ⇒ page 170
Part II ⇒ page 171
168 Rep. gr.21 - Turbocharging/supercharging

Toledo 2013 ➤
1. Exhaust turbocharger 169

Toledo 2013 ➤
1.2 Exhaust gas turbocharger – Assembly overview (Part I )
1 - Turbocharger with exhaust

manifold
⇒ page 172
compressor housing
and turbine housing
⇒ page 177 .
❑ Checking turbocharger
vacuum unit
⇒ page 181 .
vacuum unit for turbo‐
charger ⇒ page 183 .
❑ Adjust the turbocharger
pressure capsule
⇒ page 185 .
Specified torques:
❑ Protected
Fastening screws
by copyright. of for
Copying the private or commercial purposes, in part or in whole, is not
pressure
permitted capsule
unless authorised by on
SEATtheS.A. SEAT S.A does not guarantee or accept any liability with
exhaust
respect toturbocharger:
the correctness of information in this document. Copyright by SEAT S.A.
20 Nm
❑ Lock nut to vacuum unit
rod: 10 Nm.
2 - O-ring
❑ replace
3 - Turbocharger air recircula‐
tion valve - N249-
4 - 11 Nm
5 - Coupling hose
6 - Inlet connection
7 - 10 Nm
8 - Coupling hose
9 - Spring type clip
10 - Electronic pressure limiter valve for supercharger - N75-
11 - 10 Nm
12 - Coupling hose
13 - Coupling hose
14 - Support plate
❑ To coolant hose

Toledo 2013 ➤
1.3 Exhaust gas turbocharger – Assembly overview (Part II)
1 - Oil supply pipe

❑ Observe specified tight‐
ening torques
⇒ Item 20 (page 172) .
2 - 8 Nm
3 - 8 Nm
5 - Support plate
6 - 8 Nm
7 - O-ring
❑ replace
8 - 8 Nm
9 - 20 Nm
10 - 8 Nm
12 - Seal
❑ replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - 8 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.
14 - Oil return line

15 - 8 Nm
16 - Turbocharger with ex‐
haust manifold
⇒ page 172
compressor housing
and turbine housing
⇒ page 177 .
Note
♦ The studs need to be renewed as

well as the securing nuts.
♦ Screw the headless screw into
the cylinder head until a length of
25 mm on the outside.
17 - Seal
❑ replace
18 - 25 Nm
❑ replace
❑ Lubricate studs of exhaust manifold with high-temperature lubricant.
Note


Toledo 2013 ➤

19 - Support plate
20 - Hollow bolt
❑ replace
Tightening torque:
❑ Banjo bolt on the controller housing: 20 Nm
21 - Oil seal
❑ replace
1.4 Turbo compressor: removing and fitting

♦ Hose clip pliers - VAS 6340-

Toledo 2013 ➤
Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. To avoid subsequent damage, carry out the
following operations:
♦ Ensure that the air filter housing, the cartridge and the
vacuum hoses are not dirty.
♦ Ensure that there are no foreign bodies in the supercharg‐
er air circuit and the intercooler.
If foreign matter is found in the charge air system, clean all
relevant ducts and hoses and renew the charge air cooler if
necessary.
Removing
Note
Before carrying out further work, disconnect battery earth strap.

Therefore check whether a coded radio is fitted. Obtain anti-theft
coding first if necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

necting and reconnecting battery
– Using hose clamps -3094- disconnect the coolant hoses to the
exhaust gas turbocharger.

guide -3-.

Toledo 2013 ➤
– Remove the hose -1- from the intake connecting pipe of the
exhaust gas turbocharger.
– Remove the connector -2- of the charge pressure sender -
G31- with input air temperature sender 2 - G299- and unscrew
the fixing screws -3-.
– Press securing clips -1- outwards and pull pressure hose -2-
upwards.
– Then disconnect the pressure hose -2- from the turbocharger.
– Unscrew the fastening bolts -arrows- and remove the heat

protection plate from the turbocharger.
– Remove the coolant pipe from the coolant tube -1-.

– Unscrew the securing screws -2- and remove the coolant pipe
-3-.
– Removing air conditioning compressor ⇒ Heating, Air condi‐
tioning; Rep. gr. 87 .
Note

– Check that the conducts have not been bent.

Toledo 2013 ➤
– Unscrew the securing bolts on the exhaust gas turbocharger

-arrows-.
– Unclip the cable lines -1- from the main catalytic converter.
– Unplug connectors -2-.

– Unscrew the securing nut -3- and remove the seal.
– Remove catalytic converter downwards.
– Unscrew the fastening bolts -arrows- on the heat protection

plate and remove the plate in the -direction of arrow- by dis‐
connecting the exhaust manifold.
– Remove securing bolts -1- for oil supply pipe -3-.
– Unscrew the banjo bolt -2- of the cylinder block and remove
the oil supply pipe.
– Unscrew the fixing screws -4- and remove the holder -5- down‐
wards.

Toledo 2013 ➤
– Unscrew securing bolts -1- for oil return pipe -2- and remove
pipe.
Note
The alternator must only be loosened with fixing nuts with internal
splines.
– Loosening alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐

nator; removing and installing
– Unscrew all the fastening nuts from the exhaust manifold -1-
and remove the support -3- from the studs.
– Remove the exhaust manifold with the turbocharger -2- from
the cylinder head.
Installation
– Attach the exhaust turbocharger with the exhaust manifold
and a new gasket to the cylinder head.
– Tighten the fixing nuts to 25 Nm with the intended sequence.

The remaining installation steps are carried out in reverse se‐
quence - note the following points:
♦ Always replace seals, gaskets and self-locking nuts.
♦ Fill the turbocharger at the coupling of the oil supply pipe with
engine oil.
♦ After fitting the turbocharger, allow the engine to run at idle for
1 min to ensure turbocharger oil supply.
Specified torques:
Exhaust gas turbocharger – Assembly overview (Part I )
⇒ page 170
Exhaust gas turbocharger – Assembly overview (Part II)

⇒ page 171
Assembly overview - catalytic converter and add-on parts
⇒ page 232
– Check coolant level and add, if necessary ⇒ page 116 .
– Hang the coolant hoses -2- on the engine cover and press the
cover downwards.
– Tighten hub securing bolt -1- of the engine cover to a tighten‐
ing torque of 8 Nm.

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1.5 Removing and installing compressor

housing and turbine housing
Note
Please use a suitable repair kit for the following work sequence
⇒ Electronic Parts Catalogue (ETKA) .

♦ Engine bung set - VAS 6122-
♦ Torque wrench - V.A.G 1331-
♦Protected
Hot air blowerCopying
by copyright. - V.A.G 1416-
for private or commercial purposes, in part or in whole, is not
Removing
– Remove turbocharger ⇒ page 172 .
– Checking vacuum unit for turbocharger ⇒ page 181 .

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– Seal all openings in turbocharger -arrows- with suitable plugs

from engine bung set - VAS 6122- .
– Remove circlip -1- using screwdriver -2-.

