MANUAL

Service
Workshop Manual
Arosa 1997 ➤
001 Automatic gearbox
Edition 10.02
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, Housing
38 - Gears, Hydraulic controls
39 - Final drive, Differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Seat S.A S01B0018620

Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 ...................................................................... 1
2 ...................................................................... 2
3 Code letters, group numbers, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 ...................................................................... 6
5 General instructions for gearbox repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Identifying the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Torque converter: empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Torque converter seal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Torque converter: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
37 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Connect fault reader V.A.G 5051 and select the functions . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Electrical/electronic components and their location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Vehicle components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Gearbox electrical/electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Gear drive mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Gear drive mechanism: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 Selector lever cable: check and adjust (vehicles up to 06.00) . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Selector lever cable: check and adjust (vehicles from 07.00 onwards) . . . . . . . . . . . . . . . . 25
3.4 Gear drive mechanism: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . 26
3.5 Selector lever: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . . . . . . . 29
3.6 Selector lever: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . . . . . . . 32
3.7 Selector lever cable: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . . . 33
3.8 Gear drive mechanism: dismantling and fitting (vehicles from 07.00 onwards) . . . . . . . . . . 36
3.9 Selector lever cable: removing and fitting (vehicles from 07.00 onwards) . . . . . . . . . . . . . . 38
3.10 Gear selector knob: removing and fitting (vehicles from 07.00 onwards) . . . . . . . . . . . . . . 41
4 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 ATF level: checking and filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1 ATF level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2 Replace ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3 Changing the ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Gearbox with control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 Control elements position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Gearbox: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 ATF radiator and ATF filling tube: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.2 Planet gears: generalpermitted
assembly diagram
unless authorised . . .S.A.
by SEAT . . SEAT
. . . S.A
. . does
. . . not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
. . . .with
....... 60
7.3 I - ATF pump up to the large planet gear: general assembly diagram . . . . . . . . . . . . . . . .
62
7.4 II - Cover for the gearbox casing up to the drive sprocket: general assembly diagram . . . . 63
7.5 Planet gears: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 General overview for the all adjustments to the planet gear . . . . . . . . . . . . . . . . . . . . . . . . 86
7.7 Reverse gear brake -B1- adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8 2nd and 4th gear brake -B2-: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9 Clutch clearance: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
38 - Gears, Hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1 ATF pump: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Contents i
Arosa 1997 ➤
2 Free sprocket: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

3 Clutch for 1st to 3rd gears -K1-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . 98
4 Reverse gear clutch -K2-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5 Clutch 3rd and 4th gear -K3-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . 104
6 Reverse gear brake -B1-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7 2nd and 4th gear brake piston -B2- dismantling and assembling . . . . . . . . . . . . . . . . . . . . 109
8 Slide box: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.1 Slide box (vehicles up to 06.00): removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.2 Slide box (vehicles from 07.00): removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9 Parking lock: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
39 - Final drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1 Articulation flange seals: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Articulation flange seals: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2 Final drive: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.1 Final drive: general assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.2 Differential: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.3 Engine shaft: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3 Differential: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4 Final drive: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.1 Final drive: Overview of check steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.2 Adjustments to be carried out when changing components . . . . . . . . . . . . . . . . . . . . . . . . 139
4.3 Differential: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.4 Engine shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
ii Contents
Arosa 1997 ➤
00 – Technical data
1 Identifying the gearbox
Location on the gearbox
The 001 4-speed automatic gearbox is fitted to the Arosa 1997 ▸,
combined with the 4 cylinder engine. Correspondence
⇒ page 3 , code letters, group numbers, ratios, equipment
Code letters and dates of manufacture of gearbox -arrow-
Example
ESK 10 05 0
I I I I
Codes Day Month Year of manufacture
2000
Any additional data refer to the manufacturing process.
Note!
The additional gearbox code letters are also on the customer ve‐
hicle service schedule.
1. 1
Arosa 1997 ➤
2 Notes on “Automatic gearbox 001”

Gear change
The 001 automatic 4-speed gearbox is fitted with four hydrauli‐
cally controlled gears. 3rd and 4th gear are controlled mechani‐
cally when the clutch cancellation of the torque converter is
closed, thus avoiding torque converter slipping.
Control unit -J217-
The control device has two programmes for two different driving
styles; sports (“SPORT” programme) and economic (“ECO” pro‐
gramme).
These two programmes are automatically connected by the con‐
trol device.
The automatic gearbox control unit -J217- receives information
from the components which influence the gear change. This is
transmitted to the slide box with the solenoid valves which in turn
activate the final control elements via hydraulic connections.
So that the cause of an electrical/electronic component failure or
a short circuit can be quickly discovered, the control unit is fitted
with a fault memory. Faults are recognised via electrical signals
and are memorised in the fault memory.
Torque converter
The torque converter is fitted with a cancelling clutch. The can‐
celling clutch closes according to load and speed, engaging 3rd
and 4th gears mechanically and with no slipping.
ATF
The ATF in the gearbox does not need to be changed. It does not
need to be changed during routine maintenance.
If it is necessary to top up, only use ATF fluid ref. no.:
G 052 990 A2
The ATF level in the planet gears and drive shaft is checked and
filled together ⇒ page 53 , ATF level: checking and filling.
2 Rep. Gr. 00 - Technical data

Arosa 1997 ➤
3 Code letters, group numbers, ratios, equipment

Automatic gearbox 001
Gear change Codes CMJ DPP
Torque converter Codes AAN AAN
Slide box Codes IIJ/BAH IIJ/BAH
Number of discs Inner Outer Inner Outer
-K1- clutch 5 5 5 5
-K2- clutch 2 2 2 2
-K3- clutch 3 3 3 5
Brake -B1- 5 4 5 4
Brake -B2- (band brake)
Piston ∅ mm
2nd gear (stepped piston) 50 + 31 50 + 31
4th gear 44 44
Allocation Model Arosa 1997 ▸ Arosa 1997 ▸
Engine 1.4 l 44 kW 1.4 l 44 kW
Gear change Codes CMJ DPP

Ratio 1st gear 2.875 2.875
2nd gear 1.510 1.510
3rd gear 1.000 1.000
4th gear 0.726 0.726
Reverse 2.656 2.656
Intermediate shaft Number of teeth Drive sprocket 49 49
Driven 53 53
sprocket
Ratio 1.082 1.082
Final drive Number of teeth Pinion wheel 20 20
Crown 81 81
Ratio
4.05 4.05
∅ Drive
permitted shaft
unless flange
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with 90 mm Tripod
CAN-Bus No No
Type of accelerator Mechanical Mechanical

Gear change Codes EAS EHD
Torque converter Codes AAN AAN
Slide box Codes CCC CCC
Number of discs Inner Outer Inner Outer
-K1- clutch 5 5 5 5
-K2- clutch 2 2 2 2
-K3- clutch 3 5 3 5
Brake -B1- 5 4 5 4
Piston ∅ mm
3. Code letters, group numbers, ratios, equipment 3

Arosa 1997 ➤

2nd gear (stepped piston) 50 + 31 50 + 31
4th gear 44 44
Allocation Model Arosa 1997 ▸ Arosa 2001 ▸
Engine 1.4 l 44 kW 1.4 l 44 kW

Ratio 1st gear 2.875 2.875
2nd gear 1.510 1.510
3rd gear 1.000 1.000
4th gear 0.726 0.726
Reverse 2.656 2.656
Intermediate shaft Number of teeth Drive sprocket 49 49
Driven 53 53
sprocket
Ratio 1.082 1.082
Final drive Number of teeth Pinion wheel 20 20
Crown 81 81
Ratio 4.05 4.05
∅ Drive shaft flange 90 mm 90 mm
CAN-Bus Yes Yes
Type of accelerator Electronic Electronic
Automatic gearbox permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with 001
Gear change Codes FMA
Torque converter Codes AAN
Slide box Codes CCC
Number of discs Inner Outer
-K1- clutch 5 5
-K2- clutch 2 2
-K3- clutch 3 5
Brake -B1- 5 4
Piston ∅ mm
2nd gear (stepped piston) 50 + 31
4th gear 44
Allocation Model Arosa 2001 ▸
Engine 1.4 l 44 kW

Ratio 1st gear 2.875
2nd gear 1.510
3rd gear 1.000
4th gear 0.726

Arosa 1997 ➤

Reverse 2.656
Intermediate shaft Number of teeth Drive sprocket 49
Driven sprocket 53
Ratio 1.082
Final drive Number of teeth Pinion wheel 20
Crown 81
Ratio 4.05
∅ Drive shaft flange 90 mm
CAN-Bus Yes
Type of accelerator Electronic
3. Code letters, group numbers, ratios, equipment 5

Arosa 1997 ➤
4 Filling amount
Planet gears and final drive
Filling amounts Automatic gearbox 001
First load 5.7 l
(Permanent filling)
Lubricant ATF
Spare no.:
G 052 990 A2
The planet gears and drive shaft must be checked and filled to‐
gether as described ⇒ page 53 , ATF level: checking and filling.

Arosa 1997 ➤
5 General instructions for gearbox re‐

pairs
To achieve a perfect and successful repair of the gearbox, it is
imperative to keep everything scrupulously clean and use the
correct tools in perfect working order. When carrying out repairs,
bear in mind basic safety rules.
Here is a summary of general instructions for certain repair jobs,
which would otherwise appear several times in the different sec‐
tions of this Workshop Manual. Thus, these instructions must be
taken into account for this Workshop Manual.
Gear change
♦ Before fitting the gearbox to the engine, make sure that the
dowel pegs between both elements are in good condition and
correctly seated
♦ Clean contact surfaces on fitting blocks, supports or waxed
components. The surfaces must be completely free from wax
or grease
♦ If the automatic gearbox has been replaced, check and top up
with ATF if necessary. Filling amounts and oil type specifica‐
tions ⇒ page 6
Oil seals
♦ Before fitting the radial oil seals, fill the space between the
sealing lips with grease
♦ Replace O-rings
♦ After fitting, check the ATF fluid level and top up if necessary
Sealing paste
♦ Clean contact surfaces thoroughly and apply -D 176 404 A2-
sealing paste
♦ Note the use-by date of the sealant.
♦ After applying the sealing paste, bolt up the components within
5 minutes
♦ After assembly, the sealant should be dry in approx. 30 mi‐
nutes Then fill with ATF
Safety locks
5. General instructions for gearbox repairs 7

Arosa 1997 ➤
♦ Renew all safety rings, taking care not to stretch them exces‐
sively when fitting
♦ The safety rings must be perfectly seated in their groove
♦ Renew all split pins
♦ On fitting split pins, the expansion groove should be facing the
direction of power transmission, as seen in the illustration
Bolts, nuts
♦ Always loosen and tighten nuts and bolts on covers and casing
in diagonal sequence
♦ For delicate parts, e.g. the slide box , always loosen and tight‐
en the bolts in stages and in diagonal sequence
♦ Tightening torques are specified for nuts and bolts without lu‐
brication
♦ Always replace any self-locking nuts and bolts
♦ Bolts with torque and stretch specifications must always be
renewed
♦ If the bolt threads have remains of locking paste, clean with a
wire brush. Then insert the bolts with -AMV 185 100 A1-
♦ The bolts and nuts of all threaded joints will be waxed when
fitted (if necessary)
Bearings
♦ Partially lubricate all gearbox bearings with ATF fluid before
fitting
♦ Fit new roller bearings as supplied, without lubrication, espe‐
cially the conical bearings
♦ Place the axial needle bearings in their correct position
⇒ page 65
♦ Bearings corresponding to the same shaft will be all replaced
together, especially conical bearings. If possible, use parts
from the same manufacturer
♦ Do not mix up the inner and outer rings of the same size bear‐
ings. The bearings come in matched pairs
♦ Heat the inner roller bearing ring to 100°C before press fitting
Removal of outer rings of roller bearings and bearing bushes with
tool set -T20140-
Remove the outer rings of the roller bearings
Protectedorbythe bearing
copyright. bush‐
Copying for private or commercial purposes, in part or in whole, is not
es as follows: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Measure (if possible) the internal diameter of the external ring
of the roller bearing or the bearing bush.
– Select the correct clamp from the tool set according to:
If the diameter measured is less than 30 mm:
– Fit the plunger for small clamps/10 and the correct clamp for
internal diameters.
If the diameter measured is more than 30 mm:
– Fit the plunger/28 and clamp /29 and the correct claws for the
internal diameter.
– Screw nut /5 and washer on the plunger.

Arosa 1997 ➤
– Place the tool on the outer ring of the roller bearing or the
bearing bush and fit the threaded legs so that they are firmly
secured.
Note!
The legs of bridge /1 have different-sized cut-outs -arrows- to fa‐

cilitate support on surfaces with different heights, edges or ribs.
– Adjust the threaded legs of the bridge /1 so that the bridge is

parallel to the surface of the casing.
– Open the clamps until the bar is housed below the exterior
roller bearing or the bearing bush.
– Action the extractor until the outer ring of the roller bearing or
bearing bush is extracted.
Note!
Due to the fact that on some occasions the space for the claw is
minimal, a first extraction should be carried out to remove the
bush, and then open the claws as far as possible to ensure the
maximum contact surface. Then continueProtected
with the extraction.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
Piston rings
♦ Do not open excessively when removing or fitting
Shims
♦ Before fitting shims, check thickness measuring several points
of the surface with a micrometer
♦ The existence of different thicknesses allows the exact cali‐
bration of the thickness of the shim needed
♦ Check they have no lips and that they are not damaged. Only
fit shims in perfect state
Clutches and brakes
♦ Clutches K1, K2 and K3 should be dismantled for cleaning;

assign the faulty components (e.g. outer and inner discs) ac‐
cording to the gearbox code.
♦ Before fitting the piston, coat the sealing lips and oil seals with
ATF
♦ After fitting the clutches or brakes, it should be possible to turn
the piston in both directions by hand -arrow- . If this is not the
case, perhaps the sealing lips or oil seals are incorrectly fitted
or damaged.
– If this is the case, remove the piston again.
– Check for damage in the sealing lips or oil seals and replace
if necessary.
– Refit the piston and check again.
Slide box
♦ If any control elements are burnt, the slide box should be re‐
placed
Inner discs

Arosa 1997 ➤
♦ Fit the new inner discs, before fitting soak in ATF for 15 mi‐
nutes.
Self-diagnosis
♦ Before carrying out repairs in the automatic gearbox, the pos‐
sible cause of the problem should be determined with preci‐
sion: ⇒ VAS 5051; Vehicle self-diagnosis

Arosa 1997 ➤
32 – Torque converter
1 Torque converter
1.1 Identifying the torque converter

There are various torque converters. They can be differentiated
by the code -arrow- .
Numbers allocated to torque converter/gearbox ⇒ page 3 , Code
letters, group numbers, ratios, equipment.
Torque converter code

(assembled gearbox)
– Remove the protection plate -arrow- .
1.2 Torque converter: empty

Special tools and workshop equipment required
♦ Oil extractor -SAT 1100-
1. Torque converter 11
Arosa 1997 ➤
If dirt and abrasive particles are present in the ATF or if a general

revision is made of the gearbox, the converter should be emptied.
– The converter oil can also be syphoned off with the -SAT 1100-
unit.
1.3 Torque converter seal: removing and in‐

stalling
♦ Extractor -T20143-
♦ Plunger -U-40002-
– Using extractor -T20143- , disengage the torque converter

housing bracket from the torque converter.
12 Rep. Gr. 32 - Torque converter

Arosa 1997 ➤
– Using plunger -U-40002- , assemble the torque converter

housing bracket onto the torque converter.
1.4 Torque converter: removing and instal‐

ling
♦ Holding tool -T20157-
1.4.1 Removing
– Place tool -T20157- onto one of the torque converter bolts and
fit it with its corresponding nut.
– Tilt the gear approx. 60°, and remove the torque converter,
while preventing the ATF from falling out.
1.4.2 Fitting
Only use ATF with part number -G 052 990 A2- .
– Fill the converter with 1.5 litres of ATF.
– Fit the torque converter.
1. Torque converter 13
Arosa 1997 ➤
The ATF pump is activated via the torque converter -arrows- .
– Tilt the gear approx. 60°, in such a manner that when the con‐
verter is inserted, the ATF does not fall out.
– Place the torque converter in the housing, taking into account
its position with
Protected respectCopying
by copyright. to the ATF orpump
for private sprocket.
commercial purposes, in part or in whole, is not
– Turn the gear intosuch
respect a wayofthat
the correctness the converter
information remains
in this document. level.
Copyright by SEAT S.A.
– Fit the converter into the cutouts of the ATF pump sprocket.
The converter has been correctly fitted when the measurement

between the joining flange and the contact surface of the conver‐
ter's guide stem is 18 mm.
14 Rep. Gr. 32 - Torque converter

Arosa 1997 ➤
37 – Controls, Housing
1 Connect fault reader -V.A.G 5051-
and select the functions
All functions which could previously be performed with -
V.A.G 1551/1552- can also be performed with the new tester -
VAS 5051- in the operating mode “vehicle self-diagnosis” : ⇒
Instruction manual for Vehicle Diagnosis, Testing and Information
System VAS 5051.
♦ -VAS 5051- diagnosis operations central
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
Caution
♦ During the test drive, testing and measuring instruments

must always be installed in the rear seat
♦ While the vehicle is in motion, this equipment should only
be operated by a person other than the driver
Checking conditions
• Selector lever in position “P” and hand brake on
• Battery voltage must be at least 11.5 V
• All fuses correct, according to current flow diagrams
• All fuses in the battery box, correct
• Check earth connections for gearbox:
– Check the earth connections for corrosion and loose contacts
and, if necessary, repair them.
– The earth connection fixing point is situated under the battery.
– Check the battery earth strap and earth strap between the
bodywork and the starter motor.
1. Connect fault reader V.A.G 5051 and select the functions 15

Arosa 1997 ➤
Connecting -VAS 5051-

– With the ignition switched off, fit the connector from diagnosis
cable -VAS 5051/1- or -VAS 5051/3- to the diagnosis connec‐
tion. Connectors for the diagnosis connection
⇒ Item 9 (page 18) .
Select operating mode
– Press button on display for “Vehicle self-diagnosis” .
Select vehicle system
– Press the button on the screen of the system that is to be
checked.
The control unit code and identification appear on the screen.
Select diagnostic function
All diagnosis functions available are indicated on the display.
– Press button on display for desired function.
Note! permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
The display zones in the functions “04 - Basic setting” or “08 -

Read measured value block” , will be listed from top to bottom.
– Continue with the self-diagnosis of the vehicle system which

has to be checked with the descriptions of the repairs.
16 Rep. Gr. 37 - Controls, Housing

Arosa 1997 ➤
2 Electrical/electronic components and

their location
Gearbox electrical/electronic components ⇒ page 20
2.1 Vehicle components
Note!
If replacing any components labelled with * a basic adjustment should be carried out ⇒ VAS 5051, Vehicle self-
diagnosis
1 - Automatic gearbox control

unit -J217- *
❑ Location ⇒ page 18
❑ Dismantling and fitting
⇒ page 18 ,
❑ Checked by self-diag‐
nosis ⇒ VAS 5051,
Fahrzeug-Eigendiag‐
nose
2 - Engine control unit*
❑ Location: in the plenum
chamber, on the right
❑ Checking ⇒ VAS 5051,
Vehicle self-diagnosis
❑ Renew ⇒ Rep. Gr. 24 ;
Engine control unit
3 - Throttle valve control unit -
J338- *
❑ Location: in the throttle
valve
❑ With throttle valve po‐
tentiometer -G69-
❑ Removing and installing
⇒ Rep. Gr. 24 ; Injec‐
tion system: repairing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Electrical checking ⇒ respect to the correctness of information in this document. Copyright by SEAT S.A.
Rep. Gr. 24 ; Checking
components
❑ This can be checked
with the measured value
block ⇒ VAS 5051, Ve‐
hicle self-diagnosis
❑ The throttle potentiome‐
ter signal is transmitted
to the gearbox control
unit via the engine control unit
❑ If the self-diagnosis reveals a fault in the throttle valve control unit, also conduct a self-diagnosis of the
engine control unit
4 - Gearbox
❑ Gearbox electrical/electronic components ⇒ page 20
5 - Kick-down switch -F8-
❑ In vehicles up to 06.00
2. Electrical/electronic components and their location 17

Arosa 1997 ➤
❑ Dismantling and fitting ⇒ page 20

❑ In vehicles equipped with an electronic accelerator, the kick-down switch signal is generated in the ac‐
celerator pedal position senders -G79- and -G185-
❑ This can be confirmed during the electrical check ⇒ VAS 5051; Vehicle self-diagnosis
6 - Brake light switch -F-
❑ Location: in the brake pedal
❑ Removal, fitting and adjustment ⇒ Brake system; Rep. Gr. 45 ; Electrical/electronic components and
their location
❑ This can be checked with the measured value block and during the electrical check ⇒ VAS 5051, Vehicle
self-diagnosis
7 - Starter blocking relay -J207-
❑ Location: in the relay bracket plate ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
❑ The relay is coded with the number 53
8 - Magnet for selector lever locking -N110-
❑ Removing and installing:
❑ Vehicles up to 06.00 ⇒ Item 6 (page 30)
❑ Vehicles from 07.00 onwards ⇒ Item 14 (page 37)
❑ This can be checked with the measured value block and during the electrical check ⇒ VAS 5051; Vehicle
self-diagnosis
9 - Connection for diagnosis
❑ Up to 06.00 ⇒ page 19
❑ from 07.00 onwards ⇒ page 19
Removal and assembly of the automatic gearbox control unit -

J217-
Location: the gearbox control unit -arrow- is in the plenum cham‐
ber.
2.1.1 Removal
– Switch ignition off.
– Remove wiper arms and cowl panel: ⇒ Electrical system; Rep.
Gr. 92 ; Windscreen wiper system . copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected by
– Partially remove windscreen wiper

rods.
– Release the multiple connector and disengage from the con‐

trol unit.

Arosa 1997 ➤
– Remove the bolts -arrows- , and move the control unit toward
the right to remove it.
2.1.2 Installation
– Secure the control unit.
– Fit the multiple connector to pins -1- and -2- in the control unit
and then block the multiple connector -arrow- .
Note!
When fitting it, make sure that the guides -1- fit into the pins in the
control unit
– Carry out basic adjustment: ⇒ VAS 5051; Vehicle self-diag‐

nosis
Diagnosis connection in vehicles up to 06.00

Location: the diagnosis connection is located behind the tray on
the driver side, on top of the fuseholder.
Diagnosis connection in vehicles from 07.00 onwards

Location: the diagnosis connection -arrow- is located in the cen‐
tral console.
– To access the connector, remove the casing from inside the
ashtray in the central console, by levering it.

Arosa 1997 ➤
Kick-down switch -F8-

Location: the kick-down switch -arrow- is incorporated in the ac‐
celerator cable and is located in front of the bulkhead wall, in the
engine compartment.
2.1.3 Removal and installation of the kick-

down switch
– For removal and assembly of the kick-down switch, the accel‐
erator cable should be removed and fitted, and then adjusted.
Vehicles from 07.00 onwards
The kick-down switch signal is generated in the electronic accel‐
erator and is transmitted to the gearbox control unit via the data
bus.
– Remove the electronic accelerator: ⇒ Rep. Gr. 20 ; Electronic
power control (EPC) .
2.2 Gearbox electrical/electronic components

Arosa 1997 ➤
1 - Bolt
❑ 6 Nm
2 - Previous resistance -N207-
nosis ⇒ VAS 5051; Ve‐
❑ Uncouple the terminal
connector ⇒ page 23
❑ Only in vehicles up to
06.00
3 - Wiring harness
4 - Road speed sender -G68-
❑ Location, removal and
installation ⇒ page 22
5 - Bolt
❑ 6 Nm
6 - Bolt
❑ 6 Nm
7 - Gearbox rev. speed sender
-G38-
❑ With connection cable
❑ Location, removal and Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
installation ⇒ page 22
8 - Gearbox
9 - Wiring harness
❑ For solenoid valves and gearbox oil temperature sender (ATF) -G93-
❑ Location, removal and installation ⇒ page 22
10 - Multi-function switch -F125-
❑ Adjustment ⇒ page 23
❑ Checked by self-diagnosis ⇒ VAS 5051; Vehicle self-diagnosis
11 - Combi bolt
❑ 3 Nm
12 - Rod
❑ For the selector rod
13 - Nut
❑ 17 Nm

Arosa 1997 ➤
Wiring harness for solenoid valves and gearbox oil temperature

sender -G93- (ATF)
Location: the wiring harness is located in the oil sump beneath
the slide box.
2.2.1 Dismounting and installing of unless

theauthorised
wiringby SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
harness respect to the correctness of information in this document. Copyright by SEAT S.A.
The wiring harness can be replaced with the gearbox installed,

without removing the slide box.
– Drain the gearbox oil (ATF) ⇒ page 57 , Changing the ATF.
– Remove oil sump ⇒ page 66 , Planet gears: dismantling and
assembling.
– Disconnect the wiring harness connector.
– Block the terminal connector -arrows- and remove it from the
gearbox casing.
– Unlock the solenoid valve connectors by pressing the tabs
-arrow 1- and pulling them off -arrow 2- .
Install in reverse order.
The cable colours correspond to the colours on the corresponding
solenoid valves.
– Install the oil sump ⇒ page 66 , planet gears: dismantling and
assembling.
– Replace the ATF oil ⇒ page 56 , Replace ATF.
Gearbox rev. speed sender -G38- and Road speed sender -G68-
Location: the senders are located in the upper part of the gearbox.
A - -G38-
B - -G68-
Removal and installation of the senders
– Separate the sender connector.
– Remove the bolt and the sender.
Install in reverse order.
– Replace the O-ring.
– Tighten to the torque of 6 Nm.

Arosa 1997 ➤
Adjusting the multi-function switch -F125-

Prerequisites
• Adjusting selector lever cable, correct:
Vehicles up to 06.00 ⇒ page 24 .
Vehicles from 07.00 onwards ⇒ page 25 .
• Selector lever in “N”
• Loosened screws -arrows-
– Via the selection rod, guide a 4 mm bit -A- into the multifunction
switch's adjustment opening.
– In this position, tighten the multifunction switch's bolts -arrows-
to a torque of 3 Nm.
– Remove the bit.
Previous resistance -N207-

Location: the resistance is found in the upper part of the gearbox.
Only in vehicles up to 06.00
Separate the resistance connector
Uncouple the connector to measure the resistance.
– Push the tab in the direction of the arrow.

– Remove the connector from the support next to the gearbox.

Arosa 1997 ➤
3 Gear drive mechanism: repairing
Caution
Before carrying out any repairs, place the selector lever in “P”
and engage the hand brake
3.1 Gear drive mechanism: checking

Selector lever in “P” and hand brake on
• Brake pedal without depressing
The selector lever is locked and cannot be displaced from “P” .
The electromagnet for locking the selector lever locks it.
• Brake pedal depressed
The electromagnet for locking the selector lever releases the lev‐
er. A gear can be selected.
Selector lever in “N” and ignition on
• Brake pedal without depressing
The selector lever is locked and cannot be displaced from “N” .
The electromagnet for locking the selector lever locks it.
• Brake pedal depressed
The electromagnet for locking the selector lever releases the lev‐
er. A gear can be selected.
♦ In selector lever positions “1” , “2” , “3” , “D” and “R” it should
not be possible to activate the starter motor.
♦ At speeds of more than 5 km/h and changing the selector lever
to “N” , the selector lever locking electromagnet should not lock
the lever. The selector lever can select a different gear.
♦ At speeds of less than 5 km/h (almost stationary) and changing
the selector leverbyto
Protected “N” , Copying
copyright. the selector
for private lever locking
or commercial electro‐
purposes, in part or in whole, is not
magnet permitted
should lock the lever after approx. 1 second. The
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
selector lever can only be moved from “N” when the brake
pedal is depressed.
3.2 Selector lever cable: check and adjust

(vehicles up to 06.00)
Vehicles from 07.00 onwards ⇒ page 25 .
3.2.1 Checking
– Move the selector lever to “P” .

Arosa 1997 ➤
– Remove the combi bolt -arrow- securing the selector lever ca‐
ble to the gear selector rod.
– Change the selector lever position from “P” to “1” .
• The gear actioning mechanism and the selector lever cable
should move freely; if necessary, replace the selector lever
cable or repair the gearbox actioning mechanism.
Note!
The safety washer of the selector lever on the gearbox counter‐

hold should always be renewed once removed.
3.2.2 Adjustment
– Raise the vehicle.
– Loosen the combi bolt securing the selector lever cable to the
gear selector rod.
– Move the selector rod shaft to “P” . The retaining lever should
engage in the park locking gear, the two front wheel are locked
(they cannot be turned together in one direction).
– Tighten the combi bolt to of the selector shaft to 23 Nm.
In case of malfunction, repeat the adjustment and check the ad‐
justment of the multifunction switch ⇒ page 23 .
3.3 Selector lever cable: check and adjust

(vehicles from 07.00 onwards)
3.3.1 Checking
3. Gear drive mechanism: repairing 25

Arosa 1997 ➤
– Disengage the actioning cable by levering on the selector rod.

– Change the selector lever position from “P” to “1” .
Note!
The safety washer of the selector lever on the gearbox counter‐

hold should always be renewed once removed.
3.3.2 Adjustment
– Move the selector rod shaft to “P” . The retaining lever should
engage in the park locking gear, the two front wheel are locked
(they cannot be turned together in one direction).
– Open the safety tab -arrow- .
– In some cases it may be necessary to loosen the adjustment

nut -arrow- .
– Clip the selector lever cable to the selector rod shaft.
– Tighten the nut -arrow- to 13 Nm.
– Close the selector lever cable safety tab.
– Press the locking key on the knob of the selector lever and
move the lever back 5 mm. Release the selector lever.
The selector lever should return to “P” by itself.
– Place the selector lever in “N” , pulling forwards and back‐
wards 5 mm (check the same as for “P” ).
The selector lever should return to “N” by itself.
In case of malfunction, repeat the adjustment and check the ad‐
justment of the multifunction switch ⇒ page 23 .
3.4 Gear drive mechanism: dismantling and assembling (vehicles up to 06.00)
Note!
Lubricate all support points and sliding surfaces with grease ref no. -G 052 142 A2-

Arosa 1997 ➤
1 - Gear lever knob

2 - Allen head bolt
❑ 1.5 Nm
3 - Cover
❑ With selection scale
❑ To remove, lever from
behind in selector posi‐
tion “P” and then re‐
move from the front
groove in selector posi‐
tion “1”
4 - Protective strap
❑ Insert in the cover -3-
5 - Trim sleeve
6 - Safety washer
❑ Assembly
⇒ Item 3 (page 27)
7 - Selector lever
❑ Dismantling and assem‐
bling ⇒ page 29
⇒ page 32
❑ Adjusting the magnet for
locking the selector lev‐
er -N110- ⇒ page 31
8 - Gasket
9 - Protective cover
❑ Do not dismantle to re‐
place the selector lever
cable or individual gear‐
box actioning compo‐
nents
❑ Remove ⇒ page 28
10 - Combi bolt
❑ 23 Nm
❑ 4 units
11 - Self-locking nut
❑ 15 Nm
❑ 3 units
❑ Always renew
12 - Spacers
13 - NutsProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To secure respect the
to thecenter
correctnessconsole
of information in this document. Copyright by SEAT S.A.
14 - Nozzle
❑ Fit onto the selector lever box before fitting the selector lever cable ⇒ page 29
15 - Selector lever cable
❑ Do not kink or bend; before fitting, grease the ring and the ends of the cable lightly
❑ Securing the selector lever cable to the selector lever ⇒ page 28
❑ Check and adjust ⇒ page 24

Arosa 1997 ➤
16 - Bolt
❑ 15 Nm
17 - Support
❑ For the gear selector cable in the mounting bracket
18 - Rod
19 - Washer
20 - Combi bolt
❑ 23 Nm
21 - Safety washer
❑ For the selector lever cable
❑ Always renew
22 - Support
❑ For the gear selector cable in the gearbox
23 - Bolt
❑ 15 Nm
24 - Support
❑ For the gear selector cable in the engine bay
25 - Gearbox
Removing the protection box

– Removing the gear selector knob ⇒ page 32 .
– Remove the trim sleeve.
– Removing the gear selector cover ⇒ Item 3 (page 27) .
– Unscrew the nuts securing the centre console
⇒ Item 13 (page 27) . to the correctness of information in this document. Copyright by SEAT S.A.
respect
– Removing the centre console: ⇒ Bodywork repairs, installa‐

tion work, interior; Rep. Gr. 68 ; Shelves, trims, covers and
trays .
– Disconnecting the selector lever locking electromagnet con‐
nector.
– Remove the front part of the exhaust pipe with catalytic con‐
verter: ⇒ Rep. Gr. 26 ; Exhaust system components: removal
and fitting .
– Remove the front and rear protective plates.
– Remove the bolts -arrows- of the protective cover.
Securing the selector lever cable to the selector lever

– Turn the locking lever downwards arrow -1- , insert the cable
ring arrow -2- into the selector lever, and secure it with a new
safety washer.

Arosa 1997 ➤
Securing the wiring harness to the selector lever box

– Fit the wiring harness to the clips and in the selector lever box
-arrows- .
Fitting the nozzle to the selector lever box

– Before fitting the selector lever cable, fit the nozzle -arrow- .
3.5 Selector lever: dismantling and assembling (vehicles up to 06.00)

Note!
♦ Lubricate all support points and sliding surfaces with grease ref no. -G 052 142 A2-
♦ To replace individual components, the gear selector lever should be removed ⇒ page 32

Arosa 1997 ➤
1 - Selector lever
❑ Assembling
⇒ page 31
⇒ page 32
2 - Scale illumination
❑ Connect the scale illu‐
mination connector
⇒ page 32
3 - Spring
4 - Push rod
❑ Lubricate contact surfa‐
ces
❑ To remove, unscrew the
star-head screw
5 - Guide bush
❑ Fit after fitting the push
rod
6 - Magnet for selector lever
locking -N110-
❑ To remove, first remove
the gear selector from
the box ⇒ page 32
❑ Adjust ⇒ page 31
❑ Checking action
⇒ page 31
❑ This can be checked
with the measured value
block and during the
electrical check ⇒
VAS 5051; Vehicle self-
diagnosis
7 - Bolt
❑ 3 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 2 permitted
units unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Fit with -D 000 600 A2- locking paste
8 - Securing bolt
❑ Screwed to the push rod
❑ Engaged with component ⇒ Item 13 (page 31)
❑ Always renew
❑ To loosen the bolt, remove the selector lever locking magnet and the scale illumination. Hold the bolt in
a vice and loosen it by turning the selector lever
❑ Fit with -D 000 600 A2- locking paste
9 - Self-locking nut
❑ 10 Nm
❑ Always renew
10 - Spring
❑ Fit together with the locking lever ⇒ Item 11 (page 30) in the selector lever
11 - Locking lever
❑ To lock the selector lever in “P” or “N”

Arosa 1997 ➤
12 - Bush
13 - Engaging piece
❑ Before fitting in the selector lever box, assemble the selector lever ⇒ page 31
14 - Combi bolt
❑ Lubricate the shaft
Assemble the selector lever before fitting

Before fitting the selector lever in the selector lever box, adjust
the selector lever locking magnet -N110- ⇒ page 31 , and check
action ⇒ page 31 .
– Insert the bolt -arrow 1- and fit the bolts -arrow 2- of the se‐
lector lever locking magnet -N110- with -D 000 600 A2- locking
paste.
Adjusting the electromagnet for the selector lever locking -N110-

– Loosen the magnet securing bolts arrow -1- .
– Press the push rod and move the magnet longways, until there
is a distance -a- of 0.3 mm between the push rod and the
locking lever.
– Apply -D 000 600 A2- locking paste to the bolts arrow -1- and
tighten them to 3 Nm.
– Checking action ⇒ page 31 .
Checking the electromagnet for the selector lever locking -N110-

action
– Move the selector lever to “P” and apply 12 V to the magnet.
The selector lever should be locked and cannot be displaced
to another gear.
– Stop the electromagnet.
The push rod should not get caught on the locking lever and all
the gears should be selectable.
– Move the selector lever to “N” and check as in “P” .

Arosa 1997 ➤
Connect the scale illumination connector

– Fit the support with the tab -arrow- until it engages.
– Fit the connector cable to the support and secure the connec‐
tor to the support.
3.6 Selector lever: dismantling and assem‐

bling (vehicles up to 06.00)
3.6.1 Removal
– Disconnect the battery earth strap.
Note!
For vehicles fitted with a coded radio, first check the anti-theft
code.

– Remove the togear selector knob byin loosening the lateral se‐S.A.
respect the correctness of information this document. Copyright by SEAT
curing bolt -arrow- .
– Remove the selector lever cover by levering first from behind
and then remove from the front groove with selector lever in
“1” .
tion work, interior; Repair group 68; Shelves, trims, covers and
trays.
– Remove the selector lever cable safety washer.

– Turn the locking lever downwards -arrow 1- , and release the
selector lever cable -arrow 2- .

Arosa 1997 ➤
– Release the wiring harness from the clips on the selector lever
box and the cable clips -arrows- .
and fitting .
– Remove the front heat shield.
– Unscrew the attachment nuts from the centre console -ar‐

rows-.
– Move the selector lever to “1” .
– Remove the gear selector assembly from the selector lever
box.
3.6.2 Installation
Install in reverse order, taking the following into account:
– Before fitting the selector lever in the selector lever box, adjust
the selector lever locking magnet -N110- ⇒ page 31 , and
check action ⇒ page 31 .
– Fitting the front part of the exhaust pipe with catalytic convert‐
er: ⇒ Rep. Gr. 26 ; Exhaust system components: removal and
fitting
– Fitting the central console: ⇒ Bodywork repairs, installation
work, interior; Rep. Gr. 68 ; Shelves, trims, covers and trays .
– Checking the gear drive mechanism ⇒ page 24 .
Tightening torques
Nuts for securing the selector lever 15 Nm
Always renew
Knob securing bolt 1.5 Nm
3.7 Selector lever cable: dismantling and

assembling (vehicles up to 06.00)
3.7.1 Removal
Note!
code.

Arosa 1997 ➤
– Remove the gear selector knob by loosening the lateral se‐

curing bolt -arrow- .
– Remove the selector lever cover by levering first from behind
and then remove from the front groove with selector lever in
“1” .
– Move the selector lever to “N” .
– Remove the selector lever cable safety washer -arrow 2- .

– Turn the locking lever downwards -arrow 1- , and release the
selector lever cable.
– Remove the selector lever cable safety washer -1- on the

gearbox bracket.
– Release the selector lever cable from the bracket in the engine
bay.
– Remove the bolt -arrow- securing the cable to the selector rod.
and fitting .

Arosa 1997 ➤
– Remove the exhaust system front bracket -arrows- .

– Release the selector lever cable from the bracket in the sub-
frame.
– Loosen the nut -arrow- and remove the selector lever cable
from the protection box.
3.7.2 Installation
♦ Check the selector lever cable sleeve for damage.
♦ Avoid bending or twisting the selector lever cable.
♦ Before fitting the cable, grease the ring on the end of the cable
lightly.
– Before fitting the selector lever cable, fit the nozzle -arrow- in
the selector lever box.
– Route the cable over the gearbox and insert it into the sub-
frame bracket and into the protection box.
– Tighten the securing bolt -arrow- .


Arosa 1997 ➤
– Turn the locking lever downwards -arrow 1- , insert the cable

ring -arrow 2- into the selector lever, and secure it with a new
safety washer.
– Insert the selector lever cable into the gearbox bracket and
secure it to the bracket in the engine bay.
– Fit a new selector lever cable safety washer -1- for the selector
lever cable on the gearbox bracket.
– Change the selector lever position from “P” to “1” . Do it by
pushing the selector lever push rod.
– Adjusting the selector lever cable ⇒ page 24 .
– Fit the front heat shield.
– Fit the front bracket and tighten the bolts to 25 Nm.
– Fit the front part of the exhaust pipe with catalytic converter:
⇒ Rep. Gr. 26 ; Exhaust system components: removal and
fittingx .
– Fit the gear lever cover.
– Fit the trim sleeve.
– Fit the selector lever knob and tighten the bolt to 1.5 Nm.
3.8 Gear drive mechanism: dismantling and fitting (vehicles from 07.00 on‐
wards)

Arosa 1997 ➤
1 - Gear lever knob

⇒ page 41
2 - Trim sleeve
3 - Frame
❑ Remove with the plastic
lever -U-30800- . Be
careful with the edges of
the frame as they are
sharp and can cut
4 - Cover
❑ Dismantling
⇒ page 38
❑ Do not dismantle
5 - Gasket
6 - Bolt
7 - Protective cover
8 - Bolt
9 - Bolt
10 - Selector lever
❑ Separate the selector
lever from the protective
box ⇒ page 38
11 - Cover
12 - Bolt
❑ 25 Nm
❑ 4 units
13 - Nut
❑ 15 Nm
❑ 3 units
❑ Always renew
14 - Electromagnet for gear lever locking -N110-
❑ To remove, separate the selector leverbyfrom
Protected theCopying
copyright. protective box
for private ⇒ pagepurposes,
or commercial 38 in part or in whole, is not
❑ Checked on the vehicle by self-diagnosis
permitted unless ⇒ VAS 5051; Vehicle self-diagnosisor accept any liability with
authorised by SEAT S.A. SEAT S.A does not guarantee
❑ Fitting ⇒ page 38
15 - Safety washer
❑ Safety washer
16 - Nut
❑ 15 Nm
❑ Always renew
17 - Bush
❑ Always renew
18 - Support
❑ To secure the selector lever cable to the sub-frame
19 - Hexagon bolt
❑ 6 Nm
20 - Support
❑ To secure the gear selector cable in the engine bay

Arosa 1997 ➤
21 - Hexagon bolt
❑ 6 Nm
22 - Selector lever cable
❑ Do not kink or bend; before fitting, grease the ring and the ends of the cable lightly
❑ Check and adjust ⇒ page 25
Fitting the electromagnet -N110-

– Fit the electromagnet control rod -arrow- into the square open‐
ing in the locking lever.
Separating the selector lever from the protective box

– Release carefully from both sides, levering at the junction
points.
3.9 Selector lever cable: removing and fit‐

ting (vehicles from 07.00 onwards)
♦ Lever -U-30800-
3.9.1 Removal

Arosa 1997 ➤
Note!
code.

– Removing the gear selector knob ⇒ page 41 .
– Remove the cover frame of the selector lever with lever -
U-30800- .
Note!
Be careful with the edges of the frame as they are sharp and can
cut

tion work,
Protected interior;
by copyright. Rep.
Copying Gr. or68
for private ; Shelves,
commercial trims,
purposes, in part covers
or in whole,and
is not
traysunless
permitted . authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove the selector lever cover by levering from the back and
front -arrow 1- , and pull upwards -arrow 2- to remove.
– Disconnecting the selector lever locking electromagnet con‐
nector.
– Remove selector lever cable ring -arrow- .

– Release the selector lever cable from the bracket in the engine
bay.

Arosa 1997 ➤
– Disengage the actioning cable by levering on the selector rod.

and fitting
– Remove the exhaust system front bracket -arrows- .

– Release the selector lever cable from the bracket in the sub-
frame.
– Remove the cable from the protection box.
3.9.2 Installation
Note!
♦ Check the selector lever cable sleeve for damage.

♦ Avoid bending or twisting the selector lever cable.
♦ Before fitting the cable, grease the ring on the end of the cable
lightly.
– Route the cable over the gearbox and insert it into the sub-
frame bracket and into the protection box.

Arosa 1997 ➤
– Fit a new bush and insert the cable ring into the selector lever
-arrow- .
– Insert the selector lever cable into the gearbox bracket and
secure it to the bracket in the engine bay.
– Change the selector lever position from “P” to “1” . Do it by
pushing the selector lever push rod.
– Adjusting the selector lever cable ⇒ page 25 .
– Fit the front heat shield.
– Fit the front bracket and tighten the bolts to 25 Nm.
– Fit the front part of the exhaust pipe with catalytic converter:
⇒ Rep. Gr. 26 ; Exhaust system components: removal and
fitting
– Fitting the selector lever position illumination connector.
– Fit the gear selector cover by pressing down until it engages.
– Fitting the central console: ⇒ Bodywork repairs, installation
work, interior; Rep. Gr. 68 ; Shelves, trims, covers and trays .
– Fit the selector lever cover frame.
Note!
Be careful with the edges of the frame as they are sharp and can
cut.
– Fit the trim sleeve.

– Fitting the gear selector knob ⇒ page 41 .
3.10 Gear selector knob: removing and fitting

(vehicles from 07.00 onwards)

There are different knobs that are removed and fitted in different
ways.
– Before any assembly work, push the gear lever bush down a
little.
– Note the colour of the plastic piece of the knob.
If it is black: Dismantling and fitting ⇒ page 42 .
If it is red-brown: This knob can substitute the one with black syn‐
thetic part.

Arosa 1997 ➤
3.10.1 Knob with red-brown plastic part: re‐

moval and installation
– Only pull the knob, without pressing the key.
If the button has entered the knob by mistake, it can be removed
using compressed air carefully.
– Before fitting make sure the button projects at least 10 mili‐
meters, dimension -a- .
To do this extract the key by hand overcoming the resistance, thus
it will not go in again.
– To fit, move the lever to “D” and press the knob in the selector
lever.
3.10.2 Removing the knob with black synthetic

part
– Move the selector lever to “R” .
– Push the sleeve -1- downwards.
– Extract key -2- out of the knob -3- just enough so that the little
lever -arrow- is hanging down.
– Now remove the gear selector knob.
Installation
– Move the selector lever to “R” .

Arosa 1997 ➤
– Extract key -2- out of the knob -3- just enough so that the little
lever -arrow- is hanging down.
– Press the knob onto the gear lever as far as it will go. Assembly
position: the key should be facing the driver.
– Extract the key further and insert the little lever -arrow- into the
knob.
– Press the key so that the little lever is engaged with the rod
-4- . The key should jump again to the limit.
– Push the sleeve -1- upwards.
– Move the gear lever to “P” .

Arosa 1997 ➤
4 Gearbox: removing and installing
4.1 Gearbox: removing and installing
Special tools and workshop

equipment required
♦ Hydraulic column jack -SAT
1040-
♦ Torque spanners -SAT
8010-
♦ Base -T20145-

Arosa 1997 ➤
♦ Support -U-30025 E-
♦ Kit -U-40020-
♦ Compression tool -
U-30042-
4.1.1 Removing
When carrying out any repair that involves disassembly of the
gearbox, drain the oil before proceeding with disassembly
⇒ page 57 , ATF level: checking or filling, changing ATF.
– Place the selector
Protected leverCopying
by copyright. in thefor“P” position.
private or commercial purposes, in part or in whole, is not
– With the ignition switched off, disconnect battery earth strap.
Note!
For vehicles fitted with a coded radio, first check and record the
anti-theft code.
– Remove battery and battery retainer: ⇒ Electrical system;

Rep. Gr. 27 ; Battery
4. Gearbox: removing and installing 45

Arosa 1997 ➤
– Removing the air filter -arrows- (only in vehicles with an oval

filter). In vehicles from 07.00 onwards: ⇒ Rep. Gr. 24 ; Injec‐
tion system: repairing.
– Remove catch -1- on the actioning cable.
– Disengage the actioning cable by levering with
permitted unless the selection
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
rod. In vehicles up to 06.00 ⇒ page 24 .respect to the correctness of information in this document. Copyright by SEAT S.A.
– Release the main round connector in the gearbox and the re‐
maining electrical connections.
– Seal off the ATF radiator hoses with tool -U-30042- .

– Release the clips on the ATF radiator hoses with tool -T20029-
and disengage them from the radiator.
– Cap off the radiator hoses

Arosa 1997 ➤
– Remove the countersupport for the selector lever cable from

the gearbox -arrows- .
– Remove cable guide -1- from the eye -2- .
– Remove the cable guide -1- from the engine assembly bolt, by
pulling on it upwards -arrow- .
– Remove the upper bolts that secure the engine to the gearbox.
– Remove the upper bolt from the starter motor.
– Fit the bracket -U-30025E- .
Note!
Remove all cable brackets, cables and hoses that could interfere
with the fitting of support tool -U-30025E- .
– Slightly tension the engine assembly/gearbox via the spindles.