– Pull threaded rod -3- off stud.
Caution
In order to prevent the

Protected exhaust
by copyright. manifold
Copying from
for private becoming
or commercial dam‐
aged, alwayspermitted
use aluminium protective
unless authorised by SEAT S.A.jaws
SEAT S.A-1-does
fornot
the vice! or accept any liability with
guarantee
– Clamp exhaust manifold -2- in vice as shown in illustration.

Toledo 2013 ➤
– Use a waterproof pen to mark position of bolt -arrow- relative

to compressor housing.
– Unscrew securing nut -1- of clamp -2-, and remove clamp.
Caution
If the turbine housing is still tightly secured to the compressor

housing after the clamp -2- has been removed:
• Do not use leverage tools!
• Always use the hot air blower - V.A.G 1416- to loosen the
connection in order to prevent the centring pin on the tur‐
bine housing from becoming damaged.
If the compressor housing is still tightly secured to the turbine

housing due to deposits:
– Using hot air blower - V.A.G 1416- , apply heat evenly all
around the connection point between
Protected theCopying
by copyright. compressor housing
for private or commercial purposes, in part or in whole, is not
and the turbine housingpermitted
for about 2 minutes.
– Carefully remove compressor housing upwards.
If the centring pin -arrow- is shared off or damaged, the turbo‐

charger needs to be renewed together with the exhaust manifold.
Caution
Place compressor housing on workbench as shown in illustra‐

tion in order to prevent any damage to the turbine wheel!
Do not use compressed air to clean the compressor housing!
– Clean compressor housing all around -arrows- using, for ex‐

ample, brake cleaner and sandpaper (220 to 1000 grade).
– Remove exhaust manifold from vice.
Installation
Caution
In order to prevent the exhaust manifold from becoming dam‐

aged, always use aluminium protective jaws -1- for the vice!

Toledo 2013 ➤
– Clamp new exhaust manifold -2- in vice as shown in illustra‐

tion.
– Fit compressor housing onto turbine housing.
Make sure that centring pin -1- of turbine housing engages in hole
-2- of compressor housing.
– Using a feeler gauge -1-, measure gap -arrow- between com‐

pressor housing and turbine housing.
The gap must be even all around and must measure ≤ 1.2 mm.
– Fit new clamp around both flanges.
Note
♦ When tightening the securing nuts to 9 Nm the studs can

slightly deform. This is normal and not critical.
♦ For this reason a new clamp and new stud are always to be
used for by
Protected installing.
copyright. Copying for private or commercial purposes, in part or in whole, is not

Toledo 2013 ➤
– Align clamp so that centre of stud is flush with marking

-arrow- on compressor housing.
– Tighten the securing nuts -1- of the clamp -2- with 9 Nm.
– Apply light hammer blows alternately all around the clamp

-arrow-
in order to ensure proper seating of the clamp.
– Subsequently tighten the securing nuts again with 9 Nm.
– Push threaded rod -1- of vacuum unit onto stud -2-.

– Push new circlip -3- into groove in stud.
– Turbocharger pressure capsule: adjusting ⇒ page 185 .
– Install turbocharger ⇒ page 172 .
1.6 Turbocharger pressure capsule: check‐

ing
Removing and installing vacuum unit for turbocharger
⇒ page 183 .
Adjust the turbocharger pressure capsule ⇒ page 185 .
♦ Manual vacuum pump - VAS 6213-

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Test prerequisites
♦ The turbocharger hose, through the supercharger pressure
limiter solenoid valve - N75- , to the pressure capsule requires
open passage and must be watertight.
♦ Charge pressure control solenoid valve - N75- OK.
Work sequence
– Unscrew the bolts -arrows- and remove the heat protection
plate for the turbocharger.
– Pull hose -arrow- from vacuum unit.
– Connect hose -2- of the manual vacuum pump - VAS 6213-

on pressure capsule connection.
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
stop in direction of -arrow-.
– Operate hand vacuum pump - VAS 6213- several times.
Caution
There is a risk of damage to the pressure capsule due to ex‐

cess pressure.
Pressure must not exceed 800 Millibar!
Note
The figure shows the assembly position with the turbocharger

dismounted.

Toledo 2013 ➤
– Observe the control rod -1- of the turbocharger pressure cap‐

sule.
♦ The control rod must move from approx. 300 mbar.
♦ At approx. 800 mbar the control rod should be at the end of its
adjustment stroke.
– Ventilate the manual vacuum pump - VAS 6213- -arrow A-.

♦ The control rod should move in the opposite direction.
Note
Observe the movement of the control rod, in particular the ad‐

justment margin. It should move continuously and evenly.
Install in the reverse order to removal.

Heat protection plate tightening torque for turbocharger: 8 Nm
1.7 Removing and installing vacuum unit for

turbocharger
Removing
– Detach coolant hose -2- from engine cover panel.
– Pull oil dipstick out.
– Unscrew the bolts -arrows-, and remove the cover trim of the
engine. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the air filter respect
housing ⇒ page 205 .
to the correctness of information in this document. Copyright by SEAT S.A.

– Unscrew bolts -2- and detach retaining bracket -1-.

Toledo 2013 ➤
– Unplug the connector -3- from the charge air pressure sender
- G31- .
– Release retainers -arrows- and detach air pipe first from throt‐
tle valve module - J338- and then from turbocharger.
– Move hoses on air pipe clear.
– Unscrew the bolt -4- and remove the crankshaft sump breather
hose from the turbocharger -arrow- and set to one side
Note
Ignore positions -1, 2 and 3-.
– Choke coolant hoses with the hose clamps - 3094- , as shown

in figure.
– Unscrew the bolts -1, 3, 4, 5-.
– Disconnect the coolant pipes from the turbocharger and set to
one side.
Note
Disregard item -2-.
– Unscrew bolts -2- and -3- and remove fastening plate.
Note
Ignore positions -1- and -4-.

Toledo 2013 ➤
– Lever off safety washer -2-, then remove threaded part -1- of
the control rod in bolt -3-.
Note
Disregard item -4-.
– Remove the hose -2- of the pressure capsule for turbocharger.

– Unscrew bolts -1- and remove the pressure capsule -3- for
turbocharger.
Installation
Tightening torques ⇒ page 168
Remaining assembly or installation is carried out in reverse order
of removal.
– Insert a new locking washer for the selector linkage.
Note
Make sure that the locking washer has been fitted correctly in the
groove of the bolt.
– Turbocharger pressure capsule: adjusting ⇒ page 185 .
1.8 Adjusting vacuum unit for turbocharger

Toledo 2013 ➤

equipment required
♦ Universal dial gauge holder
- VW 387-
♦ Manual vacuum pump -
VAS 6213-
♦ Pressure limiting valve -
VAS 6342-
♦ Turbocharger tester -
V.A.G 1397A-
♦ Dial gauge kit, 4 parts - VAS
6341-
1783-
♦ Open-end spanner insert, 10 mm - V.A.G 1783/1-
Work sequence
– Detach coolant hose -2- from engine cover panel.

Toledo 2013 ➤
– Pull oil dipstick out.

– Unscrew the bolts -arrows-, and remove the cover trim of the
engine.
– Remove the air filter housing ⇒ page 205 .