– Remove the front wheels.
– Raise the vehicle. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
and fitting .
– Unscrew the drive shafts from the gearbox joint flanges with
the correct spanner from tool -U-40020- and secure them
above.

Arosa 1997 ➤
– Uncouple the speedometer connector.

– Separate the support from the electrical cables in the rear part
of the engine.
– Removing the starter motor: ⇒ Electrical system; Rep. Gr.
27 ; Starter motor .
– Remove oil sump protective plate from the gearbox oil sump.
– Remove the protective plate from the torque converter.
– Remove ribbed belt covering.
– Remove the three bolts -arrows- securing the torque converter

to the flywheel. To do so, rotate the crankshaft 1 /3 and im‐
mobilise the flywheel with tool -T20156- .
– Remove the lower plate with the registry number from the
gearbox and place tool -T20155- so that the torque converter
is immobilised. Tighten the tool's threaded bolt by hand.
Note!
Ensure that the bolt on tool -T20155- is well tightened. If the bolt
is not tightened well, the converter could disengage from the
gearbox, and risk an accident when handling the gearbox during
disassembly.
– Disengage the hoses for the power assisted steering from their
brackets in the lower part of the radiator.
Note!
The connections for the power assisted steering must be secured,

without twisting or stretching them, so that they are out of the way
when removing and fitting the gearbox.
– Remove the pendulum support, removing bolts -A- and -B- .

– Remove the sub-frame: ⇒ Running gear, axles, steering; Rep.
Gr. 40 ; Front wheel suspension: repair (vehicles with roll bar) .

Arosa 1997 ➤
– Remove the bolts securing the right part of the engine assem‐
bly from the cylinder block.
– Completely remove the left part of the engine support assem‐

bly.
– Remove bolt -A- .
– Remove the bolts -B- which secure the engine support as‐
sembly -1- to the bodywork.
– Remove bolts -C- from the gearbox console -2- .
– Using the spindles of the -U-30025 E- support tool, lower and
tilt the engine assembly, until the tensioning roller is positioned
slightly below the sill.
– Fit both base -T20138- and holding tool -T20161- to the hy‐
draulic column jack SAT 1040.
– Place tool -T20138- below the gearbox, in such a way that it

is positioned parallel and as close as possible to the gearbox.
– Secure the front part of tool -T20138- -arrow 1- with a bolt and
the right part -arrow 2- with a M10 bolt. The rear part
-arrow 3- gets fitted into one of the gearbox openings.
Note!
Lock the securing rods of tool -T20138- with the counterbolts and
tighten the central bolt.
– Remove the lower connecting bolts from the engine/gearbox.

– Separate the gearbox from the engine, pressing down on the
converter in order to disengage it from the flywheel.
– Lower
Protectedthe gearbox
by copyright. taking
Copying careor not
for private to damage
commercial purposes, any
in partcomponent.
or in whole, is not
Note!
Make sure that the torque converter does not become separated
from the gearbox.
4.1.2 Installation

Arosa 1997 ➤
– Installing the torque converter ⇒ page 13 , Torque converter:

removal and fitting.
– Make sure that the torque converter is in the correct position
and that is securely affixed with tool -T20155- .
Note!
While carrying out repairs, the converter should not slip out of
position.
– Before assembly, verify that the centering bushes are correctly

positioned between the engine and the gearbox.
– When installing the gearbox, ensure that the converter's threa‐
ded pins coincide with the bolt holes of the flywheel.
– Bring the gearbox closer to the engine, and move the -T20145-
base, and position the gearbox until it is in the correct location.
– Fit the subframe: ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Front wheel suspension: repair (vehicles with roll bar)
– Installing the drive shafts: ⇒ Running gear, axles, steering;
Rep. Gr. 40 ; IV - Drive shafts .
– Always replace the axle catch -1- des Wählhebelseilzuges im‐

mer ersetzen.
– Check the selector lever cable adjustment: Vehicles up to
06.00 ⇒ page 24 . Vehicles from 07.00 onwards ⇒ page 25 .
– Check the multifunction switch adjustment; and if necessary,
adjust ⇒ page 20 , Gearbox electrical/electronic components.
– Check the ATF level and top up ⇒ page 53 .
– Checking the connectors
Protected byof all theCopying
copyright. electrical connections
for private (vis‐ in part or in whole, is not
or commercial purposes,
ually). permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– After connecting the battery, depending on the version, vehicle

equipment will have to be encoded (encoding the radio, ad‐
justing the clock, etc.).
After assembly:
– Begin basic setting: ⇒ VAS 5051; Vehicle self-diagnosis
– Checking the gear drive mechanism ⇒ page 24 .
Tightening torques

Arosa 1997 ➤
Gearbox to engine
Posi‐ Bolt Amount Tightening torque (Nm)
tion
1 M12×6 2 80
5
2 M10×7 1 45
5
3 M7×12 2 15
4 M12×7 1 80
0
5 M8×35 1 25
6 M8×35 1 25
7 M8×35 1 25
A - Adjustment bushes for centring the gearbox.
Tightening torques
Engine assembly brackets, engine side

A - 50 Nm
B - 60 Nm
C - 25 Nm
Always renew the bolts
Engine assembly brackets,Protected

gearbox side
A - 30 Nm + 90° permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
B - 20 Nm + 45°
C - 30 Nm

Arosa 1997 ➤
Pendulum support
A - 50 Nm
B - 20 Nm + 90°
Always replace nuts and bolts
Torque converter to the flywheel 60 Nm
Driveshaft to flange connection 45 Nm
Gearbox to engine bolt M12 80 Nm
Gearbox to engine bolt M10 60 Nm
Gearbox oil sump protective plate. 15 Nm

Arosa 1997 ➤
5 ATF level: checking and filling

equipment required
8010-
♦ Drip tray -V.A.G 1306-
♦ Fault reader -V.A.G 1551-
♦ Cable -V.A.G 1551/3-
♦ Oil tester -V.A.G 1924-
Only use ATF fluid ref. no.:

G 052 990 A2
5. ATF level: checking and filling 53

Arosa 1997 ➤
– If the ATF level is checked, always replace the oil seal

-arrow- of the ATF level control bolt.
5.1 ATF level: checking

Check prerequisites
• The gearbox must not be in emergency mode and the tem‐
perature of the ATF should no be more than 30 °C approx.
• Vehicle in horizontal position
• Gear selector lever in “P”

Arosa 1997 ➤
– Attach ATF -V.A.G 1924- filling system container to vehicle.

– Connect fault reader -V.A.G 1551- . Start the engine and select
gearbox electronics with “Address code” 02.
– Place the collection recipient below the gearbox.
Indicated on the display:
Rapid data transfer HELP
Select function XX
– Press keys 0 and 8 to select the function “Read measured

value block” .
Rapid data transfer Q
08 - Read measured value block
– Confirm entry with the Q key.

Read measured value block
Input display group number XXX
– Press keys 0 , 0 and 2 (002 selects the “Display group num‐

ber 002” function).
– Confirm entry with the Q key.
Read measured value block 2 ->
0% 4% 30°C 12.9 V
The third display zone shows the ATF temperature.
Note!
At the start of verification, the ATF temperature should not be

more than approx. 30 °C.
– Set ATF at service temperature.

Test temperature: 35 °C up to 45 °C
– Unscrew the sealing screw for the ATF control -arrow- from
the oil sump.
The ATF left in the overflow tube comes out.
If ATF comes out through the opening:
it is not necessary to add ATF.
– Tighten the sealing screw with a new seal, to a torque of 15
Nm. The ATF check is now finalised.

Arosa 1997 ➤
If ATF does not come out through the opening:

– Top up with ATF ⇒ page 56 .
5.2 Replace ATF

– Remove the cap which secures the plug, levering with a screw‐
driver -arrow- . On doing this the protection of the cap is broken
and it must always be replaced.
– Remove the filling hose cap.
– Refill ATF with -V.A.G 1924- until ATF comes out through the
control opening -arrow- .
permittedCaution
Either insufficient or excessive fluid can alter the functioning of

the gearbox
– Tighten the level plug with a new seal -arrow 1- to 15 Nm.

– Fit the cap in the filling tube until the safety tab is seated.
– Fit a new cap to the locking cap arrow -2- .
– Seat the cap.
Caution
Always replace the cap because it secures the sealing lid

Arosa 1997 ➤
5.3 Changing the ATF

– Unscrew the sealing screw for the ATF control -arrow- from
the oil sump.
– Unscrew the overflow tube (golden coloured) through the con‐
trol orifice.
– Let the ATF come out.
– Fit the overflow tube.
– Fit the sealing bolt by hand.
Refill with ATF ref. no.:
G 052 990 A2
– Approx. 2 litres of ATF (G 052 990 A2) through the filling tube.
– Then start the engine, and with the vehicle stationary, check
the selector in all positions.
– Then check the level of ATF and top up ⇒ page 53 .

Arosa 1997 ➤
6 Gearbox with control elements

Placement of control elements
1 - Clutch 3rd and 4th gear -K3-

2 - Reverse gear brake -B1-
3 - Free sprocket
4 - Reverse gear clutch -K2-
5 - Clutch 1st and 3rd gear -K1-
6 - 2nd and 4th gear brake -B2-
7 - Torque converter clutch
cancellation incorporated into
the torque converter -ÜK-
Before working on the gear‐
box, you must first run the self-
diagnosis ⇒ VAS 5051; Vehi‐
cle self-diagnosis
6.1 Control elements position

In case of complaints about insufficient
permitted acceleration
unless authorised andS.Aspeed,
by SEAT S.A. SEAT does not guarantee or accept any liability with
or in general, in order to locate transmission
respect faults,
to the correctness the table
of information con‐ Copyright by SEAT S.A.
in this document.
tains information about which control elements are actuated with
each gear. This information can facilitate determining which con‐
trol elements are not functioning correctly.
All gears must be replaced hydraulically.
At certain speeds and throttle settings, 3rd and 4th gears are ac‐
tuated mechanically when the converter clutch cancellation en‐
gages.
Range B1 B2 K1 K2 K3 F ÜK
R X X
1H -X- X X
2H X X
3H X X

Arosa 1997 ➤
Range B1 B2 K1 K2 K3 F ÜK
3M X X X
4H X X
4M X X X
X = pinion not working, brakes or clutches closed

-X- = -B1- is used as an engine brake only when the lever
is in “1”
H = hydraulic
M = mechanics
6. Gearbox with control elements 59

Arosa 1997 ➤
7 Gearbox: dismantling and assem‐

bling
Removing and fitting the ATF radiator and filling tube
⇒ page 60 .
General installation position for the planet gear ⇒ page 60 .
Dismantling and assembling the planet gear ⇒ page 66 .
Assembling the planet gear of the gearboxes up to 06.00
⇒ page 74
Assembling the planet gear of the gearboxes from 07.00 onwards
⇒ page 80
General overview for the all adjustments to the planet gear
⇒ page 86 .
Remove and fit slide box ⇒ page 111 .
7.1 ATF radiator andauthorised

ATFbyfilling
SEAT S.A.tube:
SEAT S.Aremoving
does not guaranteeand
or acceptinstalling
permitted unless any liability with
1 - Gearbox casing
2 - O-ring
❑ Always renew
3 - Sealing screw
❑ 8 Nm
4 - Bolt
❑ 25 Nm
5 - O-ring
❑ Always renew
6 - ATF radiator
7 - O-ring
❑ Always renew
8 - O-ring
❑ Always renew
9 - ATF filling tube
10 - Bolt
❑ 8 Nm
11 - O-ring
❑ Always renew
12 - Sealing plug
13 - Cap
❑ Always replace the seal‐
ing cap, after checking
ATF level ⇒ page 53 ,
ATF level: checking and
completing
7.2 Planet gears: general assembly diagram

Dismantling and assembling the planet gear ⇒ page 66

Arosa 1997 ➤
Assembling the planet gear of the gearboxes up to 06.00

⇒ page 74
Assembling the planet gear of the gearboxes from 07.00 onwards
⇒ page 80
General overview for the adjustment washer and the axial needle
bearings in the planet gear ⇒ page 65
I - ATF pump up to the large

planet gear: General installa‐
tion position ⇒ page 62
II - Gearbox casing cover up to
the drive sprocket: General in‐
stallation position ⇒ page 63
7. Gearbox: dismantling and assembling 61

Arosa 1997 ➤
7.3 I - ATF pump up to the large planet gear: general assembly diagram
1 - Bolt
❑ 20 Nm
2 - ATF pump
bling ⇒ page 95
3 - Gasket
❑ For the ATF pump
4 - Brake strap -B2-
❑ Brake for 2nd and 4th
❑ Place in installation po‐
sition ⇒ page 66
❑ Place the sprocket pres‐
sure bar
and adjusting screw
⇒ Item 6 (page 62) into
the moulded part of the
brake strap
5 - Nut
❑ 45 Nm
6 - Adjusting screw
❑ For brake strap -B2-
❑ Always renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Adjusting the brake respect to the correctness of information in this document. Copyright by SEAT S.A.
strap ⇒ page 88
7 - Shim
❑ Determine the thickness
of the shim by adjusting
clutch clearance be‐
tween -K2- and the ATF
pump ⇒ page 90
❑ Dismantling and assembling ⇒ page 101
9 - Axial needle bearing
❑ Note installation position ⇒ page 65
10 - Clutch from 1st up to 3rd gear -K1- with turbine shaft
12 - Input shaft
13 - Axial needle bearing with washer
14 - Large planet gear
15 - Engine shaft
❑ The corresponding gearbox code is assigned to this spare part

Arosa 1997 ➤
16 - Gearbox casing
17 - Safety ring
18 - Cover
❑ With brake activating piston for 2nd and 4th gears
19 - Brake activating piston for 2nd and 4th gears
20 - Spring
21 - Spring
7.4 II - Cover for the gearbox casing up to the drive sprocket: general assembly
diagram
1 - Bolt
❑ 20 Nm
2 - Gearbox casing cover
❑ With piston and spring
support for reverse gear
brake -B1-
bling ⇒ page 107
❑ Note installation posi‐
tion ⇒ page 65
4 - Safety ring
5 - Plate spring
❑ Take note of assembly
position: large diame‐
ters should coincide Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Thrust disc -B1- respect to the correctness of information in this document. Copyright by SEAT S.A.
7 - Outer disc -B1-

❑ Number of outer discs -
B1- ⇒ page 3
8 - Inner disc -B1-
❑ Number of inner discs -
B1- ⇒ page 3
❑ Before installing, leave
in ATF 15 minutes
9 - Support disc -B1-
10 - Clutch 3rd and 4th gear -
K3-
bling ⇒ page 104
12 - Satellite carrier
❑ When placing the free sprocket, turn toward the left (anti-clockwise)

Arosa 1997 ➤
13 - Safety ring
❑ For the free sprocket ⇒ Item 15 (page 64)
14 - Thrust washer
❑ For the free sprocket ⇒ Item 15 (page 64)
15 - Free sprocket
16 - 60 Nm
❑ Secure the drive sprocket
17 - Safety plate
❑ For the support bolt
❑ Always renew
❑ Introduce the 4 tabs of the safety plate into the gearbox housing recesses
18 - Safety ring
❑ For the ring wheel
❑ The ring tab fits into one of the spaces between the drive sprocket teeth
❑ For gearboxes from 07.00 onwards ⇒ page 64
19 - Ring wheel
20 - Drive sprocket
❑ With roller bearings
❑ The bearings of the roller bearings cannot be removed from the drive sprocket
21 - Gearbox casing
Ring wheel and drive sprocket from 07.00 onwards

– To remove them, press the safety ring.

Arosa 1997 ➤
7.4.1 Installation position for the adjustment washer -F- and for the axial needle
bearings in the planet gear
Measurement of the adjustment washer -F- and the axial needle

bearings
bearings/ washer ∅ internal ∅ external
mm mm
A 22.10 40.00
B 30.00 45.00
C 29.00 48.00
D 18.35 34.50
E from 32 to 34 49.50
F 53.30 70.00

Arosa 1997 ➤
7.5 Planet gears: dismantling and assembling

equipment required
♦ Bracket -AR-2203 A-
8010-
♦ Rotation tool -T10003-
♦ T20053 bracket
7.5.1 Planet gears: remove

• Drain gearbox oilpermitted
before removing it from the vehicle
– Place the -V.A.G 1306- drip tray under the gearbox.

– Drain gearbox oil by unscrewing the oil drain plug -1- .

– Drain ATF from the tray by unscrewing the sealing screw -2-
and the ATF overflow tube -3- .

Arosa 1997 ➤
– Fit the gearbox to support flange -T20053- -arrows- .

– Place into column -AR-2203A- , and secure support flange -
T20053- into openings nº 4 and 5.
– Remove the torque converter ⇒ page 13 , Torque converter:
removal and fitting.
– Unscrew bolt -arrow A- for the selector rod shaft.

– Remove the bolts -arrows B- from the gearbox for the multi‐
function switch.
– Remove the electrical connections and the gearbox senders.
– Remove the ATF radiator from the gearbox, removing the bolt
-arrow- .
– Remove the sump, unscrewing the bolts -arrow- .

Gearboxes up to 06.00

Arosa 1997 ➤
– Remove ATF temperature sender -A- .

– Unlock connectors from solenoid valves -arrows- , pressing
the tabs -arrow 1- and pulling them off -arrow 2- .
solenoid valves.
– To remove the slide box, only loosen the indicated bolts

-arrows- .
When removing the slide box, the manual slide -1- remains in the
box.
– Secure the manual slide so that it does not fall out.
Gearboxes from 07.00 onwards
– Separate the ATF temperature sender -5- from its support.

– Separate solenoid valve connectors -2- and open the plate
flange -3- .
– Unlock connector from the solenoid valve -1- , pressing the
flange inwards and remove by pulling it backwards.
– Remove the slide box, by loosening only the bolts indicated
with arrows A, B, and C (of different lengths).
– Secure the manual slide -4- so that it does not fall out.
Continued for all gearboxes
– Remove O-rings -A- .

– Release the harness from the clips -arrows- , and remove the
solenoid valves' wiring harness.

Arosa 1997 ➤
– Remove the left and right articulation flanges ⇒ page 121 ,

Articulation flange oil seals: removal and fitting.
– Unscrew the converter housing's securing bolts (20 sets).
– Remove the converter housing.
– Remove the differential arrow -A- from the gearbox casing.

– Remove the O-ring -arrow B- from the gearbox casing.
– Remove the O-ring -arrow C- from the turbine shaft.
– Remove the bolts -arrows- from the ATF pump.
– Remove the ATF
respect pump
to the gasket
correctness -1- from
of information the
in this gearbox
document. flange/
casing.
– Remove shim -2- from the reverse gear clutch -K2-. It may be
that the shim has remained adhered to the ATF pump.

Arosa 1997 ➤
– Loosen the locknut -1- on the adjusting screw -2- for brake
strap -3- .
– Remove securing bolt -2- .
– Remove brake strap -3- .
– After removing the brake strap, secure it so that it cannot be

opened, e.g. with a wire stirrup -A- .
– Remove the reverse gear clutch -1- .
– Remove the clutch from 1st to 3rd gears -B- together with the
axial needle bearing -A- .

Arosa 1997 ➤
– Remove the axial needle bearing -1- from the input shaft -2- .
– Remove the input shaft -2- .
– Remove the needle bearing -A- together with the large planet
gear -B- .
– Remove the engine shaft -1- from the gearbox casing.

– Rotate gearbox 180° in column -AR-2203A- .
– Progressively loosen the bolts for the cover in diagonal se‐

quence.
– Remove the gearbox casing cover, turning it in the direction of
the arrow to free it from the support for column -AR-2203A- .
Note!
In the case that the cover is stuck to the gearbox tray, due to
sealant, softly tap it with a plastic hammer, while taking care since
the cap will jump due to the force of the springs.

Arosa 1997 ➤
– Remove the O-rings -arrows- from the gearbox casing.

– Remove the clutch -A- from 3rd and 4th gears together with
the axial needle bearing -B- .
– Remove the axial needle bearing -A- from the satellite carrier
-B- .
– Remove satellite carrier -B- .
– Remove the safety ring from the ring wheel.

– Remove ring wheel from the drive sprocket.
Continued for all gearboxes
– Remove the safety ring for the reverse gear brake -B1- with a
screwdriver.
– Remove the washers, the thrust disc, the discs and the brake
support disc for the reverse gear -B1-.

Arosa 1997 ➤
– Remove the safety ring -A- for the free sprocket with a screw‐
driver.
– Remove the free sprocket from the gearbox casing together
with thrust washers -B- .
– Using a screwdriver, bend the safety plate tabs for securing

bolt -A- in such a way that they are made straight.
– Using tool -T10003- , unscrew the supporting screw from the

gearbox casing.
– Remove the drive sprocket -A- from the gearbox.

Gearboxes from 07.00 onwards
– Using a screwdriver, bend the safety plate tabs for securing
bolt in such a way that they are made straight.

Arosa 1997 ➤
– Using tool -T1003- , unscrew the supporting screw from the

gearbox casing.
– Remove the drive sprocket out of the gearbox casing.
– Remove the safety ring -A- for the free sprocket with a screw‐
driver.
– Remove the free sprocket from the gearbox casing together
with thrust washers -B- .
Remove the drive sprocket from the ring wheel ⇒ page 64 .
7.5.2 Planet gears up to 06.00: assembly

Assembly of planet gears from 07.00 onwards ⇒ page 80 .
Place the axial needle bearing in installation position ⇒ page 65
– Place drive sprocket -A- into the gearbox casing.
– Place a new safety plate fitting its tabs into the gearbox casing
recesses.
– Using tool -T10003- , tighten securing bolt to 60 Nm.

– Secure the securing bolt with the safety plate.
– Fit the free sprocket together with thrust washers.
– Take note of assembly position when placing the free sprocket
⇒ page 97 .
– Secure the free sprocket with the safety ring.

Arosa 1997 ➤
– Place the ring wheel on top of the drive sprocket.

– Using a screwdriver, remove the ring securing the ring wheel
to the drive sprocket.
– Insert satellite carrier -B- into the ring wheel, and at the same
time, into the free sprocket.
– Place the axial needle shoulder -A- on top of satellite carrier
-B- , in such a way that the dark surface remains visible.
– Checking action of free sprocket. permitted
The satellite carrier can only
be turned in an anti-clockwise direction.
– Fit discs -B1- in the following manner:

– Place a support disc -5- of the corresponding thickness on top
of the safety ring -6- .
– Insert inner discs -7- and outer discs -4- of -B1-.
– Place on top of thrust disc -3- .
– Insert the springs from plate -2- according to the installation
position (the large diameters face each other).
– Fit safety ring -1- .
– Verify the measurement of the reverse gear brake -B1-
⇒ page 88 .
– Place the clutch for the 3rd and 4th gear -A- .
– Put the O-rings -arrows- on top of the gearbox casing.

Arosa 1997 ➤
– Fit the spring cage into the guide pivots for piston -B1-.
One of the guide pivots -A- is thicker than the others, supporting
in this way the spring cage.
– Completely fill the axial needle bearing -B- with ATF, so that
the bearing adheres when it is installed onto the cover for the
gearbox casing.
Place the axial needle bearing onto the cover in accordance with
the correct installation position (the dark surface remains visible).
– Cut the tube nozzle off at the front mark (nozzle diameter: ap‐
prox. 3 mm).
– Apply silicone sealing compound -D 176 404 A2- onto the
clean sealing surface of the cover. The bead should be 3-4
mm thick.
– Place the gearbox casing cover, turning it in the counterclock‐

wise to the arrow in order to avoid the support for column -
AR-2203A- .
– Tighten the bolts uniformly and in diagonal sequence to a tor‐
que of 20 Nm.
– Turn the gearbox 180°.
– Insert the pinion attack shaft -1- .

Arosa 1997 ➤
– Place large planet gear -B- into the gearbox casing.

– Place the axial needle bearing -A- onto the large planet gear
-B- in accordance with the correct installation position (the
smooth surface remains visible).
– Insert the input shaft -1- into the large planet gear.
– Place the axial needle bearing -1- onto the input shaft in ac‐
cordance with the correct installation position (the dark surface
remains visible).
– Insert the clutch for the 1st and 3rd gear -B- .
Note!
When inserted, the input shaft must completely enter the clutch
for the 1st and 3rd gear. If necessary, fit them together before
inserting them into the casing.
– Place the axial needle bearing -A- on the clutch for the 1st and
3rd gear in accordance with the correct installation position
(the dark surface remains visible).
When replacing individualpermitted
components of the planet gears, the
axial needle bearings must be respect

calibrated anew ⇒ page 90in ,thisAd‐
to the correctness of information document. Copyright by SEAT S.A.
just the clearance for the clutch.
– Place the reverse gear clutch -1- .

Recesses -A- must be placed on top of lugs -B- .

Arosa 1997 ➤
– Place shim -2- on top of the reverse gear clutch -K1-.

When replacing individual components of the planet gears, the
shim must be calibrated anew ⇒ page 90 , Adjust the clearance
for the clutch.
– Fit gasket -1- of the ATF pump.
– Fit the brake strap in the following manner:

– Place the new adjusting screw -2- with counter nut -1- in the
gearbox.
Do not yet screw in the covered part of the screw threads. The
screw must be fitted after fitting the ATF pump ⇒ page 90 , Ad‐
justing the brake strap.
– Install brake strap -3- .
– Line up the ATF pump to the gearbox casing. Take note of the
position of the shim, the ATF pump gasket, and the ATF
pump's piston segments when installing.
– Tighten the ATF pump bolts -arrows- to a torque of 20

Protected Nm. Copying for private or commercial purposes, in part or in whole, is not
by copyright.
– Enter the differential -arrow A- .

– Place the new O-rings -arrow B- into the gearbox casing and
-arrow C- into the turbine shaft.
clean sealing surface of the converter casing. The bead should
be 3-4 mm thick.
– Place the converter housing onto the gearbox casing; to do
so, take note of the adjusting bolt and ATF pump O-ring.
– Tighten the converter casing bolts to a torque of 30 Nm.

Arosa 1997 ➤
– Install the left and right articulation flanges -arrow-

⇒ page 121 , Articulation flange oil seals: removal and fitting.
– Install the connectors together with the solenoid valve wiring
harnesses.
– Fit the new O-rings -A- into the gearbox casing.
– Place the slide box on top and insert the toothed washer bolt
into the groove of the selected -1- slide box.
– Tighten bolts -arrows- to a torque of 8 Nm.
– Install ATF temperature sender -A- .

– Install the connectors -arrows- of the solenoid valves.
solenoid valves.
Apply sealant paste -D 176 404 A2- to the oil sump in the following
manner:

Arosa 1997 ➤
prox. 3 mm).
mm thick.
– Assemble the oil sump and tighten the securing nuts in diag‐
onal sequence to a torque of 8 Nm.
– Fit the ATF radiator -arrow- into the gearbox and tighten the
bolt to a torque of 25 Nm.
– Install the torque converter ⇒ page 13 .
– Fitting the gearbox ⇒ page 44 .
– Fill ATF, then check the level of ATF and top up ⇒ page 53 .
7.5.3 Planet gears from 07.00 onwards as‐

sembly
Place the axial needle bearing in installation position ⇒ page 65 .
– Assemble the drive sprocket and the ring wheel.
Take note of assembly position when placing the free sprocket
⇒ page 97 .
– Fit the free sprocket together with
respect to the thrust ofwashers
correctness -B-
information in this.document. Copyright by SEAT S.A.
– Secure the free sprocket with the safety ring -A- .

– Place the drive sprocket with the ring wheel.
– Place a new safety plate fitting its tabs into the gearbox casing
recesses.

Arosa 1997 ➤
– Using tool -T10003- , tighten securing bolt to a torque of 60

Nm.
– Secure the securing bolt with the safety plate.
– Insert satellite carrier -B- into the ring wheel, and at the same
time, into the free sprocket.
– Place the axial needle shoulder -A- on top of satellite carrier
-B- , in such a way that the dark surface remains visible.
– Checking action of free sprocket. The satellite carrier can only
be turned in an anti-clockwise direction.
– Fit discs -B1- in the following manner:

– Place a support disc -5- of the corresponding thickness on top
of the safety ring -6- .
– Insert inner discs -7- and outer discs -4- of -B1-.
– Place on top of thrust disc -3- .
– Insert the springs from plate -2- according to the installation
position (the large diameters face each other).
– Fit safety ring -1- .
– Verify the measurement of the reverse gear brake -B1-
⇒ page 88 .
– permitted
Assemble the clutch
unless authorised -A-S.A.
by SEAT forSEAT
theS.A
3rd and
does 4th gear.
not guarantee or accept any liability with
– Place the gearbox casing O-rings -arrows- .

Arosa 1997 ➤
One of the guide pivots -A- is thicker than the others, supporting
in this way the spring cage.
– Completely fill the axial needle bearing -B- with ATF, so that
the bearing adheres when it is installed onto the cover for the
gearbox casing.
Place the axial needle bearing onto the cover in accordance with
the correct installation position (the dark surface remains visible).
prox. 3 mm).
mm thick.
– Place the gearbox casing cover, turning it in the counterclock‐

wise to the arrow in order to avoid the support for column -
AR-2203A- .
que of 20 Nm.
– Turn the gearbox 180°.
– Insert the pinion attack shaft -1- .

Arosa 1997 ➤
– Place large planet gear -B- into the gearbox casing.

– Place the axial needle bearing -A- onto the large planet gear
-B- in accordance with the correct installation position (the
smooth surface remains visible).
– Insert the input shaft -2- into the large planet gear.
– Place the axial needle bearing -1- onto the input shaft in ac‐
cordance with the correct installation position (the dark surface
remains visible).
– Insert the clutch for the 1st and 3rd gear -B- .
Note!
When inserted, the input shaft must completely enter the clutch
for the 1st and 3rd gear. If necessary, fit them together before
inserting them into the casing.
– Place the axial needle bearing -A- on the clutch for the 1st and
3rd gear in accordance with the correct installation position
(the dark surface remains visible).
axial needle bearings must be calibrated anew ⇒ page 90 , Ad‐
just the clearance for the clutch.
– Place the reverse gear clutch -1- .

Recesses -A- must be placed on top of lugs -B- .

Arosa 1997 ➤
– Place shim -2- on top of the reverse gear clutch -K1-.

shim must be calibrated anew ⇒ page ⇒ page 90 , Adjust the
clearance for the clutch.
– Fit gasket -1- of the ATF pump.
– Fit the brake strap in the following manner:

– Place the new adjusting screw -2- with counter nut -1- in the
gearbox.
Do not yet screw in the covered part of the screw threads. The
screw must be fitted after fitting the ATF pump ⇒ page 90 , Ad‐
justing the brake strap.
– Install brake strap -3- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Line up the ATF pump to the gearbox casing. Take note of the
position of the shim, the ATF pump gasket, and the ATF
pump's piston segments when installing.
– Tighten the ATF pump bolts -arrows- to a torque of 20 Nm.
– Enter the differential -arrow A- .

– Place the new O-rings -arrow B- into the gearbox casing and
-arrow C- into the turbine shaft.
clean sealing surface of the converter casing. The bead should
be 3-4 mm thick.
– Place the converter housing onto the gearbox casing; to do
so, take note of the adjusting bolt and ATF pump O-ring.
– Tighten the converter casing bolts to a torque of 30 Nm.

Arosa 1997 ➤
– Install the left and right articulation flanges -arrow-

⇒ page 121 , Articulation flange oil seals: removal and fitting.
– Install the connectors together with the solenoid valve wiring
harnesses.
– Fit the new O-rings -A- into the gearbox casing.
– Place the slide box on top and insert the securing disc bolt into
the groove of the selected -4- slide box.
– Take into account the length of the screws:
A - M6×80 mm
B - M6×68 mm
C - M6×40 mm
– Tighten the screws to a torque of 9 Nm.
– Install solenoid valve connectors -2- and hook the cables into
the support -3- .
– Attach ATF temperature sender -5- .
– Fit solenoid valve connector -1- .
Apply sealant paste -D 176 404 A2- to the oil sump in the following
manner:
prox. 3 mm).
mm thick.
– Assemble the oil sump and tighten the securing nuts in diag‐
onal sequence to a torque of 8 Nm.

Arosa 1997 ➤
– Fit the ATF radiator -arrow- into the gearbox and tighten the
bolt to a torque of 25 Nm.
– Install the torque converter ⇒ page 13 .
– Fitting the gearbox ⇒ page 44 .
– Fill ATF, then check the level of ATF and top up ⇒ page 53 .
7.6 General overview for the all adjustments to the planet gear
I - Reverse gear shaft -B1-

❑ A - Thrust disc
❑ Determine thickness
⇒ page 86 , Adjusting
the reverse gear shaft -
B1-
II - 2nd and 4th gear brake -B2-
❑ B - Brake strap
❑ Adjusting the brake
strap ⇒ page 88 , Ad‐
justing the 2nd and 4th
gear brake -B2-
III - Clutch clearance
❑ C - Axial needle bearing
the clutch clearance be‐
pump
❑ D - Shim Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Determine thickness permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the clutch clearance be‐
pump
7.7 Reverse gear brake -B1- adjusting

♦ Feeler gauge
– Installing components for reverse gear brake adjustment -B1-
in the gearbox casing ⇒ page 74 , Planet gears: assembly

Arosa 1997 ➤
1 - Gearbox casing
2 - Safety ring
3 - Support disc
4 - Inner disc -B1-
❑ Part number ⇒ page 3
5 - Outer disc -B1-
6 - Thrust disc
❑ Installing for the adjust‐
ment
❑ Installing with the corre‐
sponding thickness af‐
ter making the measure‐
ment
7 - Plate spring
❑ Take note of assembly
position: large diame‐
ters should coincide
8 - Safety ring
9 - Spring support plate
❑ With springs
❑ With piston -B1-
❑ Before removing or in‐
stalling the cover, first
remove road speed
sender -G68-
⇒ page 22 , Electrical/
electronic components
and their locations;
Gearbox electrical/elec‐
tronic components
11 - Bolt
❑ 20 Nm
Thrust disc -A- to be determined

– Installing all components for reverse gear brake adjustment -
B1- in the gearbox casing ⇒ page 86 .

Arosa 1997 ➤
– Fit the cover of the gearbox casing, turning it counter-clock‐

wise to the arrow.
que of 20 Nm.
– Fill the pressure channel with compressed air -arrow- . When

the piston compresses the disc package, it must be audible.
In the case there is no air, the clutch pedal should return to its
resting position.
Measuring the play for the reverse gear brake -B1-

– Using a feeler gauge -A- , measure the play between the safety
ring -1- and the support disc -2- .
Play: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
min. = 0.8 mm respect to the correctness of information in this document. Copyright by SEAT S.A.
max. = 1.1 mm
7.8 2nd and 4th gear brake -B2-: adjusting

– Installing components necessary for 2nd and 4th gear brake
adjustment -B2- ⇒ page 74 , Planet gears: assembly

Arosa 1997 ➤
1 - Gearbox casing
❑ Planet gear installed up
to the reverse gear
clutch -K2- ⇒ page 74 ,
Planet gears: assembly
2 - Adjusting screw
❑ Always renew
❑ Place on the moulded
part of the brake strap -
B2-
3 - Nut
❑ 45 Nm
5 - Gasket
6 - ATF pump
bling ⇒ page 95
7 - Bolt
❑ 20 Nm
8 - Spring
9 - Spring
10 - Brake activating piston for
2nd and 4th gears
❑ Place the pressure bar Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
onto the moulded part of permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the brake strap

11 - Cover
12 - Safety ring
– Tighten the ATF pump bolts -arrows- to a torque of 20 Nm.

Arosa 1997 ➤
Adjusting the brake strap -3-

– Tighten the adjusting screw -2- to a torque of 5 Nm.
– Unthread the adjusting screw 2 and a half turns.
– Tighten nut -1- to a torque of 45 Nm. When doing so, secure
the adjusting screw so that it does not turn at the same time.
7.9 Clutch clearance: adjusting

♦ Depth gauge
– The planet gear set must be installed, with the exception of the
axial needle bearings ⇒ Item 3 (page 91) , the shim
⇒ Item 5 (page 91) , and the ATF pump
– Install clutch clearance play without
– Adjusting the clutch play between -K1- and the ATF pump
⇒ page 91
– Adjusting the clutch play between -K2- and the ATF pump
⇒ page 93
– Take a measurement to verify the clutch play ⇒ page 94

Arosa 1997 ➤
1 - Gearbox casing
❑ Planet gear installed up
to the input shaft
⇒ page 74 , Planet
gears: assembly
2 - Clutch for 1st to 3rd gears -
K1- with turbine shaft
3 - Axial needle bearing with
washer
tion ⇒ page 65
❑ Do not install for the
clutch play adjustment
5 - Shim
❑ Do not install for the
clutch play adjustment
6 - Gasket
7 - ATF pump
8 - Bolt
❑ 20 Nm
7.9.1 Adjusting the clutch play between -K1-

and the ATF pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Determine the thickness of axial needle bearing -A-to the correctness of information in this document. Copyright by SEAT S.A.
respect
The thickness of the axial needle bearing is determined with the

separation measurement “x” and should be selected in accord‐
ance with the table ⇒ page 92 .
Separation measurement x = a - b
A - Axial needle bearing -A- (not installed when calibrating)
D - Gasket
1 - ATF pump
3 - Clutch for 1st to 3rd gears -K1-
4 - Gearbox casing
Determine to

Arosa 1997 ➤
– Placing straight edge “A” on the gearbox housing.

– Measuring with depth gauge “B” inside of -K1-.
Example:
Measured value 1 = 54.8 mm
– Fit gasket “C” on top of the pump flange in the gearbox casing.
– Measuring with depth gauge “B” on top of gasket “C” in the

gearbox casing.
Example:
- Measured value 2 = - 23.20 mm
Determined value to = 31.60 mm
Determine b
– Place straight edge “B” on the ATF pump.

– Measure with depth gauge “A” on top of the pump flange.
Example:
Measured value = 33.80 mm
- Straight edge = - 5.70 mm
Determined value b = 28.10 mm
Separation measurement x = a - b
= 31.60 mm - 28.10 mm = 3.50 mm
– Using the table, establish the thickness of the axial needle
bearing and determine the part number according to the Parts
Catalogue.
Table “Axial needle bearing”
Separation measurement “x” Axial needle bearing (mm)
(mm)
2.95 ... 3.14 2.70
3.15 ... 3.34 2.90
3.35 ... 3.54 3.10
3.55 ... 3.74 3.30
3.75 ... 3.94 3.50
3.95 ... 4.14 3.70

Arosa 1997 ➤
7.9.2 Adjusting the clutch play between -K2-

and the ATF pump
Determine the thickness of shim -B-
The shim thickness is determined by the separation measure‐
ment “y” and should be selected in accordance with the Table
⇒ page 94 .
Separation measurement y = c + d
B - Shim (not installed when calibrating)
D - Gasket
1 - ATF pump
3 - Clutch for 1st to 3rd gears -K1-
4 - Gearbox casing
Determine c
– Placing straight edge “A” on the ATF housing.

– Measure with depth gauge “B” on top of the pump housing.
Example:
– Measure with depth gauge

Protected “A” onCopying
by copyright. top of the pump
for private flange.
or commercial purposes, in part or in whole, is not
Example: respect to the correctness of information in this document. Copyright by SEAT S.A.

- Measured value 2 = -33.80 mm
Determined value c = 0.20 mm
Determine d
– Placing straight edge “A” on the gearbox housing.

– Measure with depth gauge “B” on top of the ignition collar for
the reverse gear clutch -K2-.
Example:
– Fit gasket “C” on top of the pump flange in the gearbox tray.

Arosa 1997 ➤
– Place straight edge “A” on top of the gearbox casing and

measure with depth gauge “B” on top of gasket “C” in the
gearbox casing.
Example:
- Measured value 2 = -23.20 mm
Determined value d = 1.50 mm
Separation measurement y = c + d
= 0.2 mm + 1.5 mm = 1.70 mm
– Using the table, establish the shim thickness of and determine
the part number according to the Parts Catalogue.
Table “Shims”
Separation measurement “y” Shims
(mm) (mm)
1.35 ... 1.54
respect to the correctness of information in this 0.80 Copyright by SEAT S.A.
document.
1.55 ... 1.74 1.00
1.75 ... 1.94 1.20
1.95 ... 2.14 1.40
2.15 ... 2.34 1.60
2.35 ... 2.54 1.80
2.55 ... 2.74 2.00
2.75 ... 2.94 2.20
– To verify, measure the clutch play after installing the ATF
pump ⇒ page 94 .
7.9.3 Verification measurement (clutch play)

– The clutch play can be measured after installing the ATF
pump.
– Fit the bracket for the clock gauge into the gearbox tray and
place the clock gauge with 1 mm of pretension on top of the
turbine shaft.
– Move the turbine shaft up and down, and read the play with
the clock gauge.
Play:
min. = 0.25 mm
max. = 0.55 mm

Arosa 1997 ➤
38 – Gears, Hydraulic controls

1 ATF pump: dismantling and assem‐
bling
♦ -T20026- bracket
♦ Clock gauge
♦ Feeler gauge
1 - Piston ring
❑ Checking the correct
adjustment
❑ Do not over-expand
2 - Bolt
❑ 10 Nm
3 - Steered wheel support
4 - Outer sprocket
❑ Check for wear
⇒ page 96 and
⇒ page 96
5 - Inner sprocket
❑ Check for wear
⇒ page 96 and
⇒ page 96
6 - ATF pump housing
7 - O-ring
❑ Always renew
8 - Torque converter seal
1. ATF pump: dismantling and assembling 95

Arosa 1997 ➤
⇒ page 13
Axial deterioration of the outer and inner sprockets with respect

to the ATF pump housing
– Place tool -T20026- together with the measuring device on top
of the ATF pump housing.
– If the measured value exceeds the wear limit indicated in the
table, the pump should be replaced.
Measured dimen‐ Wear limit (mm)
sion
Height difference be‐ 0.04
tween the ATF pump
housing and the out‐
er sprocket
Height difference be‐ 0.04
tween the ATF pump
housing and the in‐
ner sprocket
Measure the play between the outer and inner sprockets

A - Feeler gauge of 0.15 mm
– When it becomes possible to insert the feeler gauge between
the outer and inner sprockets, the pump should be replaced.
96 Rep. Gr. 38 - Gears, Hydraulic controls

Arosa 1997 ➤
2 Free sprocket: dismantling and assembling
1 - Thrust washer
❑ Place on the cage item
❑ The smooth face out‐
wards
2 - Cage with securing ele‐
ments
❑ Fit to the outer ring of
the free sprocket
⇒ page 97
3 - Outer ring for free sprocket
❑ Assembly position: The
letters and the bevel
-arrow- should be facing
the satellite holder
Assemble the free sprocket

– Fit the outer ring -arrow C- on the workbench so that the bevel
-arrow B- faces downwards.
– Fit the cage -arrow D- onto the outer ring so that the conical
guide tabs -arrow A- are facing downwards.
– Push the securing elements inwards at the same time as the
cage is fitted to the outer ring with the guide tabs.
– Fit the thrust washers onto the cage.
– Checking action of free sprocket:
• Place the free sprocket in assembly position (the letters and
the bevel facing upwards).
• Place the satellite holder into the cage.
Turn the satellite holder to the left- “free sprocket open”
Turn the satellite holder to the right- “free sprocket closed”
2. Free sprocket: dismantling and assembling 97

Arosa 1997 ➤
3 Clutch for 1st to 3rd gears -K1-: dis‐

mantling and assembling
♦ Plunger -T20023-
Checking clutch action ⇒ page 100
1 - Safety ring
❑ Remove by levering
with a screwdriver
2 - Support disc
❑ Fitting ⇒ page 99 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Determine thickness permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ page 99
3 - Inner disc
❑ Part number ⇒ page 3 ,
Code letters, group
numbers, ratios, equip‐
ment
4 - Outer disc
❑ Part number ⇒ page 3 ,
Code letters, group
numbers, ratios, equip‐
ment
5 - Plate spring
❑ The convex side (small
diameter) should face
the clutch bell housing
6 - Safety ring
⇒ page 99
7 - Oil seal
❑ Always renew
8 - Piston cover
❑ Before fitting, soak in oil
seals with ATF
9 - Spring
❑ Place between the piston and the piston cover

Arosa 1997 ➤
10 - Oil seal
❑ Always renew
❑ The sealing lip should be facing the clutch bell housing
11 - Oil seal
❑ Always renew
12 - Piston
❑ Before fitting, moisten the sealing lips with ATF
❑ On fitting, turn the piston slightly
❑ After fitting, it should be possible to rotate the piston in the clutch bell housing
13 - Clutch bell housing with turbine shaft
14 - Piston ring
❑ Checking the correct adjustment
Removing and installing the safety ring

– Push the spring piston cover downwards with tool -T20023-
until the safety ring can be fitted into the recess.
Fitting the inner and outer discs

The convex side of the plate spring (small diameter) should face
the clutch bell housing.
– Fit the outer discs -2- and inner discs -4- onto the plate spring
-3- .
– Fit the support disc -5- onto the last inner disc.
– Fit the safety ring -1- in the recess of the clutch bell housing.
Determining the thickness of the support disc

– Using a feeler gauge “A” , measure the play between the safety
ring and the support disc.
Component Dim. Wear limit
Clutch K1 0.45 ... 0.85 mm 1.05 mm
– If the wear limit is reached with the used clutch, it will be nec‐
essary to change the discs and select a new
Protected support
by copyright. disc.for private or commercial purposes, in part or in whole, is not
Copying
– Choose the discs and the support disc according to the gear‐
box code.
3. Clutch for 1st to 3rd gears -K1-: dismantling and assembling 99

Arosa 1997 ➤
Checking the clutch action

– Before fitting the piston, moisten the sealing lips and oil seals
with ATF.
– Turn the piston slightly when fitting,.
– Once the piston is fitted to the clutch or brakes, it should be
possible to turn it easily by hand in both directions -arrows- .
– If this is not the case, perhaps the sealing lips or oil seals are
incorrectly fitted or damaged.
– Check the lips or oil seals for damage and replace if neces‐
sary.
– Refit the piston and check again.
– Blow compressed air into the pressure channel -arrow- .

– Seal the orifice on the opposite side.
– The clutch piston should compress the disc package.
– Release the air pressure. The discs should return to their rest‐
ing position.

Arosa 1997 ➤
4 Reverse gear clutch -K2-: disman‐

tling and assembling
♦ Kit -U-40450A-
Checking the clutch action ⇒ page 103
4. Reverse gear clutch -K2-: dismantling and assembling 101

Arosa 1997 ➤
1 - Safety ring
❑ Mark when dismantled
and assemble in the
same position
2 - Support disc
⇒ page 103
3 - Inner disc
4 - Outer disc
5 - Safety ring
with a screwdriver
❑ With springs
7 - Oil seal
❑ Always renew
8 - Piston
❑ Choose the spare part
according to the gear‐
box code
9 - Oil seal
❑ Always renew
❑ The sealing lip should be facing the clutch bell housing
10 - Clutch bell housing
Fitting the safety ring

– Place the support plate and springs on the clutch piston -K2-.
– Fit the safety ring onto the support plate.
– With the aid of tools -T10002- and -U-40450A/3- , push the
safety ring downwards carefully together with the plate until
the safety ring can be heard to engage in the groove.

Arosa 1997 ➤

The ring oil seal lip should be facing the clutch bell housing.
– Fit the outer discs -3- and inner discs -4- onto the clutch bell
housing.
– Fit the safety ring -1- in the groove of the clutch bell housing.

– Fit the shim between the clutch -K2- and the ATF pump.
– Fit the clutch -K2- onto the ATF pump and press downwards.
– Release the compressed air. The discs should return to their
resting position.

Clutch K2 0.5 ... 0.8 mm 1 mm
essary to change the discs and select a new appropriate
support disc.
box code.
4. Reverse gear clutch -K2-: dismantling and assembling 103

Arosa 1997 ➤
5 Clutch 3rd and 4th gear -K3-: disman‐

Take note of the number of discs and their assembly position

when dismantling ⇒ page 105
Checking the clutch action ⇒ page 105
1 - Safety ring
with a screwdriver
2 - Support disc
⇒ page 106
3 - Inner disc
4 - Outer disc
5 - Safety ring
⇒ page 105
❑ With springs
7 - Oil sealrespect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Always renew
8 - Oil seal
❑ Always renew
9 - Piston
❑ The corresponding
gearbox code is as‐
signed to this spare part
❑ Before fitting, moisten
the sealing lips with ATF
❑ On fitting, turn the piston
slightly
❑ After fitting, it should be possible to rotate the piston in the clutch bell housing

Arosa 1997 ➤
10 - Clutch bell housing

– Push the piston cover downwards with tool -T20023- until the
safety ring can be fitted.
Note that the amount and assembly positions of the discs are dif‐
ferent
I - -K3- with 5 exterior discs
II - -K3- with 3 exterior discs
A - Safety ring
– Fit the outer discs -4- and inner discs -3- onto the clutch bell
housing.
– Fit the safety ring -1- in the groove of the clutch bell housing.

– Place the axial needle bearing on the gearbox casing cover.
– Fit the clutch -K3- onto the gearbox casing cover and press
downwards.
– Release the air pressure. The discs should return to their rest‐
ing position.
5. Clutch 3rd and 4th gear -K3-: dismantling and assembling 105
Arosa 1997 ➤

Clutch K3 1.8 ... 2.2 mm 2.4 mm
essary to change the discs and select a new appropriate
support disc.
box code.

Arosa 1997 ➤
6 Reverse gear brake -B1-: dismantling and assembling
1 - Gearbox casing
2 - Safety ring
with a screwdriver
3 - Support disc
⇒ page 86
4 - Inner disc -B1-
5 - Outer disc -B1-
6 - Thrust disc
7 - Plate spring
❑ Note fitting position: the
large diameters should
coincide ⇒ page 108 ,
8 - Safety ring
with a screwdriver
❑ With springs
❑ Fitted onto the piston
-12- ⇒ page 108
10 - Oil seal
❑ Always renew
11 - Oil seal
❑ Always renew
12 - Piston -B1-
❑ Before fitting the oil seals, moisten them with ATF
13 - Piston ring
❑ Checking the correct adjustment
14 - Gearbox casing
respect cover of information in this document. Copyright by SEAT S.A.
to the correctness
15 - O-ring
❑ Always renew
16 - Sealing screw
❑ 8 Nm
6. Reverse gear brake -B1-: dismantling and assembling 107

Arosa 1997 ➤
Removing the brake piston -B1-

– Remove the piston from the gearbox casing by levering with
a screwdriver in several places.
Place the support plate and springs on the piston -B1-

One of the guide pivots -A- of eachpermitted
group is thicker
unless than
authorised theS.A.
by SEAT oth‐
SEAT S.A does not guarantee or accept any liability with
ers, supporting in this way the spring cage.
Fitting the outer and inner discs

– Place the support disc -5- on the safety ring -6- that secures
the free gear.
– Fit the outer discs -4- and inner discs -7- onto the gearbox
casing.
– Fit the thrust disc -3- onto the last inner disc.
– Fit the springs of plate -2- in their corresponding positions, so
that the large diameters coincide.
– Fit the safety ring -1- in the groove of the gearbox casing.

Arosa 1997 ➤
7 2nd and 4th gear brake piston -B2- dismantling and assembling
1 - Safety ring
⇒ page 110
2 - O-ring
❑ Always renew
3 - O-ring
❑ Always renew
4 - Cover
❑ Remove from the gear‐
box casing once the
safety ring has been ex‐
tracted
5 - O-ring
❑ Always renew
6 - 4th gear actioning piston
7 - O-ring
❑ Always renew
8 - O-ring
❑ Always renew
9 - Piston cover
❑ 2nd gear actioning pis‐
ton
gearbox code
respect iscorrectness
to the as‐ of information in this document. Copyright by SEAT S.A.
10 - 2nd gear actioning piston
11 - Spring
12 - Spring
❑ Place in the assembly position ⇒ page 110 ,
14 - Adjusting screw
15 - Nut, 45 Nm
❑ 45 Nm
16 - Gearbox casing
7. 2nd and 4th gear brake piston -B2- dismantling and assembling 109
Arosa 1997 ➤

– Fit a 300 mm clamp -A- as in the illustration.
– Press the cover with the screw of the clamp -A- .
– Remove the safety ring -B- by levering with a screwdriver.
Release the brake strap -B2-

– After dismantling, secure the brake strap, e.g. with a wire stir‐
rup -A- so it cannot open.

Arosa 1997 ➤
8 Slide box: removing and installing

Assembly procedure ⇒ page 66 , Planet gears: dismantling and
assembling
Caution
Do not start the engine or tow the vehicle without the sump
fitted or without ATF
– Slide box in vehicles up to 06.00 ⇒ page 111

– Slide box in vehicles from 07.00 onwards ⇒ page 114
Note!
♦ The slide box or wiring harness can also be removed with the
gearbox fitted
♦ The solenoid valves can be replaced
♦ Do not use fluffy cloths
♦ After refitting the sump, check the level of ATF and top up
⇒ page 53
♦ After assembly, carry out basic setting ⇒ VAS 5051; Vehicle
self-diagnosis
8.1 Slide box (vehicles up to 06.00): removing and installing

Vehicles from 07.00 onwards ⇒ page 114
Notes to consider before removing the slide box ⇒ page 111
8. Slide box: removing and installing 111

Arosa 1997 ➤
1 - Sealing screw
❑ 15 Nm
❑ Always renew the seal
⇒ page 113
❑ ATF level: checking and
topping up ⇒ page 57
2 - O-ring
❑ Always renew
3 - Solenoid valve -N90-
❑ Grey
❑ Identification
⇒ page 114
4 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always renew permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 - O-ring
❑ Always renew
❑ Pink
❑ Identification
⇒ page 114
7 - O-ring
❑ Always renew
❑ Blue
❑ Identification
⇒ page 114
9 - Support
❑ For the solenoid valves
10 - Nut
❑ 9 Nm
11 - O-ring
❑ Always renew
❑ Yellow
❑ Identification ⇒ page 114
❑ Green
14 - O-ring
❑ Always renew
15 - Bolt
❑ 8 Nm
16 - Slide box
❑ Dismantling and fitting ⇒ page 66 , Planet gears: dismantling and assembling
17 - Manual slide
❑ Secure so that it does not come out when removing the slide box

Arosa 1997 ➤
18 - Wiring harness
19 - O-ring
❑ Always renew
❑ For the wiring harness connector
20 - Connector
❑ For the wiring harness
❑ Remove ⇒ page 66 , Planet gears: dismantling and assembling
❑ Engage on fitting to the gearbox casing
21 - O-ring
❑ Always renew
22 - Gearbox casing
23 - Bolt
❑ 9 Nm
24 - ATF strainer
❑ To replace, it is necessary to remove the sump and fit it again
25 - Magnet
❑ Fit to the sump filler neck
26 - Overflow pipe
❑ Remove to let the ATF come out ⇒ page 57 , ATF level: checking and filling; Changing ATF
27 - Bolt
❑ 8 Nm
28 - Sump
❑ Assembly procedure ⇒ page 66 , Planet gears: dismantling and assembling
Renew the plug oil seal

– Cut the seal -arrow- with a pair of cutting pliers, always renew
the seal.
– After the repairs, fit the plug by hand with a new o-ring and fill
with ATF.º
– Fill with ATF, check ATF level and top up ⇒ page 57 .
Identification of therespect
slidetoboxthe correctness of information in this document. Copyright by SEAT S.A.
The code is stamped on a plate -arrow- , which should always be

assigned to its corresponding slide box.

Arosa 1997 ➤
Identification of the solenoid valves

A - Solenoid valve -N88- (green)
B - Solenoid valve -N89- (yellow)
C - Solenoid valve -N90- (grey)
D - Solenoid valve -N91- (blue)
E - Solenoid valve -N93- (pink)
1 - Nut for securing the solenoid valves. Tightening torque 9 Nm
8.2 Slide box (vehicles from 07.00): removing and installing

Notes to consider before removing the slide box ⇒ page 111
1 - Sealing screw
❑ 15 Nm
❑ Always renew the seal
⇒ page 115
❑ Check the ATF level and
top up ⇒ page 57
2 - Overflow pipe
❑ Remove to let the ATF
come out ⇒ page 57 ,
ATF level: checking and
filling; Changing ATF
3 - Bolt
❑ 8 Nm
4 - Sump
❑ Assembly procedure
gears: dismantling and
assembling
5 - Magnet
❑ Fit to the sump filler
neck
6 - Bolt
❑ 8 Nm
7 - ATF strainer
⇒ page
respect 116
to the correctness of information in this document. Copyright by SEAT S.A.
8 - Bracket
❑ With solenoid valves: -
N88- , -N89- , -N90- , -
N91- , -N92-
⇒ page 116
9 - Bolt
❑ M6×35 mm
❑ 8 Nm
10 - Bolt
❑ M6×68 mm

Arosa 1997 ➤
❑ 8 Nm
11 - Bolt
❑ M6×12 mm
❑ 8 Nm
13 - Bolt
❑ M6×75 mm
❑ 8 Nm
14 - Disc-shaped washer
15 - Sleeve
16 - O-ring
❑ Always renew
17 - O-ring
❑ Always renew
18 - Bolt
❑ 8 Nm
19 - Slide box
❑ Identification ⇒ page 116 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismantling and fitting ⇒ page 66 , Planetrespect
gears: dismantling and assembling
20 - Manual slide
❑ Secure so that it does not come out when removing the slide box
21 - O-ring
❑ Always renew
22 - Gearbox casing
23 - Connector
❑ For wiring harness
❑ Engage on fitting to the gearbox casing
24 - O-ring
❑ Always renew
25 - Wiring harness
Renew the plug oil seal

– Cut the seal -arrow- with a pair of cutting pliers, always renew
the seal.
– After the repairs, fit the plug by hand with a new o-ring and fill
with ATF.
– Fill with ATF, check ATF level and top up ⇒ page 57 .

Arosa 1997 ➤
Identification of the slide box

The code is stamped on the plate -arrow- , which should always
be assigned to its corresponding slide box.
Dismantling and fitting solenoid valve -N93-

– Remove bolt -1- and remove the valve cable.
– Remove bolts -arrows- .
– Uncouple the connector -2- .
– Remove valve -N93- -3- .
– Replace the O-ring.
Follow the directions given in reverse order to disassemble, taking
the following into account:
– Tighten bolts -1- and -arrows- to 8 Nm.
Dismantling and fitting the bracket with solenoid valves -N88- to

-N92-
– Removing solenoid valve -N93- ⇒ page 116 .
– Uncouple the connector -1- .
– Remove bolts -A- , -B- and -C- .
– Tighten bolts -A- , -B- and -C- to 8 Nm.
Removing and installing the ATF strainer

– Do not mix up bolts -A- - and -B- ; fit them in their original
positions.
– Tighten bolts -A- and -B- to 8 Nm.
– Fit brackets -1- and -2- and plate -3- as described in the illus‐
tration.

Arosa 1997 ➤
9 Parking lock: dismantling and assem‐

bling
Note!
♦ To remove and assemble the parking lock, remove the engine shaft along with the parking lock wheel and
the slide box
♦ Adjusting the multi-function switch ⇒ page 23
9. Parking lock: dismantling and assembling 117

Arosa 1997 ➤
1 - Oil seal
❑ Fit ⇒ page 119
2 - Selector rod
⇒ page 119
❑ When transporting the
gear, avoid axial blows
to the control lever shaft,
as this could sever the
screw
3 - Bolt
❑ 10 Nm
❑ Fit the selector rod
⇒ Item 2 (page 118) to
the the gearbox casing
4 - Control piece spring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Do not press excessive‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ly respect to the correctness of information in this document. Copyright by SEAT S.A.
5 - Bolt
❑ 5 Nm
6 - Control part
7 - Support sleeve
❑ For control part
❑ Release with a drift
❑ Insert, tapping it after fit‐
ting the control part
⇒ page 119
8 - Support sleeve
❑ For the rod ⇒ Item 9 (page 118)
❑ Release with a drift
❑ Insert after placing the rod ⇒ page 119
9 - Rod
❑ Replace with the meshing lever item ⇒ Item 10 (page 118) before fitting it to the selector rod
10 - Meshing lever
❑ Place into the selector rod along with the rod
11 - Bolt
❑ 27 Nm
12 - Support tab
❑ For the meshing lever
13 - Bolt
❑ 5 Nm
14 - Cover
❑ Secure the shaft for the retention lever
15 - Shaft for the retention lever
❑ It can be fitted and removed by hand

Arosa 1997 ➤
16 - Recuperation spring
17 - Retention lever
Removing the control lever shaft oil seal

– Lever it with tool -T20143- to remove it.
Fitting the selector rod oil seal

– Fill the space between the lips of the new oil seal with universal
grease.
– Insert the oil seal to the limit with tool -T20153- .
Remove and fit tensioning sleeves -1-

Releasing
– Release the tensioning sleeves on rod -4- by tapping them with
a drift, and tapping control element -5- enough to remove the
selector rod -2- .
Fitting
– After inserting the selector rod into the control element and into
the rod, fit the sleeves Protected
by tapping them.
– Fit selector rod with bolt -3- , tightening to a torque of 10 Nm.
9. Parking lock: dismantling and assembling 119

Arosa 1997 ➤
Removing and installing retaining lever -3- together with the re‐
cuperation spring
Removing
– Unscrew the bolt -arrow-.
– Remove cover -1- , and remove the retaining lever shaft.
– Remove the recuperation spring -2- and the retention lever.
Fitting
– Hook the angular end of the spring into the lever and leave the
other end in such a way that it is in contact with the gearbox
housing.
– Tighten the bolt -arrow- to 5 Nm.

Arosa 1997 ➤
39 – Final drive, Differential

1 Articulation flange seals: removing
and installing
1.1 Articulation flange seals: removing and

installing
(Gearbox fitted to vehicle)

equipment required
♦ Kit -U-40020-
♦ Kit -U-40100-
♦ Compression tool -T20005-
♦ Pressure hose -T20133-
8010-
1.1.1 Removing
In order to avoid the planet gears from falling toward one side of
the differential, always assemble/remove only one of the articu‐
lation flanges.
– With the ignition switched off, disconnect the battery earth
strap.
1. Articulation flange seals: removing and installing 121

Arosa 1997 ➤
Note!
code.
– Remove the insulation tray, if fitted: ⇒ Bodywork Repairs, in‐

stallation work, exterior; Rep. Gr. 50 ; Bodywork, front .
Articulation flange oil seal, right
– Remove the protective cover for the driveshaft, if fitted.
– Remove the bolts securing the driveshafts to the gearbox
flanges, with the correct spanner on tool -U-40020- .
– Pull driveshaft to one side and secure it, taking care that it is
not damaged.
Articulation flange oil seal, left
flanges, with the correct spanner on tool -U-40020-
– Turn the steering toward the right.
– Release the ball joint from the left-hand wheel bearing casing
with tool -T20147- .
Note!
Leave the hexagon nut on the ball joint threads to protect them.
– Fold the swinging arm down to remove the ball joint from the
wheel bearing casing.
– Fold the wheel spindle outwards.
– Remove the left driveshaft from between the sub-frame and
the gearbox.
Articulation flange oil seals, right/left:
– Place a container under the gearbox.
– Remove the articulation flange bolt; to do this, thread two bolts

into the flange and immobilize the shaft with a lever.
122 Rep. Gr. 39 - Final drive, Differential

Arosa 1997 ➤
– If the gearbox is out of the vehicle, remove the articulation

flange oil seal with tool -U-40100/4- . Activate the hammer until
the oilseal is removed.
– If the gearbox is fitted in the vehicle, remove the articulation
flange oil seal by levering it with a screwdriver.
Note!
Take care not to damage the oil seal housing in the gearbox.
1.1.2 Fitting
– Fill the space between the lip seal and the dust guard with -G
052 128 A1- grease.
Note!
With the gearbox removed, use tools -U-40450A/3- and -

U-40450A/6- to fit the seal into the housing.
– With the gearbox fitted, use tool -T20134- to fit the new seal,
threading the spindle into the differential's threaded part.
– Rotate the nut until the new seal is well fitted.
– Fit the articulation flange with the spring, thrust washer, and
conical ring.
– Fit securing bolt to articulation flange. Use tool -T20005- and

tighten the bolt to 25 Nm.
Articulation flange oil seal, left
– Place the driveshaft in the engine bay, and fit it into the wheel
hub.
1. Articulation flange seals: removing and installing 123

Arosa 1997 ➤
– Fit the ball joint into the wheel bearing housing. Lock the ball
joint with a Torx -T40- key and tighten the new self-locking nut
to 20 Nm + 90°.
1 - Torx -T40- (shortened approx. 10 mm)
2 - -SAT 8010/18A-
3 - -SAT 8010-
Note!
Make sure that the ball joint dust sleeve is not damaged or twisted.
Articulation flange oil seal, right

– Fit the protective cover for the driveshaft, in case it is fitted, to
the engine and tighten to a torque of 35 Nm.
Articulation flange oil seals, right/left
– Fit driveshaft to gearbox flange and tighten bolts to 70 Nm in
two stages (I - 10 Nm, II - 70Nm), with the correct spanner from
tool -U-40020- .
– Checking gearbox oil level ⇒ page 53 .
– Install the insulation tray, if fitted: ⇒ Bodywork Repairs, in‐
stallation work, exterior; Rep. Gr. 50 ; Bodywork, front
– Connect the earth battery strap.
Note!
When the battery is re-connected, depending on which version,

the vehicle equipment will have to be encoded.

Arosa 1997 ➤
2 Final drive: removing and installing
2.1 Final drive: general assembly diagram
1 - Planet gears
bling ⇒ page 66
2 - Engine shaft
assembling
bling ⇒ page 127
❑ Number of teeth
⇒ page 3 , Code letters,
group numbers, ratios,
equipment
3 - Differential Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismantling andpermitted
fittingunless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ page 126

bling ⇒ page 133
4 - Driven sprocket
⇒ page 127
5 - Drive sprocket
assembling
2. Final drive: removing and installing 125

Arosa 1997 ➤
2.2 Differential: removing and installing
1 - Bolt
❑ 30 Nm
2 - Torque converter casing
3 - Articulation flange oil seal
❑ Before fitting, fill the
space between the seal‐
ing lips with universal
grease
⇒ page 121
4 - Bolt
❑ 22 Nm
❑ Before fitting, apply -G
052 128 A1- sealing
paste
5 - Right-hand articulation
flange
❑ Do not mix up left and
right-hand articulation
flanges, they are differ‐
ent lengths.
6 - Articulation flange pressure
spring
7 - Thrust washer
❑ Assembly position: col‐
lar towards the spring,
core towards the conical
ring
8 - Conical ring
❑ With slots for the thrust
washer
❑ Assembly position: con‐
ical side facing the dif‐
ferential casing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Safety ring
❑ Maintains the position of the conical ring, thrust washer and pressure spring of the articulation flange
when dismantled
10 - Articulation flange
❑ Do not mix up left and right-hand articulation flanges, they are different lengths
11 - Differential
12 - Pin
❑ To centre the gearbox casing and the torque converter
13 - Gearbox casing
❑ Before assembling the gearbox casing and the torque converter, apply -D 176 404 A2- sealing compound
onto the sealing surfaces
14 - Guide bush
❑ For the speedometer control
15 - Speedometer control

Arosa 1997 ➤
2.3 Engine shaft: dismantling and assembling

equipment required
♦ Kit -T20022-
♦ Rotation tool -T20024-
♦ Kit -U-40100-
♦ Kit -U-40200A-
♦ Kit -U-40300-

Arosa 1997 ➤

8010-
♦ Kit -T20140-
Note!
♦ To remove the engine shaft, first remove the planet gear until the large planet, once the torque converter
casing has been dismantled ⇒ page 60 , Planet gears: dismantling and assembling
♦ To avoid premature wear and noise, the roller bearings on a shaft should be replaced at the same time

Arosa 1997 ➤

2 - Shim
⇒ page 142 , crown/pin‐
ion sprocket: adjusting
3 - Outer ring of roller bearing
❑ Release ⇒ page 129
4 - Inner ring of roller bearing
5 - Engine shaft
❑ Number of teeth
group
unlessnumbers, ratios,
permitted authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
equipment

6 - Parking lock sprocket
7 - Driven sprocket
❑ Number of teeth
group numbers, ratios,
equipment
8 - Nut
❑ 145 Nm
❑ Always renew
❑ Loosen and tighten
⇒ page 132
❑ Secure ⇒ page 132
11 - Gearbox casing
Removing the outer ring of the roller bearing from the torque con‐
verter housing
– Remove the outer ring of the small roller bearing with tool -
T20140-
Procedure for extracting the outer ring ⇒ page 8 , General in‐
structions for gearbox repairs.

Arosa 1997 ➤
Fitting the outer ring of the roller bearing into the torque converter
housing
– Place the torque converter casing on a workbench, so it is to‐
tally flat.
Removing the inner ring of the roller bearing
Note!
If the bearing cage breaks on extraction, use tool -T20022- with

claws -T20022/44- to remove the internal bearing ring
Inserting the inner ring of the roller bearing by pressure

– Place tool - U-40100/3- under the driven sprocket, without
damaging the inner ring of the roller bearings.
– Fit tool -T20024- inside tool -T20152- , and rest it on the inner
ring of the roller bearing.
Remove the driven sprocket by pressure

– Fit tool -U-40100/2- between the driven sprocket and the park‐
ing lock gear.
– Place tool -T20061- over the threaded shaft of the crown pin‐
ion shaft.

Arosa 1997 ➤
Fit the driven sprocket

– Fit tool -U-40300/1- to the layshaft under the crown pinion
shaft so as not to damage the bearing.
– Fit tool -U-40200/15- above the driven sprocket so that the
shaft in within the tool.

– Place the engine shaft in a vice with protected jaws.
– Remove the inner ring with tool -T20022- and claws -
T20022/44- .
Fitting the inner ring of the roller bearing

– Place tool -U40100/3- between the crown pinion and the roller
bearing without damaging them.
– Fit tool -T20024- inside tool -T20152- , and rest it on the inner
ring of the roller bearing.
Remove the outer ring of the roller bearing from the gearbox cas‐
ing
T20140-

Arosa 1997 ➤
Fitting the outer ring of the roller bearing into the gearbox casing
Loosen and tighten the hexagon nut

– Hold the engine shaft in a vice with protected jaws -A- .
– Tighten with torque spanner -SAT 8010- -B- to 145 Nm.
Secure the hexagon nut

– Secure the collar of the hexagon nut with a punch in the ma‐
chined grooves of the engine shaft -arrows- .

Arosa 1997 ➤
3 Differential: dismantling and assembling

equipment required
♦ -T20022- Kit
♦ Pressure tool -T20047-
♦ -U-40100- Kit
♦ -U-40200 A- Kit
♦ -U-40300- Kit
3. Differential: dismantling and assembling 133

Arosa 1997 ➤
♦ -T20140- Kit
Note!
To avoid premature wear and noise, the roller bearings on a shaft should be replaced at the same time

Arosa 1997 ➤

⇒ page 126
❑ Oil pipe: removing and
installing ⇒ page 136
2 - Thrust washer
❑ For satellite
3 - Satellite
4 - Thrust washer
❑ For the planet gear
5 - Planet gear
6 - Threaded component
7 - Support sleeve
❑ To hold the satellite
shaft
❑ Extract and replace with
a punch
8 - Satellite shaft
❑ Extract by striking with a
punch
❑ On fitting, do not dam‐
age the thrust washers
❑ Fit into the differential
housing ⇒ page 137
❑ Fit into the gearbox casing ⇒ page 136
11 - Gearbox casing
❑ Differential: removing and installing ⇒ page 126
12 - Bolt
❑ 80 Nm
13 - Differential casing
14 - Crown
❑ Number of teeth ⇒ page 3 , Code letters, group numbers, ratios, equipment
15 - Speedometer drive sprocket permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Fit the projections of the drive sprocket into the groove in the differential casing, flat side facing outwards

18 - Shim
❑ Determine thickness ⇒ page 140

Arosa 1997 ➤
Removing and fitting the oil pipe -1-

– Remove the bolts -arrows- from the oil pipe clamps.
– Remove the oil pipe from the torque converter casing.
– On fitting, press the oil pipe into the torque converter box by
hand as far as it will go.
Fitting planet gears

– Lubricate the satellite thrust washers and the satellites and fit
them.
– Fit the satellites and insert the satellite shaft by tapping.
– Fit a new support sleeve.
– Lubricate the planet gear thrust washers and fit them.
– Fit the threaded component to the planet gears.
– Fit the satellite gears at 180° and rock them -arrow- .

– Fit tool -U-40300/11- to the base and remove the inner ring of
the roller bearing with extractor -U-40100/1- .
Fitting the inner ring of the roller bearing into the gearbox casing
– Use tool -T20047- with tool -T20152- to fit the inner ring of the
roller bearing.
– Bolt up tool -T20047- until the inner ring of the roller bearing
is fitted.

Arosa 1997 ➤
Removing the outer ring of the roller bearing

– Fit tool -U-40300/13- to the shaft, fit tool -U-40100/1- on it and
remove the outer ring of the roller bearing.
Fitting the outer ring of the roller bearing into the differential casing
– Use tool -T20152- with tool -T20027- to fit the outer ring.
– Locate tool -U-40300/13- on the differential.

– Place extractor -U-40100/1- on tool -U-40300/13- . Remove
the bearing.
Note!
If the bearing cage breaks on extraction, use tool -T20022- with

claws -T20022/48- to remove the internal bearing ring
Inserting the inner ring of the roller bearing by pressure

– Fit the inner ring of the roller bearing into the differential casing
with tools -T20052- and -T20024- .

Arosa 1997 ➤
Fitting the outer ring of the roller bearing into the torque converter
housing
T20140-
Press fitting the outer ring of the roller bearing into the torque
converter housing

Arosa 1997 ➤
4 Final drive: adjusting
4.1 Final drive: Overview of check steps
1 - Drive sprocket
2 - Engine shaft
3 - Engine shaft roller bearings
❑ Always replace together
❑ On replacing the roller
bearing, re-establish the
thickness of the shim
4 - Engine shaft shim
⇒ page 142
5 - Differential
6 - Differential shim
❑ Dicke bestimmen
⇒ page 140
7 - Differential roller bearing
❑ Always replace together
❑ On replacing the roller
bearing, re-establish the
thickness of the shim
8 - Driven sprocket
4.2 Adjustments to be carried out when

changing components
If work is carried out on the gearbox, it will only be necessary to
readjust the engine shaft and the driven sprocket or the differen‐
tial casing
respect when parts
to the correctness havein been
of information replaced
this document. that
Copyright directly
by SEAT S.A. influence
the differential adjustment. To avoid unnecessary work check the
following table:
Should be adjusted
Component replaced Differential Engine shaft with the driven
⇒ page 140 sprocket ⇒ page 142
Gearbox casing X X
Torque converter casing X X
Driven sprocket X
Engine shaft X
4. Final drive: adjusting 139

Arosa 1997 ➤
Should be adjusted
Engine shaft roller bearings X
Differential casing with sprocket X
Differential roller bearing X
4.3 Differential: adjusting

equipment required
♦ Bracket -T20020-
♦ Kit -T20140-
♦ Kit -U-40200 A-
♦ Kit -U-40300-
Adjust the differential when one of the following elements has
been replaced:
♦ Gearbox casing
♦ Torque converter casing
♦ Differential
♦ Differential roller bearings
Prerequisites:
• Remove the planet gears from the ATF pump, including the
large planet ⇒ page 66 , Planet gears: dismantling and as‐
sembling

Arosa 1997 ➤
• Remove the engine shaft ⇒ page 66 , Planet gears: disman‐

4.3.1 Adjusting
– Fit the outer ring of the roller bearing to the torque converter
housing without shims tools, using tool -U-40200/10- and -
U-40300/12- .
– Fit the differential in the gearbox casing.
– Fit the torque converter casing on top and tighten the bolts to
30 Nm.
– Fit the dial gauge bracket.

– Adjust the dial gauge to “0” with a pre-tension of 1 mm.
– Move the differential up and down.
– Read the play measured on the gauge and take note.
Note!
When measuring, do not turn the differential, because the roller

bearings may settle and the reading
Protected could
by copyright. be for
Copying erroneous.
Determining thickness of shim
The pre-tension of the bearings is obtained by adding a constant
pressure value (0.16 mm) to the obtained measurement value.
Example
Measured value 0.94 mm
+ Pressure (const. value) 0.16 mm
=Thickness of shim 1.1 mm
– Unbolt the torque converter casing and remove the differential
from the gearbox casing.

Arosa 1997 ➤
T20140-
– Determining shim thicknesses according to the table:
Spare no.: ⇒ Parts Catalogue.
Table “Shims” :
Shims (mm)
0.12 0.40 0.72
0.14 0.44 0.76
0.16 0.48 0.80
0.20 0.52 0.84
0.24 0.56 respect to the correctness 0.88

0.28 0.60 0.92
0.32 0.64 0.98
0.36 0.68 1.44
If the thickness needed is greater than that indicated on the table,
two shims can be used to attain the value.
– Press fit the outer ring of the roller bearing to the torque con‐
verter housing with established shims (in the example 1.1 mm)
using tools -U-40200/10- and -U-40300/12- .
4.4 Engine shaft: adjusting

Arosa 1997 ➤

equipment required
♦ Kit -T20140-
♦ Kit -U-40200 A-
♦ Kit -U-40300-
Adjust the engine shaft when one of the following elements has
been replaced:
♦ Gearbox casing
♦ Torque converter casing
♦ Driven sprocket
♦ Engine shaft
♦ Roller bearings
Prerequisites
• Remove the planet gears from the ATF pump, crown pinion
included ⇒ page ⇒ page 66 , Planet gears: remove
• Remove the sump and the slider box ⇒ page 66 , Planet gears:
remove

Arosa 1997 ➤
4.4.1 Adjusting
– Fit the outer ring of the roller bearing to the torque converter
housing without shims tools, using tool -U-40200/10- and -
U-40300/14- .
– Insert the engine shaft into the gearbox casing.
– Fit the torque converter casing on top and tighten the bolts to
30 Nm.
– Fit universal support -T20020- and measuring device (meas‐

uring range 3 mm) with an extension -A- of 100 mm approx.

Arosa 1997 ➤
– Move the crown pinion shaft up and down with a screwdriver

at the driven sprocket.
– Read the play measured on the gauge and take note (exam‐
ple: 1.02 mm).
Note!
When measuring the crown pinion shaft do not turn it, because
the roller bearings may settle and the reading would be errone‐
ous.
Determining thickness of shim

The pre-tension of the bearings is obtained by adding a constant
pressure value (0.18 mm) to the obtained measurement value.
Example:
Measured value permitted unless authorised by SEAT S.A. SEAT S.A 1.02doesmmnot guarantee or accept any liability with
=Thickness of shim 1.2 mm
– Determining shim thicknesses according to the table:
Spare no.: ⇒ Parts Catalogue.
Table “Shims”
Shims (mm)
0.10 0.44 0.72
0.20 0.48 0.76
0.24 0.52 0.80
0.28 0.56 0.84
0.32 0.60 0.88
0.36 0.64 0.94
0.40 0.68
If the thickness needed is greater than that indicated on the table,
two shims can be used to attain the value.
– Remove the converter housing.
– Remove the engine shaft.
T20140-
– Determining shim thicknesses according to the parts cata‐
logue:

Arosa 1997 ➤
– Fit the outer ring of the roller bearing with the correct shim (in
this example 1.2 mm).

Service
Workshop Manual
Arosa 1997 ➤
02J 5-speed manual gearbox
Edition 10.00

Service
Repair Group
00 - Technical data
30 - Clutch
35 - Gears, Shafts

Copyright © 2015 Seat S.A S01B02J8620

Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 ...................................................................... 1
1.1 Identification initials, assignation of groups, reductions, filling amounts . . . . . . . . . . . . . . 1
2 Power transmission diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Calculating the “i” reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General instructions for repairing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Mechanism for working the clutch: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Assembly chart -foot pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Neutral overrun spring: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Neutral overrun spring: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Assembly chart-hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Clutch pump: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 Clutch system: bleeding the air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Declutching unit: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Clutch: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1 Mechanism for working the gearbox: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Position for assembly of the mechanism for working the gearbox . . . . . . . . . . . . . . . . . . . . 24
1.2 Handle and cover of the gear stick: dismounting and assembling . . . . . . . . . . . . . . . . . . . . 27
1.3 Gear stick and protective box: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4 Mechanism and working cables: dismounting and assembling; assembly chart . . . . . . . . 30
1.5 Mechanism for working the gearbox: dismounting and assembling . . . . . . . . . . . . . . . . . . 31
1.6 Mechanism for working the gearbox: adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 02J Gearbox: Dismount and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 02J Gearbox: Dismount and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Checking the oil level for the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Gearbox: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Order for dismounting and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Cover of the gearbox casing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3 Working for the gearbox and casing: dismounting and assembly . . . . . . . . . . . . . . . . . . . . 46
4.4 Primary shaft, secondary shaft, differential gear and gearbox forks: dismounting and
assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.5 Sequence for assembly: Gearbox dismounting and assemble . . . . . . . . . . . . . . . . . . . . . . 48
5 Gearbox casing and clutch casing: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 Gear selector axle: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 Gearbox forks: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Main shaft: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2 Main shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Secondary shaft: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
4 Secondary shaft: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
5 Axle for reverse gear pinion: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . 98

1 Retainers for coupling flanges: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Retainers for coupling flanges: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . 101
Contents i
Arosa 1997 ➤
2 Differential: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3 Adjustments Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4 Differential crown: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 Differential crown: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5 Differential: adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ii Contents
Arosa 1997 ➤
Location in the gearbox
The 02J 5-speed gearbox is assembled in the Arosa 1999 ▸ in
combination with the three cylinder Turbo Diesel engine.
Identification initials and date of manufacture -arrow 1- , type of
gear-change -arrow 2- .
Assignment of reduction groups ⇒ page 1
Type of gear-change
02J manual 5-speed gearbox -arrow 2- .
Identification initials and date of manufacture for the gearbox

-arrow-
Example: XXX XX XX X
I I I I
I I I I
Identification Day Month Year of manufac‐
letters ture
The additional data refers to the manufacturing process.
Note!
The identification letters for the gearbox also appear on the ve‐
hicle data sheet.
1.1 Identification initials, assignation of groups, reductions, filling amounts

Manual gearbox 02J 5-speed gear-change
Identification letter ESP/EXB
Corresponding to of information in this

Type Arosa by 1997
respect to the correctness document. Copyright SEAT S.A.
Engine 1,4 ltr. - 55 kW
Reduction: Drive train 60 : 19 = 3.158
Z2 : Z1 :
gear 33 : 10 = 3.300
2nd gear 35 : 18 = 1.944
3rd gear 34 : 26 = 1.308
1. 1
Arosa 1997 ➤
Manual gearbox 02J 5-speed gear-change

Identification letter ESP/EXB
4th gear 34: 35 = 0.971
5th gear 34 : 45 = 0.756
6th
gear —
Reverse gear 17 : 10 x 36 : 20
=3.060
Speedometer 13 : 22 = 0.591
Identification letters ESP/EXB

Specification API GLS SAE 75 W
Amount for filling 2.0 Liter
Clutch control Hydraulic
Clutch disk ∅ mm 215 mm
Articulated train flange ∅ mm Tripod
itotal in the longest gear 2.387 mm

Arosa 1997 ➤
2 Power transmission diagram

Name
The -arrows- indicate the vehicle's running direction.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Main shaft
5 - Secondary shaft /drive pin‐
ion shaft
6 - Differential
Reductions
The -arrows- indicate the vehicle's running direction.
2. Power transmission diagram 3

Arosa 1997 ➤
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
R - Reverse gear
A - Train drive
T - Operation of the speedom‐
eter

Arosa 1997 ➤
3 Calculating the “i” reduction ratio

The reduction ratio between two pinions is obtained by dividing
the number of cogs in the pinion driven by the number of cogs in
the drive pinion.
Example:
5th gear Tapered unit

Drive Pin‐ 45 (Z1 Main) 19 (Z1 Pinion)
ion
(main)
Driven 34 (Z2 Secondary) 60 (Z2 Crown)
Pinion
(secon‐
dary)
i = Z2 : Z1 1)
Hence, you can find:
ig = Reduction ratio in a gear
ig = Z2 SecondaryZ1 Main = 3445 = 0.756
ia = Reduction ratio for the cone unit
ia = Z2 CrownZ1 Pinion = 6019 = 3.158
itotal = Total reduction ratio
It is obtained by multiplying the reduction ratios from the highest
gear and the cone unit.
itotal = iG x iA = 0.756 x 3.158 = 2.387
1) Z1 = Number of cogs on the drive pinion, Z2 = number of cogs on the driven
pinion.
3. Calculating the “i” reduction ratio 5

Arosa 1997 ➤
4 General instructions for repairing the

gearbox
In order to repair the gearbox successfully, it is essential to work
under maximum conditions of cleanliness and care as possible.
Additionally, all tools used should be in excellent working order.
When carrying out repairs, all basic safety standards must be fol‐
lowed.
What follows is a summary of a number of general guidelines for
certain repair operations, which would otherwise appear several
times in many sections of this Repairs Manual. Therefore, these
guidelines are valid and must be taken into account for this Re‐
pairs Manual.
Gearbox
♦ Before assembling the gearbox in the engine, make sure that
the centring sleeves arranged between the engine and the
gearbox are in proper condition and fit correctly.
♦ In the event of replacing the gearbox, fill it with oil up to the
lower edge of the filling hole. Amounts
Protected by copyright.for filling
Copying for and
privatetype of oil purposes, in part or in whole, is not
or commercial
⇒ page 1 . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Seals
♦ Always replace the O-ring seals.
♦ Before applying sealing products (sealing liquid), clean the
contact surfaces well and apply -AMV 188 200 03- sealing
paste.
Retainers
♦ Before they are fitted, cover them lightly with oil for gears on
the outer diameter and fill the space between the watertight
lips with grease.
♦ Once the retainers have been assembled, check the oil level
for the gearbox and fill up if necessary.
Safety rings

Arosa 1997 ➤
♦ Always replace the safety rings; try not to stretch them out of
shape when putting them into place.
♦ The safety rings must fit perfectly into the bottom of the inser‐
tion slot.
♦ Always replace the elastic guide pins.
♦ When assembling the plastic guide pins, their slot must be
positioned longitudinally with respect to the direction of the
drive, as shown in the figure.
Bolts and nuts
♦ Always loosen and tighten the bolts and nuts in a cross-shape
for attaching covers and casings.
♦ With delicate parts, such as, for example, the clutch press, do
not tilt them and carry out the operation gradually.
♦ Self-locking bolts and nuts must always be replaced.
Bearings
♦ When new conical bearings are assembled, they shall be as‐
sembled as they arrive, without greasing.
♦ The needle bearings must be assembled with the thickest side
of the plate facing towards the assembly axle-tool.
♦ All the bearingspermitted
for theunless
gearbox must be put into place slightly
oiled for the gears. Take
respect special care ofwhen
to the correctness oiling
information them
in this for the
document. Copyright by SEAT S.A.
friction torque measurements.
♦ The bearings belonging to the same shaft must be replaced
together. Use parts from the same manufacturer as far as
possible.
♦ For putting the bearings into place, they must first be heated
to a temperature of approximately 100 °C. Use the -SAT 1416-
electrical blower and the -SAT 4002- digital thermometer to
check the temperature.
♦ Do not confuse or exchange the outer tracks for the bearings
of the same size; the bearings come in pairs.
Adjustment washers
♦ Before assembling the adjustment washers, their thickness
must be checked by measuring them with a micrometer at
several points on their surface.
♦ The presence of washers with different tolerances allows the
precise thickness of the washer that is needed to be achieved.
♦ The washers must not have rough edges or defects.
♦ Assemble only adjustment washers that are in perfect condi‐
tion.
Synchronising rings
♦ Do not mix synchronising rings together with different gears.
If they must be used again, place them in the same gear as
before.
♦ Check them for wear and replace them if necessary.
♦ For their assembly, cover them with oil for gears.
Gears
♦ Before assembling them, clean them very carefully. They must
first be heated to a temperature of approximately 100 °C. Use
the -SAT 1416- electrical blower and the -SAT 4002- digital
thermometer to check the temperature.
4. General instructions for repairing the gearbox 7

Arosa 1997 ➤
30 – Clutch
1 Mechanism for working the clutch: repair
Note!
♦ Disconnect the ground strip from the battery.

♦ In vehicles with a coded radio, consult the code before disconnecting the ground strip from the battery.
♦ Lubricate all the support points and contact surfaces with -G 052 142 A2- lubricant.
♦ Do not work the pedals or open the installation during the repair work.
I - Assembly chart -foot pedals

⇒ page 9
II - Assembly chart -hydraulics
⇒ page 13
8 Rep. Gr. 30 - Clutch

Arosa 1997 ➤
1.1 Assembly chart -foot pedals
1 - Support for pedals

❑ Before dismounting it,
dismount the steering
column ⇒ Drive train,
drive axles; Rep. Gr.
48 ; Airbag, steering
wheel, steering column .
2 - Hexagonal bolt, 25 Nm
3 - Brake light switch
❑ When dismounting or
assembling the switch,
press down the brake
pedal by hand as far as
you can.
❑ Before dismounting the
brake pedal, dismount
the switch by turning it
90º to the right and re‐
move it through the as‐
sembly opening.
❑ For its assembly, guide
the switch through the
assembly opening and
fix it into place by turning
it 90º to the left.
❑ Check the working of
the brake light.
4 - Hexagonal self-blocking
nut, 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 5 units
❑ For attaching the pedal
support to the servo-
brake.
5 - Clutch pedal switch
❑ When dismounting or
assembling the switch, press down the clutch pedal by hand as far as you can.
❑ Before dismounting the clutch pedal, dismount the switch by turning it 90º to the right and remove it
through the assembly opening.
❑ For its assembly, guide the switch through the assembly opening and fix it into place by turning it 90º to
the left.
6 - Rubber plug
❑ Fit it into place in the support for the pedals.
7 - Housing for neutral overrun spring
❑ Dismount by turning it to the right.
❑ Assemble by turning it to the left.
8 - Neutral overrun spring
❑ Dismounting and assembling ⇒ page 13 .
9 - Stop for the clutch pedal
❑ Position for assembly ⇒ page 16
10 - Dashboard
11 - Seal
❑ Always replace
1. Mechanism for working the clutch: repair 9

Arosa 1997 ➤
12 - Flexible tube
13 - Clutch pump
❑ Dismounting and assembling ⇒ page 16 .
14 - Hexagonal self-blocking nut, 25 Nm
❑ Always replace.
15 - Housing
❑ Dismount and assemble ⇒ page 13
16 - Axle for clutch and brake pedals
17 - Washer
18 - Bearing sleeve
❑ For clutch pedal
❑ Lubricate with -G 052 142 A2- grease
19 - ClutchProtected
pedalby copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismount and
respect assemble
to the ⇒information
correctness of page 11 . document. Copyright by SEAT S.A.
in this
20 - Bearing sleeve
❑ For housing the drive column
21 - Bearing sleeve
❑ For brake pedal
❑ Put it into the bearing sleeve ⇒ Item 20 (page 10) and then put the brake pedal into place.
22 - Washer
23 - Hexagonal nut, 25 Nm
24 - Brake pedal

Arosa 1997 ➤
1.2 Neutral overrun spring: dismounting and assembling

equipment required
♦ Dynometric keys -SAT
8010-
♦ Tool for dismounting/as‐
sembling clutch pedal over‐
run spring -T20117-
♦ Pliers for releasing the rod
for working the clutch pedal
at the pump -T20059A-
1.2.1 Dismounting
Note!
If the vehicle has a coded radio, first note down the code.
– With the ignition disconnected,Protected

remove the ground
by copyright. strip
Copying for from
the battery. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Extract the objects-holder tray and the lower casing from the
driver's side ⇒ Bodywork, assembly works; Rep. Gr. 68 ; ob‐
jects-holder, coverings, show covers .

Arosa 1997 ➤
– Take out the bolts that attach the fuse box support to the
dashboard.
– Move the fuse box support downwards -arrow 1- and fix it into
place in this position.
– Extract the nuts that attach the relay plate by moving it care‐
fully to the left.
– Uncouple the clutch pedal from the control pump working rod
⇒ page 16 and press down the working rod to the stop in the
direction of the engine housing.
– Dismount the neutral overrun spring ⇒ page 13 .
– Take out the hexagonal nut -arrow 1- which attaches the pedal
axle to the steering column.
– Carefully remove the pedal axle -arrow 2- . Fix the brake pedal
into its position at the same time with an M 8 bolt or a pin with
the same Ø through the right hand side -arrow 1- .
– Carefully move the pedal axle to the left, and try not to damage
the electrical cables.

Note!
Do not move the brake pedal or the steering column. They remain
loose once the pedal axle has been extracted.
– Remove the clutch pedal.
1.2.2 Assembly
Perform the operations described for the dismounting in the re‐
verse order taking into account the following points:
– Lubricate the axle and the bearing sleeve before their assem‐
bly using -G052 142 A2- lubricating grease.
– Fit the clutch and brake axle up to the stop; if necessary, move
the brake pedal a little to make its assembly easier, and at the
same time extract the pin or the bolt used earlier.
– Put the washer into place with its nut and tighten at the re‐
quired torque.
Tightening torque: 25 Nm
– Assemble the neutral overrun spring ⇒ page 13 .
– Push the clutch pedal in the direction of the -arrow- in order to
fit it into the housing over the pedal, make sure that it has been
fitted into place properly.
Note!
The housing -A- must be over the working bar -B- of the clutch
pump.

Arosa 1997 ➤
1.3 Neutral overrun spring: dismounting and

assembling
♦ Tool for assembling -T20117-
1.3.1 Dismounting:
– Dismount the covers from the lower part on the driver's side
⇒ Bodywork, assembly works; Rep. Gr. 68 ; objects-holder,
coverings, show covers .
– Release the clutch pump control lever from the housing for the
clutch pedal ⇒ page 16 .
– In order to dismount the clutch pedal, tighten the neutral over‐
run spring with the aid of the clutch pedal and fit in into place
from below with the tool -T20117- .
– Put the clutch pedal into the rest position towards the dash‐
board, at the same time remove the neutral overrun spring
downwards together with the tool -T20117- .
1.3.2 Assembly:
– Put the clutch pedal into the rest position, towards the dash‐
board.respect to the correctness of information in this document. Copyright by SEAT S.A.
– First put the neutral overrun spring into place downwards to‐
gether with the tool -T20117- , on the rear side support of the
pedal support -arrow B- .
– Tress down the clutch pedal until the neutral spring and the
assembly tool remain in the pivot for the pedal housing
-arrow A- .
– Move the clutch pedal to the rest position and at the same time
remove the assembly tool.
– Press the clutch pedal in the direction of the arrow in order to

fit the housing over the pedal coupling, make sure that it has
been fitted into place properly.
1.4 Assembly chart-hydraulics

Arosa 1997 ➤
1 - Brake liquid tank

2 - Flexible tube for reflux
3 - Elbow
4 - Reflux flexible tube
❑ Lower part
5 - Clutch pump
❑ Dismounting and as‐
sembling ⇒ page 16
6 - Clip
7 - Clutch pedal
8 - Housing
❑ Replace only with the
clutch pump dismoun‐
ted ⇒ page 15
❑ Dismount ⇒ page 15
9 - Hexagonal self-blocking
nut, 25 Nm
❑ Always replace.
10 - O-ring seal
❑ Fit it into the connection
for the tube
❑ Put it into place with
brake liquid
11 - Set of pipes and flexible
tube
❑ Consult the Spares Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Catalogue in order to assign it permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
12 - Support for the pipes
❑ Fix in onto bodywork
13 - Protective hood
14 - Air bleed valve
❑ Bleeding the air from the clutch ⇒ page 18
15 - Small clutch pump
❑ Before dismounting it, the following parts must be dismounted:
❑ Gearbox cable from the link rod of the selector lever ⇒ page 30
❑ Return level and drag element for the gear selection cable ⇒ page 24
❑ After the assembly, the gear operating mechanism must be adjusted ⇒ page 33
16 - Clip
18 - Gear box
19 - O-ring seal
❑ Fit it into the connection for the tube
❑ Put it into place with brake liquid

Arosa 1997 ➤
20 - Support for the flexible tube

❑ It must be fixed into place on the support for the gear control operating cables.
Take out the housing -A- by levering in the direction of the arrow
Fit the housing -A- to the rod for working the clutch pump in the
direction of the arrow

Arosa 1997 ➤
1.5 Clutch pump: dismounting and assembling

equipment required
8010-
♦ Tool for dismounting/as‐
sembling clutch pedal over‐
run spring -T20117-
♦ Pliers for releasing the rod
for working the clutch pedal
at the pump -T20059A-
1.5.1 Dismounting
– Dismount the engine cover.
Note!
In order to carry out these jobs, it is necessary to remove the

ground strip from the battery. For this purpose, you must check
whether the vehicle has a coded radio on board, consulting,
where appropriate, the anti-theft code.
– With the ignition disconnected, remove the ground strip from

the battery.