– Unscrew bolts -2- and detach retaining bracket -1-.
– Unplug the connector -3- from the charge air pressure sender
- G31- .
– Release retainers -arrows- and detach air pipe first from throt‐
tle valve module - J338- and then from turbocharger.
– Move hoses on air pipe clear.
– Unscrew the bolt -4- and remove the crankshaft sump breather
hose from the turbocharger -arrow- and set to one side
Note
Ignore positions -1, 2 and 3-.

Toledo 2013 ➤
– Choke coolant hoses with the hose clamps - 3094- , as shown

in figure.
– Unscrew the bolts -1, 3, 4, 5-.
– Disconnect the coolant pipes from the turbocharger and set to
one side.
Note
Disregard item -2-.
– Unscrew bolts -2- and -3- and remove fastening plate.

Ignore positions -1- and -4-.
– Remove the hose -2- of the pressure capsule for turbocharger.
Note
Disregard item -1-.
– Interconnect measurement and test equipment, as shown in

the figure, and connect to terminal “II” of the turbocharger test‐
er - V.A.G 1397A- and the turbocharger pressure capsule.
– Close the lever -1- in the pressure regulating valve - VAS

6342- .
– Move sliding ring -2- of the manual vacuum pump - VAS 6213-
to the limit in the -direction of the arrow-.
– Activate the turbocharger tester - V.A.G 1397A- and move the
sliding switch to position “II”.
– Activate the manual vacuum pump - VAS 6213- several times
until a pressure of 800 mbar is obtained.
Caution
There is a risk of damage to the pressure capsule due to ex‐

cess pressure.
Pressure must not exceed 800 Millibar!

Toledo 2013 ➤
– Ventilate the manual vacuum pump - VAS 6213- -arrow A- to

allow adjustment linkage of the supercharger pressure control
in the turbocharger to move freely.
– Repeat procedure 5 times.
– Fix the universal dial holder - VW 387- on the turbocharger, as
shown in the figure.
– Fix the dial gauge - VAS 6341/1- with the flat contact - VAS
6341/4- to the universal dial holder - VW 387- .
– Set the dial gauge - VAS 6341/1- to a pretension of 1 mm with
a pressure of 0 bar.
– Set the dial gauge - VAS 6341/1- indicator to “0”.
until a pressure of 385 mbar is shown on the turbocharger dial
gauge - V.A.G 1397A- .

Toledo 2013 ➤
Dial gauge - VAS 6341/1- specification: 1 mm distance
Note
♦ If the theoretical value is not obtained, loosen the lock nut

-4-.
♦ Lever off safety washer -2-, then remove threaded part -1- of
the control rod from the bolt -3-.
♦ Turn the threaded part on the control rod until the theoretical
value is reached. To check, connect the threaded part to the
control lever rod.
♦ If the bore of the threaded piece does not fit onto the pin in this
position, the threaded piece may be rotated one-half turn in
either direction.
♦ Secure the threaded part with the safety washer -2- on the
control lever rod and tighten the counter nut -4-.
Check the setting of the pressure capsule

– Set the dial gauge - VAS 6341/1- to a pretension of 1 mm with
a pressure of 0 bar.
Measurement 1:
until a pressure of 750 ... 800 mbar is shown on the turbo‐
charger dial gauge - V.A.G 1397A- .
– Release pressure in the pressure control valve - VAS 6342- to
375 mbar.
– Read and note the value indicated by the gauge - VAS
6341/1- .
0 mbar.
until a pressure of 375 mbar is shown on the turbocharger dialCopying for private or commercial purposes, in part or in whole, is not
gauge - V.A.G 1397A- . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
6341/1- .
– Calculate average value; by adding values “1” and “2” and di‐
viding by 2.
Specification: 1 mm
Measurement 2:
until a pressure of 750 ... 800 mbar is shown on the turbo‐
charger dial gauge - V.A.G 1397A- .
475 mbar.
6341/1- .
0 mbar.
– Set the dial gauge - VAS 6341/1- indicator to "0".
until a pressure of 475 mbar is shown on the turbocharger dial
gauge - V.A.G 1397A- .

Toledo 2013 ➤

6341/1- .
– Calculate average value; by adding values “1” and “2” and di‐
viding by 2.
Specification: 5 mm
– If theoretical values are not obtained, the adjustment should
be repeated.
Tightening torques ⇒ page 168
Install in the reverse order to removal.

Toledo 2013 ➤
2 Supercharger air system:
Note
♦ We recommend using spring-type clip pliers - VAS 5024A- or

spring-type clip pliers - VAS 6340- for installation of spring-
type clips.
♦ The couplings and air hoses of the supercharging system must
be free from oil and grease before assembling.
♦ Charge air system must be free of leaks.
⇒ “2.1 Supercharger air system - Assembly overview”,

page 192 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “2.2 Charged airrespect
cooler: removing and fitting”, page 194
to the correctness of information in this document. Copyright by SEAT S.A.
⇒ “2.3 Removing and installing radiator and charge air cooler”,

page 195
2.1 Supercharger air system - Assembly

overview
Note
♦ Radiator and charge air cooler are two separate components.

♦ The radiator is located above the charge air cooler.
♦ Radiator and charge air cooler are removed and installed to‐
gether.
♦ Coolant hose schematic diagram ⇒ page 116
♦ Use pliers for spring-type clips - VAS 6340- when removing
and installing the spring-type clips.

Toledo 2013 ➤
1 - Radiator
the radiator ⇒ page 123
2 - Intake manifold
⇒ page 210
3 - Waterproof strip
❑ Check that the charged-
air cooler is fitted in the
correct installation posi‐
tion.
4 - Seal
❑ replace
❑ Check that the charged-
air cooler is fitted in the
correct installation posi‐
tion.
5 - Charge air cooler intake
pipe
⇒ page 194
6 - Coolant hose
❑ To turbocharger
7 - 7 Nm
❑ Observe tightening se‐
quence ⇒ page 194 .
8 - Coolant hose
❑ to the expansion reser‐
voir
9 - Hose clip
❑ Fixed onto the upper
valve timing housing
10 - Coolant hose
❑ To turbocharger
11 - Coolant pump - V50-
❑ Fitting location: under intake manifold
12 - 8 Nm
13 - Support plate
15 - 10 Nm
16 - Coolant hose
❑ To fuel radiator Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 - Pipe for coolant respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Attached to the sump

18 - 8 Nm
19 - Coolant hose
20 - Intercooler system
2. Supercharger air system: 193

Toledo 2013 ➤
2.2 Charged air cooler: removing and fitting

♦ Support bridge - 3250- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing
– Remove intake manifold ⇒ page 210 .
– Unscrew the securing bolts of the charge-air cooler in the fol‐
lowing order -A - to -F-.
– Separate the charge-air cooler from the intake manifold.
Installation
Note
The charge-air cooler in the intake manifold is assembled with a

workshop press.

Toledo 2013 ➤
– Slide the sealing strip -1- onto the edge of the charge-air cooler
in -the direction of the arrow-.
– Check that the new gasket is perfectly adjusted in the intake
manifold.
– Insert the charge-air cooler to the end of the intake manifold.
The charge-air cooler must remain straight during the assembly.
Note
♦ Place the intake manifold correctly on the workshop press ta‐

ble.
♦ The housing of the charge-air cooler -1- must be aligned hor‐
izontally.
♦ Use a timber block or something similar as a base.
– Centre the engine support - 3250- on the charge-air cooler.