Arosa 1997 ➤
– Take out the connector from the sensor for the coolant liquid
level -arrow 1- .
– Take out the side cover for the cooling water tank by pulling it
upwards.
– Disconnect the cooling water tank -arrow 2- and move it to one
side without forcing any flexible tube.
Note!
♦ Do not open the cooling system.

♦ When handling the brake liquid tubes, take care not to allow
any liquid to spill onto the bodywork.
– Dismount the covers from the lower part on the driver's side
⇒ Bodywork, assembly works; Rep. Gr. 68 ; objects-holder,
coverings, show covers .
– Unblock the clutch pedal, of the rod for working of the pump
as described below:
– Place the tool -T20059A- on the flanges of the housing

-arrow- , using the tips -T20059A/1- with a Ø of 5.6 with the
cross-shaped reeding, in such a way that the longest tip will
remain on the right side of the pedal.
– Compress the flanges of the housing with the tool -T20059A- ,
and move the clutch pedal towards the dashboard at the same
time.
– Extract the flexible tube for reflux -A- which leads to the brake
liquid tank and block it up.
– Extract the clip -B- that attaches the piping/flexible tube to the
clutch pump, by levering it out with a screwdriver.
– Take out the piping/flexible tube unit -C- from the clutch pump
and block it up.

Arosa 1997 ➤
– Turn the stop -A- for the clutch pedal in the direction of the
arrow 1 and remove it from its housing.
– Turn the housing -B- for the neutral overrun spring in the di‐
rection of the -arrow 2- and remove it from its housing.
– Remove the nuts that attach the clutch pump: Always replace.
– Then turn the pump in the direction of the arrow 3 in order to
remove it from the support block, by passing the rod through
the left of the clutch pedal.
1.5.2 Assembly
Perform the operations in the reverse order to those described for
the dismounting, taking the following into account:
Note!
The attachment nuts for the clutch should always be replaced.
– Position for assembly:
– The bead -arrow 1- of the stop for the clutch pedal must be
facing towards the clutch pump -B-by. copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– The appendage -arrow 2- of therespect
spring
to thehousing
correctness-C- must re‐
main mounted in the bottom left corner of the part for attaching
the pump.
– Couple the clutch pedal to the rod for working the clutch pump:
To do so, the housing -A- must be put into place on the rod for
working -B- the clutch pump.
– Push the clutch pedal in the direction of the arrow in order to
fit the housing over the clutch pedal, make sure that it is fixed
into place properly.
– After the assembly of the clutch pump, bleed the air from the
system ⇒ page 18 .
1.6 Clutch system: bleeding the air


Arosa 1997 ➤
♦ Apparatus for filling and bleeding the air for the brakes -SAT
1150-
♦ In order to bleed the air, you must use, if required, the flexible
tube for bleeding -V.A.G 1238/B3- , which is 670 mm long.
♦ Use only new brake liquid as per the standards US FMVSS
116 DOT 4.
– Connect the flexible pressure tube to the brake liquid tank.
– Join the flexible tube for bleeding to the storage bottle in the
device for bleeding the brakes.
– Place the flexible tube for bleeding -A- in the air bleeding valve
for the small pump in the clutch and open the valve.
– After completing the operation for bleeding out the air, the
clutch pedal should be worked several times.
Note!
Try to prevent the brake liquid from spilling onto the bodywork or
any other part that it might damage.

Arosa 1997 ➤
2 Declutching unit: repair
1 - Gearbox
2 - Spherical pivot, 25 Nm
❑ Grease with -MoS2- lu‐
bricant
3 - O-ring seal for main shaft
❑ Replace ⇒ page 58
4 - Guide sleeve
❑ With vulcanised O-ring
seal
❑ Change the guide
sleeve and the O-ring
seal together should the
latter be damaged
❑ Grease the guide sleeve
with -MoS2- lubricant
through the area of the
declutching collar
5 - Attachment spring
❑ Attach it to the declutch‐
ing lever
6 - Lag screw, 20 Nm
7 - Declutching lever
8 - Declutching collar
❑ Do not wash the collar.
It should only be
cleaned with a cloth
❑ Replace noisy clutch
collarsProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Grease the contact
points with the declutch‐
ing lever with -MoS2- lu‐
bricant
9 - Bolt with collar, 20 Nm
10 - Small clutch pump
11 - Pusher
❑ Grease the tip of the pusher with -MoS2- lubricant.
12 - Assembly bolt
❑ Secure the declutching lever when assembling the gearbox.
❑ It must be unscrewed after assembling the gearbox.
Note!
If there is no assembly bolt

⇒ Item 12 (page 20) an M8×25 bolt
may be used.

Arosa 1997 ➤
3 Clutch: repair
(Gearbox dismounted)

equipment required
8010-
♦ Centre the clutch disk with
the tool -U-10050-8/F-
♦ Tool for blocking the engine
wheel -T20075A-
Note!
♦ Replace the disks and clutch presses that have damaged or loose riveted joints.
♦ Make the disk match the corresponding clutch press, as per the Microfiche for Spares and the identification
letters for the engine.
3. Clutch: repair 21
Arosa 1997 ➤
1 - The engine wheel

❑ Make sure that the cen‐
tring linchpins are well
placed.
❑ The contact surface with
the clutch disk should
not have any grooves
and they must be free
from oil and grease.
2 - Disk of clutch
❑ Diameter ⇒ page 1
❑ Position for assembly:
the spring housing must
remain facing towards
the clutch press.
❑ Grease the notches
slightly.
Note!
♦ Clean the notches in the main
shaft, and in the clutch disk used,
remove the corrosion and apply
a very fine layer of grease Spare
No. -G 000 100- , on the notches
in the main shaft.
♦ Then the clutch disk must be
moved back and forth over the
main shaft until the hub slides
smoothly across the shaft. Re‐
move the remains of excess
grease.
3 - Clutch press
❑ Check the ends of the diaphragm ⇒ page 23
Note!
The clutch press is now greased

and protected against corrosion.
Only the contact surface can be
cleaned, otherwise the useful life of
the clutch is reduced.
4 - Bolt
❑ Consult the microfiche for Spares in order to assign it.
❑ Loosen and tighten in a cross in several stages until achieving the recommended torque.
❑ Tightening torque 20 Nm

Arosa 1997 ➤
Dismounting and assembling the clutch press and centring the

clutch disk
– Loosen and then tighten the bolts in a cross and in several
stages, using the tool -T20075- for blocking the engine.
– Centring the clutch disk, to do so, use the tool -U-10050-8-
with the adapter F.
Note!
The contact surface of the clutch press and the lining of the clutch
disk must rest completely over the wheel of the engine. Tighten
the attachment bolts uniformly and in a cross to prevent damage
to the drill holes for centring the clutch press and the anchors bolts
for centring the wheel of the engine.
Checking
permitted the ends
unless authorised of the
by SEAT diagram
S.A. SEAT S.A does not guarantee or accept any liability with
• Wear is allowed of up to half of the thickness at the ends of
the diagram -arrows- .
3. Clutch: repair 23
Arosa 1997 ➤
1 Mechanism for working the gearbox:
repairing
1.1 Position for assembly of the mechanism for working the gearbox
-Arrow A- movement for the connection of gears.
-Arrow B- movement for the selection of gears.
A - Cable for changing gears

B - Cable for selecting gears
C - Heat protection plate
❑ It must be dismounted
before dismounting the
working for the gearbox
1 - Selection link rod
2 - Return lever
Mechanism for working the gearbox: dismounting and assem‐

bling ⇒ page 31
Mechanism for working the gearbox: adjust ⇒ page 33

Arosa 1997 ➤
Note!
♦ In order to carry works on the mechanism for working the gearbox in the engine span, the negative terminal
must be disconnected from the battery.
♦ In vehicles fitted with a coded radio, first consult the anti-theft code.
I - Handle and cover for the

gear stick: dismounting and
assembling ⇒ page 27
II - Gear stick and protective
box: repair ⇒ page 28
III - Cables for the mechanism
for working: dismounting and
assembling; general chart for
assembly ⇒ page 30
1. Mechanism for working the gearbox: repairing 25

Arosa 1997 ➤

equipment required
8010-
♦ Pliers for clamps -T20072-
♦ Gear stick linchpin gauge -
T10027-

Arosa 1997 ➤
1.2 Handle and cover of the gear stick: dismounting and assembling
1 - Handle for the gear stick

❑ Dismount and assemble
together with the cover
2 - Cover
❑ Remove from the han‐
dle ⇒ page 27
❑ Attach to the handle be‐
fore assembling it
⇒ page 27
together with the handle
for the gear stick
3 - Attachment sleeve
4 - Clamp
❑ For attaching the handle
to the gear stick
❑ Tighten ⇒ page 28
5 - Rubber protection
❑ It is fitted into the flanges
for attaching the cover
Assemble the handle of the gear stick

– Turn the cover inside out and insert the handle of the gear stick
inside it -arrow- .
– Put the attachment sleeve into its housing.
Note!
The flanges for the attachment sleeve must remain fitted into the
housing in the handle.
– Put the clamp over the handle

Protected and assemble
by copyright. it on
Copying for private the gearpurposes, in part or in whole, is not
or commercial
stick, fitting it in aspermitted
far asunless
it willauthorised
go. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

Arosa 1997 ➤
Tighten the clamp -arrow- for the handle of the gear stick
Note!
To tighten the clamp, tool -T20072- can also be used.
– Fit the cover into the central console.
1.3 Gear stick and protective box: repair
Note!
Lubricate the support points and the slide surfaces with grease -G 052 142 A2- .
1 - Safety washer
⇒ page 29
2 - Sleeve
3 - Compression spring
4 - Sleeve
5 - Torx Bolt, 5 Nm
6 - Top
7 - Half bearing
8 - Shock absorber
9 - Gear stick guide
10 - Shock absorber washer
11 - Seal
❑ Between the protective
box and the body
❑ Self-adhesive
❑ Stick it onto the protec‐
tive box
12 - Gear stick
13 - Plastic nut Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For attaching the con‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
sole to the protective
box.

Arosa 1997 ➤
14 - Shock absorber
15 - Protective box for the gear
stick
16 - Bearing sleeve
17 - Bolt, 25 Nm
18 - Shaft
19 - Guide sleeve
❑ Assembly ⇒ page 29
21 - Selection bracket
22 - Bolt Torx, 5 Nm
23 - Lower plate
❑ In order to dismount it, open the flanges
24 - Safety washer
25 - Cable for changing gears
❑ Fit the selection bracket into place
27 - Bearing sleeve
❑ It fits into a single position
28 - Safety washer
Dismounting and assembling the safety washer
– For dismounting and assembling the safety washer, pull the
gear stick in the direction of the arrow -A- and at the same time
press downwards until reaching the stopper for the separating
sleeve with a screwdriver in the direction of the arrow -B -.
Note!
Do not tilt the separating sleeve when pressing it down. It must

be able to easily access the slot for housing the safety washer in
the gear stick.
Assembly of the compression spring

– Put the spring into place in such a way that the part -A- will
remain under the pivot -arrow- .
– Then pull back the part B towards the gear stick until it stays
on the upper part of the pin -arrow- .

Arosa 1997 ➤
1.4 Mechanism and working cables: dismounting and assembling; assembly

chart
Note!
Lubricate the support points and the sliding surfaces with grease -G 052 142 A2- .

❑ Fit into the guide for the
gear stick
❑ Position for assembly
⇒ page 24
2 - Cable for selecting gears
❑ It is connected to the se‐
lection bracket
⇒ page 24
3 - Safety washer
4 - Safety washer
❑ Do not damage the ca‐
bles when dismounting
it
5 - Protective box for the gear
stick
6 - Support
❑ For the support for the
gear connection cables
8 - Hose
❑ Housing for the support
for the gear connection
cables to the gearbox
9 - Separating piece
10 - Part for attaching the cable
❑ In order to attach the ca‐
ble for the gearbox to
the return lever
11 - Part for attaching the cable
❑ In order to attach the cable for the gearbox to the link rod for selection
12 - Return lever
❑ Position for assembly ⇒ page 31 .
13 - Bearing sleeve
14 - Safety washer
15 - Guide block
16 - Selection linking rod
❑ With counterweight
❑ Put it into place in such a way that the uninterrupted division of the cogs matches the selection axle
❑ Once it has been put into place, adjust the mechanism for working the gearbox ⇒ page 33

Arosa 1997 ➤
Position for assembling the link rod for selection and the return
lever
1- Lever for connection: With counterweight.
2- Lever for selection: It is fitted into the guide of the lever for
connection by means of a block -arrow- .
1.5 Mechanism for working the gearbox:

dismounting and assembling
1.5.1 Dismount
– Remove the cable for selection -A- and the cable for changing
gears from the gearbox -B- , by levering with a flat key.
1 - Flat head key size 13
Note!
If necessary, dismount the air filter.
– Dismount the cable holder from the gearbox -arrows- , if nec‐

essary, remove the flexible tube support from the clutch hy‐
draulic system.

Arosa 1997 ➤
– Remove the cover from the central console by carefully mov‐

ing it forwards.
– Turn the cover inside out and remove the handle from the gear
stick, by loosening the clamp -arrow- .
– Unthread the attachment nuts from the central console

-arrow- .
– If there is one, dismount the soundproofing casing located be‐
neath the engine/gearbox.
– Dismount the two brackets located under the system of es‐
cape. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the exhaust gas system through
respect the double
to the correctness hose
of information clipdocument. Copyright by SEAT S.A.
in this
behind the front exhaust pipe ⇒ Rep. Gr. 26 ; Components
for the exhaust system; dismount and assemble .
– Dismount the front and rear heat insulation plate.
– Remove the protective box by pulling it downwards.
– Extract the bolts that hold down the protective box for the op‐
erating mechanism to the bodywork.
– Turn the protective box for the gearbox lever downwards and
remove it together with the cables, attempting not to cause
damage to any mechanical part or to the bodywork.
1.5.2 Assemble
Carry out the operations described the assembly in reverse order
to that for dismounting, taking into account the following.

Arosa 1997 ➤
Whenever the same cables are used again, the attachment parts
for them must be changed.
– Apply a small amount of grease to the oil catcher in the part
for attaching the cable for changing gears -A- and the cable
for selection -B- .
Note!
The outer seal lips -arrows- of the oil-catcher must be completely

free from grease.
– Fit the cable for changing gears into the link rod for selection
and the cable of selection into the return lever -arrows- .
– Adjusting the mechanism for working the gearbox
⇒ page 33 .
Tightening torques
– Attachment of the protective box to the bodywork: 25 Nm
– Attachment of the cross bar to the bodywork: 25 Nm
– Counter support for the gearbox cables: 25 Nm
1.6 Mechanism for working the gearbox: ad‐

just
♦ Linchpin -T10027-
Note!
♦ In order to properly adjust the working for the gearbox , the

following points must be taken into account:
♦ The gearbox, the working of the clutch and the clutch must all
be in perfect working condition.
♦ The working of the gear change must be smooth and without
difficulties.
– Place the gear stick into neutral.

Arosa 1997 ➤
– Pull forwards, to the end, of the safety mechanism for the gear
cables and for selection of gears -arrow 1- and block it into
place by turning it to the left -arrow 2- .
Fix the selector rod into place for adjusting it: by performing the
following steps:
– Push the gear stick downwards -arrow 1- .

– Turn and push the elbow -A- in the direction of the -arrow 2-
until the rod its locked into place.
Note!
In this position the inner end of the elbow -A- is housed in the gear
stick by blocking it into the adjust position.
– Remove the cover from the central console, by carefully mov‐

ing it forwards.
Fix the gear lever into place for adjusting it: by performing the
following steps:
– Put the gear stick into the neutral position.
– Place the linchpin -T10027- into the hole -B- through the hole
-A- .
Note!
In order to make it easy to put the tool -T10027- into place, move
the gear stick until the two holes face each other.

Arosa 1997 ➤
– Turn the safety mechanism for the gearbox cables and for gear
se ection to the right in the direction of the -arrows- , up to the
end.
– The spring presses the safety mechanism to the outlet posi‐
tion.
– Turn the elbow -A- in the direction of the arrow, until returning
it to its original position.
– Remove the linchpin -T10027- and assemble the cover for the
gear stick on the central console.
1.6.1 Checking the functioning of the mecha‐

nism for working the gearbox
The gear stick must be in the position for neutral, in the track for
3rd / 4th gear. The lower part of the gear stick must be in an upright
position.
– Work the clutch pedal: Connect and disconnect all the gears
several times, make sure especially that the reverse gear con‐
nection works properly.
Note!
If, when putting a gear into position several times it still sticks, you
must check the selector lever unit in the following manner:
– Engage the first gear.
– Move the gear stick to the left up to the end and then release
it again.
– At the same time, the switch axle for the gear box must be
examined (2nd mechanic).
– When moving the gear stick, it must perform a run of approx‐
imately 1 mm. Direction of the -arrow- .
– If, when engaging a gear over and over again, there are still
blocks or interferences, or should the run of the gear stick not
be the right one, perform the adjustment again for the mech‐
anism for working the gear box ⇒ page 33 .

Arosa 1997 ➤
2 02J Gearbox: Dismount and assem‐

ble
2.1 02J Gearbox: Dismount and assemble

equipment required
♦ Crossbar for supporting en‐
gine and gearbox -
U-30025-
♦ Hydraulic jack for steering
column -SAT 1001-
♦ Set of cog wrenches XZN -
U-40020-
2.1.1 Dismounting
– Extract the cover from the engine.
Note!
To carry out this work, it is necessary to remove the ground strip

from the battery. For this purpose, you must check whether the
vehicle has a coded radio on board, where appropriate you should
consult anti-theft code.
– With the ignition disconnected, release the ground strip from

the battery.
– Dismount the battery and its support.

Arosa 1997 ➤
– Disconnect the cable for selection -A- and the gear connection
cable from the gearbox -B- by levering out with a fixed key for
16 mm.
– Extract the cable holder for the gear connection in the gearbox
-arrows- if necessary, first remove the flexible pressure tube
from the hydraulic control system for the clutch.
– Extract the central nut from the counterweight -1- from the se‐
lection lever and remove it by uncoupling it from the shoe
arrow -of the return lever -2- .
– Extract the clutch pump, from the gearbox casing, move it and
attach it again.
Note!
♦ Do not work the clutch pedal during the repair work.

♦ Do not open the brake pressure system.
2. 02J Gearbox: Dismount and assemble 37

Arosa 1997 ➤
– Uncouple the connector -arrow 1- from the starter.

– Uncouple the connector for the reverse gear lights -arrow 2- .
– Dismount the cables support A from the starter -arrow 3- .
– Extract the upper attachment bolt from the starter.
– Uncouple the connector from the speedometer transmitter

-arrow- .
– Extract the upper bolts that hold down the engine.
– Uncouple the flexible tubes and cables that might remain in

the area of the engine where the rings are located that are
used to couple the hooks for the support device -U-30025- .
– Couple up the support device -U-30025- and pre-tighten the
engine drive unit using the screws.
– DismountProtected
the starter ⇒ Rep. Gr. 27 ; starter: dismount and
assemble . unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
– If it has one, dismount the heat insulation cover from the en‐
gine for the inner right homokinetic seal.
– Turn the wheels to the left.
– Uncouple the bearings from the flanged axles and attach them
in such a way that they will remain as high as possible without
damaging the protection for the surfaces.
– Extract the small protective plate -A- from the engine wheel
located behind the right flanged axle -arrows- if it were as‐
sembled.
– Remove the exhaust fume system through the double clip that
is located behind the front exhaust pipe ⇒ Rep. Gr. 26 ; Ex‐
haust system; dismount and assemble .

Arosa 1997 ➤
– Dismount the pendular support -arrows A- and -B- .
– Extract the support for holding the hexagonal bolts -arrow-

from the left support for the engine drive unit.
– Put the drive engine unit into a sloped position, to do so, lower
it using the left screw from the tool -U-30025- .
Note!
When lowering the engine drive unit,
respect make
to the sureofthat
correctness the oil
information sump
in this document. Copyright by SEAT S.A.
is not resting on the unit holder.
In this position, you must be able to gain access to the bolts

-arrows- that attach the console to the gearbox -A- .
– Dismount the console from the gearbox -arrows A- .
– Place the hydraulic jack for the steering column -SAT 1001-
under the gearbox in such a way that the gearbox is held up.
– Dismount the lower bolts for engine/gearbox connection.
– With the help of another mechanic, separate the gearbox from
the engine guide sleeves at the same time as it is moved for‐
wards in order to make it easier to remove it. Move the gearbox
until removing it from the engine and extract it from the vehicle
without causing damage to any of the parts.
Note!
When lowering the gearbox, take into account the piping on the
servo-drive and gearbox support side as well as the piping for the
cooling circuit on the upper part.

Arosa 1997 ➤
2.1.2 Assembly
Note!
♦ Before assembling the gearbox, the declutching lever must be

pressed down towards the gearbox casing and attached into
place with an assembly bolt or an M 8 x 35 bolt. The bolt must
be removed after assembling the gearbox. The hole is closed
by the third attachment bolt for the counter support of the op‐
erating cables.
♦ If the gearbox had to be replaced, the speedometer transmit‐
ter, the lever for selection and that for return must be used
again in the new gearbox. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Clean the notches in the main shaft and lubricate them slightly
with lubricant grease -G 000 100- .
– The clutch disk must be able to move from one side to the other
over the main shaft.
– Check whether there are adjustment sleeves for centring the
gearbox in the engine block; if not, install them.
– Make sure that the intermediate plate is properly housed in the
base of the engine.
– Centre the drive engine unit in order to put it into the position
for assembly.
– Assemble the gearbox unit in the engine, free from stresses,
putting it into place by shaking.
– Put the two bolts partially into place that attach the gearbox to
the engine.
– The assembly shall be made in the opposite way to that for
dismounting.
Note!
Do not remove the support device -SAT 1001- until the bolts for
the left console of the gearbox have been tightened with their
recommended torque.
Tightening torques

Arosa 1997 ➤
Gearbox to the engine

Pos. Bolt Amount Nm
12)
M 12 x 55 3 80
2 M 12 x 150 2 80
3 M 10 x 50 2 40
43) M 12 x 50 2 80
54) M 6 x 12 1 10
2) Double bolt
3) Additional bolt for attaching the starter
4) Small plate for protecting the inertia wheel
Pos. A+B adjustment sleeves
Attaching the console -A- to the gearbox.

Bolts -arrows- 50 Nm
– Replace the bolts.
Attaching the gearbox to the bodywork
Bolts -arrows- 50 Nm
– Replace the bolts.
Rear support for the gearbox

Bolt -A- : 80 Nm
Bolt -B- : 50 Nm
– Replace bolts.
Note!
Assemble the support for the engine drive unit without tightening
⇒ Rep. Gr. 10 ; Engine; dismount and assemble .
Bearing to flanged axle: 40 Nm

Support for cables to gearbox: 25 Nm
Counterweight to the selection link rod: 25 Nm
From the thermal insulation cover of the bearing to the engine: 35
Nm

Arosa 1997 ➤
3 Checking the oil level for the gearbox

Specifications for the oil for gears ⇒ page 1 .
– Dismount the soundproofing case, lower part, if the vehicle
has one.
– Unscrew the inspection cover for the oil level -arrow- .
– The oil level is correct when the oil reaches the lower edge of
the filling inlet.
– Tighten the inspection cover for the oil level -arrow- .
In order to completely fill the tank with new oil you must:
– Unthread the control top for the oil level. Fill with oil up to the
inner edge of the hole for filling.
– Tighten the control top for the oil level and put the engine into
gear, let the gearbox tick over for about 2 minutes by engaging
a gear.
– Stop the engine, unthread the control top and check the oil
level again, fill up if necessary.

Arosa 1997 ➤
4 Gearbox: dismounting and assembling

Assembly chart
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox casing
❑ Repair ⇒ page 58
7 - Gearbox operation
❑ Connection forks
⇒ page 66
8 - Control pinion for 1st gear
and reverse gear
9 - Primary shaft
⇒ page 70
10 - Secondary shaft
⇒ page 83
11 - Differential gear
⇒ page 104
12 - Clutch casing
4. Gearbox: dismounting and assembling 43

Arosa 1997 ➤
4.1 Order for dismounting and assembling the gearbox
I - Cover of the gearbox casing

and 5 th gear ⇒ page 45
II - Gearbox casing and gear
selector axle ⇒ page 46
III - Primary shaft, secondary
shaft, differential gear and
gear forks ⇒ page 47

Arosa 1997 ➤
4.2 Cover of the gearbox casing and 5th gear

Assembly chart
❑ For the cover of the
gearbox casing
2 - Cover of the gearbox casing
Note!
♦ If the cover of the gearbox casing

is mounted with the gearbox al‐
ready mounted in the vehicle, the
oil level must be checked for the
gearbox in the following way:
♦ Loosen the top of the oil level
control in the gearbox.
♦ Refill with oil for gearboxes until
achieving the proper level. Type
of oil and amounts for filling
⇒ page 1 Technical data; Identi‐
fication initials, assigning of Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
groups, reductions, filling permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
amounts. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Tighten the inspection cover for

the oil level in the gearbox.
♦ Tightening torque: 25 Nm.
♦ Turn on the engine, engage a
gear and leave it running for 2
minutes.
♦ Stop the engine and refill with oil
for gearboxes until achieving the
proper level.
3 - Seal
4 - Torx Bolt M10, 80 Nm
❑ Replace
❑ A collar at the head of the bolt keeps the plate spring in the right position.
5 - Plate spring
6 - Bolt. 25 Nm
❑ For attaching the anchor bolts for the fork for 5th gear to the gearbox casing
7 - Anchor bolt for the 5th gear fork

8 - Fork for the 5th gear
9 - Movable sleeve for 5th gear
❑ Adjustment ⇒ page 57
10 - Synchroniser unit and pinion for 5th gear
❑ Check for wear ⇒ page 55

Arosa 1997 ➤
11 - Needle bearing
12 - 5th gear pinion
4.3 Working for the gearbox and casing: dismounting and assembly
Assembly chart
1 - Bolt. 25 Nm
2 - Coupling flange
⇒ page 50
3 - Torx Bolt. 30 Nm
❑ For supporting the re‐
verse gear axle
❑ Self-blocking
❑ Always replace
4 - O-ring seal
❑ Always replace
5 - Support bolt
6 - Bolt. 25 Nm
7 - Bolt. 25 Nm
8 - Closing cover
9 - Gearbox casing
10 - Clutch casing
❑ In case of replacement,
see adjustment chart
⇒ page 109
11 - Hexagonal Bolt. 25 Nm +
90º
12 - Gear selector axle
13 - Bolt. 25 Nm

Arosa 1997 ➤
4.4 Primary shaft, secondary shaft, differential gear and gearbox forks: dis‐
mounting and assembling
Assembly chart
1 - Differential gear
⇒ page 104
2 - Seal ring
❑ 4 units
❑ Always replace
3 - Secondary shaft
⇒ page 83
4 - Support for reverse gear
axle
⇒ page 98
5 - Reverse gear shaft
⇒ page 51
6 - Primary shaft
⇒ page 70
7 - Fork for reverse gear
⇒ page 53
8 - Bolt. 25 Nm
9 - Forks for operating gearbox
⇒ page 66
10 - Clutch casing
❑ Repair ⇒ page 58 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Nut. 25 Nm + 90º
❑ 4 nuts for attaching the

secondary shaft
12 - Coupling flange
13 - Bolt. 25 Nm

Arosa 1997 ➤
4.5 Sequence for assembly: Gearbox dismounting and assemble

equipment required
♦ Gearbox-differential sup‐
port column -AR-2203A-
♦ Case of extractors for gears
-U-40100-
♦ Case for repairing gears -
U-40200-
♦ Electrical blower -SAT
1416-
♦ Set of notched spanners
XZN -U-40020-
4.5.1 Dismounting
– Attach the gearbox onto the column -AR-2203A- . Use drill
holes Nos. 1 and 6.
– Empty the gearbox oil. Unscrew the top off for emptying the
gearbox oil.
– Dismount the release bearing and the release fork.
– Remove the bolts for attaching the guide sleeve.
♦ Remove the bolts attaching the guide sleeve with a suitable
diameter spanner from tool -U-40020- .
♦ Remove the guide sleeve, with a vulcanised O-ring seal.

Arosa 1997 ➤
– Unscrew the cover for the gearbox casing -arrow- and remove
the seal.
– Remove the bolts -arrow- and take out the fork for the 5th gear.
Note!
Before lifting out the movable one, remove the spring and the
block body. Next put the movable one back in, without the fork,
over the body of the synchroniser.
– In order to be able to loosen the two bolts -A- that attach the
5th gear pinion and the synchroniser, perform the following
steps: push the movable sleeve for the 5th gear downwards
-arrow 1- . Also connect the 1st gear by pushing the selector
lever inwards -arrow 2- and turning -arrow 3- .
– The primary and secondary shafts remain blocked since two
gears are connected; the synchronising bushing and the 5th
gear pinion do not turn. Unscrew the bolts -A- and take them
out.
– Remove the movable sleeve for the 5th gear.
– Dismount the synchronising bushing and the 5th gear pinion.

Use the tool -U-40100/1- .
– Remove the needle bearing for the 5th gear pinion.

Arosa 1997 ➤
– Remove the 5th gear pinion. Use the tool -U-40100/1- .
Note!
♦ In order to remove the 5th gear pinion, first heat to about 80

ºC using the electrical blower -SAT 1416- .
♦ During the removal work, check that the legs of the extraction
device do not bend outwards. Check that the 5th gear pinion
is not damaged.
– Remove the right-hand and left-hand coupling flanges.

– Remove the coupling flanges together with the springs, the
thrust washers and the tapered rings.
– Dismount the two bolts -arrows- for supporting the reverse

gear axle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Put the gear selector axle into neutral. Extract the attachment
bolts -arrow- and remove the gear selector axle from the gear‐
box casing.

Arosa 1997 ➤
– Dismount the close cover -A- and the support bolts -B- from
the lower part of the gearbox, first extracting the bolts -1- and
-2- .
– Dismount the support bolts -A- from the upper part of the gear‐
box and the bolts -B- for attaching the gearbox casing to the
clutch casing.
– Dismount the bolts -A- for attaching the clutch casing to the
gearbox casing.
Note!
Do not remove the nuts -B- for attaching the secondary shaft.
– Separate the gearbox casing by hitting lightly with a plastic

hammer. Do not damage the surfaces for fitting them together.

Arosa 1997 ➤
– Extract the forks -A- together with the connection guides.

– Remove the bolt -B- and extract the fork for the reverse gear.
– Extract the nuts for attaching the secondary shaft -B- .

Note! respect to the correctness of information in this document. Copyright by SEAT S.A.
Place the gearbox axles in an upright position before completing

the removal of all the bolts -B- .
– Extract from the clutch casing, in the following order, the re‐
verse gear axle -A- , the main shaft -B- and the secondary shaft
-C- .
– Withdraw the differential unit from the clutch casing.

Arosa 1997 ➤
4.5.2 Assembly
– Place the differential into the clutch casing.
Note!
The seal rings must always be replaced. The figure only shows 3
of the 4 bolts with their seal rings.
– Place the main shaft, the secondary shaft and the axle for the
reverse gear pinion together.
– Partially tighten the 4 nuts in a cross for the bearing cover for
the secondary shaft, finish tightening up to their tightening tor‐
que.
Tightening torque: 25 Nm + 90º
Note!
Clean the remains of the safety agent from the support thread for
the reverse gear axle. To do so, use a threaded tap.
– Put the support for the reverse gear axle into place.
– Assemble the fork for the reverse gear.

Position for assembling the axle and
permitted theauthorised
unless reverse gearS.A.
by SEAT fork.
– Assemble the forks together with the connection guides.
– Screw in a stud bolt -A- M 8 x 100 mm into the support for the
reverse gear axle so that it will be aligned after putting the
gearbox casing into place.
– Align the connection guides.
– Check that the blocks of the gearbox forks are housed in their
respective movable sleeves.
– Check that the magnet is not broken or cracked and put it into
its housing in the clutch casing.
– Assemble the gearbox casing over the clutch casing.

Arosa 1997 ➤
– Screw in the bolts for attaching the clutch casing to the gear‐
box casing.
– Assemble the bolts for the reverse gear axle support -arrow-
as stated below:
– Place the bolt -a- , unscrew the stud bolt -A- M 8 x 100 mm -
Figure V34-2008 - assemble the bolt -b- and tighten it by hand.
Order for tightening:
1. Bolt -a- 30 Nm
2. Bolt -b- 30 Nm
– Assemble the support anchor bolts -arrow- for the gearbox

forks. Use a screwdriverProtected
to align the connection
by copyright. guides
Copying for private in suchpurposes, in part or in whole, is not
or commercial
a way that each support anchor bolt may be put into its hous‐
ing.
– Assemble the seal cover for the gear selector axle.
Assemble the gear selector axle in the following way:
– Put the connection guides into the position for neutral.
– Put the boss -arrow 2- onto the gearbox casing trimming. As‐
semble the gear selector axle so that the connection finger
-arrow 1- will fit between the connection guides.
– Screw in the bolts for attaching the gear selector axle to the
gearbox casing.
5th gear pinion
Position for assembly:
– The existing trimming on the inner diameter of the pinion must

face towards the gearbox casing.

Arosa 1997 ➤
– Fit onto the secondary shaft for the 5th gear, using the tool -
U-40200/20- .
Check for wear on the 5th gear synchroniser ring
– Before the check for wear, clean the synchroniser ring and the
5th gear pinion very carefully
– Put the synchroniser ring onto the 5th gear pinion. Press the
synchroniser ring down over the pinion and measure the gap
“a” with a thickness gauge.
Synchronisier ring Measure “a” on new Limit for wear
synchroniser
5th gear 1.1 … 1.7 mm 0.5 mm
– Put the 5th gear intounless
permitted place with bythe
authorised needle
SEAT S.A. SEATbearing.
S.A does not guarantee or accept any liability with
– Put the 5th gear synchroniser ring over the moving pinion.
– Before the assembly, mount the body for the synchroniser/
moving body of the 5th gear ⇒ page 76 .
– Place the 5th gear pinion on the main shaft.
– Put the synchroniser ring over the 5th gear pinion.

– Assemble the 5th gear synchroniser unit by carrying out the
following steps:
– Place the movable sleeve -2- over the synchroniser bushing
-3- so that the trimmings coincide -A- for housing the block pins
-4- for both components and that the cogs with pointed ends
of the movable sleeve are situated in the same direction as the
largest boss -B- of the bushing.
– Assemble the pins for blocking -4- and fit them into place with
the springs -1- by offsetting them 120º between each other and
under the steps for the blocking pins.

Arosa 1997 ➤
Position for assembling the 5th gear synchronised/movable body

– Put the 5th gear pinion into the main shaft in such a way that
the pointed cogs of the movable pinion -arrow 1- and the high
collar of the synchronised body -arrow 2- face towards the
gearbox casing.
– The housings for the synchronising body -arrow 3- are aligned
with the block parts of the synchronised ring.
5th gear synchronised ring with blocking parts built in -arrow-
– Fit in the movable sleeve set and synchroniser bushing onto

the 5th gear pinion. Use the tool -U-40200/20- .
Note!
When fitting the movable sleeve unit and synchroniser bushing

onto the 5th gear pinion, check that the 5th gear synchroniser ring
can turn freely.
– Partially screw in the bolts for attaching the synchroniser bush‐

ing and the 5th gear pinion.
Position
Protectedfor assembly
– The concave
respect side ofofthe
to the correctness plateinsprings
information -arrow-
this document. must
Copyright beS.A.
by SEAT facing
towards the synchroniser bushing and the 5 gear pinion. th

Arosa 1997 ➤
Before tightening the bolts attach the synchroniser bushing and

the 5th gear pinion -arrows- two gears must be connected
⇒ page 49 .
The primary and secondary shafts are blocked since two gears
are engaged; the synchroniser bushing and the 5th gear pinion do
not turn. Tighten the bolts -A- .
– Assemble the connection fork for 5th gear.
Adjust the movable sleeve and the fork for the 5th gear
– Engage the 5th gear and untighten the bolt -1- Press the mov‐
able sleeve in the direction of the arrow, then tighten the bolt
-1- .
Note!
Between the movable sleeve and the moving pinion, there cannot
be apermitted
gap ofunless
over 0.15 mm. If necessary, repeat the adjustment
process. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Disengage the 5th gear. The movable ring must be placed in

neutral, the ring synchronised in this must position must be
able to turn freely.
– Check whether all the gears can be engaged easily.
– Put the seal for the gearbox casing cover into place -arrow- .
– Tighten the bolts for attaching the gearbox casing cover.
– Assemble the guide sleeve for the clutch release bearing and
attach it to the casing with the three lag bolts ⇒ page 21 .
– Assemble the thrust washers, the springs, the tapered rings

and the coupling flanges.

Arosa 1997 ➤
5 Gearbox casing and clutch casing: repair

Assembly chart
1 - Gearbox casing
❑ In the event of replace‐
ment, see adjustment
chart ⇒ page 109
2 - Secondary shaft needle
bearing
❑ For secondary shaft
❑ Assemble and fix into
place ⇒ page 61
3 - Lid for control of oil level. 25
Nm
❑ Without magnet
4 - Primary shaft needle bear‐
ing
chart ⇒ page 79
5 - Outer track, tapered roller
bearing for main shaft
⇒ page 70
chart ⇒ page 109
bearing for secondary shaft
⇒ page 94
chart ⇒ page 109 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Adjustment washer for sec‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
ondary shaft
❑ In the event of replacement, see adjustment chart ⇒ page 96
8 - Outer track, tapered roller bearing for main shaft
9 - Axial/radial needle bearing for reverse gear axle
10 - Centring bushes
❑ 2 units
11 - Bush-bearing for the start motor
❑ Assemble ⇒ page 62
❑ It may be replaced with the gearbox mounted.
12 - Clutch casing

Arosa 1997 ➤
13 - Guide sleeve
❑ With retainer for main shaft and vulcanised O-ring seal
❑ In order to replace the retainer for the main shaft it is necessary that the guide sleeve be dismounted.
❑ Replace the guide sleeve if the O-ring seal is damaged.
14 - Bolt for attaching the guide sleeve. 20 Nm
❑ Self-blocking
❑ Always replace
❑ Tightening torque: 20 Nm
15 - Retainer for right coupling flange
❑ Replacement with the gearbox mounted in the vehicle ⇒ page 101
16 - Plate sleeve
❑ For coupling flange retainer ⇒ Item 15 (page 59)
17 - Shaft for operating speedometer 30 Nm
18 - Top for emptying oil. 25 Nm
❑ Without a magnet
19 - Outer track for the tapered roller bearing in the differential
❑ In the event of replacement, adjust the differential ⇒ page 113
20 - Magnet
❑ It is held between the casings for the gearbox and the clutch
21 - Outer track for the tapered roller bearing in the differential
❑ Protected
In thebyevent ofCopying
copyright. replacement, adjust the
for private or commercial differential
purposes, in part or in⇒ page
whole, 113
is not
22 - Adjustment
respect to thewasher
correctnessfor differential
❑ Finding the thickness ⇒ page 115

23 - Retainer for left flange
❑ Replacement with the gearbox mounted in the vehicle ⇒ page 101
5. Gearbox casing and clutch casing: repair 59

Arosa 1997 ➤

equipment required
♦ Gearbox repairs case -
U-40200-
♦ Gearbox repairs case -
U-40300-
♦ Taps for Ø 11 and Ø 14 with
plunger -U-40087-
♦ Tool for assembling starter
sleeve -U-40027-
♦ Support column for gear‐
box-differential -
AR-2203A-
Dismounting the needle bearing for the secondary shaft

– Dismount the needle bearing from the gearbox casing using
tool -U-40200/10- and the tool -U-40300/1- .

Arosa 1997 ➤
Assembling and fitting the needle bearing for the secondary shaft
– Assemble the needle bearing in the gearbox casing using tool
-U-40200/10- and the tool -U-40300/12- .
– Fit the bearing by making three marks with a marking hammer
set out with 120º between each other.
Dismount the retainer for the main shaft in the guide sleeve
– Dismount the retainer for the main shaft in the guide sleeve by
carrying out the following steps:
– Place the guide sleeve over tool -U-40300/9- .
– Dismount the retainer for the main shaft in the guide sleeve
using tool -U-40300/2- with side A facing towards the sleeve
and tool -U-40200/10- .
Assemble the retainer for the main shaft in the guide sleeve
– Assemble the retainer for the main shaft in the guide sleeve,
carrying out the following steps:
– Place the guide sleeve over the tool -U-40300/9- .
– Assemble the retainer for the main shaft in the guide sleeve
using tool -U-40300/2- with side B facing towards the sleeve
and tool -U-40200/10- .
Dismounting the sleeve-bearing for the start-up motor

– Place the top of tool -U-40087- on the sleeve and tighten it
right to the end.
– Work the initiator until extracting the sleeve.
5. Gearbox casing and clutch casing: repair 61

Arosa 1997 ➤
Assembling the sleeve-bearing for the start-up motor

– Lubricate the sleeve-bearing with oil.
– Fit it into the clutch casing, with tool -U-40027- side B, right up
to the top.
Dismounting the plate sleeve for the coupling flange retainer

– Remove the sleeve by levering out carefully with a screwdriv‐
er.
♦ If the sleeve is damaged or has defects, it must be replaced.
Assembling the plate sleeve for the coupling flange retainer

– Impregnate the contact surface of the sleeve with sealing
paste.
– Fit in the sleeve using tool -U-40200/13- with the trimming of
the tool facing towards the sleeve and tool -U-40200/10- .

Arosa 1997 ➤
6 Gear selector axle: repair

♦ Gear repair case -U-40200-
Assembly chart
6. Gear selector axle: repair 63

Arosa 1997 ➤
1 - Selection axle
2 - Stop ring
3 - Ball bearing sleeve
4 - Seal ring
with a screwdriver
5 - Connection top
6 - Crown
❑ The bead faces towards
the switch for the re‐
verse gear light
❑ Apply a fine layer of -
MoS2- grease onto the
bead
❑ Self-blocking
❑ Always replace
8 - Support
❑ For the reverse gear
light switch.
9 - Bolt
10 - Top
❑ Vent top for the gear‐

box.
11 - Sleeve
❑ Fit it to the end, if it
comes as an individual
component
12 - Selection lever
❑ Position for assembly: The cog of the gear stick only fits in with the cog of the gear stick in one position
❑ It can be changed with the gear stick mounted in the vehicle
13 - Return lever
14 - Nut, 15 Nm
15 - Drag part
❑ With the axle for housing the return lever
16 - Bolt
❑ Insert it into the drag part.
17 - O-ring seals
❑ Assemble them on the axle of the drag parts.
18 - Separating part
❑ Insert it on the return lever
19 - Bolt for blocking, 40 Nm
20 - Seal top

Arosa 1997 ➤
Dismounting the sleeve from the connection top

– Before extracting the ball bearing sleeve, break the plastic
holder and remove the ball bearings.
– The extraction of the ball bearing sleeve is done with the tool
-U-40300/4- without expanding.
Fit the ball bearing sleeve into the connection top
Fit in the seal ring to the end
6. Gear selector axle: repair 65

Arosa 1997 ➤
7 Gearbox forks: repair

♦ Pliers for opening elastic rings -A-81124-
Assembly Chart

Arosa 1997 ➤
1 - Gear switch anchor bolt

❑ Identification
⇒ page 68
❑ After assembling the
safety washer, the
blocks must be able to
move slightly.
2 - Pressure washer
❑ Separate the pressure
washer by levering
carefully with a screw‐
driver.
❑ Always replace
3 - 5th gear fork
4 - 5th gear connection hub
5 - Bolt, 25 Nm
6 - 5th gear connection guide
7 - Safety ring
8 - Washer
9 - Connection guide for 3rd
and 4th gears
10 - Connection guide for 1st
and 2nd gears
11 - Connection guide for re‐
verse gear
12 - Fork for 3rd and 4th gears
❑ With switch anchor bolt
for gears ⇒ page 69
13 - Switch anchor bolt for gears
❑ After the assembly of the safety washer, the blocks must be able to move slightly
14 - Ball bearing
15 - Inner ring of the ball bearing
❑ Dismount ⇒ page 68 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Fitting ⇒ page 68 respect to the correctness of information in this document. Copyright by SEAT S.A.
16 - 1st /2nd gear fork

❑ With blocks for the gearbox forks ⇒ page 69
17 - Reverse gear switch anchor bolt
❑ After the assembly of the safety washer, the blocks must be able to move slightly.
18 - Safety ring
19 - Support for reverse gear fork
20 - Reverse gear fork
21 - Spring
22 - Sliding block
7. Gearbox forks: repair 67

Arosa 1997 ➤
Identifying the blocks for the gearbox forks

Gap height -a-
1- 1st and 2nd gears = 12.1 mm
2- 3rd and 4th gears = 7.7mm
3- 5th gear = 12.1 mm
Assembly of the pressure washers

– Press down the pressure washer into the groove for the block
with a box spanner with a handle.
Note!
After the assembly of the safety washer, the blocks should be able
to move slightly.
A - Box spanner with handle, with 10 mm

B - Protective grips
Dismount the ball bearing
Note!
When dismounting and assembling the bearings, do not bend the

forks.
Fit in to the top of the inner ring of the ball bearing
Note! Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
When dismounting and assembling the bearings, do not bend the
forks.

Arosa 1997 ➤
Fork with blocks mounted

Gap height -a- (mm)
1st /2nd gear fork 87.2 … 87.9
3rd /4th gear fork 96.0 … 96.7
Identification of the blocks for the gearbox forks ⇒ page 68 .
7. Gearbox forks: repair 69

Arosa 1997 ➤
35 – Gears, Shafts
1 Main shaft: dismounting and assembling
Assembly Chart
1 - Clutch casing
bearings
❑ Dismounting
⇒ page 72
❑ Assembling
⇒ page 73
3 - Tapered roller bearing
❑ Dismounting
⇒ page 73
❑ Assembling Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 73
4 - Main shaft
❑ Adjusting the main shaft
⇒ page 77
5 - 3rd gear pinion
❑ Dismounting
⇒ page 74
❑ Assembling
⇒ page 74
the collar must remain
facing towards the 4th
gear pinion.
6 - Safety ring
❑ Use tool -A-81124- for
extracting the safety
ring.
❑ Always replace
7 - 4th gear pinion
❑ Dismount it together
with the tapered roller
bearing ⇒ Item 8 (page 70) , the stop washer ⇒ Item 9 (page 70) and the sleeve for the needle bearing
⇒ Item 13 (page 71) , ⇒ page 73
❑ Assembling ⇒ page 74
❑ Position for assembly: the collar must remain facing towards the 3rd gear pinion.
❑ Dismount it together with the 4th gear pinion ⇒ Item 7 (page 70) , the stop washer ⇒ Item 9 (page 70)
and the sleeve for the needle bearing ⇒ Item 13 (page 71) , ⇒ page 73
9 - Stop washer
10 - Outer track, tapered roller bearing
❑ Dismounting ⇒ page 75
70 Rep. Gr. 35 - Gears, Shafts

Arosa 1997 ➤
11 - Adjustment washer
❑ For the main shaft
❑ Finding the thickness ⇒ page 77
12 - Gearbox casing
13 - Sleeve for needle bearing
❑ Dismount together with the 4th gear pinion ⇒ Item 7 (page 70) , the tapered roller bearing
⇒ Item 8 (page 70) and the stop washer ⇒ Item 9 (page 70) , ⇒ page 73
❑ Before assembling it, put the stop washer into place ⇒ Item 9 (page 70)
14 - Needle bearing
❑ Dismount it together with the 5th gear synchroniser unit ⇒ page 45
16 - 5th gear synchroniser ring

❑ Check the wear ⇒ page 45
17 - Spring
18 - Blocking pins
19 - Synchronised boss
20 - Movable sleeve for 5th gear
❑ Assembling ⇒ page 76 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
21 - Plate spring permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Position for assembly: the concave side must remain facing towards the 5th gear pinion ⇒ page 45
22 - Bolt for attaching the 5th gear pinion. 80 Nm

❑ The head of the bolt has a slot for housing the plate spring ⇒ Item 21 (page 71)
1. Main shaft: dismounting and assembling 71

Arosa 1997 ➤

equipment required
♦ Case for extractors for
gearboxes -U-40100-
♦ Gearbox repair case -
U-40200-
♦ Pliers for opening elastic
rings -A-81124-
Dismounting the outer track of the tapered roller bearing

– Dismounting the outer track of the tapered roller bearing from
the main shaft in the clutch casing using tool -U-40200/20- .

Arosa 1997 ➤
Assembling the outer track of the tapered roller bearing

– Assemble the outer track of the tapered roller bearing for the
main shaft in the clutch casing, using tool -U-40200/10- and
tool -U-40200/11- .
Dismounting the tapered roller bearing

– Place the tool -U-40100/4- between the bearing and the main
shaft pinion.
– Place the main shaft on tool -U-40100/4- , as shown on the
drawing. Work the press in order to extract the bearing.
Assembling the tapered roller bearing

– Assemble the bearing over the main axle using tool -
U-40100/3- with the help of a press.
– Place the main shaft with the tapered bearing over the base
of the tool -U-40100/3- , as shown in the drawing. Operate the
press until the bearing is mounted in its position.
Dismounting the 4th gear pinion, the tapered roller bearing, the
stop washer and the sleeve for the needle bearing
The 4th gear pinion is dismounted together with the tapered roller
bearing, the stop washer and the sleeve for the needle bearing.
– Assemble the tool -U-40100/3- in the main shaft, underneath
the 4th gear pinion.
– Put the main shaft and the tool -U-40100/3- over the press as
shown in the drawing.
– Work the press until the tapered roller bearing and the 4th gear
pinion and the stop washer remain outside of the coupling.

Arosa 1997 ➤
Dismounting the 3rd gear pinion

– Assemble the tool -U-40100/3- in the main shaft, underneath
the 3rd gear pinion.
– Put the main shaft and the tool -U-40100/3- over the press as
shown in the drawing.
– Work the press until the 3rd gear pinion is removed from the
main shaft.
Assembling the 3rd gear pinion

– Assemble the tool -U-40100/3- underneath the 3rd gear pinion.
– Place the tool -U-40100/3- with the pinion in a press, as shown
in the drawing. Assemble the main shaft inside the pinion. The
cogs of the pinion and the main shaft should match.
The collar of the pinion should remain facing towards the 4th gear
pinion.
– Work the press until the pinion remains assembled in its po‐
sition.
Assembling the 4th gear pinion

– Assemble the tool -U-40100/3- underneath the 4th gear pinion.
– Place the tool -U-40100/3- with the 4th gear pinion in a press,
as shown in the drawing . Assemble the main shaft inside the
pinion. The cogs of the pinion and the main shaft should
match.
The collar of the pinion should remain facing towards the 3rd gear
pinion.
– Work the press until the pinion remains assembled in its po‐
sition.

Arosa 1997 ➤

– Assemble the tool -U-40100/3- over the base of the 2nd gear
pinion and the main axle.
– Put the stop washer into place before placing the sleeve for
the needle bearing.
– Put the tool -U-40100/3- on the press as is shown in the draw‐
ing.
– Fit in the tapered roller bearing, using tool -U-40200/19- . Work
the press until the bearing is assembled in its position.
Assembling the sleeve for the needle bearing

– Assemble the tool -U-40100/3- over the base of the 2nd gear
pinion and the main axle.
– Place the shaft of the main axle with the 2nd gear pinion and
tools -U-40100/3- and -U-40300/8- on a press as is shown in
the drawing.
– Work the press until the sleeve is mounted in its position.
Dismounting the outer track of the tapered roller bearing

– Extract the outer track of the tapered roller bearing of the main
shaft in the gearbox casing using tool -U-40200/10- .
Assembling the outer track of the tapered roller bearing

main shaft in the gearbox casing using tool -U-40200/10- and
tool -U-40200/11- .
Note!
If the main shaft has been adjusted, the stop washer must be
assembled before assembling the outer track for the tapered roller
bearing.

Arosa 1997 ➤
Assembling the 5th gear synchroniser unit

– Assemble the 5th gear synchroniser unit by carrying out the
following steps:
– Place the movable sleeve -2- over the synchroniser sleeve
-3- in such a way that the trimmings coincide -Afor housing the
block pins -4- for both components and that the pointed cogs
of the movable sleeve are situated in the same direction as the
most pronounced edge -B-of the bushing.
– Assemble the blocking pins -4- and fix them in place with the
springs -1- spreading them out 120º away from each other and
under the projections of the blocking pins.
Assemble the springs in the 5th gear synchroniser unit

– Check that the pointed cogsunless
permitted -A- authorised
of the movable
by SEAT S.A.sleeve
SEAT S.A are
does not guarantee or accept any liability with
facing in the same direction as tothe
respect most pronounced
the correctness of information inboss
this document. Copyright by SEAT S.A.
-B- of the bushing.
– Check that the blocking pins are assembled correctly
⇒ page 76 .
– Place the springs spread out 120º from each other, under‐
neath the projections -C- of the blocking pins. The bent ends
of the springs -arrows- must be located outside of the pins for
blocking.

Arosa 1997 ➤
2 Main shaft: adjusting

equipment required
♦ Case for repairing gearbox‐
es -U-40200-
♦ All-purpose support for
tester -T20020-
♦ Support column for gear‐
box-differential -
AR-2203A-
8010-
Adjust the main shaft when any of the following components have
been replaced:
♦ Gearbox casing
♦ Clutch casing
♦ Main shaft
♦ 4th gear pinion
♦ Tapered roller bearings in the main shaft
So as to avoid unnecessary adjustment work, consult the Chart
for Adjustment ⇒ page 109 .
2. Main shaft: adjusting 77

Arosa 1997 ➤
main shaft in the gearbox casing without the adjustment wash‐
er, using tool -U-40200/10- and tool -U-40200/13- .
– Place the main shaft into its housing in the clutch casing.
– Assemble the gearbox casing over the clutch casing and tight‐
en the bolts for attaching them.
– Place tool -T20020- with a tester over the gearbox casing.

Place the end of it over the main shaft.
– Turn the main shaft a few times in order to settle the tapered
roller bearings.
– Adjust the tester to “0” with a prior stress of 1 mm.
Note!
The adjustment to “0” for the tester must be repeated each time
that the measurement is made, otherwise, the tester will not go
back to the initial position.

Arosa 1997 ➤
– On the lower part of the gearbox, put pressure on the main

shaft in the direction of the tester.
– Note the reading given on the tester (Example: 1.21 mm).
Note!
The tester does not return to the initial position.
♦ The adjustment washer needed is found by means of the fol‐

lowing Table ⇒ page 79 .
Example:
♦ Set in the tester = 1,21 mm.
♦ According to the Table for a set for the main shaft from 1.200
to 1.224 mm, a thickness of 1.175 mm would correspond to it.

Arosa 1997 ➤
Table of adjustment washers

Height Adjustment washer
measured for bearing Thickness Spares No.
set (mm) (mm)
0.671 … 0.699 0.650 02A 311 140
0.700 … 0.724 0.675 02A 311 140 A
0.725 … 0.749 0.700 02A 311 140 B
0.750 … 0.744 0.725 02A 311 140 C
0.775 … 0.799 0.750 02A 311 140 D
0.800 … 0.824 0.775 02A 311 140 E
0.825 … 0.849 0.800 02A 311 140 F
0.850 … 0.874 0.825 02A 311 140 G
0.875 … 0.899 0.850 02A 311 140 H
0.900 … 0.924 0.875 02A 311 140 J
0.925 … 0.949 0.900 02A 311 140 K
0.950 … 0.974 0.925 02A 311 140 L
0.975 … 0.999 0.950 02A 311 140 M
1.000 … 1.024 0.975 02A 311 140 N
1.025 … 1.049 1.000 02A 311 140 P
1.050 … 1.074 1.025 02A 311 140 Q
1.075 … 1.099 1.050 02A 311 140 R
1.100 … 1.124 1.075 02A 311 140 S
1.125 … 1.149 1.100 02A 311 140 TT
1.150 … 1.174 1.125 02A 311 140 AA
1.175 … 1.199 1.150 02A 311 140 AB
1.200 … 1.224 1.175 02A 311 140 AC
1.225 … 1.249 1.200 02A 311 140 AD
1.250 … 1.274 1.225 02A 311 140 AE
1.275 … 1.229 1.250 02A 311 140 AF
1.300 … 1.324
Protected 1.275for private
by copyright. Copying 02A 311 140purposes,
or commercial AG in part or in whole, is not
1.325 … 1.349 1.300
respect to the correctness 02Ain311
of information 140 Copyright by SEAT S.A.
this document.
02A 311 140
1.350 … 1.374 1.325 02A 311 140
02A 311 140 A
1.375 … 1.399 1.350 02A 311 140 A
02A 311 140 A
1.400 … 1.424 1.375 02A 311 140 A
02A 311 140 B
1.425 … 1.449 1.400 02A 311 140 B
02A 311 140 B
1.450 … 1.474 1.425 02A 311 140 B
02A 311 140 C
1.475 … 1.499 1.450 02A 311 140 C
02A 311 140 C
1.500 … 1.524 1.475 02A 311 140 C
02A 311 140 D
1.525 … 1.549 1.500 02A 311 140 D
02A 311 140 D
1.550 … 1.574 1.525 02A 311 140 D
02A 311 140 E
1.575 … 1.599 1.550 02A 311 140 E
02A 311 140 E
1.600 … 1.624 1.575 02A 311 140 E
02A 311 140 F
1.625 … 1.649 1.600 02A 311 140 F
02A 311 140 F
1.650 … 1.674 1.625 02A 311 140 F
02A 311 140 G

Arosa 1997 ➤
Height Adjustment washer

1.675 … 1.699 1.650 02A 311 140 G
02A 311 140 G
1.700 … 1.724 1.675 02A 311 140 G
02A 311 140 H
1.725 … 1.749 1.700 02A 311 140 H
02A 311 140 H
1.750 … 1.774 1.725 02A 311 140 H
02A 311 140 J
1.775 … 1.791 1.750 02A 311 140 J
02A 311 140 J
– Once the adjustment washer needed has been foand, remove
the comparator.
– Remove the bolts that attach both casings and take out the
gearbox casing.
– Remove the main shaft from the casing.
– Remove the outer track of the tapered roller bearing for the
main shaft in the gearbox casing using tool -U-40200/10- and
tool -U-40200/13- .
– Place the adjustment washer with the thickness calculated (in
this case, 1.175 mm) into the housing for the outer track of the
tapered roller bearing.
– Assemble the outer track of the tapered roller bearing of the

main shaft in the clutch casing using tool -U-40200/10- and
tool -U-40200/13- .
– Carry out a measurement for control.
Measurement for control
– Place the main shaft into its housing in the clutch casing.

Arosa 1997 ➤
– Place the tool -T20020- over the gearbox casing with a tester.
– Place the end of the tester on the main shaft.
– Turn the main shaft a few times in order to settle the tapered
roller bearings.
– Adjust the tester to “0” with a pretension of 1 mm.
– On the lower part of the gearbox, put pressure on the main
shaft in the direction of the tester.
– The bearing play should range between a minimum of 0.01
mm and a maximum of 0.1 mm.
Note!
If it is not possible to note any play in the bearing, but however

the first shaft has quite a visible play that allows a smooth turn,
the adjustment is right.

Arosa 1997 ➤
3 Secondary shaft: dismounting and assembling

Assembly Chart
1 - Nut, 25 Nm + 90º
❑ 4 units
❑ For attaching the secon‐
dary shaft
2 - Clutch casing
❑ For the secondary shaft
❑ Finding the thickness
⇒ page 94
bearing
❑ Dismounting
⇒ page 86
❑ Assembling
⇒ page 87
❑ Dismounting
⇒ page 87
❑ Assembling
⇒ page 87
6 - Secondary shaft
❑ It is coupled with the pin‐
ion for the control drive
trains; in the event of re‐
placement they should
be changed together.
ment ï Identification ini‐
tials, assignation of
groups, reductions,
amounts for filling
⇒ page 1
❑ Adjustment for the sec‐
ondary shaft ⇒ page 94
7 - Tapered roller bearing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismounting ⇒ page 88 respect to the correctness of information in this document. Copyright by SEAT S.A.
8 - Seal ring
❑ 4 units
❑ Always replace
❑ For the bolts for attaching the cover for the secondary shaft bearing ⇒ Item 9 (page 83)
9 - Cover for the secondary shaft bearing
❑ It includes the outer track for the tapered roller bearing ⇒ Item 7 (page 83) .
❑ The cover for the secondary shaft bearing must be replaced together with the outer track for the tapered
roller bearing and the tapered roller bearing ⇒ Item 7 (page 83) .
10 - Stop washer
❑ The edge of the washer must be facing towards the tapered roller bearing.
3. Secondary shaft: dismounting and assembling 83

Arosa 1997 ➤
11 - 1st gear pinion

❑ Before assembling the 1st gear pinion assemble the stop washer ⇒ Item 10 (page 83) .
12 - Needle bearing for 1st gear pinion

13 - Synchroniser ring for 1st gear
❑ Identification ⇒ page 90 and ⇒ page 90
❑ Check that the flanges have no signs of wear.
14 - Synchroniser unit for 1st and 2nd gears
❑ Dismounting the secondary shaft ⇒ page 88 .
❑ Desmontagem ⇒ page 89
❑ Assembling the components ⇒ page 89 and ⇒ page 89 .
❑ Assembly of the secondary shaft ⇒ page 90 .
15 - Safety ring
❑ Use tool -A-81124- for extracting thepermitted
safety ring.
❑ Always replace
16 - Outer synchroniser ring for 2nd gear

❑ Identification ⇒ page 90 and ⇒ page 90 .
❑ Check for wear ⇒ page 90 .
❑ Assembly: the trimmings of the synchroniser ring must always be fitted with the pins in the synchroniser
unit for 1st and 2nd gear ⇒ Item 14 (page 84) .
17 - Intermediate synchroniser ring for 2nd gear
❑ Place it on the outer synchroniser ring ⇒ Item 16 (page 84) .
❑ Replace it if it shows signs of wear or cracks.
18 - Inner synchroniser ring for 2nd gear
❑ Identification ⇒ page 90 and ⇒ page 90 .
❑ Check that the flanges do not show any signs of wear.
19 - 2nd gear pinion
20 - Needle bearing for 2nd gear pinion
21 - Stop washer
❑ Dismounting, together with the 2nd gear pinion ⇒ page 88 .
23 - Needle bearing for 3rd gear pinion
24 - 3rd gear pinion
25 - Synchroniser ring for 3rd gear
26 - Synchroniser unit for 3rd and 4th gears
❑ Dismounting the secondary shaft ⇒ page 87 .
❑ Dismounting the synchroniser unit ⇒ page 92
❑ Assembling the components ⇒ page 92 and ⇒ page 92 .

Arosa 1997 ➤

❑ Assembly for the secondary shaft ⇒ page 93 .
27 - Casquilho Sleeve for needle bearingrolamento de agulhas
❑ Dismounting together with the synchroniser unit for 3rd and 4th gears ⇒ Item 26 (page 84) ,
⇒ page 87
28 - Needle bearing for 4th gear pinion
29 - Synchroniser ring for 4th gear
31 - Stop washer
32 - Needle bearing for the secondary shaft
❑ Dismounting and assembling ⇒ page 58
33 - Gearbox casing
❑ Dismounting ⇒ page 87
❑ Dismounting and assembling ⇒ page 45
36 - Plate spring
❑ Position for assembly: the concave side must remain facing towards the 5th gear pinion.
37 - Bolt for attaching the 5th gear pinion

❑ The head of the bolt includes a housing for the plate spring ⇒ Item 36 (page 85)

Arosa 1997 ➤

equipment required
gearboxes -U-40100-
U-40200-
U-40300-
♦ Pliers for opening elastic
rings -A-81124-
Dismounting the outer track for the tapered roller bearing

– Dismount the outer track for the tapered roller bearing by car‐
rying out the following steps:
– Assemble the grips -U-40300/17- on the tool -U-40300/16-
using its attachment bolts. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Place the set of tools on the lower part of the outer track of the
tapered roller bearing. Expand the tool -U-40300/16- by tight‐

ening the bolt -1- .
– Place the extractor tool -U-40300/15- on the clutch casing and
tighten the axle of the extractor in the tool -U-40300/16- .
– Turn the nut -2- until extracting the outer track of the tapered
roller bearing.

Arosa 1997 ➤
Assemble the outer track of the tapered roller bearing

secondary shaft, on the clutch casing, with the tool -
U-40200/12- and the tool -U-40200/10- .

– Assemble the tool -U-40100/4- on the secondary shaft ander‐
neath the front pinion.
– Place the secondary shaft and the tool -U-40300/2- on the
press, as is shown on the drawing.
– Work the press until the tapered roller bearing is extracted.

– Assemble the tool -U-40100/3- on the secondary shaft ander‐
neath the front pinion.
– Place the tool -U-40200/19- on the press as is shown on the
drawing.
– Work the press until the tapered roller bearing is mounted in
its position.
Dismounting the sleeve for the needle bearing, the 4th gear pin‐
ion, the synchroniser unit for 3rd and 4th gears and the 3rd gear
pinion of the secondary shaft
The 3rd gear pinion will be assembled jointly with the sleeve for
the needles bearing, the 3rd and 4th gear synchroniser unit and
the 4th gear pinion.
– Place the tool -U-40100/3- on the secondary shaft ander the
3rd gear pinion.
– Place the secondary shaft with the tool -U-40100/3- on the
press as is shown in the drawing.
– Work the press and extract at the same time the sleeve for the
needle bearing, the 4th gear pinion, the synchroniser unit for
3rd and 4th gears and the 3rd gear pinion.

Arosa 1997 ➤
Dismounting the sleeve for the needle bearing, the 2nd gear pin‐
ion, the synchroniser unit for 1st and 2nd gears and the 1st gear
pinion of the secondary shaft
– Remove the safety ring using the tool -A-81124- .
– Assemble the tools -U-40100/3- and -U-40300/10- on the sec‐
ondary shaft anderneath the 2nd gear pinion.
– Put the secondary shaft and the tools -U-40100/3- and -
U-40300/10- over the press, as is shown.
– Work the press and extract at the same time the sleeve for the
needle bearing, the 2nd gear pinion, the synchroniser unit for
1st and 2nd gears and the 1st gear pinion of the secondary
shaft.

– Assemble the tool -U-40100/4- anderneath the tapered roller
bearing
– Place the tool -U-40100/4- over the press, as is shown.
– Work the press until extracting the tapered roller bearing.

– Assemble the tools -U-40100/3- and -U-40200/18- with side
-A- facing towards the tapered bearing, over the secondary
shaft.
– Place the secondary shaft using tools -U-40100/3- and -
U-40200/18- over the press, as shown in the drawing.
The side with the smallest external diameter of the tapered roller
bearing must be facing towards tool -U-40200/18- .
– Put the tool -U-40200/4- between the press and the secondary
shaft.
its position.
Control for wear on the synchroniser rings for the 1st , 3rd and
4th gears
– Before the control for wear, carefully clean the synchroniser
rings and their corresponding pinions.
– Place the synchroniser ring onto the cone of the corresponding
pinion. Press down the synchroniser onto the pinion and
measure the gap height “a” with a gauge.
Synchroniser ring Measurement “a” in Wear limit
a new synchroniser
1st gear 1.0 … 1.7 mm 0.5 mm
3rd gear
4th gear

Arosa 1997 ➤
Dismounting and assembling the synchroniser unit for 1st and

2nd gears
– In order to dismount the synchroniser unit for 1st and 2nd gears,
remove the springs -1- and move the movable sleeve -B- com‐
pletely upwards.
– Assemble the synchroniser unit for 1st and 2nd gears by car‐
– Place the movable sleeve -2- onto the synchroniser hub -3- so
that the trimmings for housing the blocking pins -4- for both
components coincide.
– Mount the movable sleeve over its boss in such a way that
after they are assembled they will be located so that the widest
collar of the synchroniser boss -A- and the inner teeth of the
movable sleeve -B- are facing in opposite directions.
– Assemble the blocking pins -4- and fix them into place with the
springs -1- placing them at 120° from each other.
Dismounting and assembling the synchroniser unit for 1st and

nd
2 gears permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– With the synchroniser unit assembled, mount the springs at
120° from each other. The bent ends of the springs must re‐
main inside the blocking pins.
Position for assembling the synchroniser unit for 1st and 2nd gears
– The cogs -1- of the movable sleeve must be facing towards
the gear teeth -A- for housing the synchroniser unit for 3rd and
4th gears.
– The collar -2- of the synchroniser hub must be facing towards
the pinion -B- for the 1st gear.

Arosa 1997 ➤
Assembly of the synchroniser unit for the 1st and 2nd gears in the
secondary shaft
– Place the synchroniser ring for the 1st gear on the 1st gear
pinion.
– Assemble the synchroniser unit for the 1st and 2nd gears in the
secondary shaft by carrying out the following steps:
– Place the tool -U-40100/3- and the tool -U-40200/19- in a
press with side A facing upwards.
– Place the secondary shaft on the tool -U-40200/19- .
– Place the tool -U-40300/9- between the press and the secon‐
dary shaft.
– Turn the synchroniser ring so that the parts of the block for the
synchroniser unit coincide with the housings of the pins for the
synchroniser ring.
– Work the press until the synchroniser unit for the 1st and 2nd
gears is mounted in its position.
– Mount the safety ring using the tool -A-81124-
⇒ Item 15 (page 84) .
Identification of the synchroniser rings for 1st and 2nd gears

– Synchroniser ring for 1st gear: 3 cogs cut down to half size
-arrow- .
– Synchroniser ring for 2nd gear: 2 or 3 cogs cut down to half
size -arrow- .
– The synchroniser ring for the 2nd gear is only supplied as a
spare part, with 2 cogs cut down to half size.
Identification of the synchroniser rings for 1st and 2nd gears

– Synchroniser ring for
permitted unless 2nd gear:
authorised by SEAT3 trimmings
S.A. -arrows-
SEAT S.A does . or accept any liability with
not guarantee
– Synchroniser ring for 1st gear: without trimmings.
Control for the wear on the outer synchroniser ring for the 2nd gear
measure the gap “a” with a gauge.
a new synchroniser
2nd gear 1.2 … 1.8 mm 0,5 mm

Arosa 1997 ➤
Position for the assembly of the intermediate synchroniser ring

for the 2nd gear
– The bosses -arrows- must be facing towards the pinion for
1st gear -A- .
Control for the wear on the inner synchroniser ring for the 2nd
gear
measure the gap “a” with a gauge.
a new synchroniser
2nd gear 0.75 … 1.25 mm 0,3 mm
Position for the assembly of the inner synchroniser ring for 2nd
gear
– The bosses -arrows 1- of the synchroniser ring for the 2nd gear
-A- must fit in the trimmings -arrows 2- of the synchroniser ring
-B- .
Position for assembling the 2nd gear pinion

– The collar -A- of the 2nd gear pinion must be facing towards
the 1st gear -B- pinion.
– The trimmings arrows of the 2nd gear pinion -A- must fit into
the bosses of the intermediate synchroniser ring ⇒ page 91 .

Arosa 1997 ➤

– Assemble the needle bearing for the 2nd gear pinion and the
stop washer in the secondary shaft.
– Place the tool -U-40100/3- and tool -U-40200/19- in a press
with side -A- facing upwards.
– Place the secondary shaft onto the tool -U-40200/19- .
– Place the tool -U-40300/8- with side -B- facing towards the
sleeve and the tool -U-40300/9- , between the press and the
secondary shaft.
– Work the press until the sleeve for the needle bearing is moun‐
ted in its position.
Dismounting and assembling the synchroniser unit for 3rd and

4th gears
– In order to dismount the synchroniser unit for 3rd and 4th gears,
remove the springs -1and move the movable sleeve -3com‐
pletely upwards.
– Assemble the synchroniser unit for 3rd and 4th gears by car‐
– Place the movable sleeve -3- onto the synchroniser hub -4- so
that the trimmings for housing the blocking pins -2- for both
components coincide.
– Assemble the blocking pins -2- and fix them into place with the
springs -1- placing them at 120° from each other.
Dismounting and assembling the synchroniser unit for the 3rd and
4th gears in the secondary shaft
– The movable sleeve must be mounted on the synchroniser
hub.
– Place the springs at unless
permitted 120°authorised
from eachby SEATother. The
S.A. SEAT S.Abent ends
does not of or accept any liability with
guarantee
the springs must remain
respect toinside the blocking
the correctness pins.
Position for assembling the synchroniser unit for 3rd and 4th gears
– The collar with bevel -arrow- of the synchroniser hub must be
facing towards the 4th gear pinion.

Arosa 1997 ➤
Assembly of the synchroniser unit for the 3rd and 4th gears in the
secondary shaft
– Assemble the synchroniser unit for the 3rd and 4th gears in the
secondary shaft by carrying out the following steps:
– Assembling o casquilho para rolamento de agulhas.
– Situar o utensílio-ferramenta -U-40300/9- entre a prensa e o
veio secundário.
– Turn the synchroniser ring so that the parts of the block for the
synchroniser unit coincide with the housings of the pins in the
synchroniser ring.
– Work the press until the synchroniser unit for the 3rd and 4th
gears is mounted in its position.

– Place
Protected the secondary
by copyright. shaftor on
Copying for private the tool
commercial -U-40200/19-
purposes, . is not
in part or in whole,
– Place
respect tothe tool -U-40300/8-
the correctness with
of information in side -B-
this document. facingby towards
Copyright SEAT S.A. the
sleeve and tool -U-40300/9- , between the press and the sec‐
ondary shaft.

– Place the tool -U-40300/8- with side A facing towards the
sleeve, between the press and the secondary shaft.

Arosa 1997 ➤
4 Secondary shaft: adjustment

equipment required
U-40200-
U-40300-
♦ Multi-purpose stand for the
-T20020- comparator
8010-
Adjust the secondary shaft when any of the following components

have been replaced:
♦ Clutch casing
♦ Secondary shaft
♦ Tapered roller bearing in the secondary shaft
So as to avoid unnecessary adjustment work, consult the Chart
for Adjustment ⇒ page 109 .
– Dismount the outer trackpermitted
of theunless
tapered roller
authorised bearing
by SEAT byS.A
S.A. SEAT car‐
rying out the following steps: respect to the correctness of information in this document. Copyright by SEAT S.A.
using its attachment bolts.
roller bearing.

Arosa 1997 ➤

secondary shaft, in the clutch casing, with an adjustment
washer 0.65 mm thick, using tool -U-40200/10- and tool -
U-40200/12- .
– Put the secondary shaft into its housing in the gearbox casing.
– Tighten the bolts for attaching the secondary shaft to the gear‐
box casing.
4. Secondary shaft: adjustment 95

Arosa 1997 ➤
– Place tool -T20020- with a comparator over the clutch casing.

Place the end of it over the secondary shaft.
– Adjust the comparator to “0” with a prior tension of 1 mm.
– Alternatively move the secondary shaft in the direction of the
comparator.
– Note down the reading obtained on the comparator. Example,
0.30 mm.
Note!
When taking the measurement do not turn the secondary shaft.

The tapered roller bearings do not settle and they give a false
reading.
Calculating the adjustment washer

The thickness of the adjustment washer to be mounted is found
by adding the reading values obtained with the comparator, the
thickness of the adjustment washer mounted earlier and a set
value.
Example:
Reading obtained with the comparator 0.30
mm
Thickness of the washer already mounted 0.65
mm
Set value 0.20
mm
Thickness of the adjustment washer needed 1.15
mm
The adjustment washer needed is to be found using the following
Table:
Adjustment Table
Thickness (mm) Spare No.
0.65 020 311 391 P
0.70 020 311 391 Q
0.75 020 311 391
0.80 020 311 391 A
0.85 020 311 391 B
0.90 020 311 391 C
0.95 020 311 391 D
1.00 020 311 391 E
1.05 020 311 391 F
1.10 020 311 391 G
1.15 020 311 391 H
1.20 020 311 391 J
1.25 020 311 391 K
1.30 020 311 391 L
1.35 020 311 391 M
1.40 020 311 391
Protected N Copying for private or commercial purposes, in part or in whole, is not
by copyright.
The diversity of the adjustment washers available allows you to
find exactly the right thickness needed to perform a proper ad‐
justment of the secondary shaft.

Arosa 1997 ➤
– Should the thickness of the adjustment washer needed be

thicker than the thicknesses that appear in the Table, two ad‐
justment washers may be fitted, the thicknesses for which
when added together, correspond to the reading required.
– Once the adjustment washer needed has been determined,
remove the comparator.
– Separate the secondary shaft.
– Dismount the outer track for the tapered roller bearing by car‐
using its attachment bolts.
tighten the axle of the extractor into the tool -U-40300/16- .
roller bearing.
– Remove the washer that is 0.65 mm thick.
– Place the adjustment washer with the thickness calculated.

Example, 1.15 mm, in the housing for the outer track of the
tapered roller bearing of the secondary shaft.
secondary shaft, in the clutch casing, using tool -U-40200/10-
and the tool -U-40200/12- .
– Lubricate the tapered roller bearing with oil for gearboxes.
– Place the secondary shaft into its housing in the gearbox cas‐
ing.
– Tighten the bolts for attaching the secondary shaft to the gear‐
box casing.
4. Secondary shaft: adjustment 97

Arosa 1997 ➤
5 Axle for reverse gear pinion: dismounting and assembling

Assembly Chart
1 - Clutch casing
2 - Axial/radial needle bearing
❑ Dismounting
⇒ page 99
❑ After the dismounting,
the axial/radial needle
bearing must always be
replaced.
❑ Assembling
⇒ page 100
3 - Reverse gear pinion
4 - Safety ring
❑ Use the tool -A-81124-
for extracting the safety
ring
❑ Always replace
5 - Reverse gear moving pinion
the collar of the pinion
must face towards the
reverse gear pinion.
6 - Axle for reverse gear pinion
❑ Dismounting
⇒ page 47 .
7 - Axial/radial needle bearing
❑ Dismounting
⇒ page 100 .
❑ After the dismounting,
the axial/radial needle
bearing must always be
replaced.
❑ Assembling
⇒ page 100 .
8 - Support for the reverse gear axle
❑ Dismounting and assembling ⇒ page 47 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

Arosa 1997 ➤

equipment required
gears -U-40100-
U-40200-
U-40300-
Dismounting the axial/radial needle bearing

– Dismount the axial/radial needle bearing by carrying out the
following steps:
– Place the tool -U-40300/6- on the lower part of the axial/radial
needle bearing.
– Expand the grips of tool -U-40300/6- by tightening the bolt
-1- .
tighten the axle of the extractor in the tool -U-40300/6- .
– Turn the nut -2- until extracting the axial/radial needle bearing.
5. Axle for reverse gear pinion: dismounting and assembling 99

Arosa 1997 ➤
Assembling the axial/radial needle bearing

– Assemble the axial/radial needle bearing in the clutch casing
with the tool -U-40200/10- and tool -U-40300/7- .
Dismounting the axial/radial needle bearing for supporting the re‐

verse gear shaft
– Place the tool -U-40100/3- under the support for the reverse
gear axle.
– Dismount the axial/radial needle bearing from the support for
the reverse gear shaft, with the tool -U-40200/10- and the tool
-U-40200/5- .
Assembling the axial/radial needle bearing for supporting the re‐

verse gear shaft
– Place the tool -U-40100/3- under the support for the reverse
gear axle.
– Assemble the axial/radial needle bearing from the support for
the reverse gear axle, with the tool -U-40200/10- and the tool
-U-40300/7- .

Arosa 1997 ➤

1 Retainers for coupling flanges: dis‐
1.1 Retainers for coupling flanges: dis‐

(Gearbox mounted in the vehicle)

equipment required
♦ Set of notched spanners
XZN -U-40020-
gears -U-40100-
♦ Tool for holding coupling
flanges -T20005-
♦ Case for dismounting/as‐
sembling hub-bearing and
coupling flanges-drive train
-U-40450A-
1.1.1 Dismounting
Bear in mind the general instructions for the repair of the gearbox
⇒ page 6 .
1. Retainers for coupling flanges: dismounting and assembling 101

Arosa 1997 ➤
Note!
♦ Remove the negative terminal from the battery.

♦ In vehicles that are fitted with a coded radio, first consult the
anti-theft code.
Retainer for right coupling flange:

– Dismount the counterweight from the unit holder.
♦ Mark the position for the assembly of the counterweight.
Right or left retainer for coupling flange:
– Extract the attachment bolts from the drive train to the gearbox
flange.
♦ Use a spanner with a suitable diameter from the tool -
U-40020- .
– PutProtected
the drive train to one side and support it appropriately and
try not to damage it.by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless authorised
– Empty the oil from the gearbox.
– Remove the attachment bolt from the coupling flange.
– Take out the coupling flange together with the spring, the
thrust washer and the tapered ring.
– Dismount the retainer for the coupling flange using the tool -
U-40100/2- . Work the hammer until extracting the retainer.
Note!
Try not to cause any damage to the housing for the retainer in the
gearbox.
1.1.2 Assembly
– Lubricate the retainer properly.

Arosa 1997 ➤
– Fit in the retainer using the tools -U-40450A/3- and -

U-40450A/10- .
♦ Try not to introduce the retainer tilted.
– Assemble the coupling flange together with the spring, the
thrust washer and the tapered ring.
– Assemble the bolt for attaching the coupling flange. Use the
tool -T20005- .
– Assemble the coupled differential shaft on the gearbox flange.
♦ Use a spanner with the appropriate diameter from tool -
U-40020- .
Retainer for right coupling flange:
– Assemble the counterweight -A- on the unit holder.
♦ Position for assembly: According to the mark made for the
dismounting. If no mark has been made, the counterweight
must be assembled on the unit holder so that the greatest dis‐
tance between the edge of the counterweight and the attach‐
ment bolts is facing forwards.
– Check the oil level in the gearbox ⇒ page 42 .
– Remove the negative terminal from the battery.
1. Retainers for coupling flanges: dismounting and assembling 103

Arosa 1997 ➤
2 Differential: dismounting and assembling

Assembly chart
1 - Gearbox casing
2 - Bolt
3 - Differential box
ment, consult the Ad‐
justments Chart
⇒ page 109 .
4 - Crown for the riveted differ‐
ential
❑ Factory riveted
❑ Assembly with bolts
⇒ page 112
ment, the crown of the
differential and the sec‐
ondary shaft must be re‐
placed together.
sembly ⇒ See crown of
the differential: dis‐
mounting and assem‐
bling ⇒ page 110
5 - Plate washer
6 - Nut. 70 Nm
❑ Determine the thickness
⇒ page 115
bearing
❑ permitted
Assemble ⇒ page 107


10 - Differential unit
❑ In the event of replacement, the crown of the differential and the secondary shaft must be replaced
together. Consult the Adjustments Chart ⇒ page 109 .
❑ Factory riveted crown
❑ Drilling of the rivets and assembly with bolts ⇒ page 110 .
11 - Pinion for working the speedometer
❑ Dismount it by levering with a flat screwdriver
❑ Assembly: fit it in up to the top in the differential box before assembling the tapered roller bearing
13 - Outer track, tapered roller bearing

Arosa 1997 ➤

14 - Clutch casing
15 - Bush
❑ Retainer for the coupling flange
16 - Retainer for the coupling flange
17 - Bolt. 25 Nm
❑ Screw in with the threaded part for attaching the coupling flanges ⇒ Item 25 (page 105)
18 - Coupling flanges
19 - Spring for coupling flange
❑ Assemble it behind the coupling flange
20 - Front washer
❑ Position for assembly: Collar facing towards the spring, core facing towards the tapered ring
21 - Tapered ring permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ With trimmings for fitting the front washer
❑ Position for assembly: tapered side facing towards the differential box
22 - Safety ring
❑ Keeps the tapered ring, the washer and the spring for the coupling flange in position when the latter is
dismounted.
23 - Set of friction washers
❑ Coat them with gearbox oil before assembling them
24 - Differential side gear
25 - Threaded part for attaching the coupling flanges
26 - Axle for satellites
❑ Dismount it by striking with a punch.
27 - Elastic linchpin
❑ Dismount it by striking with a suitable punch
❑ Assemble ⇒ Fit it up to the stop
28 - Satellite
29 - Differential side gear
2. Differential: dismounting and assembling 105

Arosa 1997 ➤

equipment required
♦ Case of tools for repairing
gearboxes -U-40200-
♦ Case of tools for repairing
gearboxes -U-40300-
♦ Pincer extractor tool with
grippers -T20022-
Dismount the outer track of the tapered roller bearing
Note!
The procedure and the tools needed for dismounting the outer
tracks of the tapered roller bearings are the same in the gearbox
casing and in the clutch casing.
– Extract the outer track of the tapered roller bearing from the
gearbox casing with tool -U-40200/10- and -U-40300/14- .

Arosa 1997 ➤
Assemble the outer track for the tapered roller bearing
Note!
The procedure and the tools needed for assembling the outer
tracks for the tapered roller bearings are the same as for the
gearbox casing and the clutch casing.
– Assemble the outer track for the tapered roller bearing in the
clutch casing using tool -U-40200/10- and tool -U-40300/12- .
Dismount the tapered roller bearing

– Place tool -U-40300/13- on the differential.
– Place the extractor tool -U-40100/1- over the -U-40300/13-
trying to ensure that the grippers are inserted in the notches
that are located in the differential box.
– Extract the bearing. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If the bearing holder is broken during the extraction process,

use tool -T20022- for extracting the inner ring from the bearing.
Assemble the tapered roller bearing
Note!
♦ Before assembling the bearing in the differential box, heat it to

approximately 100 ºC with the electrical blower -SAT 1416- .
The temperature may be checked with the digital thermometer
-SAT 4002- .
♦ The procedure and the tools needed for assembling the ta‐
pered roller bearings are the same on both sides of the differ‐
ential box.
– Assemble the pinion for working the speedometer.

– Place the tool -U-40300/13- into a press.
– Place the differential unit over the tool -U-40300/13- .
– Place the tool -U-40300/11- with side B facing towards the
bearing, over the differential unit.
its position.
2. Differential: dismounting and assembling 107

Arosa 1997 ➤
Assemble sun gears and planetary gears

– Impregnate the friction washers with gear oil and assemble in
the differential housing.
– Fit the differential side gears -Aand attach them with the cou‐
pled flanges -B- .
– Introduce a planetary gear and turn it 180°.
– Place a second planetary gear opposite the first.
– In this position, turn the planetary gears towards the inside of
the differential housing by means of the coupled flanges until
they coincide with the holes in the planetary gear shaft.
– Insert the planetary gear shaft until it goes through the first
planetary gear.
– Assemble the threaded parts to secure the coupled flanges
and completely insert the planetary gear shaft right to its final
position.
– Attach the spring pin to secure the planetary gear shaft.

Arosa 1997 ➤
3 Adjustments Chart
It is only necessary to adjust the main shaft, the secondary shaft
or the differential when the parts have been replaced that affect
the adjustment for the gearbox. In order to avoid useless adjust‐
ment work, consult the following Table.
The following must be adjusted:
Primary Secondary Differential
shaft shaft ⇒
⇒ page 77 ⇒ page 94 page 113
Part replaced Gearbox casing x x
Clutch casing x x x
Primary shaft x
Secondary shaft (Front pinion-differential x
crown)
Differential box x
Tapered roller bearingin the main shaft x
Tapered roller bearingin the secondary shaft x
Tapered roller bearingin the differential x
4th gear pinion x
3. Adjustments Chart 109

Arosa 1997 ➤
4 Differential crown: dismounting and

assembling
4.1 Differential crown: dismounting and assembling

equipment required
♦ Electrical blower -SAT
1416-
♦ Digital thermometer -SAT
4002-
♦ Case for tools to repair
gearboxes -U-40300-
4.1.1 Dismount
Note!
♦ Protect the tapered roller bearings and the pinion for working
the speedometer in order to avoid possible damage or scraps
of metal from getting inside.
♦ Before and after drilling the rivets, clean the differential box
very carefully.

Arosa 1997 ➤
– Drill the head of the rivets on the side opposite the pinion for
working the speedometer using a 12 mm ∅ bit.
– Remove the rivets from their housing with the help of a punch.
– Place the differential box into a press.
– Place the tool -U-40300/13- over the differential.

– Work the press until the differential box comes away from the
crown.
4.1.2 Assembly
– Before assembling the crown of the differential, consult sec‐
tion for Identification initials, assignation of groups, reductions,
amount for filling ⇒ page 1 .
– Carefully clean the surfaces of contact for the crown of the
differential and of the differential box. Use a wire brush and a
scraper. Never use emery cloth or sandpaper. The surfaces
for contact must be completely free from oil and grease.
– Check the position for the assembly of the crown with regards
to the differential box.
The inner groove -A- in the crown of the differential must be facing
towards the opposite side to the housing for the differential side
gears.
– Heat the crown of the differential with the electrical blower -
SAT 1416- to 150 ºC. Check the temperature with the digital
thermometer -SAT 4002- .
4. Differential crown: dismounting and assembling 111

Arosa 1997 ➤
– Assemble the crown of the differential over the differential box

whilst respecting the position for assembly. Use two bolts -A-
from the repair set for guiding the crown into its housing.
Note!
♦ To correctly assemble the differential crown wheel onto the

differential housing, you must act rapidly and without interrup‐
tions and screw them right in.
♦ If both parts lock or get stuck on being assembled, interrupt
the assembly process and begin again.
– Screw down both components with the special replacement

screws ⇒ Replacement Parts Microfiche .

Arosa 1997 ➤
5 Differential: adjust

equipment required
es -U-40200-
es -U-40300-
♦ Multi-purpose stand for the
tester -T20020-
8010-
Adjust the differential when any of the following components have

been replaced:
♦ Gearbox casing
♦ Clutch casing
♦ Differential box
♦ Tapered roller bearings in the differential
So as to avoid unnecessary adjustment work,
permitted consult
unless the
authorised Chart
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
for Adjustment ⇒ page 109 . respect to the correctness of information in this document. Copyright by SEAT S.A.
5. Differential: adjust 113

Arosa 1997 ➤
– Extract the outer track of the tapered roller bearing from the
gearbox casing and clutch casing using tool -U-40200/10- and
tool -U-40300/14- .
Note!
♦ The procedure and the tools needed for dismounting the outer
tracks of the tapered roller bearings are the same in the gear‐
box casing and in the clutch casing.
♦ The tapered roller bearings and their corresponding outer
tracks come in pairs. Do not mix them up or exchange them
with other bearings.
– Assemble the outer track of the tapered roller bearing in the

differential into the gearbox casing and clutch casing using tool
-U-40200/10- and tool -U-40300/12- .
Note!
The procedure and the tools needed for dismounting the outer
tracks of the tapered roller bearings are the samerespectin thecorrectness
to the gearbox of information in this document. Copyright by SEAT S.A.
casing and in the clutch casing.
– Place the differential over the clutch casing.

– Assemble the gearbox casing onto the clutch casing and tight‐
en the 5 bolts for attaching them in the area of the differential.

Arosa 1997 ➤
– Place the tool -T20020- with a tester onto the gearbox casing.
Place the end of the tool on the differential and fit the tool -
U-40300/13- between them.
– Adjust the tester to “0” with a prior stress of 1 mm.
– Move the differential alternatively in the direction of the arrows.
– Write down the reading obtained on the tester (Example, 0.70
mm).
Calculation for the adjustment washer
The thickness of the adjustment washer to be assembled is found
by adding the valued from the reading obtained with the tester
and a set value (0.40 mm).
Example:
Reading obtained with the tester 0.70 mm
Set value 0.40 mm
Thickness of the adjustment washer 1.10 mm
The adjustment washer needed is found by using the following
Table:
Thickness (mm) Spares No.
0.65 02A 409 210
0.70 02A 409 210 A
0.75 02A 409 210 B
0.80 02A 409 210 C
0.85 02A 409 210 D
0.90 02A 409 210 E
0.95 02A 409 210 F
1.00 02A 409 210 G
1.05 02A 409 210 H
1.10 02A 409 210 J
1.15 02A 409 210 K
1.20 02A 409 210 L
1.25 02A 409 210 M
The diversity of by
Protected the adjustment
copyright. washers
Copying for that exist
private or commercial allows
purposes, the
in part or nec‐
in whole, is not
essary thickness
respect to becorrectness
determined precisely
of information for making
in this document. a byproper
to the Copyright SEAT S.A.
adjustment of the differential.
– Should the thickness of the adjustment washer needed be
thicker than the thickness that appear in the Table, two ad‐
justment washers may be fitted, the thickness for which when
added together, correspond to the reading found.
– Once the adjustment washer needed has been determined,
remove the tester.
– Extract the bolts that attach both casings and separate the
gearbox casing.
– Separate the differential.
5. Differential: adjust 115

Arosa 1997 ➤
– Extract the outer track for the tapered roller bearing from the
gearbox casing with tool -U-40200/10- on the tool -
U-40300/14- .
– Place the adjustment washer with the thickness calculated (in
the example, 1.10 mm) in the housing for the outer track of the
tapered roller bearing in the gearbox casing.
– Should two adjustment washers be needed, place the washer
that is thicker first.

differential in the gearbox casing, with the adjustment washer,
with tool -U-40200/10- and tool -U-40300/12- .
– Place the differential over the gearbox casing.