– Carefully press the workshop press piston until the charge-air
cooler housing -1- is supported on the intake manifold -2-.
– Tighten the securing bolts evenly until the bolt heads make
contact.
– Tighten the securing bolts to 7 Nm in the following order -A - to
-F-.
– Installing intake manifold ⇒ page 210 .
Continue with the installation following reverse order of removal
instructions.
2.3 Removing and installing radiator and

charge air cooler
Note permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Radiator and charge air cooler are two separate components.

♦ The radiator is located above the charge air cooler.
♦ Radiator and charge air cooler are removed and installed to‐
gether.
⇒ “1.1 Assembly overview - parts of cooling system, body side”,

page 112

Toledo 2013 ➤

equipment required
♦ Refractometer - T10007A-
♦ Torque wrench - VAG
1331-
♦ Guide pins - 3411-
Removing
hose.

Toledo 2013 ➤

hose.
– Unplug connector -arrow-.
– Open the hose guides in the cowling using the -2- and press
the coolant hose to the side -1-.
– Disengage cowling with
respect radiator
to the fan
correctness - V7- from
of information in thislocking
document.hook
Copyright by SEAT S.A.
using a suitable tool.
– Push cowling together with radiator fan - V7- upwards out of
the mountings and remove downwards.
– Remove the upper coolant hoses of the radiator and charged
air cooler.
– Unplug the plug connector of the radiator outlet coolant tem‐
perature sender - G83- .
– Remove the front bumper cover ⇒ Exterior body installation
work; Rep. gr. 63 ; Front bumper trim (all versions): Removing
and installing .

Toledo 2013 ➤
– Unscrew securing bolts -arrows-.

– Bring lock plate carrier into service position: ⇒ Bodywork, ex‐
terior fitting work; Rep. gr. 50 ; Bodywork, front; Lock carrier
in service position .
– Remove the radiator from the lower tabs and press a little to
the back.
– Separate the lateral radiator coolant bracket.
– Unscrew the bolts -arrows- attaching the condenser to the ra‐

diator.
– Extract the attachment bolts -arrows- of the condenser.

– Fasten the condenser to the lock carrier using the cable tie.
– Remove the radiator and charged air cooler to the bottom.
Note

Separate the radiator from the intercooler.

– For separating the intercooler -1- from the cooler, press the
locking element using a suitable tool.

Toledo 2013 ➤
– Move the intercooler -1- to the right and remove from the cool‐
er -2-.
Installation
the following:
WARNING
Make sure that the locking elements have been connected

correctly from the radiator to the supercharger.
– Electrical connections and routing: ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations
– Bring lock plate carrier into service position: ⇒ Bodywork, ex‐
terior fitting work; Rep. gr. 50 ; Lock carrier in service position .
Method for filling fresh coolant ⇒ page 116 .
Specified torques:
Component Nm
Radiator bracket to lock carrier plate 5
Compressor line support bracket from the air 5
conditioner to the radiator
Radiator to condenser 5

Toledo 2013 ➤
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Parts I and II intake pipe - assembly overview”,
page 200
⇒ “1.2 Assembly overview - part I, intake manifold”, page 202
⇒ “1.3 Assembly overview - part II, intake manifold”, page 203
⇒ “1.4 Fuel rail with injection valves - Summary of components”,
page 204
⇒ “1.5 Assembly overview - air filter”, page 205
⇒ “1.6 Removing and installing air filter housing”, page 205
⇒ “1.7 Throttle valve control unit J338 : removing and fitting”,
page 206
⇒ “1.8 Throttle valve control unit J338 : cleaning”, page 209
⇒ “1.9 Remove and install the inlet manifold”, page 210
⇒ “1.10 Assembly overview - high-pressure pump”, page 211
⇒ “1.11 Check fuel pressure sender G247 ”, page 212

⇒ “1.12 Removing and installing high-pressure pump”,

page 215
⇒ “1.13 Removing and installing injectors”, page 219
⇒ “1.14 Replace the Teflon seal and support washer on the in‐
jection valve”, page 222
⇒ “1.15 Safety precautions”, page 225
⇒ “1.17 Technical data”, page 227
General notes on the injection system
♦ The engine control unit - J623- is equipped with self-diagnosis.
Before carrying out repairs and fault finding, the event memory
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.
♦ The vehicles are equipped with a fuel shut-off system in the
event of collisions. It reduces the danger of a vehicle fire after
a crash as the fuel pump is switched off via 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.
1.1 Parts I and II intake pipe - assembly overview
200 Rep. gr.24 - Mixture preparation - injection

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1. Injection system 201

Toledo 2013 ➤
1.2 Assembly overview - part I, intake manifold
1 - Coupling hose
2 - Fuel line
❑ High-pressure.
❑ Tightening torques of
connection nuts:
at the high-pressure pump: 18
Nm
Intake manifold (top section):

20 Nm
3 - 8 Nm
4 - Clip
5 - Fuel hose
❑ Low-pressure.
❑ To high pressure pump
6 - Spring type clip permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ing the hose clip pliers -
VAS 6340- .
❑ For the fuel supply
8 - Retaining valve
❑ For crankcase breather
9 - 8 Nm
10 - O-ring
❑ replace
❑ To distribution casing
12 - Impulse line
❑ From turbocharger
13 - Coupling hose
❑ To camshaft housing
14 - Retaining valve
15 - Coupling hose
❑ To air filter housing
16 - Coupling hose
❑ to active carbon reservoir
17 - Activated charcoal filter solenoid valve 1 - N80-
18 - Coupling hose
19 - Clip
20 - Coupling hose
21 - Coupling hose
❑ to turbocharger

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1.3 Assembly overview - part II, intake manifold
1 - Retaining clip
2 - 7 Nm
3 - Impulse line
4 - O-ring
❑ replace
5 - Charge air pressure sender
- G31- with intake air tempera‐
ture sender 2 - G299-
6 - 5 Nm
7 - 7 Nm
8 - Adapter
9 - Intake manifold
⇒ page 210
10 - Intake manifold pressure
sender
Protected - G71-Copying for private or commercial purposes, in part or in whole, is not
by copyright.
11respect
- 5 Nmto the correctness of information in this document. Copyright by SEAT S.A.
12 - 20 Nm
13 - Throttle valve module -
J338-
⇒ page 206
❑ Cleaning ⇒ page 209
❑ During the replacement,
erase the self adapting
values and adapt to the
engine control unit -
J623- ⇒ Vehicle diag‐
nostic tester “Guided
function”
14 - Oil seal
❑ replace
15 - Fuel pressure sender - G247- , 22 Nm
❑ Check the fuel pressure sender - G247- ⇒ page 212
16 - 80 Nm
17 - Intake manifold lower part:
To remove:
❑ Remove throttle valve module - J338- ⇒ page 206 .
❑ Removing and installing intake manifold ⇒ page 210
18 - Seal
❑ replace
19 - 20 Nm

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1.4 Fuel rail with injection valves - Summary of components
1 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
2 - Elastic element
❑ Renew each time after
removing lower part of
intake manifold.
❑ Check that it is properly
fitted on the injector
3 - Injector, cylinder 4 - N33-
❑ Injector, cylinder 1 -
N30-
N31-
N32-
❑ With Teflon seal and
support washer
❑ After dismounting the in‐
jector, the Teflon seal
and support washer
should be replaced
⇒ page 222
❑ Remove and fit the in‐
jectors ⇒ page 219 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Intake manifold lower part: respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ The throttle valve mod‐

ule - J338- and the in‐
take manifold must be
removed and installed
for the removal
⇒ page 206

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1.5 Assembly overview - air filter
1 - O-ring
❑ Remove and install with
hose clip pliers - VAS
6340- .
4 - Air intake hose
5 - Vacuum hose
❑ From the cylinder head
cover
7 - Air cleaner (top section)
8 - 1.6 Nm
❑ Tighten with torque
screwdriver - VAS
6494- .
9 - Filter element
10 - Rubber mounting
11 - Air filter bottom part
⇒ page 205
12 - 8 Nm
13 - Rubber mounting
14 - Draining water support
15 - Intake air duct
16 - 3 Nm
17 - 10 Nm
1.6 Removing and installing air filter hous‐

ing
Removing
– Unbolt the screws -arrows- of the intake air duct and the intake
permitted connecting
unless authorisedpipe onS.A.the exhaust gas turbocharger.
by SEAT SEAT S.A does not guarantee or accept any liability with

Toledo 2013 ➤
– Remove vacuum hose -1- under the intake hose.

– Unscrew securing bolt -2-.
– Pull the air filter housing upwards.
Installation
– Push the air filter housing from the top onto the support pins.
– Connect the intake hose -1-.
– Tighten bolts -arrows-.

Tightening torques
Intake hose on the exhaust gas turbocharger, 10 Nm
Intake duct: 3 Nm
1.7 Throttle valve control unit - J338- : re‐

moving and fitting

Toledo 2013 ➤
Removing
– Remove the dip stick
– Unhook the hoses -1- and -2- from the pressure pipe.
– Remove the connector of the charge pressure sender - G31-
with input air temperature sender 2 - G299- -4- and unscrew
the fixing screws -3-.
– Press securing clips -1- outwards and pull pressure hose -2-
upwards.
– Then disconnect the pressure hose -2- from the turbocharger.

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– Unplug the connector -1- from the throttle valve module -

J338- .
– Unscrew the fastening bolts -2- and remove the throttle valve
module -3-from the intake manifold.
Installation
– Place a new seal on the throat of the intake manifold.
– Place the throttle control unit -3 - together with the adapter

-2- and the fastening bolts -1- on the intake manifold -4-.

– Connect the electrical connection -1- to the throttle valve con‐
trol unit -3-.
Note
Apply a little engine oil to the O-rings on the turbocharger and the
pressure pipe before fitting.
– Connect pressure pipe -2- to turbocharger.

– Press pressure pipe -2- on throttle control unit.
The fastening clips -1- should snap into position.

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– Tighten the securing bolts -3- of the retaining clips to 7 Nm.

– Plug in the electrical connector on the charge air pressure
sender - G31- on intake air temperature sender 2 - G299- .
– Press the hoses -1- and -2- on the pressure pipe fastenings
– Hook the coolant hoses -2- on the engine cover and place this
on the camshaft casing.
If a new throttle control unit has been fitted:
– Delete the learnt values and adapt engine control unit - J623-
to throttle valve module ⇒ Vehicle diagnostic tester “Guided
functions”.
1.8 Throttle valve control unit - J338- : clean‐

ing
Note Copying for private or commercial purposes, in part or in whole, is not

♦ If a new engine control unit - J623- has been fitted, the throttle
control unit must be adapted. Adaptation must be performed

only with a new or cleaned throttle valve module, because
soiling or coking at the end stop of the throttle valve can lead
to incorrect adaptation values.
♦ The throttle valve support must not be scratched when clean‐
ing.
– Remove the throttle control unit ⇒ page 206 .

– Open the throttle by hand and lock it in an open position with
an appropriate tool, such as a plastic or wooden wedge
-arrow-.
WARNING
Acetone is highly inflammable. Please observe the accidental

regulations and safety notes when handling with highly inflam‐
mable fluids. Do not use compressed air to clean the throttle
valve. Wear safety goggles and protective clothing to avoid
possible injury and skin contact.

Toledo 2013 ➤
– 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.
– Wait for the acetone to evaporate completely and then fit the
clean control unit.
– Delete the learnt values and adapt engine control unit - J623-
to throttle valve module ⇒ Vehicle diagnostic tester “Guided
functions”.
1.9 Remove and install the inlet manifold

Removing

Toledo 2013 ➤
– Remove the throttle control unit ⇒ page 206 .

– Press the release tab -2- and remove the fuel supply line.

– Clamp off coolant hoses -4- with hose clips up to 40 mm -
3093- .
– Open the clamp and remove the coolant hose -4-.
– Unclip the line -2- from its mount.
– Unscrew securing bolts -3- of intake manifold.
– Unclip all remaining lines.
– Remove intake manifold.
Installation
of removal.
Tightening torque of intake manifold fixing screws: 20 Nm
Tightening torque and sequence of installation of the charged air
cooler ⇒ page 192
1.10 Assembly overview - high-pressure

pump
WARNING

prox. 6 bar).
appropriate procedure is described in the chapter on releasing
pressure in the high-pressure section ⇒ page 130 .

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1 - 20 Nm
❑ Low-pressure.
❑ Remove and install with
hose clip pliers - VAS
6340- .
4 - Fuel hose
❑ Low-pressure.
❑ With spring clip
5 - Union nut, 18 Nm
❑ Always follow safety
precautions
⇒ page 129 .
❑ When removing the
connection hose, it must
be retained at the high-
pressure pump side
7 - High-pressure pump with
fuel pressure regulating valve -
N276-
8 - Tappet with roller
9 - O-ring
❑ replace
1.11 Check fuel pressure sender - G247-


Toledo 2013 ➤
♦ Polygonal wrench with 3/8´´ ratchet, 27 mm
♦ Pressure sensor tester - VAS 6394/1-

♦ Adapter - VAS 6394/2-
♦ Test instrument adapter - VAS 5570-
Work sequence
WARNING

prox. 6 bar).
– Remove the fuel pressure sender - G247- -1- using an open-

ended spanner.
– Lubricate the taper seal of the adapter - VAS 6294/2- with

clean engine oil and screw into the fuel rail. Tightening torque:
22 Nm

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– Unscrew the sealing plug -2- and screw in the fuel pressure
sender - G247- into pressure tester - VAS 6394/1- . Specified
torque: 22 Nm.
– Connect the pressure line of the pressure tester - VAS 6394/1-
to the adapter - VAS 6394/2- .
– Connect the fuel pressure sender -1- and its connector to the
adapter for the testing function - VAS 5570- .

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– Switch on the pressure tester - VAS 6394/1- by pressing the

switch -A- once.
Note
♦ When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.
♦ If the pressure tester - VAS 6394/1- does not indicate 0 bar,
calibrate the tester by setting to zero ⇒ Operating instructions .
– Connect vehicle diagnosis tester to diagnostic connection.