Service
Workshop Manual
Arosa 1997 ➤
3-cyl. diesel engine, mechanics
Engine ID AMF
Edition 01.03

Service
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
21 - Charging
23 - Mixture preparation, Injection
26 - Exhaust system permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
28 - Glow plug system

Copyright © 2015 Seat S.A S01AAMF8620

Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Engine: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Engine: fixing to the trestle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Installation: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Engine unit supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Vehicles with air conditioning: additional instructions and installation work . . . . . . . . . . . . 7
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Engine: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Poly-V belt: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Sealing flanges and engine flywheel: removing and in-stalling . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Crankshaft seal - pulley side: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Sealing flange - pulley side: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
3 Stabiliser bar and axle support: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .
22
3.1 Stabiliser bar: removing and in-stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Crankshaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Piston and connecting rod: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Position of the piston at TDC: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Dimensions of pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1 Cylinderhead: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Toothed belt: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Toothed belt: removing, installing and tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Compression: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Valve control: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Valve seats: re-cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Valve guides: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Valve guides: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4 Valve stem seals: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Camshaft: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.6 Camshaft seal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Lubrication system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Oil sump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Oil pressure and oil pressure switch: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1 Cooling system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.1 Cooling system components, bodywork side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.2 Cooling system components, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.4 Coolant: draining and filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Contents i
Arosa 1997 ➤
1.5 Radiator: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.6 Coolant pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.7 Coolant thermostat: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

1 Fuel supply system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Fuel tank and accessory parts: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Fuel filter: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Safety measures for work on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Fuel radiator: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.6 Fuel tank: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Accelerator control: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.8 Accelerator pedal position sender: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.9 Accelerator pedal position sender: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.10 Tandem pump: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.11 Tandem pump: respect toremoving and
the correctness installing
of information . . . . . . Copyright
in this document. . . . . . by
. .SEAT
. . . S.A.
. . . . . . . . . . . . . . . . . . . . . . . . 102
21 - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1 Supercharging system with exhaust gas turbocompressor . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Exhaust gas turbocompressor with attachments: removing and installing . . . . . . . . . . . . . . 106
1.2 Intercooler system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.3 Supercharging pressure control hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . 110
1.4 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Supercharging system: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Pressure unit for supercharging pressure control valve: test . . . . . . . . . . . . . . . . . . . . . . . . 112
2.2 Pressure unit for supercharging pressure control valve: removing and installing . . . . . . . . 112
2.3 Supercharging pressure control: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1 Direct diesel injection system: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.2 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.3 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.4 Intake manifold flap: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.5 Injector-pump unit: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.6 O-rings for injector-pump unit: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . 123
1.7 Pump-injector set: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2 Components and functions: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.1 Voltage supply of the direct diesel injection system: testing . . . . . . . . . . . . . . . . . . . . . . . . 131
2.2 Engine revs sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.3 Intake manifold pressure sender and altimetric sender: testing . . . . . . . . . . . . . . . . . . . . . . 132
2.4 Coolant temperature sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.5 Brake light and brake pedal switches: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.6 Clutch pedal switch: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.7 Intake manifold temperature sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.8 Temperature sender fuel: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.9 Air mass meter: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.10 Intake manifold flap switch-over: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.11 Injector-pump unit valves: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.12 Hall camshaft position sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3 Supplementary signals: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.1 Speed signal: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.2 Signals from/to air conditioning: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.3 Rev signal: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
ii Contents
Arosa 1997 ➤
3.4 Data bus: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

4 Engine control unit: replacing, encoding and adapting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.1 Engine control unit: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.2 Engine control unit: encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.3 Engine control unit: adapting to the electronic immobiliser . . . . . . . . . . . . . . . . . . . . . . . . 158
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

1 Exhaust system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.1 Exhaust pipe front with catalyst and accessory parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.2 Silencer with holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Exhaust recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.4 Exhaust recirculation system components: removing and installing . . . . . . . . . . . . . . . . . . 162
1.5 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.6 Mechanical exhaust recirculation valve: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.7 Exhaust recirculation: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 Pre-heating system: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.1 Glowplugs: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Contents iii
Arosa 1997 ➤
iv Contents
Arosa 1997 ➤
1 Technical data
1.1 Engine number

The engine number (“code letters” and “correlative number” ) is
stamped on the engine block next to the engine/gearbox joint.
There is also a sticker with “the engine code letters” and “the cor‐
relative number” on the toothed belt shield.
The engine code letters are also on the vehicle data plate.
1.2 Engine characteristics

Code letters AMF
Exhaust emissions in accordance with D3 Standard
Displacement l 1.4
Output kW/rpm 55/4000
Engine torque Nm/rpm 195...2200
Cylinder bore ∅ mm 79.5
Stroke mm 95.5
Compression 19.5
Cetane number min. 49
Firing order 1-2-3
Catalyst X
Exhaust recirculation X
Supercharging X
Intercooler X
1. Technical data 1
Arosa 1997 ➤
10 – Removing and installing engine

1 Engine: removing and installing

equipment required
♦ Coupling tool -U-30034-
♦ Adjustable flanges for fixing
engine to trestle -T20082-
♦ (Mobile) engine support
trestle -Ar-2204 A-
♦ Flexible clamp pliers -
T20029-
♦ Shop lift -V.A.G. 1202 A-
♦ Tray -V.A.G. 1306-
♦ Torque spanners -SAT 8010-
2 Rep. Gr. 10 - Removing and installing engine

Arosa 1997 ➤
♦ Multiple toothed spanner set -U-40020-
♦ Lubricating grease -G 000 100-

♦ Cable clamp
1.1 Removing: instructions

For this work it is necessary to remove the battery earth strap. In

doing so, check whether the vehicle has a coded radio and, if so,
consult the antitheft code.
– The engine is removed with the gearbox, forwards.

– With the ignition off, remove the battery earth strap.
– All wire holders that are opened or cut while removing the en‐
gine must be reinstalled in the same place when installing the
engine.
– Remove the soundproofing cover from engine.
– Remove the fuel supply and return hoses from the fuel filter.
– Remove the connection line between the intercooler and the
intake manifold air intake.
– Remove the connection line between the air mass meter and
the turbocompressor.
– Remove the battery.
– Remove the battery support.
– Remove the connector from the heat switch and the radiator
fan.
– Drain the coolant ⇒ page 80
– Remove radiator hoses from the engine and the heater with
strip clamp pliers -T20029- .
1.1.1 Vehicles with air conditioning

– Bear in mind the additional instructions and installation work
⇒ page 7
– Remove the lockholder plate and the accessory parts: ⇒
Bodywork-Installation work; Rep. Gr. 50 ; Bodywork, front
Lockholder plate with accessory parts: removing and installing
– Remove all the wiring from the gearbox, alternator and starter
motor and leave them out in the open.
– Remove all other necessary wiring from the engine and leave
it out in the open.
1. Engine: removing and installing 3

Arosa 1997 ➤
– Detach the vacuum and breather hoses and from the engine.
– Remove the shift control from the gearbox: ⇒ 5-speed manual
gearbox 02J; Rep. Gr. 34 ; Shift control: repairing
– Hydraulic clutch slave cylinder (pump): removing ⇒ 5-speed
manual gearbox 02J; Rep. Gr. 30 ; Clutch control: repairing
Note!
Do not depress the clutch pedal.
– Remove the front exhaust pipe from the turbocompressor.

– Remove the Poly-V belt ⇒ page 13 .
– Unbolt the gearbox swing support -1- .
– Remove the articulated half-shafts from the gearbox: ⇒ Run‐
ning gear, axles, steering; Rep. Gr. 40 ; Articulated half-shaft:
removing and installing
– Detach and remove the connection line between the inter‐
cooler and the exhaust turbocompressor next to the oil sump.
– Remove the power steering vane pump from its support and
place it on its side; the hoses remain connected. ⇒ Running
gear, axles, steering; Rep. Gr. 48 ; Synoptic installation chart:
vane pump, reserve tank, hydraulic lines.
– Attach coupling unit -U-30034- as shown in the illustration and

raise slightly with shop lift -V.A.G. 1202 A- .
Caution
Check that the hooks are closed with the safety catches.
– Loosen the bolts that hold the engine unit to the gearbox and
engine supports -arrows- .
– Lower the engine unit until it is out of the gearbox housing.
– Remove the engine unit forwards, turning it and then lowering
it slightly.
Note!
Handle the engine unit very carefully when removing it from the
vehicle to avoid damaging the bodywork.
1.2 Engine: fixing to the trestle

For assembly work the engine must be fixed to engine support -
Ar-2204- A with flanges -T20082- .
1.2.1 Work sequence

– Remove the flanges from the gearbox.

Arosa 1997 ➤
– With the shop lift and engine lift -U-30034- , secure the engine
to engine support -Ar-2204 A- with flanges -T20082- as
shown.
Caution
Check that the hooks are closed with the safety catches.
1.3 Installation: instructions

Follow instructions for removal in reverse order, taking into ac‐
count the following:
– Check the clutch disengagement collar for wear and replace
it if necessary.
– Lightly grease the disengagement collar, the guide sleeve for
the collar and the primary shaft spline with -G 000 100- .
– Make sure the alignment sleeves for the engine unit are in
place; if not, install them.
– When installing the engine unit make sure there is sufficient
play with the half-shafts.
– Align the engine support unit, shaking it so that there no stress
points; if necessary, loosen the respect

engine support
to the atofthe
correctness body‐
information in this document. Copyright by SEAT S.A.
work too.
Note!
Tightening torques for the engine unit supports ⇒ page 6 .
– Electrical connections and wiring: ⇒ Electrical system; Rep.

Gr. 97
– Fit the connection line between the intercooler and the turbo‐
compressor next to the oil sump.
– Install the articulated half-shafts: ⇒ Running gear, axles,
steering; Rep. Gr. 40 ; Articulated half-shaft: removing and
installing.
– Install the power steering vane pump: ⇒ Running gear, axles,
steering; Rep. Gr. 48 ; Installation Chart: vane pump, reserve
tank, hydraulic lines Power steering vane pump: removing and
installing.
– Install the swing support.
– Install the front exhaust pipe ⇒ page 160 , Exhaust system
components: removing and installing.
– Install the hydraulic clutch slave cylinder (pump) ⇒ 5-speed
manual gearbox 02J; Rep. Gr. 30 ; Clutch control: repairing.
– Install the shift control: ⇒ 5-speed manual gearbox 02J; Rep.
Gr. 34 ; Clutch control: repairing.
– Install the shift control: ⇒ 5-speed manual gearbox 02J; Rep.
Gr. 34 ; Shift control: repairing.
– If necessary, adjust the gearbox cable: ⇒ 5-speed manual
gearbox 02J; Rep. Gr. 34 ; Shift control: repairing.

Arosa 1997 ➤
– Install the lockholder plate with the accessory parts: ⇒ Body‐

work-Installation work, exterior; Rep. Gr. 50 ; Bodywork, front
Lockholder plate with accessory parts: removing and instal‐
ling.
– Attach all coolant hoses to the engine.
– Install the Poly-V belt ⇒ page 13
– Install the connection lines of the air mass meter/turbocom‐
pressor, intercooler/turbocompressor (oil sump side) and in‐
tercooler/air intake line.
– Fill coolant ⇒ page 80
– Check and, if necessary, correct headlamp adjustment: ⇒
Millimetric maintenance
– Road test the vehicle and consult the fault memory: ⇒ Vehicle
diagnosis, testing and information system VAS 5051
1.4 Tightening torques

Bolted connection Tightening tor‐
que
Bolts, nuts M6 10 Nm
permitted unless authorised by SEAT S.A. SEAT S.A does M8not guarantee or 20 Nm
accept any liability with
M10 45 Nm
M12 60 Nm
Different tightening torques
Front exhaust pipe to exhaust turbocompres‐ 25 Nm
sor
1.5 Engine unit supports
1.5.1 Tightening torques

Engine unit supports, engine
A 1) = 20 Nm + 90° (1/4 turn)
B 1) = 40 Nm + 90° (1/4 turn)
1) = replace
Engine unit supports, gearbox

A 2) = 40 Nm + 90° (1/4 turn)
B 2) = 20 Nm + 90° (1/4 turn)
C 2) = 40 Nm + 90° (1/4 turn)
2) = replace

Arosa 1997 ➤
Swing support
A 3) = 90 Nm + 90° (1/4 turn)
B 3) = 40 Nm + 90° (1/4 turn)
C 3) = 90 Nm + 90° (1/4 turn)
3) = replace
1.6 Vehicles with air conditioning: additional

instructions and installation work
Note!
♦ In order to remove the engine, the air conditioning cooling

agent circuit must be opened.
♦ To avoid damaging Protected
the condenser
by copyright.or the cooling
Copying agent
for private or hoses/
lines, make sure the linesunless
permitted areauthorised
not pinched or twisted.
– Drain the cooling agent from the air conditioning cooling agent
circuit. ⇒ Heating, air conditioning; Rep. Gr. 87 ; Repairs in
the cooling agent circuit, which may only be done in shops with
qualified mechanics (Official Repair Shops specialised in air
conditioning).
– Open the air conditioning cooling agent circuit at the top of or
bottom of the condenser and at dashboard plate ⇒ Heating,
air conditioning; Rep. Gr. 87 ; Repairs in the cooling agent
circuit, which may only be done in shops with qualified me‐
chanics (Official Repair Shops specialised in air conditioning).
Note!
Do not remove the air conditioning compressor.

Arosa 1997 ➤
13 – Crankshaft group
1 Engine: disassembly and assembly
Note!
♦ When repairing the engine, if significant quantities of metal shavings and particles due to wear or abrasion,
e.g. damage to the mount or connecting rod bearings are found in the oil, in order to avoid further damage,
not only must the oil lines be cleaned carefully but the oil radiator must also be replaced.
♦ Before installation work, oil the support and slide surfaces.
I ⇒ page 8 II ⇒ page 10 III ⇒ page 12
Part I
8 Rep. Gr. 13 - Crankshaft group

Arosa 1997 ➤
1 - Upper part of the toothed

belt shield
2 - Toothed belt
❑ Before removing, mark
the direction of rotation
❑ Check for wear
❑ Do not fold
❑ Remove and install
⇒ page 38
3 - 20 Nm + 45° (1/8 turn)
4 - Tensioning roller
5 - 100 Nm
6 - 25 Nm
7 - Camshaft pinion
8 - Hub respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ With sender rotor

❑ For loosening and tight‐
ening, use countersup‐
port -T10051-
❑ For removing, use ex‐
tractor -T10052-
⇒ page 55 Camshaft:
9 - 10 Nm
10 - Rear toothed belt shield
11 - Plug
❑ Replace if worn
12 - Toothed belt tensioner
13 - Return roller
14 - Coolant pump
❑ Remove and install ⇒ page 83
15 - Toothed belt-crankshaft pinion
16 - 120 Nm + 1/4 turn (90°)
❑ Replace
❑ For loosening and tightening use countersupport -T20018A-
❑ Do not oil or grease the thread or the collar
❑ Retighten in various stages
17 - 15 Nm
❑ For the vane pump
18 - 20 Nm
19 - Lower toothed belt shield
20 - Pulley/vibration dampener
❑ Installation is only possible in one position - the holes are arrayed asymmetrically
21 - 10 Nm + 1/4 turn (90°)
22 - Middle toothed belt shield
1. Engine: disassembly and assembly 9

Arosa 1997 ➤
Part II
1 - Cylinderhead cover
❑ With oil filler hole
❑ If the cylinderhead cov‐
er is worn, the oil filler
hole must also be re‐
placed
❑ Before fitting it, clean
the filling surface well
with a clean cloth
2 - To turbocompressor
3 - 10 Nm
❑ First tighten all the bolts
by hand
❑ Then, tighten the two
upper bolts first and
then the other bolts in a
crossing pattern from in‐
side out to the correct
tightening torque
4 - Pressure regulator valve
❑ To the engine block vent
5 - Plug
❑ Replace the gasket if

Arosa 1997 ➤
worn
6 - Ring gasket
❑ Replace if worn
7 - Oil filler hole
❑ Replace
8 - Support
❑ With fuel line
9 - Cylinderhead cover gasket
❑ Replace if worn
10 - 20 Nm
11 - Ring
12 - 10 Nm
13 - Middle connector
❑ For the pump injector
14 - From the brake servo
15 - Tandem pump
❑ For the fuel supply and the vacuum
❑ Test ⇒ page 100
16 - 25 Nm
17 - Supply hose
❑ From the fuel filter ⇒ page 89
❑ White or white mark
❑ Check for firm seating
❑ Immobilise with elastic strip clamps
18 - Return hose
❑ To the fuel filter ⇒ page 89
❑ Blue or blue mark
19 - Gasket
❑ Replace
20 - Bolt, 10 Nm
❑ For the engine cover respect to the correctness of information in this document. Copyright by SEAT S.A.
21 - Support
22 - Hexagonal conical nut
23 - Cylinderhead gasket
❑ Replace
❑ Check the identification ⇒ page 34
❑ After replacing it, change all the coolant
24 - Hall sender -G40-
❑ For the camshaft position
❑ For removing, remove the sealing plug from the rear of the toothed belt shield
❑ Test: ⇒ page 119

Arosa 1997 ➤
25 - Cylinderhead bolt
❑ Replace
❑ Follow the installation order when loosening and tightening ⇒ page 39 , cylinderhead: removing and
installing
❑ Before installation, fit the washers on the cylinderhead ⇒ Item 4 (page 53) , Valve activation: repairing
26 - Pump injector
Part III
1 - 45 Nm
2 - Engine support
3 - Engine block Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Sealing flanges and en‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
gine flywheel: removing
and installing
⇒ page 16
❑ Piston and connecting
rod: disassembly and
4 - Connection sleeve, 40 Nm
❑ For the turbocompres‐
sor oil return line
❑ Replace
5 - Spacer bushing
6 - Rubber bushing
7 - Support
❑ For connectors of the
camshaft position Hall
sender -G40- and en‐
gine revs sender -G28-
8 - 10 Nm
9 - Gasket
❑ Replace
10 - Oil filter support
❑ Disassemble and as‐
semble ⇒ page 69
11 - 15 Nm + 1/4 turn (90°)
❑ Replace
❑ Fit the upper left and

Arosa 1997 ➤
lower right bolts first and

then tighten the four bolts in a cross pattern
12 - O-ring
❑ Replace
13 - 15 Nm
14 - 15 Nm + 1/4 turn (90°)
❑ Test ⇒ Vehicle diagnosis, testing and information system VAS 5051
15 - Connection sleeve
❑ For coolant thermostat
16 - Coolant thermostat
17 - 45 Nm
❑ Follow the tightening order ⇒ page 79
18 - Compact support
❑ For alternator, air conditioning compressor, power steering vane pump and Poly-V belt tensioner
19 - Tensioner
❑ For the Poly-V belt
20 - 25 Nm
21 - Oil sump
❑ Before installation, clean the sealing surface
❑ Install with silicone-base sealant -D 176 404 A2- ⇒ page 70
❑ To remove the oil sump the gearbox must be removed ⇒ 5-speed manual gearbox 02J; Rep. Gr. 34 ;
Gearbox: removing and installing
22 - 15 Nm
❑ To remove the bolts that hold the sump (gearbox side), the gearbox must be removed ⇒ 5-speed manual
gearbox 02J; Rep. Gr. 34 ; Gearbox: removing and installing
23 - Cover
❑ With gasket
❑ Clean the filter if dirty
24 - Axle support
❑ Before installation check that alignment sleeve for centring the engine block is there and that it is fitted
on the axle support
25 - Shield
❑ For the articulated half-shaft
1.1 Poly-V belt: removing and installing


Arosa 1997 ➤
♦ Pin -T10060-
♦ Spanner e/c 15
1.1.1 Remove
– Remove the soundproofing sump: ⇒ Bodywork-installation
work; Rep. Gr. 50 ; Bodywork, front Installation Chart
– Remove the soundproofing cover from the engine.
– Remove the connection line between the intercooler and the
intake manifold air intake.
– Remove the air mass meter unit and lay it to one side.
– Mark the direction of rotation of the Poly-V belt.
– Pivot the tensioning roller in the direction of the arrow (see
illustration).
– Immobilise the tensioner with pin -T10060- .

– Remove the Poly-V belt.
1.1.2 Install
– Install in reverse order.

Arosa 1997 ➤
Note!
♦ Before installing the Poly-V belt check that the units (alterna‐
tor, air conditioning compressor, vane pump) are well fitted.
♦ When installing the Poly-V belt check that the rotation direction
is correct and that it is correctly seated on the pulleys.
♦ On vehicles without air conditioning, fit the Poly-V belt on the
alternator last.
♦ On vehicles with air conditioning, fit the Poly-V belt on the air
conditioning compressor last.
After finishing the work:

– Start the engine and check the functioning of the belt.
Routing of the belt without air conditioning compressor
Routing of the belt with air conditioning compressor

Arosa 1997 ➤
2 Sealing flanges and engine flywheel: removing and in-stalling
Note!
⇒ 5-speed manual gearbox 02J; Rep. Gr. 30 ; Clutch: repairing
1 - Seal
❑ Do not apply more oil or
grease to the seal lip
❑ Before installation clean
excess oil from the
crankshaft journal with a
clean cloth
❑ Replace the crankshaft
seal - pulley side
⇒ page 17
2 - Sealing flange
❑ Must fit in alignment
sleeves
⇒ page 18
❑ Install with silicone-
base sealant -D 176 404
A2- ⇒Protected
page by18copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Engine block
❑ Crankshaft: removing
and installing
⇒ page 28
❑ Piston and connecting
rod: disassembly and
4 - Engine flywheel
❑ To remove and install
the engine flywheel, im‐
mobilise with the -
T20075A-
5 - 60 Nm + 1/4 turn (90°)
❑ Replace
6 - Intermediate plate
sleeves
❑ Do not bend or damage during in-stallation work
7 - 15 Nm
8 - Sealing flange with seal
❑ Always replace the unit
❑ Do not apply more oil or grease to the seal lip
❑ Before installation clean excess oil from the crankshaft journal with a clean cloth
❑ Use the support sleeves supplied for installation
❑ The support sleeve can only be removed after fitting the sealing flange over the crankshaft journal

Arosa 1997 ➤
2.1 Crankshaft seal - pulley side: replacing

equipment required
♦ Seal extractor -T20031B-
♦ Countersupport -T20018A-
♦ Plungers for fitting seals -
T20081B-
8010-
2.1.1 Remove
– Remove the Poly-V belt ⇒ page 13
– Remove the toothed belt ⇒ page 38
– Remove the toothed belt-crankshaft pinion. To do so, immo‐
bilise the toothed belt pinion with countersupport -T20018A- .
– Hand tighten the middle bolt in the crankshaft all the way to
guide the extractor.
2. Sealing flanges and engine flywheel: removing and in-stalling 17

Arosa 1997 ➤
– Oil the threaded head of the extractor -T20031B- / ∅ 35, apply

it and, pressing hard, screw it as far as possible into the seal.
– Turn the inner bolt interior against the crankshaft until the seal
comes out.
2.1.2 Install
Note!
The seal lip may not be further oiled or greased.
– Eliminate the excess oil on the crankshaft journal with a clean

cloth.
– Fit the seal over the guide sleeve of the -T20081B/6- and fit
the unit on the crankshaft journal.
– Fit the seal with the pressure sleeve -T20081B/1- all the way
with the centre bolt.
– Install the crankshaft pinion and immobilise it with counter‐
support -T20018A- .
– Toothed belt, install, tighten ⇒ page 38 .
2.2 Sealing flange - pulley side: removing and installing

Arosa 1997 ➤

equipment required
♦ Countersupport -T20018A-
T20081B-
8010-
♦ Hand drill with plastic rotat‐
ing brush
♦ Silicone sealant -D 176 404
A2-
♦ Flat scraper
2.2.1 Remove
– Remove the toothed belt-crankshaft pinion. To do so, immo‐
bilise the toothed belt pinion with the -T20018A- .
– Drain the engine oil.
– Remove the oil sump ⇒ page 71
– Remove the bolts that hold the front sealing flange.
– Remove the sealing flange. If necessary, loosen it with taps
from a rubber mallet.
– Eliminate excess sealant from the engine block with a flat
scrapper.
– Cover the seal with a clean cloth.

Arosa 1997 ➤
– With a rotating plastic brush, eliminate excess sealant from the

sealing flange (use shop goggles).
– Clean the contact surfaces of oil and grease.
2.2.2 Install
Note!
♦ Check the use-by date on the sealant.

♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone-base sealant.

Arosa 1997 ➤
– Cut the nozzle of the tube at the front mark (nozzle diameter:
approx. 3 mm).
– Apply the silicone-base sealant to the clean contact surface of
the sealing flange, as shown in the illustration. The bead must:
♦ Sealant bead thickness: 2...3 mm
Note!
♦ The sealant bead must be no thicker: otherwise it could get

into the oil sump, clog the filter in the shaft support cover and
drip on the sealing surface of the crankshaft seal.
♦ Before applying the sealant, clean the sealing surface with a
clean cloth.
– Immediately fit the sealing flange and tighten all the bolts
slightly.
Note!
Use the guide sleeve of the -T20081B/6- to fit the sealing flange
with the seal fitted.
– Tighten the sealing flange bolts in a crossing pattern. Tight‐

ening torque: 15 Nm
– Clean the excess sealant.
– Install the oil sump ⇒ page 71
Note!
After installing the oil sump, let the sealant dry for approx. 30 mi‐
nutes, after which the engine oil can be filled.
– Installation of the toothed belt and setting distribution timing

⇒ page 38

Arosa 1997 ➤
3 Stabiliser bar and axle support: removing and installing
Note!
Before installation work, oil the support and slide surfaces.
1 - Chain
❑ Check the installation
position ⇒ page 24 ,
Stabiliser bar: removing
and installing
2 - 100 Nm + 1/4 turn (90°)
❑ Replace
❑ Retighten in several
stages
ening, use the -T10061-
3 - Counterweight
❑ Installation is only pos‐
sible in one position
4 - Chain wheel
❑ For stabiliser bar
5 - Alignment sleeve
6 - 20 Nm + 1/4 turn (90°)
❑ Replace
7 - Chain wheel
❑ For oil pump

Arosa 1997 ➤

8 - Cover
❑ With gasket
9 - 5 Nm
10 - O-ring
❑ Replace
❑ Apply a little oil for the installation
11 - 15 Nm
12 - Oil pump
❑ With discharge valve 11.5 bar
❑ Before installation, check that the two alignment sleeves for centring are in place
13 - Stabiliser bar
14 - Axle support
❑ Before installation check that alignment sleeve for centring the engine block is there and that it is fitted
on the axle support
15 - O-ring
❑ Replace
❑ Check that it seats firmly on the axle support
16 - Engine block
17 - Pinion/return pulley
18 - 20 Nm
19 -byChain
Protected tensioner
copyright. withorslide
Copying for private rail purposes, in part or in whole, is not
commercial
❑ To remove lock with -T10060-
20 - 9 Nm
3. Stabiliser bar and axle support: removing and installing 23

Arosa 1997 ➤
3.1 Stabiliser bar: removing and in-stalling

equipment required
♦ Pin -T10060-
♦ Tool -T10061-
8010-
♦ Flat spanner (e/c 24/27)
3.1.1 Remove
– Remove the oil sump ⇒ page 71
– Remove the pulley side sealing flange ⇒ page 18
– Remove the cover bolts.
– Free the cover from the axle support.

Arosa 1997 ➤
– Immobilise the chain tensioner with pin -T10060- -arrow- .

– Unbolt the pinion/return pulley -1- from the axle support.
– Remove the fixing bolts -2- of the chain tensioner and remove
the tensioner.
– Remove the chain from the pinions and place the chain on a
clean surface.
– Immobilise the stabiliser bar as shown in the illustration with a

flat spanner (e/c 24/27) -1- .
Note!
The spanner must be centred with the counterweight of the sta‐

biliser bar, and perpendicular to the stabiliser bar.
– Loosen the fixing bolt -2- of the counterweight.
Note!
The fixing bolt -2- of the counterweight only needs to be loosened,

not removed completely.
– Unbolt the axle support -3- of the engine block and remove it
along with the stabiliser bar.
– Place the axle support on a clean surface.
– Remove the fixing bolt of the counterweight.
– Remove the counterweight and the pinion of the stabiliser bar.
– Turn the stabiliser bar unit it can be removed from its housing.
3.1.2 Installation
– Oil the rolling surfaces of the stabiliser bar.
– Fit the stabiliser bar in its housing.
– Fit the pinion and the counterweight over the stabiliser bar.
Note!
Installation of the pinion and the counterweight is only possible in

one position.
– Hand-tighten the bolt that fixes the counterweight and the pin‐
ion.
– Hand-tighten the axle support, taking up all play with the en‐
gine block.

Arosa 1997 ➤
Note!
♦ During installation of the axle support check that the alignment

sleeve is fitted on the engine block and the O-ring on the axle
support.
♦ Fit the axle support such that it is flush with the outer edge of
the engine block on the pulley side.
– Bolt the stabiliser bar support to the engine block Tightening

torque: 15 Nm
– Check that the axle support is flush with the outer edge of the
engine block on the pulley side.
– Immobilise the stabiliser bar with a flat spanner (e/c 24/27)
-1- as shown in the illustration.
Note!
The spanner must be centred with the counterweight of the sta‐

biliser bar, and perpendicular to the stabiliser bar.
– Tighten the fixing bolt -2- of the counterweight Tightening tor‐

que: 100 Nm + 1/4 turn (90°)
Note!
The fixing bolt is an expansion bolt and must always be replaced.
– Install the chain tensioner Tightening torque: 9 Nm

– Clean the chain with a cloth that does not shed fibres.
– Check that the mark -arrow- on the crankshaft pinion is at the

top.
– Fit the chain on the pinion/crankshaft, pinion/oil pump and the

pinion/stabiliser bar. The marks on the pinion/crankshaft and
the pinion/stabiliser bar must coincide with the coloured links
of the chain -arrows- .
Note!
The coloured links are also marked with a groove.
– Fit the pinion/return pulley on the chain and bolt the pinion/
return pulley to the axle support. Tightening torque: 20 Nm
– Remove pin -T10060- from the chain tensioner.

Arosa 1997 ➤
– Check that the marks on the pinion/crankshaft and the pinion/

stabiliser bar coincide with coloured links -arrows- .
Note!
The coloured links are also marked with a groove.
– Install the sealing flange of the pulley side ⇒ page 18 .

– Fit the cover on the stabiliser bar Tightening torque: 5 Nm
Note!
♦ Before fitting the cover, oil to O-ring of the oil pump and the
flange inside the cover.
♦ Check that the gasket is well seated in the cover.
♦ Check that the cover fits well on the axle support.
– Install the oil sump ⇒ page 71 .

– Install the Poly-V belt ⇒ page 13 .

Arosa 1997 ➤
4 Crankshaft: removing and installing
Note!
♦ Before removing the crankshaft, prepare an adequate base so that the sender rotor
( ⇒ Item 5 (page 28) ) does not support weight or get damaged.
1 - Half-bearings 1, 2 and 4
❑ For caps, without lubri‐
cation slot
❑ For engine block, with
lubrication slot
❑ Do not swap the used
half-bearings (mark
them)
2 - 65 Nm + 1/4 turn (90°)
❑ Replace
❑ To measure the radial
play, tighten to a torque
of 65 Nm, but do not re-
tighten
3 - Caps
❑ Cap 1: Pulley side
❑ The tabs of the engine
block half-bearings and
of the caps must coin‐
cide
4 - Half-bearing 3
❑ For cap, without lubrica‐
tion slot
❑ For engine block, with
lubrication slot
5 - Sender rotor
❑ For revs sender
❑ Replace if worn permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
6 - 10 Nm + 1/4 turn (90°)
❑ Replace
7 - Pin
❑ Measure projection of
the pin above the crankshaft ⇒ page 31
8 - Crankshaft
❑ Before removing it, check the note ⇒ page 28
❑ Axial play, new: 0.07...0.17 mm Wear limit: 0.37 mm
❑ Measure the radial play with Plastigage New: 0.03...0.08 mm Wear limit: 0.17 mm
❑ When measuring the radial play, do not turn the crankshaft
❑ Crankshaft dimensions ⇒ page 29
9 - Drive washer
❑ For engine block, bearing 3

Arosa 1997 ➤
Measure projection of the pin above the crankshaft

♦ Depth calliper
Test process
– With depth callipers measure the projection -a- of the pin with
the sender rotor -1- removed.
1 - Sender rotor
2 - Bolt
3 - Projection pin -3- of the crankshaft
a = 2.5...3.0 mm
4.1 Crankshaft dimensions

(Dimensions in mm)
Re-cutting di‐ ∅ mounting ∅ mounting
mension bearing bearing
journals journals
Basic - 0.022 54.00 - 0.022 47.80
dimension - 0.042 - 0.042
Stage I - 0.022 53.75 - 0.022 47.55
- 0.042 - 0.042
Stage II - 0.022 53.50 - 0.022 47.30
- 0.042 - 0.042
Stage III - 0.022 53.25 - 0.022 47.05
- 0.042 - 0.042
4. Crankshaft: removing and installing 29

Arosa 1997 ➤
5 Piston and connecting rod: disassembly and assembly
Note!
Before installation work, oil the support and slide surfaces.
1 - Piston ring
❑ Stagger the cuts in 120°
❑ Remove and install with
piston ring pliers
❑ The mark “TOP” must
point towards the piston
head
❑ Measure the play be‐
tween the edges of the
rings ⇒ page 31
❑ Measure the coupling
play between the rings
and the slots of the pis‐
ton ⇒ page 32
2 - Piston
❑ With combustion cham‐
ber
❑ Mark the installation po‐
sition and the corre‐
spondence to the re‐
spective cylinder
❑ Installation position and
piston/cylinder corre‐
spondence
⇒ page 33 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ The arrow on the respect

pistonto the correctness of information in this document. Copyright by SEAT S.A.
head must point to‐

wards the pulley
❑ Install with ring fitting
sleeve
❑ If the piston rod is
cracked, replace the
piston
❑ Test the position of the
piston at TDC

Arosa 1997 ➤
⇒ page 33
3 - Piston rod
❑ If movement is difficult, heat the piston to 60 °C
❑ Remove and install with -T20019-
4 - Lock washer
5 - Connecting rod
❑ Replace only the unit
❑ Mark the correspondence to the cylinder -A-
❑ Installation position: the marks -B- must point towards the pulley
6 - Half-bearing
❑ Check the installation position
❑ Bear in mind the version: Upper half-bearing (towards the piston) of wear-resistant material Mark: Black
strip on the slide surface, in the area of separation
❑ Do not swap the used half-bearings
❑ Fit and centre the half-bearings
❑ Outer edge half-bearing to outer edge connecting rod/connecting rod cap 2.5 mm, measured on one side
❑ Axial play Wear limit: 0.37 mm
❑ Measure the radial play with Plastigage: Wear limit: 0.08 mm When measuring the radial play do not turn
the crankshaft
7 - Engine block
❑ Measure the bore of the cylinders ⇒ page 32
❑ Dimensions of pistons and cylinders ⇒ page 34
8 - Connecting rod caps
❑ unless
permitted Check the installation
authorised by SEAT S.A. SEATposition
9 - Oil injector
❑ For cooling the pistons
❑ Check the installation position: Turn the oil injector counter-clockwise until it touches the engine block
and tighten it in this position
10 - 25 Nm
❑ Fit without sealant
11 - Connecting rod bolt, 30 Nm + 1/4 turn (90°)
❑ Replace
❑ Lubricate the thread and the support surface
❑ Tighten uniformly to a torque of 5 Nm
❑ Use the old bolt to measure the radial play
Edges of the piston rings: testing play

– Fit the ring from above so that it is at a right angle to the lower
opening of the cylinder, with a separation of approx. 15 mm
from the edge of the cylinder.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.25...0.40 1.0
2nd compression ring 0.20...0.40 1.0
Oil scrapper ring 0.25...0.50 1.0
5. Piston and connecting rod: disassembly and assembly 31

Arosa 1997 ➤
Test the coupling play between the rings and the slots of the pis‐
ton
First clean the piston housing slots.
Dimensions in mm
Oil scrapper ring 0.03...0.06 0.15
Measure the bore of the cylinders

♦ Interior permitted
callipers 50...100
unless authorisedmm
– Measure across three different points crosswise -A- and
lengthwise -B- . Difference over the nominal dimension 0.10
mm max.

Arosa 1997 ➤
Note!
Do not measure of the bore of the cylinders when the engine block
is fixed to the installation trestle with engine support -Ar-2204 A- :
doing so could result in erroneous measurements.
Installation position of pistons and piston/cylinder correspond‐

ence
Pistons in cylinders 1 and 2:
Large hole for intake valve towards the flywheel side -arrows- .
Pistons in cylinders 3:
Large hole for intake valve towards the pulley side -arrows- .
Note!
♦ The new pistons have the numbering of the corresponding

cylinders in colour on the piston head.
♦ Pistons for cylinders 1 and 2: Numbering 1/2
♦ Pistons for cylinder 3: Numbering 3
5.1 Position of the piston at TDC: testing

♦ -T20026-
5.1.1 Test process

When installing new pistons or a stripped engine, test the position
of the piston at TDC. Depending on the measurement of piston
projection, install the corresponding cylinderhead gasket, accord‐
ing to the following table:
Note!
To measure the position of the piston at TDC, turn the engine over
clockwise.
Piston projection Identification

notches/holes
0.91 mm ... 1.00 mm 1
1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3
5. Piston and connecting rod: disassembly and assembly 33

Arosa 1997 ➤
5.1.2 Identification of the cylinderhead gasket

♦ Part number = arrow -1-
♦ Processing code = arrow -2- (ignore!)
♦ Holes = arrow -3-
Note!
If divergent values are obtained in the measurement of the di‐

mension of piston projection, use the maximum dimension to
select the correct gasket.
5.2 Dimensions of pistons and cylinders

Re-cutting ∅ piston ∅ cylinder
dimension bore
Basic dimension mm 79.47 79.51
I re-cut mm 79.97 80.01

Arosa 1997 ➤
15 – Cylinder head, Valve gear

1 Cylinderhead: removing and instal‐
ling
Test the compression ⇒ page 44
Note!
♦ When installing a replacement cylinderhead with the camshaft

installed, oil the contact surfaces between the plungers and
the cam slide tracks before installing the cylinderhead cover.
♦ Oil the support and slide surfaces before installing.
♦ Do not remove the plastic bases included for the protection of
the open valves until just before fitting the cylinderhead.
♦ Change all the coolant after replacing the cylinderhead.
1 - Upper toothed belt shield

2 - Toothed belt
❑ Before removing, mark
the direction of rotation
❑ Check for wear
❑ Do not fold
❑ Remove and install,
tighten ⇒ page 38
3 - 10 Nm permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 - 25 Nm
5 - 100 Nm
6 - Camshaft pinion
7 - Hub
❑ With sender rotor
ening use countersup‐
port -T10051-
❑ For removing, use ex‐
tractor -T10052-
⇒ page 55 , Camshaft:
8 - Inner toothed belt shield
9 - Sealing plug
❑ Replace if worn
❑ For the camshaft posi‐
tion
❑ For removing, remove
the sealing plug
1. Cylinderhead: removing and installing 35

Arosa 1997 ➤
⇒ Item 9 (page 35) of the

inner toothed belt shield
❑ Test: ⇒ page 119
❑ Replace
❑ Follow the installation order when loosening and tightening ⇒ page 42 , Cylinderhead: removing and
installing
❑ Before installation, fit the washers on the cylinderhead ⇒ Item 4 (page 53) , Valve control: repairing
12 - Bolt, 10 Nm
❑ For the engine cover
13 - Cylinderhead cover
❑ With oil filler hole
❑ If the cylinderhead cover is worn, the oil filler hole must also be replaced
❑ Before fitting it, carefully clean the sealing surface of the cylinderhead with a clean cloth
14 - To turbocompressor
15 - 10 Nm
❑ First tighten all the bolts by hand
❑ Next, first tighten the two bolts of the upper part and then the other bolts in a crossing pattern working
inside out to the correct tightening torque
16 - Pressure regulator valve
❑ To the engine block vent
17 - Oil filler hole
❑ Replace
18 - Plug
❑ Replace the gasket if worn
19 - Ring gasket
❑ Replace if worn
20 - Support
❑ With fuel lines
21 - Cylinderhead cover gasket
❑ Replace if worn
22 - 20 Nm
23 - Ring
24 - Pump injector
25 - Middle connector
❑ For pump injector
27 - Tandem pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For the fuel supply and the vacuum respect to the correctness of information in this document. Copyright by SEAT S.A.

28 - Supply hose
❑ From the fuel filter ⇒ page 89
36 Rep. Gr. 15 - Cylinder head, Valve gear

Arosa 1997 ➤
29 - Return hose
❑ Towards the fuel filter ⇒ page 89
30 - Gasket
❑ Replace
31 - Support
32 - Hexagonal conical nut
33 - Cylinderhead
34 - Cylinderhead gasket
❑ Replace
❑ Check the identification ⇒ page 37
35 - Glowplug
❑ 15 Nm
37 - 20 Nm + 45° (1/8 turn)
Check the cylinderhead for deformations

Maximum admissible deformation: 0.1 mm
Note!
Diesel cylinderheads cannot be re-cut.
Identification of the cylinderhead gasket

♦ Part number = arrow -1-
♦ Processing code =byarrow
permitted unless authorised -2-SEAT
SEAT S.A. (ignore!)
Note!
Depending on the dimension of piston projection, cylinderhead

gaskets of different thicknesses are fitted. When replacing the
gasket, replace it with one with the same identification.

Arosa 1997 ➤
1.1 Toothed belt: removing and installing

equipment required
♦ Camshaft locking tool -
T20102-
♦ Distribution belt tensioning
tool -U-30009A-
♦ Distribution retaining ten‐
sioner tool -T10008-
♦ Crankshaft sprocket lock‐
ing tool -T10050-
♦ Torque spanner -SAT
8010-
♦ Engine and gearbox sup‐
port cross member -
U-30025-
♦ 4 mm ∅ bit
1.1.1 Removing
Note!
Adjustment of the toothed belt must only be done with the engine
cold.
– Remove ribbed belt ⇒ page 13

– Remove tensioning element for ribbed belt.
– Unbolt pendulum support from gearbox.
– Remove upper toothed belt guard.

Arosa 1997 ➤
– Fit the engine cross member -U-30025- as shown and receive

engine in assembly position.
– Remove bolts from engine unit supports, engine -arrows- and

completely remove from the unit support.
– Remove engine block support.
– Remove central toothed belt guard.
– Carefully lower the engine until the vibration damper/belt pul‐
ley can be removed.
– Remove lower toothed belt guard.
– Position crankshaft at TDC cylinder 1.
Note!Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Turn crankshaft until the mark on the crankshaft toothed belt
wheel is up and the arrow on the toothed belt coincides with the
lugs of the hub sender wheel -arrows- .
– Immobilise the hub with the locking pin -T20102- . This can be
done by moving the pin through the left-hand hole up to the
cylinder head hole.
– Secure crankshaft toothed belt sprocket by locking with lock‐
ing tool -T10050- . This can be done by moving the crankshaft
locking tool from the front of the toothed belt sprocket to the
sprocket teeth.
Note!
The marks of the wheel of the toothed belt of the crankshaft and
the crankshaft immobiliser have to align. The crankshaft locking
tool stub must fit into the hole in the sealing flange.
– Mark D.O.R. of toothed belt.

Arosa 1997 ➤
– Fully introduce an Allen key in the eccentric of the tensioning

roller and press the tensioning roller in the direction of the
-arrow- until the tensioning device of the toothed belt with the
locking plate -T10008- can be immobilised.
Note!
If the Allen key is not inserted enough the internal hexagonal may
break.
– Loosen fixing nut on tensioning roller.
– Remove securing bolts -1- of the toothed belt tensioner and

remove tensioner.
– Remove toothed belt.
1.1.2 Installation
Note!
Adjustment of the toothed belt must only be done with the engine
cold.
– Remove the securing bolts -1- from the camshaft wheel until
the camshaft wheel can be turned
– Turn the camshaft wheel clockwise in its elongated holes
-arrow- up to the limit.
– Carefully turn the excentric clockwise with tool -U-30009A-

until the excentric is just reaching the stop -B- .
– Fit the toothed belt on the camshaft wheel, the tensioning roll‐
er, the crankshaft sprocket and finally on the coolant pump
wheel.
– Fit the toothed wheel tensioner.

Arosa 1997 ➤
– Turn the excentric anti-clockwise with tool -U-30009A- (the

excentric lug moves towards stop -A- ) until the locking plate -
T10008- can be removed freely.
– Release tensioner clockwise (excentric lug moves towards
stop -B- ) until the dimension -a- is attained. Specification di‐
mension -a- : 4 ±1 mm.
Note!
♦ The dimension -a- lessens while tightening the fixing bolts of

the tension roller. Thus adjust generously with the 4 mm di‐
ameter drill.
♦ Dimension -a- can decrease up to 1 mm when the engine is
hot.
– Keep the tensioner

respect toroller in thisofposition and tighten Copyright
the ten‐
the correctness information in this document. by SEAT S.A.
sioner nut to torque 20 Nm + 45° (1/8 turn)
– Tighten the camshaft wheel bolts -1- to a torque of de 25 Nm.

– Remove locking tool -T20102- and crankshaft immobiliser -
T10050- .
– Continue turning crankshaft two turns in the direction of engine
rotation and re-set at TDC cylinder 1.
Note!
♦ The crankshaft locking tool stub must fit into the hole in the
sealing flange while turning.
♦ If the crankshaft is turned beyond Cyl. 1 TDC and the crank‐
shaft immobiliser could not be completely inserted into the
sealing flange, turn crankshaft 1/4 turn backwards to return it
to Cyl. 1 TDC. The immobiliser insertion position cannot be
corrected by turning the crankshaft contrary to engine rotation.
– After introducing the crankshaft immobiliser -T10050- , check

that: 1) dimension -a- is attained and 2) the hub can be im‐
mobilised with the locking tool -T20102-
If dimension -a- is not attained:
– Re-tension the tensioning roller. For this, secure the tension‐
ing roller with the wrench -U-30009A- , unscrew the bolt and
relax the contrary force of the tensioner until dimension -a- is
reached Specification dimension -a- : 4 ± mm
Re-tighten the fixing bolt torque 20 Nm + 45° (1/8 turn)
If the camshaft wheel can not be immobilised
– Remove the stub of the crankshaft immobiliser from the hole
in the sealing flange and turn the crankshaft until the hub can
be locked with the pin.

Arosa 1997 ➤
– Loosen bolts -1- on the camshaft wheel.
– Turn crankshaft in the opposite direction of engine rotation

until the crankshaft immobiliser stub is just opposite the seal‐
ing flange hole -arrow- .
– Turn crankshaft in the engine rotation direction until the crank‐
shaft immobiliser stub can be inserted into the sealing flange
when moving.
– Tighten the camshaft wheel bolts to a torque of de 25 Nm
– Turn the crankshaft two turns in the direction of engine rotation
until cylinder 1 TDC is again reached.
Note!
♦ The crankshaft locking tool stub must fit into the hole in the
♦ If the crankshaft is turned beyond Cyl. 1 TDC and the crank‐
shaft immobiliser could not be completely inserted into the
sealing flange, turn Protected
crankshaft 1/4 turn
by copyright. backwards
Copying to return
for private or commercial it
to Cyl. 1 TDC. Thepermitted
immobiliser insertion
unless authorised position
by SEAT S.A. SEATcannot beguarantee or accept any liability with
S.A does not
corrected by turning the crankshaft contrary to engine rotation.
– Repeat the check.

– Begin by installing lower part of toothed belt guard as well as
belt pulley/vibration damper.
– Fit central toothed belt guard.
– Fit engine mounting to cylinder block. Tightening torques:
⇒ page 6
– Fit upper toothed belt guard.
– Install ribbed belt ⇒ page 13
– Fit the air filter/turbo compressor and intercooler/breather tube
connecting hoses.
1.1.3 Remove
– Drain the coolant ⇒ page 80 .
– Remove the toothed belt ⇒ page 38 .
Note!
Both rings for the lift hook are located on the cylinderhead; thus,
it is necessary to fix an additional support to hold the engine by
the block and thus be able to remove the cylinderhead.

Arosa 1997 ➤
– Fit crossbeam -U-30025- as shown and hold the engine in in‐

stallation position.
– Carefully raise the engine slightly with the shaft -A- .
– Thread -as shown in the illustration- support -T10014- into the

threaded hole near the coolant pump in the block Tightening
torque: 20 Nm
– Raise the engine slightly with the shaft -B- , until the shaft
-A- has no load.
– Remove the shaft -A- .
– Before removing the cylinderhead, drain the fuel with vacuum
pump -SAT 1390- with purge tank -SAT 1390/1- in the tandem
pump ⇒ page 102 ; Tandem pump: removing and installing.
– Follow the order for loosening the cylinderhead bolts.
1.1.4 Install
♦ Always replace the cylinderhead bolts.

♦ In the event of reparation, carefully eliminate the remains of
the gasket from the cylinderhead and from the engine block.
Do not scratch the surfaces. If using sandpaper, the grain must
be no less than 100.
♦ Carefully eliminate abrasive particles.
♦ Do not remove the new cylinderhead gasket from its packag‐
ing until just before fitting.
♦ Handle the gasket with extreme care. Damage to the silicone
coating or grooved area may cause leaks.
– Before fitting the cylinderhead, set the crankshaft at TDC.

– Turn the crankshaft against engine rotation until the pistons
are all roughly evenly below TDC.

Arosa 1997 ➤
– Position the cylinderhead gasket.

– Position the cylinderhead, fit the 8 cylinderhead bolts and
hand-tighten them.
– Tighten the cylinderhead in four stages in the tightening order
shown below:
1. Pretightening with torque spanner:
Stage I = 40 Nm
Stage II = 60 Nm
2. Retightening with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
Note!
It is not necessary to retighten the cylinderhead bolts after repar‐

ations.
– The retightening of the bolts with rigid spanner can be meas‐

ured with the protractor -T20030- .
– After tightening the cylinderhead, turn the camshaft pinion so
that the cams of cylinder 1 point upwards uniformly. Before
fitting the toothed belt, turn the crankshaft in the direction of
engine rotation until TDC.
– After installing the cylinderhead drain the fuel with vacuum
pump -SAT 1390- with purge tank -SAT 1390/1- on the tandem
pump ⇒ page 102 ; Tandem pump: removing and installing.
– Road test the vehicle and consult the fault memory: ⇒ Vehicle
1.2 Toothed belt: removing, installing and tensioning

(Vehicle with tensioning system with internal friction damper)

Arosa 1997 ➤

equipment required
8010-
♦ holding tool -T10050-
♦ Turning tool -U-30009A-
♦ support -U-30025E-
1.2.1 Removal
Note!
Adjustment of the toothed belt should only be carried out when

the engine is cold, as the position of the tensioning indicator varies
according to the engine temperature.
– Remove the engine insulation cover, pulling upwards firmly

-arrows- .
– Remove connecting hose between intercooler and intake
hose.
– Remove ribbed belt ⇒ page 13 .
– Remove tensioning element for ribbed belt.
– Remove the insulation tray: ⇒ General body repairs - instal‐
lation work, exterior; Rep. Gr. 50 ; Body front.
– Unbolt pendulum support from gearbox.