– Switch on the ignition.
– Select the following options one after another on the display
of the vehicle diagnosis device :
Vehicle self-diagnosis
Self-diagnosis ►
01 - Engine electronics ►
011 - Measured values ►

– Select the measured value blockpermitted and
2 4 7unless confirm
authorised withS.A.
by SEAT .
Q SEAT S.A does not guarantee or accept any liability with
The actual fuel pressure value is shown in display zone 2, meas‐
ured by the fuel pressure sender - G247- .
– Start the engine.
– The value displayed on the pressure tester - VAS 6394/1- is
compared with the pressure displayed on the vehicle diagno‐
sis device .
• The pressure difference should not be more than 5 bar.
– When the difference is more then 5 bar, the fuel pressure
sender - G247- must be replaced.
WARNING

prox. 6 bar).
– Repeat the check with the new fuel pressure sender - G247-
and compare both measurement values.
If the values still do not correspond:
– Checking the wiring ⇒ Vehicle diagnostic tester.
1.12 Removing and installing high-pressure

pump

Toledo 2013 ➤
Removing
– Always follow safety precautions ⇒ page 129 .
WARNING

prox. 6 bar).
– Separate the fuel supply hose -arrow-.


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– Disconnect the plug connection -1- and the fuel supply line
-2- from the high-pressure pump.
Note
Catch the fuel coming out with a rag.
– Remove the line guide -2-.
Note
Use a spanner to counterhold threaded connections

Protected on high
by copyright. Copying pres‐or commercial purposes, in part or in whole, is not
for private
sure pump and on lower part of intake manifold
permitted when
unless authorised loosening
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
union nuts. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Loosen union nuts -1- and -3- of high-pressure line.
– Unscrew bolts -1- evenly.
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.

Toledo 2013 ➤
– Pull high-pressure pump -3- and roller tappet -1- out of cam‐
shaft housing.
Installation
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.
Note
♦ Moisten the roller tappet of the high pressure pump with clean
engine oil.
♦ The O-ring of the high-pressure pump must be renewed.
– Slide roller tappet -1- into camshaft housing.
– Place a new oiled O-ring -3- in the groove of the high-pressure

pump -2-.
– Fit the high pressure pump -3-authorised
on the by camshaft casing.
permitted unless SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Screw in the securing screws -1- by hand until the heads of

the screws rest upon the flange.
– Tighten the securing screws -1- equally until the flange rests
against she camshaft housing.

Toledo 2013 ➤
– Hand tighten the connection nuts of the high pressure line

-1- and -3-.
– Fix the line guide and tighten the screws -2- to a tightening
torque of 8 Nm.
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on lower part of intake manifold when tight‐
ening union nuts.
– Tighten the connection bolts -1- and -3- on the high pressure
line to a torque of 18 Nm.
– Fasten the fuel supply pipe -2- and the connector -1- on the
high-pressure pump.
– Connect the fuel supply hose -arrow-.
1.13 Removing and installing injectors

Note safety precautions before starting installation work

⇒ page 225 .

Toledo 2013 ➤
Note
Every time the injector is dismounted, the Teflon oil seal on the
injector must be replaced ⇒ page 222 .

♦ Torque wrench - V.A.G 1331-
♦ Tool set - T10133-
Removing
– Remove intake manifold ⇒ page 210 .
– Remove intake manifold lower section ⇒ page 203 .
– Press the O-ring upwards by hand as shown and remove from
the injector.
– Screw slide hammer - T10133/3- to puller - T10133/15- .

Toledo 2013 ➤
– Then insert puller - T10133/15- into groove -arrow- on injector.
– Remove the injector by carefully tapping.

Installation
– Thoroughly clean injector holes in cylinder head using nylon

brush - T10133/4- .
– Check whether the plastic support washer is damaged and
replace if necessary ⇒ page 222 .

Toledo 2013 ➤
– The spring element -arrow- and the Teflon seal must be re‐
newed every time the injectors are dismounted ⇒ page 222 .
– Renew O-rings between injector and lower part of intake mani‐
fold and moisten slightly with clean engine oil.
Note
The Teflon seal on the injector must not be oiled or greased.
– Fit the injector by hand as far as possible in the opening in the

cylinder head.
Note
The injector should enter smoothly. Where necessary, wait until

the seal has contracted sufficiently.
– Ensure for the correct installation position of the injectors in

the cylinder head.
– Fit the lower part of the intake manifold carefully onto the in‐
jectors and tighten the fastening bolts to 20 Nm ⇒ page 202 .
1.14 Replace the Teflon seal and support

washer on the injection valve
♦ Tool set - T10133-
Work sequence
Renew Teflon seal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove intake manifold ⇒the
respect to page 210 of. information in this document. Copyright by SEAT S.A.
correctness
– Remove intake manifold lower section ⇒ page 203 .

– Remove injectors ⇒ page 219 .
– Clean the injector thoroughly.
– Using a knife, carefully cut the seal as shown in fig. -arrow-.
Always avoid contact between the blade and the body of the
valve.

Toledo 2013 ➤
– 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 assembly sleeve - T10133/6- around (knurling no longer

points to seal) and push seal -1- to end of assembly cone -
T10133/5- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Now place the assembly cone -respect
T10133/5- with the
to the correctness 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- .
– Insert the seal by hand until it enters on the seal throat.
– Position spacer sleeve - T10133/11- onto valve body.
– Now push calibration sleeve - T10133/7- over seal to stop onto
spacer sleeve - T10133/11- .

Toledo 2013 ➤
– Pull off calibration sleeve - T10133/7- again.

– Now push calibration sleeve - T10133/8- over seal to stop onto
spacer sleeve - T10133/11- .
– Pull off calibration sleeve - T10133/8- again.
The Teflon seal now has the correct assembly measurement.

Replace the support washer
– 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.
– Slide support washer -1- into first groove -arrow- on injector
using calibration sleeve - T10133/17- (knurled side points to
injector).

Toledo 2013 ➤
– Now turn calibration sleeve - T10133/17- 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- .
– Pull calibration sleeve - T10133/17- down again.
The support washer now has the correct assembly measurement.
– Then insert a new spring element -1- at the location of the

locking washer - T10133/12- . Place a new O-ring -3- in front
of the support ring -2-.
Note
The Teflon seal must not be oiled -arrow- for the injector assem‐
bly.
– Install injectors ⇒ page 219 .

– Fit the lower part of the intake manifold carefully onto the in‐
jectors and tighten the fastening bolts to 20 Nm ⇒ page 202 .
of removal.
1.15 Safety precautions
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.
To prevent injuries to persons and/or serious damage to the fuel

injection and ignition system, the following must be noted:
♦ For safety reasons, fuse No. 27 must be removed from fuse
holder on left under dash panel before opening fuel system.
Otherwise fuel pump will be activated by driver door contact
switch.
♦ Do not touch or remove the ignition cables with the engine
running or idling.