Arosa 1997 ➤
– Fit support -U-30025E- as shown in the illustration and main‐

tain the engine in assembly position.
– Remove bolts from engine unit supports, engine -arrows- and

completely remove from the unit support.
– Remove engine block support.
– Remove central toothed belt guard.
– Carefully lower the engine until the vibration damper/belt pul‐
ley can be removed.
– Position crankshaft at TDC cylinder 1.
Note!
Turn crankshaft until the mark on the crankshaft toothed belt

sprocket is up and the arrow
Protected on Copying
by copyright. the toothed
for privatebelt coincides
or commercial with
the lugs of the hub sender
permitted wheel by
unless authorised -arrows-
SEAT S.A. .SEAT S.A does not guarantee or accept any liability with
– Immobilise the hub with the retention tool -T20102- . To do

this, move the tool through the left hole up to the cylinder head
hole.
– Immobilise the sprocket of the crankshaft toothed belt with re‐
tention tool -T10050- .
Note!
The crankshaft toothed belt sprocket marks and those on the

crankshaft retention tool must coincide. The crankshaft retention
tool stub must fit into the hole in the sealing flange.

– Loosen securing nut on tensioning roller.

Arosa 1997 ➤
– Loosen securing bolts -1- of the camshaft sprocket until it can

be turned in the slotted holes.
– Turn the excentric with tool -U-30009A- in the opposite direc‐

tion to the arrow -1- , until the tensioner roller can be locked
with retention tool -T10115- .
– Turn the tensioner roller with tool -U-30009A- to its limit in the
direction of the arrow -1- , and tighten the tensioner roller se‐
curing nut.
– First remove the toothed belt from the coolant pump and then
from the remaining sprockets.

1.2.2 Installation
Note!
♦ Adjustment of the toothed belt should only be carried out when

the engine is cold, as the position of the tensioning indicator
varies according to the engine temperature.
♦ The tensioning roller should be immobilised with retention tool
-T10115- and on the right stop.
– Fit bolts -1- and hand tighten.

– Turn the camshaft sprocket in its elongated holes in the direc‐
tion of the arrow to its limit.
– Fit the toothed belt onto the camshaft sprocket, the tensioning
roller, the crankshaft sprocket, and finally onto the coolant
pump wheel.

Arosa 1997 ➤
Note!
Make sure that the tensioner roller is correctly housed in the rear
toothed belt guard -arrow- .
– Loosen the locking nut on tensioning roller.
– Using tool -U-30009A- , loosen the tensioning roller in the op‐

posite direction to the arrow -1- , and remove with retention
tool -T10115- .
– With tool -U-30009A- , carefully turn the tensioner roller in the

direction of arrow -1- , until the indicator arm is in the central
position of the plate groove -arrow- .
– Keep the tensioner roller in this position and tighten the roller
nut to 20 Nm + 45° (1/8 turn).
– Tighten the camshaft sprocket securing bolts to a torque of de
25 Nm.
– Remove retention tools -T20102- and -T10050- .
– Turn crankshaft twice in the direction of engine rotation and
replace the distribution elements in the TDC cylinder 1.
– Insert crankshaft locking tool -T10050- into the sprocket, slid‐

ing it in until it enters the sealing flange.
Note!
♦ The crankshaft retention tool stub must fit into the hole in the
♦ The position for inserting the crankshaft retention tool cannot
be adjusted by turning the crankshaft back.permitted
♦ If the crankshaft has been turned beyond TDC for cyl. 1 and
the crankshaft retention tool could not be fully inserted in the

sealing flange, turn the crankshaft 1/4 turn backwards and set
the crankshaft again in the engine rotation direction to TDC
cyl. 1.

Arosa 1997 ➤
– After inserting crankshaft retention tool -T10050- , check that

the camshaft sprocket hub can be immobilised with tool -
T20102- .
If the hub is not immobilised:
– Remove the stub of the crankshaft retention tool from the hole
in the sealing flange and turn the crankshaft until the hub can
be locked with the tool -T20102- .
– Loosen bolts -1- on the camshaft sprocket.

Arosa 1997 ➤
– Turn crankshaft in the opposite direction of engine rotation

until the crankshaft retention tool -T10050- stub is just oppo‐
site the sealing flange hole -arrow- .
– Turn crankshaft in the direction of engine rotation until the
crankshaft retention tool stub is inserted into the sealing flange
by the movement of rotation.
– Tighten the camshaft sprocket bolts to a torque of 25 Nm.
– Remove retention tools -T20102- and -T10050- .
– Turn the crankshaft two turns in the direction of engine rotation
until cylinder 1 TDC is again reached.
Note!
♦ The crankshaft retention tool stub must fit into the hole in the
♦ If the crankshaft has been turned beyond TDC for cyl. 1 and
the crankshaft retention tool could not be fully inserted in the
sealing flange, turn the crankshaft 1/4 turn backwards and set
the crankshaft again in the engine rotation direction to TDC
cyl. 1.
– Repeat theunless
permitted former check.
– Install lower toothed belt guard as well as belt pulley/vibration
damper.
– Install central toothed belt guard.
– Fit the engine support on the engine block and tighten the bolts
to 45 Nm.
– Install the engine supports, engine. Tightening torques
⇒ page 6 .
– Screw in pendulum support to gearbox. Tightening torque
⇒ page 6
– Fit the insulation tray: ⇒ General body repairs - installation
work, exterior; Rep. Gr. 50 ; Body front.
– Remove the engine and gearbox support -U-30025E- .
– Install upper toothed belt guard
– Install ribbed belt ⇒ page 13 .
– Fit the air filter/turbocompressor and intercooler/breather tube
connecting hoses.
– Fit the engine insulation cover.
1.3 Compression: testing

Arosa 1997 ➤

equipment required
♦ Glowplug spanner -
U-40082-
8010-
♦ Adaptor -V.A.G. 1381/12-
♦ Compression gauge -
V.A.G. 1763-
1.3.1 Test condition

• Temperature of the engine oil, at least 30 °C
1.3.2 Test process

– Remove the middle connector of the pump injectors.
– Remove the connectors from the glowplugs.
– Remove all the glowplugs with spanner -U-40082- .
– Thread adaptor -V.A.G. 1381/12- into glowplug holes.
– Test the compression with the compression gauge -V.A.G.
1763- .
Note!
Use of the tester ⇒ Instructions for use .
– Activate the starter motor until the tester no longer shows an

increase in pressure.

Arosa 1997 ➤
1.3.3 Compression values

New: 25...31 bar Wear limit: 19 bar
Admissible difference between all the cylinders: 5 bar
– Install the glowplugs with spanner -U-40082- . Tightening tor‐
que: 15 Nm
– Consult the fault memory: ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051
Note!
When removing the middle connector of the pump injectors, faults

are stored. Thus, consult the fault memory and clear if necessary.

Arosa 1997 ➤
2 Valve control: repairing
Note!
♦ The cylinderheads with cracks between the valve seats can still be used without decrease in their useful
life, so long as the cracks are no wider than 0.5 mm max.
1 - 20 Nm + 1/4 turn (90°)

❑ Replace
❑ Follow the installation
order when loosening
and tightening
⇒ page 55 , Camshaft:
2 - Rocker shaft
❑ Replace
❑ Follow the installation
order when loosening
and tightening
⇒ page 39 , Cylinder‐
head: removing and in‐
stalling
❑ Before installation, fit
the washers
⇒ Item 4 (page 53) in
the cylinderhead
4 - Washer
❑ For the cylinderhead
bolts
5 - Hydraulic plunger
❑ Before removing, re‐
move the half-bearings
of the camshaft
❑ Do not swap them
❑ With hydraulic compen‐
sation of valve play
❑ Place with the slide sur‐
face down
❑ Before installation test
2. Valve control: repairing 53

Arosa 1997 ➤
the axial play of the

camshaft ⇒ page 55
❑ Lubricate the slide surface
6 - Half-cones
7 - Valve spring plate
8 - Valve spring, exterior
❑ Remove and install: Cylinderhead: removed: with -T20034/1- installed: ⇒ Item 14 (page 54) , replace
the valve stem seals
9 - Valve spring, interior
❑ Remove and install: Cylinderhead: removed: with -T20034/1- installed: ⇒ Item 14 (page 54) , replace
the valve stem seals
10 - Valve stem seal
❑ Replace ⇒ Item 14 (page 54)
11 - Valve guide
❑ Test ⇒ Item 3 (page 53)
❑ Replace ⇒ Item 6 (page 54)
❑ Repair guides, with collar
12 - Pump injector
13 - Cylinderhead
❑ Bear in mind the note ⇒ page 46
❑ Re-cut the valve seats ⇒ page 52
14 - Seal
❑ Do not apply more oil or grease to the seal lip
❑ Before installation, clean excess oil from the camshaft journal with a clean cloth
❑ For installation, cover the slot in the camshaft cone (e.g. with tape)
15 - Valves
❑ Valve dimensions ⇒ page 55
16 - Half-bearings
❑ Do not swap the used half-bearings (mark them)
❑ Check that the cylinderhead and the fixing flanges fit well in the caps
17 - Camshaft
❑ Test the axial play ⇒ page 55
❑ Test the radial play with Plastigage Wear limit: 0.11 mm
❑ Eccentricity: max. 0.01 mm
❑ Identification and distribution timing ⇒ page 56
18 - Cap
❑ Installation order ⇒ page 55 , Camshaft: removing and installing
❑ Cap 4 is marked as cap 5
❑ For installation, seal the contact surfaces of caps 1 and 4 with -AMV 17400401- ⇒ page 55
19 - 20 Nm + 1/4 turn (90°) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Replace respect to the correctness of information in this document. Copyright by SEAT S.A.

Arosa 1997 ➤
Measure the axial play of the camshaft

♦ Support universal for gauge -T20020-
♦ Gauge
Measure with the cup plungers removed and the caps installed.
Wear limit: max. 0.15 mm
Seal the contact surfaces of caps 1 and 4 with -AMV 17400401-
Apply and thin, even coating of -sealant AMV 17400401- to the
surfaces -1- .
Note!
♦ Make sure that no sealant gets into the slots -arrows- .

♦ The cap 4 is marked asProtected
cap 5.by copyright. Copying for private or commercial purposes, in part or in whole, is not
Valve dimensions
Note!
The valves can not be re-cut, only seated.
Dimension Intake valve Exhaust valve

∅a mm 35.95 31.45
∅b mm 6.980 6.956
c mm 89.95 89.95
α ∠° 45 45

Arosa 1997 ➤
Identification of the camshaft, distribution timing

Identification
♦ Basic cam diameter: a = ∅ 52.8 mm
♦ Identification with numbers and letters stamped on the front of
the exhaust valve cam in the cylinder 3.
Cylinder 3 -arrow- 045 C
Distribution timing for 1 mm of valve stroke
Intake opens after TDC 15.8°
Intake closes after BDC 25.3°
Exhaust opens before BDC 28.2°
Exhaust closes before TDC 18.7°
2.1 Valve seats: re-cutting

♦ Depth calliper
♦ Valve seat re-cutter
Note!
♦ When re-cutting engines with leaky valves, it is not enough to

re-cut or replace the valve seats and the valves. Especially for
engines with high mileage it is important to check for wear on
the valve control.
♦ Only re-cut the valve seats until an impeccable drive track is
achieved. Before re-cutting, calculate the maximum admissi‐
ble re-cutting dimension. If the re-cutting dimension is excee‐
ded the hydraulic valve play compensation is no longer
ensured and thus the cylinderhead must be replaced.
2.1.1 Calculate the maximum admissible re-

cutting dimension
– Introduce the valve and press it hard against the seat.
Note!
If the valve is changed during the reparation, use the new S.A.valve
permitted unless authorised by SEAT SEAT S.A does not guarantee or accept any liability with
for the measurement. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Measure the distance -a- between the end of the stem and the
upper edge of the cylinderhead.
– Calculate the maximum admissible re-cutting dimension start‐
ing with the distance measured -a- and the minimum dimen‐
sion.
Minimum dimensions:
Intake valve 43.4 mm
Exhaust valve 43.2 mm
Distance measured less the minimum dimension = maximum ad‐
missible recutting dimension.

Arosa 1997 ➤
2.1.2 Example:
- Distance measured 44.1 mm
Minimum dimension 43.4 mm
= Maximum admissible re-cutting dimen‐ 0.7 mm
sion
2.1.3 Intake valve seat: re-cutting

a = ∅ 35.7 mm
b = 1.6 mm
45° = Valve seat angle
Note!
The 30° backing-off of the valve seat is essential for avoiding tur‐
bulence in the intake channel.
2.1.4 Exhaust valve seat: re-cutting

a = ∅ 31.4 mm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
b = 2.7 mm permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
45° = Valve seat angle respect to the correctness of information in this document. Copyright by SEAT S.A.
2.2 Valve guides: testing

♦ Universal support for gauge -T20020-
♦ Gauge

Arosa 1997 ➤
2.2.1 Test process

– Fit the new valve in the guide. The end of the valve stem must
be flush with the guide. Due to different stem diameters always
fit the intake valves in intake guides and exhaust valves in ex‐
haust guides.
– Tilting play: max. 1.3 mm
2.3 Valve guides: replacing

♦ Punch -T20035-
♦ Manual reamer -T20066- and water-soluble oil
2.3.1 Removing
– Clean and check the cylinderhead. Cylinderheads with the
valve seat rings that can no longer be re-cut or that have been
re-cut to the minimum dimension are not fit for replacing the
valve guides.
– Dislodge the worn valve guides with the -T20035- from the
camshaft side (valve guides with collar -for replacement only-
from the combustion chamber side).
2.3.2 Installing
– Oil the new guides and, from the cylinderhead side, dislodge
them up to the collar with the -T20035- on the cold cylinder‐
head.

Arosa 1997 ➤
Note!
Once the collar of the guide is supported, do not increase the

fitting pressure by more than 1.0 t. Otherwise the collar may
break.
– Ream the guides with manual reamer -T20066- . Always use

water-soluble oil.
– Re-cut the valve seats ⇒ page 56 .
2.4 Valve stem seals: replacing

equipment required
♦ Valve removal/fitting tool -
T20034B-
♦ Valve guide seal extractor -
T20058-
♦ Valve guide seal fitting tool
-T20039-
2.4.1 Removing
(With cylinderhead installed)
– Remove the camshaft ⇒ page 55 .
– Extract the plungers and place them with the cam slide surface
downwards. Do not swap them.
– Set the piston of the respective cylinder at TDC.

Arosa 1997 ➤
– Use valve removal/fitting tool -T20034B- with pressure ele‐

ment -T20034B- /∅ 34.
Note!
The valves rest on the head of the piston.
– Remove the valve stem seals with the -T20058- .
2.4.2 Installing
– Fit the plastic sleeve -A- over the respective valve stem. In this
way damage to the new seal -B- is avoided.
– Fit the new valve stem seal with the -T20039- .
– Oil the lip of the valve stem seal and carefully slide the seal
over the valve guide.
2.5 Camshaft: removing and install-ing

Arosa 1997 ➤

equipment required
♦ Countersupport -T10051-
8010-
♦ Sealant -AMV 17400401-
2.5.1 Removing
– Remove the bolts -1- from the camshaft wheel.
– Remove the camshaft wheel from the hub.

Arosa 1997 ➤
– Loosen the hub bolt -1- .

– Use countersupport -T10051- .
– Loosen the hub bolt about two turns.
– Fit extractor -T10052- and align it with the holes in the hub.
– Screw the fixing bolts -1- into the hub.
– Pull on the hub by uniformly tightening the centre bolt -2- until
the hub comes loose from the camshaft cone.
Note!
During this process, hold the extractor with a spanner e/c 30.
– Remove the hub from the camshaft cone.

– Remove the cylinderhead cover.
– Remove the rocker shaft ⇒ page 119 .
Note!
First loosen the outer bolts and
respectthen
to the the two inner
correctness onesincrosswise.
of information this document. Copyright by SEAT S.A.
– Remove the tandem pump ⇒ page 102 .

– First remove caps 2 and 3. Loosen caps 1 and 4 alternately
and crosswise.
Note!
Cap 4 is marked as cap 5.
2.5.2 Installing
Note!
♦ When fitting the camshaft, the cylinder 1 cams must point up‐
wards.
♦ Do not swap the worn half bearings (mark them).
♦ When fitting the camshaft, check that the mounting flanges of
the half bearings seat correctly in the caps and the cylinder‐
head.
♦ Before installing the cap, check that the cylinderhead washers
are fitted on the cylinderhead.
– Lubricate the slide surfaces of the half bearings.

– Replace the cap bolts.

Arosa 1997 ➤
– Tighten caps 2 and 3 alternately and crosswise to a torque of

8 Nm + 1/4 turn (90°)
– Fit caps 1 and 4 and tighten them to a torque of 8 Nm + 1/4
turn (90°) too.
Note!
♦ Cap 4 is marked as cap 5.

♦ Seal the contact surfaces of caps 1 and 4 with -AMV
17400401- ⇒ page 55 .
♦ Cap 4 must be flush with outer edge of the cylinderhead: oth‐
erwise the tandem pump may leak.
– Fit the camshaft seal ⇒ page 58 .

– Replace the rocker shaft bolts.
– Fit the rocker shaft tighten the two inner bolts first and then the
outer ones, uniformly and crosswise, until there is no play in
the housing. Tightening torque 20 Nm + 1/4 turn (90°)
– Fit the hub on the camshaft.
– Tighten the hub bolt -1- . Tightening torque 100 Nm
– Use the countersupport -T100051- .
– Slip the camshaft wheel over the hub.
Note!
The toothed section -arrow- of the camshaft wheel must be up‐

wards.
– Align the camshaft
respect to thewheel at ofthe
correctness centre
information position
in this inCopyright
document. the elliptical
by SEAT S.A.
holes.
– Hand-tighten the bolts -1- into the camshaft until they have no
play.
– Immobilise the hub with lock pin -T20102- .
– Toothed belt: fit, tighten ⇒ page 38 .
– Poly-V belt: fit ⇒ page 13 .
– Fit the tandem pump ⇒ page 102 .
Note!
After fitting new plungers do not start the engine for approx. 30
minutes. The hydraulic compensation components must seat (the
valves may rest on the piston).

Arosa 1997 ➤
2.6 Camshaft seal: removing and installing

equipment required
♦ Seal extractor -T20031B-
T20081B-
8010-
♦ Screwdriver M12X65
2.6.1 Removing
– Remove the camshaft wheel and the hub ⇒ page 53 , Cam‐
shaft: removing and installing.
– Oil the threaded head of extractor -T20031B- /∅ 32, position
it and, pressing hard, thread it into the seal as far as possible.
– Turn the centre bolt of the extractor against the camshaft until
the seal comes free.

Arosa 1997 ➤
2.6.2 Installing
Note!
Do not apply more oil or grease to the sealing side of the seal.
– Eliminate excess oil from the camshaft journal with a clean

cloth.
– Fit the seal over the -T20081B/3- and introduce the unit into
the cam-shaft. Also add the -T20081B/5- .
– Press on the seal with pressure part of the -T20081B/1- and
bolt M12X65 as far as it will go.
– Toothed belt: fit, tighten ⇒ page 38 .
– Fit the Poly-V belt ⇒ page 13 .

Arosa 1997 ➤
17 – Lubrication
1 Lubrication system components: re‐
moving and installing
Note!
♦ When repairing the engine, if significant quantities of metal

shavings and particles due to wear or abrasion, e.g. damage
to the mount or connecting rod bearings are found in the oil,
in order to avoid further damage, not only must the oil lines be
cleaned carefully but the oil radiator must also be replaced.
♦ The oil level must not exceed the max. mark; danger of dam‐
aging the catalyst!
Test the oil pressure ⇒ page 72

Oil capacity:
With oil filter 4.2 l
Specification of the engine oil:
Use only VW 50501 standard engine oils.
Part I
Part II, Oil filter support: disassembly ⇒ page 69
66 Rep. Gr. 17 - Lubrication

Arosa 1997 ➤
1 - 15 Nm
2 - Sealing flange
❑ With seal
sleeves
⇒ page 18
❑ Install with silicone-
base sealant -D 176 404
A2- ⇒ page 18
❑ Do not apply more oil or
grease to the seal lip
❑ Before installing, clean
excess oil on the crank‐
shaft journal with a
clean cloth
❑ Replace the seal for
crankshaft - pulley side
⇒ page 17
3 - Engine block
4 - Gasket
❑ Replace
❑ Disassembly and as‐
sembly ⇒ page 69
6 - 15 Nm + 1/4 turn (90°)
❑ Replace
❑ First fit the upper left and
lower right bolts and
then tighten the four
bolts in a crossing pat‐
1. Lubrication system components: removing and installing 67

Arosa 1997 ➤
tern
7 - Oil dipstick
❑ The oil level must not exceed the max. mark!
❑ Marks ⇒ page 70
8 - Filler funnel
❑ Remove in case of draining of the oil by absorption
9 - 5 Nm
10 - Guide sleeve
11 - 10 Nm
12 - O-ring
❑ Replace
❑ Oil lightly for installation
13 - Cover
❑ With gasket
14 - 15 Nm
15 - Oil pump
❑ With discharge valve 11.5 bar
❑ Before installing, check for the two alignment sleeves for the centring
16 - Alignment sleeve
17 - 25 Nm permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
18 - Axle support
❑ Before installing check for the alignment sleeve for the centring of the engine block and that it is fitted on
the axle support
❑ Removing and installing ⇒ page 24
19 - Oil injector
❑ For cooling the pistons
❑ Check the installation position: Turn the oil injector counter-clockwise to the stop of the engine block and
tighten at this position
20 - O-ring
❑ Replace
21 - Oil sump
❑ Before installing, clean the sealing surface
❑ Install with silicone-base sealant -D 176 404 A2- ⇒ page 70
❑ To remove the oil sump, the gearbox must be removed ⇒ 5-speed manual gearbox 02J; Rep. Gr. 34 ;
Gearbox: removing and installing
22 - Support
❑ For connection line/intercooler
23 - 15 Nm
❑ To remove the sump bolts (gearbox side), the gearbox must be removed ⇒ 5-speed manual gearbox
02J; Rep. Gr. 34 ; Gearbox: removing and installing
24 - Seal
❑ Replace
25 - Oil purge bolt, 30 Nm

Arosa 1997 ➤
26 - Chain wheel
❑ For oil pump
❑ Installation is only possible in one position
27 - 20 Nm + 1/4 turn (90°)
28 - Chain
❑ Check the installation position ⇒ page 24 . Stabiliser bar: removing and installing
29 - Chain wheel
❑ For stabiliser bar
30 - 100 Nm + 1/4 turn (90°)
❑ Replace
❑ The retightening can be done in several phases
❑ Use the -T10061- for loosening and tightening
31 - Counterweight
32 - 20 Nm
33 - Pinion/return roller
34 - 9 Nm
35 - Chain tensioner with slide rail
❑ For the removal, immobilise with -T10060-
Part II

Arosa 1997 ➤
1 - Gasket
❑ Replace
2 - 25 Nm + 1/4 turn (90°)
❑ Replace
❑ First fit the upper left and
lower right bolts and
then tighten the four
bolts in a crossing pat‐
tern
4 - Seal
❑ Replace
5 - Connecting sleeve
❑ For oil feed line towards
the turbocompressor
6 - Oil feed line, 22 Nm
❑ Towards the turbocom‐
pressor
7 - 0.7 bar oil pressure switch -
F1- , 20 Nm
8 - Plug
❑ Replace respect to the correctness of information in this document. Copyright by SEAT S.A.
10 - Oil filter element

11 - Lock bolt, 10 Nm
12 - Gasket
❑ Replace
❑ Fix with the tabs on the
oil radiator
13 - Oil radiator
❑ Check the note ⇒ page 66
14 - Gasket
❑ Replace
15 - Lock bolt, 25 Nm
Marks on the oil dipstick

1 - Max. mark
2 - Min. mark
a - Area between the upper edge of the marked area and the max.
mark: do not add oil
b - The level is within the marked area: oil may be added
c - Area between the min. mark and the lower edge of the marked
area: add maximum 0.5 l of oil

Arosa 1997 ➤
1.1 Oil sump: removing and installing

♦ Hand drill with plastic brush
♦ Silicone-base sealant -D 176 404 A2-
♦ Flat scrapper
1.1.1 Removal
– Remove the soundproofing sump: ⇒ Bodywork-exterior fitting
work; Rep. Gr. 50 ; Bodywork, front Fitting chart
– Drain the engine oil.
– Remove the intercooler/turbocompressor connecting line from
the sump.
– Remove the gearbox: ⇒ 5-speed manual gearbox 02J; Rep.
Gr. 34 ; Gearbox: removing and installing
– Unbolt the oil sump.
– If necessary loosen the oil sump tapping it lightly with a rubber
hammer.
– Eliminate the sealant residues from the engine block with a flat
scraper.
– Eliminate the sealant residues from the oil sump with a rotating
brush, e.g. a hand drill with a plastic brush (use shop goggles).
– Clean the contact surfaces of oil and grease.
1.1.2 Install Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note!
♦ Check the use-by date of the sealant.

♦ The oil sump must be installed within 5 minutes of applying the
siliconebase sealant.
– Cut the nozzle of the tube at the front mark (diameter of the
nozzle: approx. 3 mm).
– Apply the silicone-base sealant to the clean contact surface of
the oil sump, as shown in the illustration.
The bead must:

Arosa 1997 ➤
♦ be 2...3 mm thick
♦ pass next to the bolts, along the inside -arrow-
Note!
The sealant bead must be no thicker; otherwise excess sealant

could get into the oil sump and obstruct the filter of the oil pump
breather pipe.
– The location of the sealant bead on the engine block can be

seen in the illustration.
– Fit the oil sump immediately and tighten all the fixing bolts
slightly.
Note!
The oil sump should be flush

Protected with Copying
by copyright. the engine
for privateblock.
– Tighten the oil sump bolts to a torque of 15 Nm
– Install the gearbox: ⇒ 5-speed manual gearbox 02J; Rep. Gr.
34 ; Gearbox: removing and installing
– Tighten the oil sump/gearbox bolts to a torque of 45 Nm.
Note!
After installing the oil sump, allow the sealant to dry for approx.
30 minutes, after which oil may be added.
Continue the installation in the reverse order of removal.
1.2 Oil pressure and oil pressure switch: testing

Arosa 1997 ➤

equipment required
♦ Oil pressure gauge -V.A.G.
1342-
♦ Diode lamp tester -V.A.G.
1527 B-
♦ Auxiliary measurement set
-V.A.G. 1594 A-
♦ Testing and reparation of optical and acoustic oil pressure in‐

dicators:
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations

Arosa 1997 ➤
1.2.1 Test process

– Remove the oil pressure switch -F1- and thread it into oil pres‐
sure gauge -V.A.G. 1342- .
– Thread the oil pressure gauge into the oil filter support in the
place of the oil pressure switch.
– Connect the brown wire of the oil pressure gauge to earth (-).
– Attach diode lamp -V.A.G. 1527 B- with auxiliary leads of the
-V.A.G. 1594 A- to battery positive (+) and to the oil pressure
switch.
– Start the engine and slowly increase the revs.
Between:
0.55...0.85 bar of pressure
The diode should light up; if not, replace the oil pressure switch.
– Continue raising the revs.
At 2,000 rpm and with the oil at a temperature of 80 °C, the oil
pressure should be 2.0 bar, minimum.
At higher revs, the oil pressure should not exceed 7.0 bar. If nec‐
essary, replace the oil pump cover with the discharge valve.

Arosa 1997 ➤
19 – Cooling system
1 Cooling system components: remov‐
ing and installing
Note!
♦ The cooling system is under pressure when the engine is hot.

This pressure must be reduced before repairing.
♦ The hose connections are fixed with strip clamps. In case of
reparation, use only strip clamps.
♦ For installing the strip clamps, pliers -T20029- are recommen‐
ded.
Test the cooling system for leaks with tester -SAT 1274- and
adaptors -V.A.G. 1274/3- and -V.A.G. 1274/4- .
Cooling system components, bodywork ⇒ page 75 .
Cooling system components, engine ⇒ page 77 .
Coolant hose connection diagrams ⇒ page 79 .
Drainbyand
Protected fill coolant
copyright. Copying for ⇒ page
private 80 . purposes, in part or in whole, is not
or commercial
Instructions for the ofcoolant
respect to the correctness informationmixture ⇒ page
in this document. 80 by
Copyright . Coolant:
SEAT S.A. drain‐
ing and filling.
1.1 Cooling system components, bodywork side
1. Cooling system components: removing and installing 75

Arosa 1997 ➤
1 - Radiator
⇒ page 82
❑ After replacing, change
all the coolant
2 - Lockholder plate
3 - Intercooler
4 - Fan screen
5 - 10 Nm
6 - Radiator fan
7 - Lower coolant hose
❑ Coolant hose connec‐
tion diagrams
⇒ page 79
8 - 10 Nm
9 - Connector
10 - Heat switch -F18- , 35 Nm
❑ For electric fan
❑ Switching tempera‐
tures: 1st gear on:
92...97 °C off: 84...91 °C
2nd gear on: 99...105 °C
off: 91...98 °C
11 - Upper coolant hose
tion diagram
12 - Expansion tank respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Test the cooling system

for leakage with tester -
SAT 1274- and adaptor
-V.A.G. 1274/3-
13 - O-ring
❑ Replace if faulty
14 - Plug
❑ Test with tester -SAT 1274- and adaptor -V.A.G. 1274/4-
❑ Test pressure 1.4...1.6 bar
15 - Cover
76 Rep. Gr. 19 - Cooling system

Arosa 1997 ➤
1.2 Cooling system components, engine side
1 - Hose
❑ Towards the heat ex‐
changer
tion diagram
⇒ page 79
3 - 10 Nm
4 - Hose
❑ From the heat exchang‐
er
tion diagram
⇒ page 79
5 - 25 Nm
6 - Hose
❑ Towards the lower part
of the expansion tank
tion diagram
⇒ page 79
7 - Mounting bracket
8 - Coolant line
tion diagram
⇒ page 79 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
9 - O-ring respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Replace
10 - Hose
❑ Towards the upper part

Arosa 1997 ➤
of the expansion tank

❑ Coolant hose connection diagram ⇒ page 79
11 - Hose
❑ Towards the radiator, upper part
12 - Hose
❑ Towards the radiator, lower part
❑ For coolant thermostat
14 - 15 Nm
❑ Check the installation position ⇒ page 84 ; Coolant thermostat: removing and installing
❑ Test: heat the thermostat in water
❑ Commencement of opening approx. 85 °C
❑ End approx. 105 °C
❑ Opening stroke at least 7 mm
16 - Coolant pump
❑ Check that it rotates freely
17 - O-ring
❑ Replace
18 - Securing clip
19 - Coolant temperature sender -G62-
❑ Test: ⇒ Vehicle diagnosis, testing and information system VAS 5051
❑ With coolant temperature gauge sender -G2-

Arosa 1997 ➤
1.3 Coolant hose connection diagram
1 - Intake manifold
2 - Expansion tank
3 - Heat exchanger for the
heating
4 - Coolant line
5 - Oil radiator
7 - Radiator
9 - Coolant pump/coolant ther‐
mostat
10 - Engine block
Tightening order of the bolts fixing the compact support to engine

block
– Position the compact support on the engine block (check the
alignment sleeve between the compact support and the en‐
gine block).
– First, hand-tighten all the fixing bolts, taking up all play.
– Tighten the compact support bolts to a torque of 45 Nm, in the
following order: 1 - bolt -A- . 2 - bolt -B- . 3 - bolt -C- . 4 - bolt
-D- . 5 - bolt -E- . 6 - bolt -F- .

Arosa 1997 ➤
1.4 Coolant: draining and filling

equipment required
♦ Antifreeze tester -T10007-
♦ Strip clamp pliers -T20029-
♦ Tray -V.A.G. 1306-
1.4.1 Drain
– Open the plug of the coolant expansion tank.
– Remove the soundproofing sump:
⇒ Bodywork-exterior fitting work; Rep. Gr. 50 ; Bodywork, front
Fitting chart
– Remove the lower radiator hose and let the coolant drain.

Arosa 1997 ➤
– For draining coolant from the engine, the coolant hoses must
also be detached from the oil radiator -arrow- .
Note!
Observe waste disposal rules!
1.4.2 Fill
Note!
♦ Only use antifreeze additive G 12 according to specification

TL VW 774 F. Identification: purple colour.
♦ The purple G 12 (TL VW 774 F standard) may be mixed with
the previously used red G 12 antifreeze additive.
♦ On no account must G 12 be mixed with other anti-freeze ad‐
ditives.
♦ If the fluid in expansion tank is brown, G 12 has been mixed
with other anti-freeze additives. In this case the coolant must
be changed.
♦ G 12 and anti-freeze additives marked “In accordance with TL
VW 774 F” prevent frostProtected
and corrosion damage, scaling and
also raise the boiling point of coolant. For bythis reason,
S.A. SEATthe
S.A sys‐
permitted unless authorised SEAT does not guarantee or accept any liability with
tem must be filled all year round with
respect to recommended
the correctness anti-
freeze and anti-corrosive additives.
♦ Because of its high boiling point, coolant improves engine re‐
liability under heavy work loads, particularly in countries with
tropical climates.
♦ Anti-freeze protection should be guaranteed to approx. -25 °
C (in countries with arctic weather up to approx. -35 °C).
♦ Coolant concentration must not be reduced by adding water,
even in warmer seasons or in warmer countries. The anti-
freeze additive ratio must be at least 40 %.
Recommended mixes:
Antifreeze pro‐ Proportion anti‐ -G12- 4) Water4)
tection to freeze
-25 °C 40 % 2.0 l 3.0 l
-35 °C 50 % 2.5 l 2.5 l
4) The quantity of coolant may vary according to the equipment on each vehicle.
– Fix the lower coolant hose to the radiator.

– Attach the coolant hoses to the oil radiator.

Arosa 1997 ➤
– Install the soundproofing sump: ⇒ Bodywork-exterior fitting

work; Rep. Gr. 50 ; Bodywork, front Fitting chart
– Fill with coolant up to the max. mark of the expansion tank.
– Close the expansion tank.
– Switch off the heating.
– Start the engine and hold engine revs at approx. 2,000 rpm for
about 3 minutes.
– Run the engine until the fan starts up.
– Check the coolant level and, if necessary, top up. With the
engine warm the coolant level must be at the max. mark, and
with the engine cold, between the min. and max. marks.
1.5 Radiator: removing and install-ing

equipment required
♦ Tray -V.A.G. 1306-
♦ Torque spanners respect
-SATto the correctness of information in this document. Copyright by SEAT S.A.
8010-
1.5.1 Remove
– Remove the front bumper: ⇒ Bodywork-exterior fitting work;
Rep. Gr. 63 ; Front bumper: removing and installing

Arosa 1997 ➤
– Remove the coolant hoses from the radiator.

– Detach the terminal connector from the heat switch.
– Remove the radiator bolts and remove the radiator down‐
wards.
1.5.2 Vehicles with air conditioning

– Remove the bolts fixing the condenser to the radiator.
– Remove the power steering reserve tank and the condenser
lines from their mounts.
– Separate the condenser as far as possible - without bending
or damaging the lines - to remove the radiator.
1.5.3 Install
Install in the reverse order, bearing in mend the following:
– Fill coolant ⇒ page 80 .
1.6 Coolant pump: removing and installing

equipment required
♦ Strip clamps pliers -
T20029-
♦ Tray -V.A.G. 1306-
8010-

Arosa 1997 ➤
1.6.1 Remove
Note!
Always replace the gaskets and the ring gaskets.

– Remove the bolts -1- from the coolant pump -2- and carefully
remove the coolant pump.
1.6.2 Install
– Install the new O-ring -3- covered with coolant.
– Fit the coolant pump -2- on the engine block and tighten the
fixing bolts -1- . Tightening torque: 15 Nm
Note!
The sealing plug for the coolant pump points downwards.

– Install the Poly-V belt ⇒ page 13 .
1.7 Coolant thermostat:

Protected removing
by copyright. Copying and installing
for private or commercial purposes, in part or in whole, is not

Arosa 1997 ➤

equipment required
♦ Tray -V.A.G. 1306-
8010-
1.7.1 Remove
Note!
Always replace the gaskets and the ring gaskets.

– Remove the alternator: ⇒ Electrical system; Rep. Gr. 27 ;
Alternator with Poly-V belt: removing and installing
– Detach the coolant hose from the connecting sleeve.

Arosa 1997 ➤
– Remove the fixing bolts -1- from the connecting sleeve -2- and
remove the connecting sleeve -2- with the coolant thermostat
-4- .
– Turn the coolant thermostat -4- 1/4 turn (90°) to the left and
remove it from the connecting sleeve -2- .
1.7.2 Install
– Wet the new O-ring -3- with coolant.
– Fit the coolant thermostat -4- in the connecting sleeve -2- and
turn 1/4 turn (90°) to the right.
Note!
The thermostat braces should be almost vertical.
– Fit the connecting sleeve -2- with the coolant thermostat -4-
on the engine block.
– Tighten the fixing bolts -1- . Tightening torque: 15 Nm

Arosa 1997 ➤
20 – Fuel supply system

1 Fuel supply system components: re‐
Note!
♦ The hose connections are fixed with tightening or screw

clamps.
♦ Always replace the tightening clamps with strip or screw
clamps.
Repair the fuel filter ⇒ page 89 .

Check the safety measures ⇒ page 90 .
Follow the cleaning rules ⇒ page 90 .
Repair the accelerator control cable ⇒ page 93 .
1.1 Fuel tank and accessory parts: removing and installing
1 - Plug
❑ Replace the gasket if
worn
2 - Fixing bolt
3 - Tank cover unit
❑ With dustboot
4 - Gravity/safety valve
❑ To remove, extract it
from the filler hole, up‐
wards
❑ Test the continuity of
flow from valve Perpen‐
dicular valve: open
Valve inclined 455:
closed
5 - O-ring
❑ Replace
6 - Earth connection
❑ Check for firm seating permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7 - Connector
8 - Plug nut
-U-40055A-
9 - Fuel level gauge sender
position on the fuel tank
⇒ page 88
10 - Ring gasket
❑ Replace if worn
❑ For installing wet with
1. Fuel supply system components: removing and installing 87

Arosa 1997 ➤
fuel
11 - Spacer bushing
12 - 15 Nm
13 - Fuel tank
❑ When removing, hold it with the engine/gearbox lift -SAT 1001-
14 - 25 Nm
15 - Holding strap
❑ Check the different lengths
16 - Supply line
❑ Towards the fuel filter ⇒ page 89
❑ Clipped to the fuel tank
❑ Black
❑ To free from the flange, press the lock on the connecting part
17 - Return line
❑ Of the fuel radiator ⇒ page 91
❑ Clipped to the fuel tank
❑ To free from the flange, press the lock on the connecting part
18 - Breather valve
❑ To remove it, extract laterally from the filler hole
❑ Before installing, remove the plug ⇒ Item 1 (page 87)
❑ Test ⇒ page 88 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation position of the fuel level gauge sender

The marks on the sender and on the fuel tank must coincide.
The connections for return line blue -1- and supply line black -2-
are marked with arrows on the cover of the fuel level gauge
sender.
Note!
Once installed the fuel level gauge sender, check that the supply
and return lines are still fixed to the fuel tank.
Test the breather valve

Lever at rest position: closed.
Lever set at position of the arrow: open.
Note!
Before installing the breather valve, remove the plug from the fuel
tank.
88 Rep. Gr. 20 - Fuel supply system

Arosa 1997 ➤
1.2 Fuel filter: repairing
1 - Return line
❑ Towards the fuel radia‐
tor ⇒ page 91
2 - Supply line
❑ Of the fuel tank
3 - Fixing clip
4 - Control valve
❑ Installation position: ar‐
row points towards the
fuel tank
❑ To change the filter, re‐
move the fixing clip and
remove the control
valve with the fuel lines
connected
❑ At less than +15 °C:
FlowCopying
Protected by copyright. towards the orfilter,
for private commercial purposes, in part or in whole, is not
open
❑ At more than +31 °C:
Flow towards the filter,
closed
5 - O-ring
❑ Replace
6 - Return line
❑ Of the tandem pump

Arosa 1997 ➤

7 - Fuel line
8 - Fuel temperature sender -G81-
9 - Retaining valve
❑ Installation position: Arrow points towards the tandem pump
10 - Supply line
❑ Towards the tandem pump ⇒ Item 13 (page 11)
11 - Fuel filter
❑ Fill with diesel fuel before installing
❑ The direction of flow is marked with arrows
❑ Do not swap the connections
❑ Replace if worn
12 - Gasket
❑ Replace if worn
13 - Water purge bolt
❑ To ventilate, remove the fixing clip of the control valve and remove the valve with the fuel lines connected
❑ Loosen and allow about 100 cm³ of liquid to escape
1.3 Safety measures for work on the fuel

supply system
When removing or installing the fuel level gauge sender from full
or partially full fuel tanks, bear in mind the following:
♦ Before beginning work, the vacuum tube of a working extractor
must be close at hand, near the fuel tank assembly opening,
to absorb the gases given off by the fuel. If an extractor is not
available, a radial fan can be used (the engine must be kept
out of the flow of air) with an air flow above 15 m³/h.
♦ Avoid contact between skin and fuel. Use fuel-resistant
gloves!
1.4 Cleaning rules

For work on the fuel supply/injection system, carefully follow the
“6 rules” of cleaning:
♦ Carefully clean the connections and the area around them be‐
fore detaching them.
♦ Place the removed parts on a clean surface and cover them.
Do not use cloths that shed fibres!
♦ If the repair work is not carried out immediately, the open com‐
ponents should be covered or carefully stored.
♦ Only install clean components: Remove the replacement parts
from their wrapping right before carrying out assembly. Do not
install components that have been stored without wrapping
(e.g. in the toolbox, etc.).
♦ As the system is open, avoid the use of compressed air when
possible. Do not move the vehicle if possible.

Arosa 1997 ➤
♦ Also make sure not to spill diesel fuel on the coolant hose. If
necessary, immediately clean the hoses. Replace affected
hoses.
1.5 Fuel radiator: removing and installing

1.5.1 Remove
Follow the cleaning rules ⇒ page 90 .
Note!
The fuel radiator is on the return line to the tank. It is fitted on the
underside of the vehicle.
– Detach the fuel lines on the fuel radiator.

– Remove the nuts -arrows- .
1.5.2 Install
Install in the reverse order, bearing mind the following:
– Tighten the nuts of the fuel radiator to a torque of 15 Nm.
1.6 Fuel tank: removing and installing


Arosa 1997 ➤
♦ Engine/gearbox lift -SAT 1001-
1.6.1 Remove
– Check the safety measures before starting removal work
⇒ page 90 .
– First check whether the vehicle has a coded radio; if so consult
the antitheft code.
– With the ignition off, disconnect the battery earth strap.
– Remove the rear axle: ⇒ Running gear; Rep. Gr. 42 ; Rear
axle: repairing Rear axle: removing and installing
– Remove the right rear mudguard: ⇒ Bodywork-fitting work;
Rep. Gr. 66 ; Wheel arch: removing and installing
– Open the tank cap.
– Empty the fuel tank and clean around the fuel filler hole.
– Remove the fixing bolt and remove the tank cap unit with the
dustboot.
– Remove the filler hole bolts.
– Fold the rear seat forward.
– Remove the cover from the fuel level gauge sender.

Arosa 1997 ➤
– Detach the fuel return line -1- (blue) and the fuel supply line
-2- from the flange.
Note!
To do so, press the lock buttons on the hose connections

-arrows- .
– Remove the connector -3- .

– Remove the holding straps on the fuel tank with engine/gear‐
box lift -SAT 1001- .
– Lower the fuel tank.
1.6.2 Install
Install in the reverse
permitted unlessorder, bearing
authorised mind
by SEAT S.A. SEATthe
S.A following:
♦ Fit the breather hoses without bends.
♦ Do not swap the supply and return lines (return line blue or
with blue mark, supply line, black).
♦ Clip the supply and return lines to the fuel tank.
The connections for return line blue -1- and supply line black -2-
are marked with arrows on the cover of the fuel level gauge
sender.
1.7 Accelerator control: repairing

Left-hand drive vehicles
Right-hand drive vehicles ⇒ page 94

Arosa 1997 ➤
1 - Support
⇒ Brake system; Rep.
Gr. 46 ; Brake, Brake
pedal, General installa‐
tion chart
2 - Connector
❑ Black, 6 contacts
3 - Accelerator pedal position
sender -G79-
❑ Cannot be adjusted
❑ The accelerator pedal
position sender trans‐
mits driver intentions to
the engine control unit
❑ To remove the sender,
remove the cover on the
footrest area
4 - 10 Nm
Right-hand drive vehicles

Arosa 1997 ➤
1 - 10 Nm
sender -G79-
3 - Pulley for cable
4 - Washer
5 - 10 Nm
6 - Threaded cage
7 - Support
⇒ Brake system; Rep.
Gr. 46 ; Brake, Brake
pedal, General installa‐
tion chart

Arosa 1997 ➤
1.8 Accelerator pedal position sender: test

equipment required
♦ Fault reader -V.A.G. 1551-
or vehicle systems checker
-V.A.G. 1552- with lead -
V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -
V.A.G. 1526 A- or multime‐
ter -V.A.G. 1715-
-V.A.G. 1594 A- or -V.A.G.
1594 C-
♦ Wiring diagram
1.8.1 Left-hand drive vehicles

Right-hand drive vehicles ⇒ page 98
1.8.2 Test process

– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with the cor‐
responding “address code” 01, select the engine electronics
control unit. When doing so, the ignition must be on. ⇒ Vehicle
Reading on the display: Rapid data transmission HELP
Select function XX
– Press 0 and 8 for the function “Read measured value block”

and press Q to confirm the entry.
Reading on the display: Read measured value block
Enter value group number XXX
– Press 0 , 0 and 2 for the “Display group number 2” and press

Q to confirm the entry.

Arosa 1997 ➤
Read measured value block 2 →

0/min 0.0 % 0 1 0 18.4 °C
– Check the reading for accelerator pedal position in field 2,

without depressing the pedal. Target value: 0.0 %
– Also check the reading for the idle switch in field 3. The middle
digit should be 1. Reading: 0 1 0
0/min 100.0 % 0 0 0 18.4 °C
– Depress the accelerator pedal slowly all the way, watching

display fields 2 and 3.
♦ Display field 2: the accelerator pedal position value should rise
continuously. Target value at full gas: 100.0 %
♦ Display field 3: the middle digit should change to 0. Reading:
000
If the final target value is not reached:
– Press → .
– Press 0 and 6 for the function “End data transmission” and
press Q to confirm the entry.
– Switch off the ignition.
– Replace the accelerator pedal position sender -G79-
If the reading does not change or only changes irregularly:
– Test the wiring of the accelerator pedal position sender as fol‐
lows:
– Remove the wiper arms and the air deflector: ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wipers Windscreen wipers:
– Attach test box -V.A.G. 1598/31- to the wiring harness of the
control unit without connecting the engine control unit.
– Remove the cover from the footrest area (driver side).
– Detach the 6-contact connector for the accelerator pedal po‐
sition sender.

Arosa 1997 ➤
– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram.
Contact 1 + female contact 63
Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires, to vehicle
earth and to battery positive. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the accelerator pedal position sender -G79- .
1.8.3 Right-hand drive vehicles

control unit. When doing so, the ignition must be on. ⇒ Vehicle
Select function XX



0/min 0.0 % 0 1 0 18.4 °C
– Check the reading for the accelerator pedal position in field 2,

without depressing the pedal. Target value: 0.0 %
– Also check the reading for the idle switch in field 3. The middle
digit should be 1. Reading: 0 1 0
0/min 100.0 % 0 0 0 18.4 °C
– Depress the accelerator pedal slowly all the way, watching

display fields 2 and 3.
♦ Display field 2: the accelerator pedal position value should rise
continuously. Target value at full gas: 100.0 %
♦ Display field 3: the middle digit should change to 0. Reading:
000
If the final target value is not reached:
– Press → .