Toledo 2013 ➤
♦ Switch off ignition before connecting or disconnecting injection

and ignition system wiring as well as test instrument cables.
Caution

tions:
Please note the following if test equipment has to be used during

a test drive:
♦ Test andrespect
measuring instruments
to the correctness must
of information in thisalways
document. be secured
Copyright toS.A.
by SEAT
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 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 4-pin connectors from the ignition coils -arrows-.
– Fit the extractor - T10094 A- on the ignition coils with output

stage -arrow- as in the illustration ⇒ page 240 .
– Lightly extract the ignition coils with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully open the connector lock and remove the connector.
– To fit the ignition coil with output stage, push the connector
until it snaps into place.

Toledo 2013 ➤
– Fit puller - T10094 A- as shown ⇒ page 240 .

– Insert the ignition coil with output stage in the cylinder head in
the -direction of the arrow-.
1.16 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. Use lint-free cloths.
♦ 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.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
1.17 Technical data

Idling speed check
Idling speed 7) RPM 600 … 800
Engine control unit - J623-
System Motronic MED 17
Speed limitation: RPM From approx. 5600-6000
7) Not adjustable

Toledo 2013 ➤
2 Engine control unit - J623-

⇒ “2.1 Removing and installing engine control unit J623 ”,
page 228
⇒ “2.2 Removing and installing anti-theft engine control unit J623
”, page 229
2.1 Removing and installing engine control

unit - J623-
When replacing the engine control unit
To replace the engine control unit, connect the vehicle diagnostic
tester and complete the guided function “Engine control unit: re‐
place”.
Removing
– Unlock the engine control unit connectors and pull them off .
– Press clips -arrows A- outwards and pull engine control unit

out to side -B-.
Installation
– Insert new engine control unit and press to the left.
– Fit connectors and lock in position.
– When replacing the engine control unit - J623- , the learn value
must be deleted and the engine control unit must be adapted
⇒ Vehicle diagnostic tester “Guided function”
– Read fault memory, repair faults if necessary and then clear
fault memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
– If the fault memory has been erased, you must
permitted generate
unless authorised theS.A. SEAT S.A does not guarantee or accept any liability with
by SEAT
readiness code again. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Install air cleaner housing ⇒ page 205 .

– Carry out a road test.
– Read control unit fault memory again.

Toledo 2013 ➤
2.2 Removing and installing anti-theft en‐

gine control unit - J623-
2.2.1 Engine control unit with antitheft protec‐

tion: removing and fitting
To replace the engine control unit, connect the vehicle diagnostic
tester and complete the guided function “Engine control unit: re‐
place”.
♦ Pneumatic sabre saw - VAG 1523B-
♦ Hot air blower, 220V/ 50 Hz - VAS 1978/14A- -1- (of the wiring
harness repair set - VAS 1978B- )
Removing
– Open the line guide -1- and lift the locking catch -2-.
– Remove the engine control unit from the bracket.
2. Engine control unit J623 229

Toledo 2013 ➤
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 on the hot air blower -4- as described
below:
– 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
respect gun. This
to the correctness reduces
the strength of the threadlocker on the thread of the breakaway
bolts to make them easier to remove.

Toledo 2013 ➤
– 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.

– Separate the protective casing from the engine control unit.
– Disconnect and separate the control unit connectors and re‐

move the engine control unit.
Installation permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
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 205 .
– Adjust the new engine control unit.
– Read fault memory, repair faults if necessary and then clear
fault memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
– If the fault memory has been erased, you must generate the
readiness code again.
– Take vehicle for a test drive.
– Read control unit fault memory again.
2. Engine control unit J623 231

Toledo 2013 ➤
26 – Exhaust system
1 Removing and installing parts of ex‐
haust 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 the double clamp and align the
silencer and the exhaust pipe so that there is always a suffi‐
cient distance to the bodywork and is evenly distributed over
the suspension elements.
♦ Always replace self-locking nuts.
⇒ “1.1 Catalytic converter and attaching parts - Assembly over‐

view”, page 232
⇒ “1.2 Silencers with suspension elements - Components over‐
view”, page 235
⇒ “1.3 Separating centre and rear silencers”, page 235
⇒ “1.4 Installation position and tightening torque of the clamping
sleeve”, page 237
1.1 Catalytic converter and attaching parts - Assembly overview
232 Rep. gr.26 - Exhaust system

Toledo 2013 ➤
1 - 10 Nm
❑ When assembling, first
tighten the fastening
bolts by hand
2 - Lambda probe after catalyt‐
ic converter - G130-
❑ Tightening torque: 50
Nm
❑ Only grease thread with
“G 052 112 A3”. The “G
052 112 A3” must not
reach the probe body
grooves
❑ In case of leakage, cut
out and replace sealing
ring
3 - Seal
❑ replace
4 - Exhaust pipe
5 - Double clamp, 25 Nm
❑ Mounting position and
specified torque
⇒ page 237
❑ For separate replace‐
ment of centre and rear
silencers
❑ Tighten bolted connec‐
tions evenly.
6 - 25 Nm
❑ replace
7 - Hanger
8 - 25 Nm
9 - 25 Nm
❑ replace
10 - Exhaust pipe
❑ With vibration damper
❑ Do not bend decoupling element more than 10°. It may be damaged
❑ Removing and installing compressor housing and turbine housing ⇒ page 177 .
Note

12 - Support plate respect to the correctness of information in this document. Copyright by SEAT S.A.
13 - Heat shield
14 - 25 Nm
❑ replace
1. Removing and installing parts of exhaust system 233

Toledo 2013 ➤
Note

❑ Lubricate studs of exhaust manifold with high-temperature lubricant.
15 - 25 Nm
❑ replace
Note
Use the clips for the installation

⇒ page 234 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
16 - Catalytic converter with exhaust pipe
Note
Use the clips for the installation.

❑ Install catalytic converter ⇒ page 234 .
17 - 23 Nm
❑ replace
18 - Lambda probe - G39- , 50 Nm
❑ Only grease thread with “G 052 112 A3”. The “G 052 112 A3” must not reach the probe body grooves
❑ Remove and install using the ring wrench set for lambda probes - 3337-
Install catalytic converter

– Push the clips onto the bracket in direction of -arrow-.
The lips of the clips face downwards.
– Tighten the new securing bolts to 25 Nm.

Toledo 2013 ➤
1.2 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
❑ Stress-free alignment of
exhaust system
❑ Separating centre and
rear silencers
⇒ page 235
2 - Bracket with mounting
3 - 25 Nm
4 - Secondary silencer
❑ Factory Silencer execu‐
ted with
Protected center
by copyright. as afor private or commercial purposes, in part or in whole, is not
Copying
component.
permitted Inbycase
unless authorised of SEAT S.A does not guarantee or accept any liability with
SEAT S.A.
repair individually
respect to the correctness re‐
placeable
❑ Stress-free alignment of
exhaust system
❑ Separating centre and
rear silencers
⇒ page 235
5 - Hanger
1.3 Separating centre and rear silencers

♦ In order to replace the centre and rear silencers separately,
the connecting pipe can be cut at the marked point.
♦ The cutting point is marked on the exhaust tube.
♦ Chain pipe cutter - VAS 6254-

Toledo 2013 ➤
♦ Pneumatic sabre saw - VAG 1523B-
Work sequence
– Cut the exhaust pipe -arrow 2- with the chain pipe cutter - VAS
6254- or the bodywork saw - VAG 1523B- .
– During assembly, the double clamp -4- must be aligned at the
side markings -arrow - -1- and -arrow 3-.
– Install the double clamp so that the bolt end does not project
over the double clamp lower edge -arrow-.
• Screw thread must face rear
– Install and adjust without strain, the secondary silencer
⇒ page 236 .
Tightening torques
Component Nm
Double pipe bracket 25
Aligning rear silencer

– Align rear silencer so that dimensions -a- are identical.

Toledo 2013 ➤
1.4 Installation position and tightening tor‐

que of the clamping sleeve
Note
Gradual introduction of clamp with continuous clip.
Tightening torque and installation position of the clamping sleeve.

Clamp -A- with 2 individual clips.
Length 95 mm
Installation dimensions -a- 5 mm (only for front clamp)
Clamp -B- with continuous clip.
Length 88 mm
Installation dimensions
permitted -a- 8.5
unless mm (only
authorised by SEATfor
S.A.front clamp)
SEAT S.A does not guarantee or accept any liability with
Installation dimension -a- for vehicles with marking -A- on front

exhaust pipe
1 - Attachment bush
2 - Pre-exhaust pipe
3 - Securing nut
4 - Securing nut
a - Installation dimension
A - Brand
Installation position of front clamp

– Install the clamp so that end of bolt -arrow- does not extend
beyond lower edge of clamp.
• Threaded connection faces right.

Toledo 2013 ➤
Installation position of rear clamp

– Install the clamp so that end of bolt -arrow- does not extend
beyond lower edge of clamp.
• Screw thread must face rear

Toledo 2013 ➤
28 – Ignition system
1 Repairing ignition system
General notes on the ignition system
♦ The engine control unit - J623- is equipped with self-diagnosis.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain tests may lead to a fault being detected and stored by
the engine control unit - J623- . Therefore, after completing all
checks and repairs, the fault memory must be read and if nec‐
essary cleared.
⇒ “1.1 Ignition system - exploded view”, page 239
⇒ “1.2 Removing and installing ignition coils with output stages”,
page 240
⇒ “1.3 Safety precautions”, page 241
⇒ “1.4 Spark plug test data”, page 242
1.1 Ignition system - exploded view
❑ 4-pin, black
❑ Loosen with the assem‐
bly tool - T10118-
2 - Ignition coil 3 with output
stage - N291-
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N292-
⇒ page 240 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Electrical connector respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ 2-pin, black
❑ For knock sensor 1 -
G61- .
❑ connectors with gold
plated contacts
4 - Knock sensor 1 - G61-
❑ connectors with gold
plated contacts
5 - 20 Nm
❑ Tightening torque influ‐
ences functions of
knock sensor
❑ 3-pin, black
❑ for Hall sender - G40-
1. Repairing ignition system 239

Toledo 2013 ➤
7 - Hall sender - G40-

8 - O-ring
9 - 10 Nm
10 - Spark plug, 25 Nm
❑ Remove and install with the spark plug spanner - 3122 B-
❑ Type and electrode spacing ⇒ page 242
11 - Wiring guide
❑ Bolt to camshaft housing with 5 Nm torque.
12 - Negative wire
❑ Loosen or tighten only if the ignition is turned off
13 - 10 Nm
❑ Loosen or tighten only if the ignition is turned off
1.2 Removing and installing ignition coils

with output stages
Note
The ignitions coils with output stages were changed. As a result,

these ignition coils can only be installed or removed using puller
- T10094 A- . The previous puller - T10094- can continue to be
used if modified as described below.
240 Rep. gr.28 - Ignition system

Toledo 2013 ➤
– Reduce marked area -2- with suitable means from the work‐
shop to the new nominal dimension -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
Protected open
by copyright. the
Copying connector
for private lockpurposes,
or commercial and remove the
in part or in connector.
whole, is not
Installation
– 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-.
1.3 Safety precautions

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.
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 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:
1. Repairing ignition system 241

Toledo 2013 ➤
– Remove the 4-pin connectors from the ignition coils with out‐
put stage -arrows- ⇒ page 240 .
– Remove the fuse for the fuel pump control unit - J538- from
the fuse holder. Fuse allocation ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
1.4 Spark plug test data

Order of starting 1-3-4-2
Spark plugs
Part number 8) 101 905 626
Electrode gap 0.8 ... 0.9 mm
Tightening torque 25 Nm
Change interval ⇒ Maintenance ; Booklet KG1 ; Additional work
according to time or mileage
8) Current spark plugs ⇒ Electronic parts catalogue (ETKA)
242 Rep. gr.28 - Ignition system

D3E804E4966-4 Cyl Petrol Engine (1 4 L Direct Injection 4V Turbocharger)

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Service

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Copyright © 2015 Seat S.A D3E804E4966

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Engine: assembly and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.2 Checking camshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1.1 Engine number

Engine code and engine number can be found on the sticker

Position of the vehicle data sheet ⇒ Maintenance ; Booklet KG1 ;

1.2 Engine characteristics

Engine identification characters CAXA

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Engine: dismounting

The engine is removed from underneath together with the gear‐

Special tools and workshop

1. Removing and positioning the engine 3

♦ Pliers - VAS 6340-

Before carrying out further work, disconnect battery earth strap.

4 Rep. gr.10 - Removing and installing engine

– Undo the fixing screws -1- from engine cover panel.

The fuel feed line is pressurized! Wear eye protection and

– Release the coolant hoses on the heat exchanger -arrow- and

1. Removing and positioning the engine 5

– Release the coolant hoses -arrow- on the gearbox ends and

– Remove the Lambda probe - G39- -1-.

– Unscrew the securing bolts on the exhaust gas turbocharger

– Unscrew the securing bolts -arrows- of the splash guard cover

6 Rep. gr.10 - Removing and installing engine

– Unplug the connector -2- from the coolant circulation - V50- .

– Remove bracket for coolant circulation pump - V50- from

– Disconnect the connector -1- of the oil level and temperature

1. Removing and positioning the engine 7

– Unclip lines -1- at catalytic converter.

Risk of damage to the vibration damper section!

– Unscrew the exhaust pipe with the decoupling element

– Unscrew the securing bolts of the double clamp -arrows- and

8 Rep. gr.10 - Removing and installing engine

All vehicles (continued)

Bolt -1- must not be loosened.

– Open cable guide fasteners -arrows-.

– Unscrew earth connection -1-.

1. Removing and positioning the engine 9

– Unscrew securing bolts -arrows- on gearbox mounting by ap‐

Do not depress the clutch pedal.

Vehicles with automatic gearbox

Vehicles with air conditioner

Danger of damage to refrigerant lines and hoses.

– Secure AC compressor to lock carrier.

Do not open the air conditioning pipes.

All vehicles (continued)

10 Rep. gr.10 - Removing and installing engine

– Tighten the adapters - T40075/4- until they make contact with

– Secure engine support - T40075A- hand-tight to crankcase

– Tighten bolts attached to engine support - T40075A- to 20 Nm.

To loosen the mounting bolts, use the stepladder - VAS 5085- .