Arosa 1997 ➤

– Adjust the accelerator pedal position sender -G79-
⇒ page 100
If the reading does not change or only changes irregularly:
– Test the accelerator pedal position sender as follows:
– Press → .
sition sender.
– permitted
Measure the resistance of the sender between contacts 1 + 3
of the connector. Target value Accelerator pedal at idling po‐

sition: 0.8 ... 1.4 kΩ

– Test the idle switch -F60- on the accelerator pedal position
sender. To do so, measure the resistance between contacts
4 + 6 of the connector.
Target value
Accelerator pedal at idling position: 0.8 ... 1.2 kΩ
Accelerator pedal depressed: ∞ Ω
– Measure the resistance of the sender between contacts 1 + 3
of the connector.
Target value
Accelerator pedal at idling position: ∞ Ω
Accelerator pedal depressed: 0.8 ... 1.2 kΩ
If target values are not reached:
– Replace the accelerator pedal position sender -G79-
– Consult the fault memory:
⇒ Vehicle diagnosis, testing and information system VAS 5051
If the target values are reached:

sition sender.

Arosa 1997 ➤
earth and to battery positive. Target value: ∞ Ω
– Replace the control unit of the direct diesel injection system -
J248- ⇒ page 157
1.9 Accelerator pedal position sender: ad‐

justing
1.9.1 Only right-hand drive vehicles

Work sequence
Adjust the pulley:
– Install the pulley in the position shown in the illustration.
– Bolt the accelerator pedal position sender with the pulley fitted
to the support.
– Attach the 6-contact connector of the sender.
Precision adjustment of the fitted sender:
– With your hand depress the accelerator pedal all the way.
If the accelerator pedal limit is not reached:
Turn the sender in the connection holes of the support.
– Once adjusted, test the sender with fault reader -V.A.G. 1551-
or vehicle systems checker -V.A.G. 1552- ⇒ page 96 , Accel‐
erator pedal position sender: test.
1.10 Tandem pump: test

♦ Pressure gauge -VAS 5187-

Arosa 1997 ➤
♦ Fault reader -V.A.G. 1551- or vehicle systems checker -V.A.G.

1552- with lead -V.A.G. 1551/3B-
1.10.1 Test conditions

• Coolant temperature, 85 °C minimum
• Pump injectors, OK
• The fuel filter and the fuel lines must not be clogged
• The retaining valve on the fuel supply line must be OK
• The fuel sender must be OK
1.10.2 Work sequences

– Remove the lock bolt -arrow- .

Arosa 1997 ➤
– Attach pressure gauge -VAS 5187- as shown in the illustration.

control unit. When doing so, the engine must be idling. ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051
Reading on the display:
Rapid data transmission HELP
Select function XX


Reading on the display: (1 ... 4 = display fields)

– Read the idling revs displayed in field 1.

– Increase the revs to 1,500 rpm.
– Check the pressure reading on the pressure gauge. Target
value: min. 3.5 bar
If the target value is not reached:
– Replace the tandem pump ⇒ page 102 , Tandem pump: re‐
moving and installing.
Note!
After removing the pressure gauge tighten the lock bolt to a torque
of 25 Nm. Replace the seal.
1.11 Tandem pump:Protected


Arosa 1997 ➤

equipment required
8010-
♦ Vacuum pump -SAT 1390-
♦ Purge tank -SAT 1390/1-
1.11.1 Remove
– Detach the supply line -1- (white mark) and the return line
-2- (blue mark) from the fuel filter.
– Attach hand vacuumpermitted
pump -SAT 1390-bywith
authorised purge
SEAT S.A. SEATtank -SAT
unless S.A does not guarantee or accept any liability with
1390/1- to the return line.respect to the correctness of information in this document. Copyright by SEAT S.A.
– Operate the hand vacuum pump until no fuel come out of the
return line. Check that fuel is not absorbed inside the vacuum
pump.
– Detach the middle connector for the pump injectors.

Arosa 1997 ➤
– Detach the vacuum hose -1- of the power brake from the tan‐
dem pump -4- .
– Detach the supply line -2- (white mark) from the tandem pump
-4- .
– Remove the bolts -arrows- .
– Remove the tandem pump -4- from the cylinderhead.
– Raise the tandem pump -4- slightly, detach the return line -3-
(blue mark) and remove the tandem pump -4- .
1.11.2 Install
Note!
♦ Check that the coupling of the tandem pump seats well on the
camshaft.
♦ Replace the gaskets of the tandem pump.
– Attach the return line -3- (blue mark) to the return connection
of the tandem pump.
– Install the tandem pump and tighten the uppers bolts to a tor‐
que of 20 Nm.
– Tighten the lower bolts to a torque of 10 Nm.
– Attach the supply line -2- (white mark) to the supply connection
and the power brake vacuum hose -1- to the tandem pump
-4- .
– Connect the middle connector of the pump injectors.

Arosa 1997 ➤
– Attach the supply line -1- (white mark) to the fuel filter.
– Attach hand vacuum pump -SAT 1390- with purge tank -SAT
1390/1- to the return line -2- (blue mark) of the fuel filter.
– Operate the vacuum pump until fuel comes out of the return
line. Check that fuel is not absorbed inside the vacuum pump.
– Attach the return line -2- (blue mark) to the fuel filter.
Note!
When the middle connector is detached from the pump injectors,

faults are stored. Thus consult the fault memory and, if necessary,
clear.

Arosa 1997 ➤
21 – Charging
1 Supercharging system with exhaust
gas turbocompressor
1.1 Exhaust gas turbocompressor with at‐

tachments: removing and installing
Observe rules for cleanliness ⇒ page 110
Note!
♦ All hose connections are secured with spring-type clips. When

repairing, only use spring-type clips.
♦ For the removing and installing spring-type clips use pliers -
T20029- .
♦ The supercharging system must be free of leaks.
♦ Renew self-locking nuts.
♦ Fill the turbocompressor with engine oil through the oil supply
pipe connection before fitting the oil supply tube.
♦ After installing the turbocompressor, run the engine and let it
run at idling speed for approximately one minute, without ac‐
celerating immediately. This will guarantee the correct lubri‐
cation of the compressor.
106 Rep. Gr. 21 - Charging

Arosa 1997 ➤
1 - Exhaust manifold
2 - 30 Nm
❑ Replace
❑ Apply -G 000 500- to the
thread and to the sup‐
port surface of the head
3 - Intake manifold
4 - Of the intercooler
5 - Gasket
❑ Replace
❑ Lining (edge) towards
the intake manifold
6 - 25 Nm
7 - Gasket
position
8 - Support
❑ For shield
9 - Washer
10 - Shield
❑ Fit in support
11 - 10 Nm
12 - Lock washer
13 - Pressure unit
❑ For supercharging pres‐
1. Supercharging system with exhaust gas turbocompressor 107

Arosa 1997 ➤
sure control valve

14 - Activating lever
15 - 10 Nm
❑ Fit with -D6-
16 - Support
17 - Comes from the air filter
18 - Hollow bolt, 15 Nm
19 - Seal
20 - Hose
❑ At the supercharging pressure control solenoid
Protected valve
by copyright. -N75-
Copying ⇒ or
for private page 110 purposes,
commercial , exhaust turbocompressor
in part or in whole, is not hose
connections permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
21 - Oil return line
❑ To the engine block
22 - 15 Nm
23 - Gasket
❑ Replace
24 - Exhaust pipe, front
25 - 25 Nm
❑ Replace
26 - Exhaust turbocompressor
❑ For removal, first remove the turbocompressor/air mass meter connection line and intake manifold/in‐
tercooler connection line and the right cover of the articulated half-shaft
❑ Test the supercharging pressure control ⇒ page 113
27 - Connection
28 - Oil feed line
❑ Of the oil filter support ⇒ Item 6 (page 70)
29 - Support

Arosa 1997 ➤
1.2 Intercooler system components: removing and installing
Note!
♦ All the hoses are fixed with clamps.

♦ The supercharging system must be airtight.
♦ For removing and installing the strip clamps use the -T20029- .
1 - Intercooler
2 - Connection hose
3 - 10 Nm
4 - Support
❑ For connection line Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Bolted to the oil sump respect to the correctness of information in this document. Copyright by SEAT S.A.
5 - Connection line
6 - Connection hose
❑ Connection line/turbo‐
compressor
7 - Connection hose
❑ Connection line/intake
hose
8 - Intake manifold tempera‐
ture sender -G72-
9 - 3 Nm
10 - O-ring
❑ Replace if worn

Arosa 1997 ➤
1.3 Supercharging pressure control hose connection diagram
1 - Intake manifold flap switch‐

ing valve -N239-
2 - Exhaust recirculation valve
-N18-
3 - Supercharging pressure
control sol-enoid valve -N75-
❑ Test the supercharging
pressure control
⇒ page 113
4 - Connecting part
5 - Towards the power brake
6 - Retaining valve
7 - Pressure unit
sure control
9 - Intercooler
10 - Intake manifold
11 - Tandem pump
❑ For the fuel supply and
the vacuum
12 - Cylinderhead
13 - Vacuum unit for intake
manifold switching
14 - Exhaust recirculation
valve
❑ Is an integral part of the
intake hole
❑ Can only be replaced along with the intake hole
15 - Air filter
1.4 Cleaning rules

For work on the turbocompressor, carefully follow the following “5
rules” for cleaning:
♦ Carefully clean the connections and the area around them be‐
fore detaching them.
from their wrapping right before carrying out assembly. Do not
install components that have been stored without wrapping
(e.g. in the toolbox, etc.).

Arosa 1997 ➤
♦ As the system is open, avoid the use of compressed air when


Arosa 1997 ➤
2 Supercharging system: test
2.1 Pressure unit for supercharging pres‐

sure control valve: test

• Engine oil temperature, 80 °C minimum.
2.1.2 Test process

– Remove the connector -2- from the supercharging pressure
control solenoid valve -N75- -1- .
– Start the engine and give a throttle burst to maximum revs.

The control rod -2- for the supercharging pressure control
valve should move.
If the control rod does not move:
– Check that lever for the supercharging pressure control valve
-1- works smoothly. If not, replace the turbocompressor.
If the control rod does not move although the lever works smooth‐
ly:
– Replace the pressure unit for the supercharging pressure con‐
trol valve -3- .
2.2 Pressure unit for supercharging pres‐

sure control valve: removing and instal‐
ling
Special tools
permitted and
unless workshop
authorised equipment
by SEAT required

Arosa 1997 ➤
2.2.1 Removal
– Remove the exhaust turbocompressor.
– Unclip the safety -4- .
– Remove the fixing nuts -1- .
– Remove the pressure unit -6- .
2.2.2 Installation
– Install the pressure unit -6- on the turbocompressor and tight‐
en the fixing nuts -1- to a torque of 10 Nm.
– Loosen the counternut -2- of the control rod -3- .
– Move the lever for supercharging pressure control valve -5- to
the stop in direction of the pressure unit and hold it.
– Adjust the length of the control rod -3- so that the hole fits
easily over the pin
Protected on theCopying
by copyright. leverfor-5- (lever
private at stop,
or commercial with play).
– From this position,

respect tothread on the
the correctness controlinrod
of information 8 turns.Copyright
this document. (reducing
by SEAT S.A.
the length)
– Tighten the counternut -2- .
– Attach the control rod over the lever and fit the safety -4- .
– Install the exhaust turbocompressor.
2.3 Supercharging pressure control: testing
2. Supercharging system: test 113

Arosa 1997 ➤

equipment required
♦ Hand vacuum pump -SAT
1390-
V.A.G. 1526 A-
-V.A.G. 1594 A- or -V.A.G.
1594 C-
♦ Test box -V.A.G. 1598/31-
V.A.G. 1551/3B-
♦ Electrical diagram

• No faults stored in the fault memory. ⇒ Vehicle diagnosis,
testing and information system VAS 5051
• There must be no leaks at either the intake or exhaust side.
• Control line to the supercharging pressure control valve not
clogged, loose or leaky.
• No faults in the engine/injection system.
• Engine oil temperature, 80 °C minimum. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.3.2 Test process respect to the correctness of information in this document. Copyright by SEAT S.A.
If test and measurement apparatuses are needed during a road

test, take into account the following:
♦ The test and measurement apparatuses must be installed in
the rear seat and operated by a second mechanic.
If the test and measurement apparatuses are operated from the
front passenger seat, in the event of an accident the person oc‐
cupying that seat could be injured by the airbag.
– The supercharging pressure is measured with fault reader -
V.A.G. 1551- during a road test.

Arosa 1997 ➤
To test the functioning of the supercharging pressure control, it is

first necessary to determine the supercharging pressure without
pressure control.

Arosa 1997 ➤

– Attach the -V.A.G. 1551- ( -V.A.G.1552- ) and, with the corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be idling: ⇒ Ve‐
Select function XX

– Press 0 , 1 and 1 for the “display group number 11”S.A.and press

Q to confirm the entry. respect to the correctness of information in this document. Copyright by SEAT S.A.

900 rpm 1020 mbar 1020 mbar 64 %
– Vehicle in 3rd gear and accelerate to full gas from approx.

1,500 rpm.
– At approx. 3,000 rpm press PRINT on the -V.A.G. 1551- .
Target value in display field 3: 1375...1625 mbar
3090 rpm 1866 mbar 1650 mbar 62 %
If the supercharging pressure is not reached:

– Test the pressure unit for the supercharging pressure control
valve, and replace if necessary.
– Test the vacuum hoses ⇒ page 110 .
– Retest the supercharging pressure.
If the supercharging pressure is still not reached:
– Replace the exhaust turbocompressor.
If the supercharging pressure is exceeded:
– Test the supercharging pressure control solenoid valve -N75-
(continuity of flow: hose of the turbocompressor, valve, and
until the pressure unit, with the connector detached).
– Test the pressure unit for supercharging pressure control
valve and the control rod, and replace if necessary.
– Check that the shaft works smoothly in its housing at the su‐
percharging pressure control valve on the turbocompressor. If
not, replace the turbocompressor.
– If the measured supercharging pressure is OK, retest the su‐
percharging pressure with supercharging pressure control
functioning:
– Connector attached to the supercharging pressure control sol‐
enoid valve -N75- .

Arosa 1997 ➤
Note!
When the connector on the supercharging pressure control sol‐

enoid valve -N75- is detached faults are stored. Thus, consult the
fault memory and clear.

– Attach the -V.A.G. 1551- ( -V.A.G.1552- ) and, with the corre‐
Select function XX

and press Q tobyconfirm
Protected the entry.
copyright. Copying for private or commercial purposes, in part or in whole, is not

– Press 0 , 1 and 1 for the “display group number 11” and press

840 rpm 938 mbar 978 mbar 92 %
– Vehicle in 3rd gear and accelerate to full gas from approx.

1,500/min.
– At approx. 3,000 rpm press PRINT on the -V.A.G. 1551- .
Target value on the -V.A.G. 1551- : 1800...2200 mbar (in display
field 3).
3090 rpm 1866 mbar 1917 mbar 62 %

– Test the supercharging pressure control solenoid valve -N75-
⇒ page 117 .
2.3.3 Test the supercharging pressure control

solenoid valve -N75-

Arosa 1997 ➤

– Measure the resistance between the valve contacts. Target
value: 25...45 Ω
– Replace the supercharging pressure control solenoid valve -
N75- .
If the target value is reached:
– Switch on the ignition.
– Test the voltage supply of the valve at the contact -1- of the
connector and earth engine. Target value: approx. battery
voltage

Contact 1 + female contacts 1 and 2
earth and to battery positive.
Target value: ∞ Ω
J248- ⇒ page 157

Arosa 1997 ➤
23 – Mixture preparation, Injection

1 Direct diesel injection system: repair‐
ing
The direct diesel injection system control unit has a fault memory.
Before repairing or adjusting, and for the fault finding, consult the
fault memory and carry out the final control diagnosis ⇒ Vehicle
diagnosis, testing and information system VAS 5051 .
Note!
♦ When carrying out test and adjustment work, the control unit
can detect and store faults.
♦ Therefore, once all test and adjustment is finished, clear the
fault memory ⇒ Vehicle diagnosis, testing and information
system VAS 5051 .
1.1 Safety measures

If testing and measurement apparatusesby SEAT are to beS.Aused during aor accept any liability with
permitted unless authorised S.A. SEAT does not guarantee
road test, the followingrespect
must becorrectness
to the taken into account:
♦ Always install test and measurement equipment in the rear

seat to be operated from there by a second mechanic.
If test or measurement equipment is operated from the front pas‐
senger seat, the operator could be injured by the airbag in the
event of an accident.
Caution
The fault reader must be installed in the rear seat and operated
from there.
In order to avoid injury to persons and/or the damage to the pre-

heating and injection system the following rules must be ob‐
served:
♦ Detach and connect the wires of the pre-heating and injection
system, including the leads of the measurement equipment,
only with the ignition off.
♦ If the engine must be turned over at start-up revs without start‐
ing it, for example: to test the compression, remove the injec‐
tor-pump unit connector from the cylinder head.
♦ In the case of a radio with anti-theft coding, consult the code
before disconnecting the battery.
♦ The battery may only be disconnected or connected with the
ignition off; otherwise, the direct diesel injection system control
unit may be damaged.
1.2 Cleaning rules

For work on the fuel supply/injection system, the following “Clean‐
ing rules” must be rigorously observed:
♦ Thoroughly clean the connections and surrounding area be‐
fore loosening them.
♦ Place the parts removed on a clean surface and cover them.
1. Direct diesel injection system: repairing 119

Arosa 1997 ➤
♦ If repairs are not done immediately, the open components

must be covered and stored with great care.
from their packaging just before assembly. Do not install com‐
ponents that have been stored without packaging (e.g. in the
toolbox, etc.).
♦ When the system is open: If possible, avoid using compressed
air. If possible, do not move the vehicle.
♦ Avoid spilling diesel fuel on the coolant hoses. If necessary,
clean the hoses immediately. The affected hoses must be re‐
placed.
1.3 Location of components

The components from A to D do not appear in the exploded view.
A - Brake pedal switch -F47-

♦ In foot rest area, brake ped‐
al
B - Brake light switch -F-
♦ In foot rest area, brake ped‐
al
C - Accelerator pedal position
sender -G79-
♦ In foot rest area, accelera‐
tor pedal ⇒ page 87
D - Clutch pedal switch -F36-
♦ In foot rest area, clutch ped‐
al
1 - Fuel filter
2 - Air mass meter -G70- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Mechanical exhaust recir‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
culation valve
❑ With intake manifold
flap
4 - Direct diesel injection sys‐
tem control unit -J248-
❑ With altimetric sender -
120 Rep. Gr. 23 - Mixture preparation, Injection

Arosa 1997 ➤
F96-
5 - Intake manifold flap switch-over valve -N239-
6 - Exhaust recirculation valve -N18-
7 - Turbocharging pressure limitation solenoid valve -N75-
9 - Fuel temperature sender -G81-
10 - Connector
❑ For injector-pump unit -N240- ...243)
11 - Engine revs sender -G28-
12 - Connector
❑ For Hall sender -G40- , for camshaft position
13 - Connector
❑ For engine revs sender -G28-
❑ For camshaft position
15 - Intake manifold pressure sender -G71- with temperature sender at the intake manifold -G72-
1.4 Intake manifold flap: repairing

The intake manifold flap closes for roughly 3 seconds during the
engine cut-out cycle and then opens again. In this way engine

Arosa 1997 ➤
run-on is avoided. Test the switching of the intake manifold flap

⇒ page 126
1 - Intake manifold
2 - O-ring
❑ Replace
4 - Air intake hole
❑ With exhaust recircula‐
tion valve and intake
manifold flap
5 - 10 Nm
6 - From the intercooler
7 - Gasket
❑ Replace
8 - Connecting line
❑ To the intake manifold
9 - 25 Nm
10 - 10 Nm
11 - Support
12 - Vacuum activator
13 - Intake manifold flap
switch-over valve
14 - Vacuum supply
❑ From the vacuum pump

Arosa 1997 ➤
1.5 Injector-pump unit: repairing
1 - 20 Nm and retighten 1/4

turn (90°)
2 - Rocker shaft
❑ With rockers
⇒ page 125 , Injector-
pump unit: disassembly
and assembly
3 - Lock nut
4 - Adjustment bolt
❑ Replace in case of in‐
stalling a new injector-
pump unit, or if worn
contact surface with the
round-headed pin of the
injectorpump unit
5 - Injector-pump unit
❑ Check the round-head‐
ed pin for wear; replace respect to the correctness of information in this document. Copyright by SEAT S.A.
it if necessary
contact surface with the
adjustment bolt
⇒ page 125
6 - O-ring
7 - O-ring
8 - O-ring
9 - Heat shield seal
❑ Replace
10 - Safety washer
11 - Cylinder head
12 - Fixing block
13 - 12 Nm + 3/4 turn (270°)
❑ Replace
1.6 O-rings for injector-pump unit: disas‐

sembly and assembly

Arosa 1997 ➤
♦ Assembly sleeves -T10056-
1.6.1 Remove
– Remove used O-rings from the injector-pump unit very care‐
fully.
– Make sure not to create any burrs in the O-ring seats.
1.6.2 Assembly
Note!
♦ Always use the sleeves for fitting the O-rings. If they are not
used, the Orings may be damaged.
♦ Make sure that the O-rings are seated in the injector-pump unit
without twisting.
– Remove the heat shield seal along with the safety washer.
– Carefully clean the O-rings support surfaces in the injector-
pump unit.
– Fit assembly sleeve -T10056/1- all the way over the injector-
pump unit.
– Carefully slide the upper O-ring over the assembly sleeve and
into its seating on the injector-pump unit.
– Remove the assembly sleeve. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fit assembly sleeve -T10056/2- all the way over the injector-
pump unit.
– Carefully slide the middle O-ring over the assembly sleeve and
– Remove the assembly sleeve.

Arosa 1997 ➤
– Fit the assembly sleeve -T10056/3- all way over the injector-
pump unit.
– Carefully slide the lower O-ring over the assembly sleeve and
– Remove the assembly sleeve.
– Fit a new heat shield sleeve along with the safety washer.
1.6.3 Installation
The already established work is carried out as follows:
Note!
Progressive introduction of O-rings without colour code. They

must be fitted in the correct order, following the grooves: the
thickness of the rings decreases the nearer they are to the injec‐
tor.
1.7 Pump-injector set: removing and installing

Arosa 1997 ➤

equipment required
♦ Universal dial gauge brack‐
et -T20020-
♦ Set of spanners -U-40020-
♦ Torque spanner -SAT
8010-
♦ Straight edge positioner for
injector - pump -T20110A-
Note!
Due to the extension of the service intervals, the adjusting screws

have been modified -1- as well as the round head pin -2- of the
pumpinjector. In older engines that do not have these extended
service intervals, a mixed assembly is permitted in pre-modified
versions.
Note!
Progressive introduction of pump-injector units with modified sol‐
enoid valve nut. Mixed assembly of both nuts is permitted.

Arosa 1997 ➤
1.7.1 Pump-injector set with pre solenoid

valve nut
– Pump-injector set with pre solenoid nut
Place the pump-injector independently of the solenoid valve nut
model so that it is perpendicular to the camshaft seatings, to do
this continue as follows:
– To install the pump-injector including both models of the sol‐
enoid valve nut , place rule -T20110- so that the corresponding
centering projection can go no further into the cylinder head
(see figure).
– Fit centraliser -T20110A/3- by the widest end and move the

pump-injector until the cylindrical part of the injector nut can
go no further into the centraliser.
1.7.2 Pump-injector unit with new solenoid

valve nut
– Pump-injector unit with new solenoid valve nut
Place the pump-injector independently of the solenoid valve nut
model so that it is perpendicular to the camshaft seatings, to do
this continue as follows:
– To install the pump-injector including both models of the sol‐
enoid valve nut , place rule -T20110- so that the corresponding
centering projection can go no further into the cylinder head
(see figure).
– Fit centraliser -T20110A/3- by the thinnest end and move the

pump-injector until the cylindrical part of the injector nut can
go no further into the centraliser.

Arosa 1997 ➤
1.7.3 Continue for both models of pump-injec‐

tor unit
– If necessary, re-adjust the pump-injector and tighten the fixing
screw as follows: 12 Nm and 270° (3/4 turn) (the tightening
process can be carried out in various stages)
– Fit the rocker arm shaft and tighten the fixing screws as fol‐
lows.
– Uniformally tighten the internal, then the external screws, by
hand. Next, and in the same order, tighten to 20 Nm and ¼
turn (90°).
1.7.4 Remove
– Remove the upper toothed belt shield and the cylinder head
cover.
– Turn the crankshaft over until the pair of injector-pump unit
cams to be removed and fitted points uniformly upwards.
– Loosen the lock nuts on the adjustment bolts -1- and unscrew
the adjustment bolts until the respective rocker rests on the
push spring of the injector-pump unit.
– With corresponding box spanner from spanner set -U-40020- ,
loosen the bolts -2- that hold the rocker shaft, beginning with
the outer ones and working inwards, and remove the rocker
shaft.
– With corresponding box spanner from spanner set -U-40020- ,
loosen the bolt -3- holding the fixing block, and remove the
block.
– Lever out the injector-pump unit connector with a screwdriver.
To avoid bending it, support the opposite side of the connector
with your finger.
– Check that each cylinder has its corresponding injector-pump
unit.
– Instead of the fixing block, fit extractor -T10055- into the side
slot of the injector-pump unit.
– Carefully remove the injector-pump unit from its seating in the
cylinder head (upwards) with soft taps.

Arosa 1997 ➤
1.7.5 Assembly
Note!
♦ If fitting a new injector-pump unit, the corresponding adjust‐

ment bolt on the rocker must also be replaced.
♦ Any time work requiring adjustment of the injector-pump unit
is carried out, clean the adjustment bolt on the rocker and the
round-headed pin on the injector-pump unit, also checking for
wear. If worn, the round-headed pin and the adjustment bolt
must be replaced.
♦ Apply -G 000 100- to the contact surfaces between the round-
headed pin and the adjustment bolt.
♦ New injector-pump units are supplied with their own O-rings
and heat shield seal.
– If the used injector-pump unit is refitted, replace the O-rings

and the heat shield seal ⇒ page 123 .
– Before assembly of the injector-pump unit, check the three
seals, the heat shield seal and the safety washer for correct
seating.
Note!
The seals must not be bent.

– Oil the seals and fit the injector-pump unit very
respect to the correctness carefully
of information in document.
in this its Copyright by SEAT S.A.
seating in the cylinder head.
– Pressing uniformly, seat the injector-pump unit all the way on
to the cylinder head.
– Fit the fixing block in the side slot of the injector-pump unit.
Note!
If the injector-pump unit is not perpendicular to the fixing block,

the fixing bolt may come loose, and this could result in damage
to the injector-pump unit or the cylinder head.
– Therefore, the injector-pump unit must be fitted as follows.

– Screw the new bolt into the fixing block until the injector-pump
unit can still be turned slightly.
– Fit a dial gauge over the injector-pump unit cam as shown in
the illustration.
– Turn the crankshaft in direct of engine turn-over until the rocker
roller is at the point of the activator cam. Side of the roller
-arrow A- is at the highest point. Dial gauge -arrow B- is at the
lowest point.
– Remove the dial gauge.
– Screw the adjustment bolt into the rocker until you feel clear
resistance (injector-pump component is at stop).

Arosa 1997 ➤
– Unscrew the adjustment bolt. 225° from the stop.

– Hold the adjustment bolt in this position and tighten the lock
nut to a torque of 30 Nm.
– Attach the connector of the injector-pump unit and fit the cyl‐
inder head cover and the toothed belt shield.

Arosa 1997 ➤
2 Components and functions: testing
2.1 Voltage supply of the direct diesel injec‐

tion system: testing
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

• Battery voltage, OK (at least 11.5 V).
2.1.2 Test process

– Attach the test box -V.A.G. 1598/31- to the wiring harness and
to the control unit.
– Measure the voltage between the followings female contacts:
1/2 and 4/5 37 and 4/5 Target value: approx. 0 V
– Measure the voltage between the female contacts again: 1/2
and 4/5 37 and 4/5 Target value: approx. battery voltage
If the target values are not reached:
– Test the voltage supply relay terminal 30 -J317- .
– Test the wiring for open circuits, short circuits and pitch resis‐
tances at the contact points, following the wiring diagram.
If no faults are found in the wiring or in the relay:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126
2.2 Engine revs sender: testing

The engine revs sender depends on revolutions and the reference

mark. The engine cuts out in the event of a fault in the sender.
♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram
2.2.1 Test process

2. Components and functions: testing 131

Arosa 1997 ➤
– Detach the grey connector from the engine revs sender -1- .
– Attach the hand-held multimeter -V.A.G. 1526- (measurement

of resistance) at contacts 1 and 2 of the engine revs sender
connector, using the test lead of the -V.A.G. 1594 A- or -V.A.G.
1594 C- . Target value: approx. 450...550 Ω
– Replace the engine revs sender -G28- . ⇒ page 8

– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the control unit.
the triple connector, following the wiring diagram. Contact 1 +
female contact 110 Contact 2 + female contact 102 Contact 3
+ female contact 102 Wiring resistance: 1.5 Ω max.
– Test for short circuit in the wiring of the triple connector, fol‐
lowing the wiring diagram. Target value: ∞ Ω
⇒ page 126 .
2.3 Intake manifold pressure sender and al‐

timetric sender: testing
The altimetric sender is housed in the direct diesel injection sys‐
tem control unit. The intake manifold pressure sender is a sepa‐
rate component. This sender and the intake manifold temperature
sender are found together in a housing at the intake manifold.

Arosa 1997 ➤
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.

1552- with lead -V.A.G. 1551/3B-
♦ Turbocompressor tester -V.A.G. 1397 A-
♦ Test box -V.A.G. 1598/31-

1715-
C-
♦ Wiring diagram
2.3.1 Test process

control unit. When doing so, the ignition must be on. (Fault
reader: connecting and selecting the engine electronics con‐
trol unit ⇒ Vehicle diagnosis, testing and information system
VAS 5051 .)
Select function XX

and confirm the entry with the Q button.
– Press 0 , 1 and 0 for “Display group number 10” and confirm

the entry with the Q button.
0 mg/stroke 1027 mbar 1013 mbar 0.0 %
– Test the values shown in fields 2 (altimetric sender -F96- ) and

3 ( intake manifold pressure sender -G71- ) and in the turbo‐
compressor tester -V.A.G. 1397/A- Target value: the pres‐
sures must coincide (tolerance of ± 30 mbar)
Note!
The turbocompressor tester is needed for obtaining an independ‐

ent comparative value. The turbocompressor tester must be set
to measurement range I (absolute pressure). In its place a bar‐
ometer may also be used.
The value displayed in field 2 differs: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm

Arosa 1997 ➤

⇒ page 126 .
If the value displayed in field 3 differs:
– Press → .
– Start the engine and select again the function 08 “Read meas‐
ured value block” .
– Detach the connector from the intake manifold pressure send‐
er ⇒ page 120
– Check the value in display field 3 (intake manifold pressure
sender).
515 mg/stroke1,009 mbar 1,009 mbar 0.0 %
– It should descend continually and then adopt the value of the

altimetric sender (display field 2).
– Replace the intake manifold pressure sender with the temper‐
ature sender on the intake manifold.
– Press → .
the control unit.
the connector, following the wiring diagram. Contact 3 + fe‐
male contact 31 Contact 4 + female contact 71 Wiring resist‐
ance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
⇒ page 126 .

Arosa 1997 ➤
2.4 Coolant temperature sender: testing

1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram
2.4.1 Test process

– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)
Select function XX

– Press 0 , 0 and 7 for the “Display group number 7” and con‐

firm the entry with the Q button.
Reading on the display: Read measured value block 7 →
15.4 °C 0% 15.9 °C 16.7 °C
– Watch the coolant temperature value in display field 4. The

value should rise uniformly without interruption.
– In the event of a fault, as supplementary values either the fuel
temperature or the value of -5.4 °C is displayed.
– If no realistic reading is displayed in field 4 or if the fuel tem‐
perature or -5.4 °C is displayed as a supplementary value, test
the coolant temperature sender and the wiring to the sender,
as follows:
– Press → .
– Remove the connector from the sender Location of compo‐
nents, ⇒ page 120

Arosa 1997 ➤
– Measure the resistance between contacts 1 + 3 on the sender.
Target value: see diagram

Zone A indicates the resistance values for the temperature range
0...50 °C, and zone B the values for the temperature range
50...100 °C.
Examples:
♦ 30 °C corresponds to a resistance of 1,500...2,000 Ω
♦ 80 °C corresponds to a resistance of 275...375 Ω
– Replace the coolant temperature sender -G62- .
– Attach the test box -V.A.G. 1598/31- to the wiring harness
respect to theof
correctness of information in this document. Copyright by SEAT S.A.
the control unit.
the 4-contact connector, following the wiring diagram. Contact
3 + female contact 112 Contact 4 + female contact 104 Wiring
resistance: 1.5 Ω max.
⇒ page 126 .
2.5 Brake light and brake pedal switches:

testing
As the injection system works with a accelerator pedal sender
(potentiometer), which can be faulty, for safety reasons, engine
supply is cut off when the brakes are applied. For this reason, the
control unit needs both the signal from the brake light switch and
the signal from the brake pedal switch. This means that if the

Arosa 1997 ➤
brakes are applied while depressing the accelerator, the engine

supply is immediately cut to idling revs. If the switches are mal‐
adjusted involuntary supply cuts may occur.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram
2.5.1 Test process

– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, via the corre‐
VAS 5051 .)
Select function XX


0 km/h 0 0 0 0.0 % 255
– Watch the value displayed in field 2. Target value: 0 0 0

– Slowly apply the brakes.
Target value: 0 1 1 The two digits should change simultaneously Read measured value block 6 →
from 0 to 1. 0 km/h 0 1 1 0.0 % 255
♦ middle value = brake pedal switch

♦ right-hand value = brake light switch
– Slowly release pressure on brake pedal.
Both digits should change back from 1 to 0. Read measured value block 6 →
0 km/h 0 0 0 0.0 % 255
If one or both digits do not change:

– Test the switches or the wiring to the switches: ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
2.6 Clutch pedal switch: testing

The clutch
Protected pedalCopying
by copyright. switch for informs the control
private or commercial unit
purposes, of or
in part the clutch
in whole, is notsit‐
uation.unless
permitted When the by
authorised clutch is depressed
SEAT S.A. SEAT S.A does not injection flow
guarantee or isany
accept briefly
liability with
reduced.
respect This avoids rough
to the correctness engine
of information performance.

1552- with lead -V.A.G. 1551/3B-

Arosa 1997 ➤
♦ Test box -V.A.G. 1598/31-

1715-
C-
♦ Wiring diagram
2.6.1 Test process

VAS 5051 .)
Select function XX
– Press 0 and 8 Protected

for thebyfunction “Readformeasured
copyright. Copying valuepurposes,
private or commercial block”in part or in whole, is not
and confirm the entryunless
permitted the Q bybutton.
withauthorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with

0 km/h 0 0 0 0.0 % 255
– Watch the value displayed in field 2. Target value: 0 0 0

0 km/h 1 0 0 0.0 % 255
– Depress the clutch pedal. The left-hand digit should change to

1. Target value: 1 0 0
– Press → .
confirm the entry with the Q button.
– Remove the clutch pedal switch connector Location of com‐
ponents, ⇒ page 120 .
– Measure the resistance at the switch contacts. Target value
Clutch without depressing: 10 Ω max. Clutch depressed: ∞ Ω
– Replace the clutch pedal switch -F36- .

Arosa 1997 ➤

the control unit.
male contact 1 Contact 1 + female contact 2 Contact 2 +
female contact 66 Wiring resistance: 1.5 Ω max.
⇒ page 126 .
2.7 Intake manifold temperature sender:

testing
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram
2.7.1 Test process

Select function XX


15.4 °C 0 % 15.9 °C 16,7 °C

Arosa 1997 ➤
– If no realistic reading or a supplementary temperature of 135.9

°C is shown in field 3, test the intake manifold temperature
sender and the wiring to the sender, as follows:
– Press → .
– Remove the connector from the sender Location of compo‐
nents, ⇒ page 120
– Measure the resistance between sender contacts 1 + 2.

50...100 °C.
Examples:
– Replace the intake manifold temperature sender -G72- .

the control unit.

Arosa 1997 ➤
male contact 52 Contact 2 + female contact 73 Wiring resist‐
ance: 1.5 Ω max.
⇒ page 126 .
2.8 Temperature sender fuel: testing

♦ Fault reader -V.A.G. 1551- or vehicle systems tester
respect -V.A.G. of information in this document. Copyright by SEAT S.A.
to the correctness
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram
2.8.1 Test process

Select function XX


15.4 °C 15.9 °C 16,7 °C
– If no realistic reading or a supplementary temperature of -5.4

°C is displayed in field 1, test the fuel temperature sender and
the wiring to the sender, as follows:
– Press → .
– Remove the connector from the fuel temperature sender Lo‐
cation of components, ⇒ page 120
– Measure the resistance between sender contacts 1 + 2.

Arosa 1997 ➤

65...100 °C.
Examples:
♦ 30 °C corresponds to a resistance of 3,790...4,270 Ω
– Replace the fuel temperature sender.

the control unit.
male contact 103 Contact 2 + female contact 111 Wiring
⇒ page 126 .
2.9 Air mass meter: testing

The control unit needs the signal from the air mass meter to cal‐
culate the admissible injection flow and to regulate exhaust recir‐
culation. The lower the signal from the air mass meter, the lower
the quantity of fuel injected.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram
2.9.1 Test process


Arosa 1997 ➤
Caution
from there.

Select function XX


209 mg/stroke 1027 mbar 1011 mbar 0.0 %
– Watch the reading in field 1.

Target value: 200...320 mg/stroke
– Test the exhaust recirculation: ⇒ page 160
– Accelerate the vehicle to full gas from approx. 1,500/min
– At approx. 3,000/min press PRINT on the -V.A.G. 1551- . The
accelerator pedal should be floored at this point.
830 mg/stroke 1027 mbar 1850 mbar 100 %
– Target value in display field 4: 100 % (accelerator position).

– Repeat the test and accelerate the vehicle to full gas.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is830
not mg/stroke 1027 mbar 1850 mbar 100 %
– Target value in display field 1 (intake air mass): over 700 mg/
stroke.
– Replace the air mass meter.
If a constant value of 539 mg/stroke (fixed supplementary value)
is shown in display field 1:
– Press → .
– Detach the air mass meter connector Location of components,
⇒ page 120

Arosa 1997 ➤
– Measure the voltage supply of the air mass meter between the
following connector contacts:
Connector in - Target value
G70- Contact
2 + earth approx. battery
voltage
2+3 approx. battery
voltage
4 + earth approx. 5 V
4+3 approx. 5 V

the control unit.
male contacts 1 and 2 Contact 3 + female contact 49 Contact
4 + female contact 30 Contact 5 + female contact 68 Wiring
⇒ page 126 .
2.10 Intake manifold flap switch-over: testing

♦ Manual vacuum pump -SAT 1390-
♦ Test box -V.A.G. 1598/31-

Arosa 1997 ➤

1715-
C-
♦ Wiring diagram
2.10.1 Test the functioning

– Start the engine and run it at idling revs.
– Watch the control lever on the intake manifold flap (a second
person is needed).
– The intake manifold flap should close when the ignition is
switched off and open again after roughly 3 seconds.
If switch-over does not occur, check the following:
– Check that the intake manifold flap switch-over mechanism
works smoothly, operating the linkage by hand.
– Test the functioning of the vacuum activator with manual vac‐
uum pump -SAT 1390- .
– Test that the vacuum lines are correctly connected.
If no fault is found in the components mechanics:
– Test the intake manifold flap switch-over valve.
2.10.2 Test process

– Remove the connector from the intake manifold flap switch-
over valve -N239- Location of components, ⇒ page 120
– Measure the resistance between the contacts of the switch-
over valve: Target value: 25...45 Ω
– Replace the intake manifold flap switch-over valve.
– Change the multimeter to voltage measurement and connect

it at contacts 1 + 2 of the detached connector of the intake
manifold flap switch-over valve.
– Start the engine and run it at idling revs. Target value: battery
voltage
– After roughly three seconds the voltage value should fall to 0
V.
If the voltage value does not vary as described:

Arosa 1997 ➤

the control unit.
male contacts 1 and 2 Contact 2 + female contact 81 Wiring
⇒ page 126 .
2.11 Injector-pump unit valves: testing

Special tools and workshop equipment requiredProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1552- with lead -V.A.G. 1551/3B-

♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram
2.11.1 Test process

Note!
If the engine will not start, test the resistances of the injector-pump
valves ⇒ page 126 .

Select function XX


Arosa 1997 ➤

Reading on the display: Read measured value block 18
0 0 0
– “0” (regulation OK) should appear in the 3 display fields.

If another number appears instead of 0:
– Press → .
– Test the resistances of the injector-pump valves ⇒ page 126 .
2.11.2 Test the resistances of the injector-

pump valves
– Detach the connector from the injector-pump
Protected unitforatprivate
by copyright. Copying the cylin‐
der head side Location of components, ⇒ page 120
– Test the resistance of the injector-pump valves between the

connector contacts cyl. 1: contact 6 + 3 cyl. 2: contact 6 +5 cyl.
3: contact 6 + 2 Target value: approx. 0.5 Ω
– Also test the wiring for short circuits between wires or vehicle
earth. Target value: ∞ Ω
– Following the wiring diagram, test the wiring to the control unit
⇒ page 146 .
– Remove the upper toothed belt shield and the cylinder head
cover.
– Lever the connectors out from the 3 injector-pump units with
a screwdriver. To avoid bending, support the opposite side of
the connector with your finger.
– Test the resistance of the injector-pump valves between the
injector-pump valve contacts Target value: approx. 0.5 Ω
– Replace the faulty injector-pump unit ⇒ page 125
– Test for open circuits in the wiring from the injector-pump unit
connector to the 3 connectors (contact 2). cyl. 1: contact 2
(grey) + contact 3 cyl. 2: contact 2 (red) + contact 5 cyl. 3:
contact 2 (yellow) + contact 2 Wiring resistance: 1.5 Ω max.
– Test for open circuits in the wiring from the injector-pump unit
connector to the 3 connectors (contact 1). Contact 1 (brown)
+ contact 6 Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires. Target
value: ∞ Ω

Arosa 1997 ➤
2.11.3 Test the wiring to the control unit

the control unit.
– Following the wiring diagram, test the wiring between the test
box and the connector for open circuits. Contact 6 + female
contact 114 Contact 3 + female contact 116 Contact 5 + female
contact 118 Contact 2 + female contact 121 Wiring resistance:
1.5 Ω max.
– Also, test the wiring for short circuits between wires, to vehicle
earth and to positive battery.
ProtectedTarget value:
by copyright. ∞ for
Copying Ωprivate or commercial purposes, in part or in whole, is not

⇒ page 126 .
2.12 Hall camshaft position sender: testing

♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram

• Fuses 23 and 37, OK
2.12.2 Test process

– Remove the 3-contact connector from the Hall sender Loca‐
tion of components, ⇒ page 120
– Set the multimeter for voltage measurement and connect it to
contacts 1 (positive) and 3 (earth) of the Hall sender connec‐
tor, using the auxiliary leads of the -V.A.G. 1594 A- or -V.A.G.
1594 C- .
– Switch on the ignition. Target value: battery voltage
If there is no voltage:

Arosa 1997 ➤

the control unit.
the triple connector, following the wiring diagram. Contact 1 +
female contacts 1 and 2 Contact 2 + female contact 109 Con‐
tact 3 + female contact 101 Wiring resistance: 1.5 Ω max.
If no fault is found in the wiring and there was voltage between
contacts 1 + 3:
– Replace the Hall sender -G40- ⇒ page 35
If no fault is found in the wiring and there was no voltage between
contacts 1 + 3:
⇒ page 126 .

Arosa 1997 ➤
3 Supplementary signals: testing
3.1 Speed signal: testing

1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
C-
♦ Diode test lamp -V.A.G. 1527-
♦ Wiring diagram

• Speedometer OK, test: ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051
Note!
To test the speed signal, the vehicle must be moving and the help
of another person is required.
Caution
from there.
3.1.2 Test process

Select function XX

– Press 0 , 0 and 6 for “Display group number” and confirm the

entry with the Q button.
– Do a road test, and compare the reading on the display (a
second person is needed) with the reading on the speedom‐
eter.
Target value, display field 1: approx. running speed. Read measured value block 6 →
55 km/h 0 0 0 60.5 % 255
– Press → .

Arosa 1997 ➤
If no speed is indicated:
the control unit.
– To measure the voltage attach the multimeter between female
contacts 4/5 + 20 of the test box.
– Raise the vehicle at the left front.
– Turn the front wheel and watch the voltage reading. Target
value: oscillating between 0 and at least 10 volts
– If the value displayed does not oscillate:
– Test for open circuits or short circuits in the wiring from contact
20 of the engine control unit connector, to the instrument pan‐
el. ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
3.2 Signals from/to air conditioning: testing

1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
C-
♦ Wiring diagram

• Functioning of the air conditioning, OK.
• The fault memory must be cleared of all faults ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051 , Fault
memory: consulting
• The vehicle must be at ambient temperature (over + 15 °C).
• Air conditioning on.
3.2.2 Test air conditioning compressor cut-out

Via the AC ready signal, the engine control unit receives the in‐
formation that the air conditioning compressor will soon be acti‐
vated.
Via another wired connection, the engine control unit can cut out
the air conditioning compressor under various operating condi‐
tions:
♦ Hard acceleration at low speeds
♦ In the emergency programme (emergency running mode)
♦ If the coolant temperature is over +120 °C
♦ During roughly 6s after each start-up respect to the correctness of information in this document. Copyright by SEAT S.A.
3.2.3 Test process

3. Supplementary signals: testing 151

Arosa 1997 ➤

Select function XX
– Press 0 and 3 for the function “Final control diagnosis” .

Reading on the display: Rapid data transmission Q
03 - Final control diagnosis
– Confirm the entry with the Q button.

Reading on the display: Final control component diagnosis →
Exhaust recirculation valve -N18
– Press → .
Reading on the display: Final control component diagnosis →
Air conditioning compressor, ready
Air conditioning compressor cut-out is tested.

The air conditioning compressor should cut out within 5 s (visual
check), and then start up every 5 s and cut out again.
If the air conditioning compressor does not cut out:
– Continue the final control diagnosis to the end.
– Attach the test box -V.A.G. 1598/31- topermitted
the respect
wiring harness of
the control unit.

– Test for open circuits in the wiring between test box female
contact 29 and the air conditioning, following the wiring dia‐
gram. Wiring resistance: 1.5 Ω max. ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
3.2.4 Test the signal from the air conditioning

for the adaptation of engine revs
The signal makes the engine control unit hold idling revs constant,
even when the air conditioning system demands a power supply
of a different magnitude.
3.2.5 Test process

Select function XX


Arosa 1997 ➤


Reading on the display: (1...4 = display fields) Read measured value block 2 →
1 2 3 4
– Watch the value in the field 3. The air conditioning should not
be on.
Target value: 0 X 0 (air conditioning signal) Read measured value block 2 →
1 2 010 4
– Switch on the air conditioning. According to the air conditioning

version, the “AC” must be pressed in the case of a manual
climate system or the “Auto” button in the case of automatic
climate control (Climatronic).
– Select the lowest temperature and the highest blower speed.
The compressor should come on.
– Watch the value in field 3.
Target value: X X 1 (air conditioning signal) Read measured value block 2 →
1 2 111 4
Target value: 1 X X (high idling revs)

Meaning if digits = 1
X X X Engine load
state
1 Air condition‐
ing compres‐
sor, on
1 Idle switch, off
1 Idling revs high
due to activa‐
tion of the air
conditioning
the control unit.
contact 34 and the air conditioning, following the wiring dia‐
gram. Wiring resistance: 1.5 Ω max. ⇒ Current flow diagrams,
3.3 Rev signal: testing

The signal generated by the engine revs sender cannot be ana‐

lysed in its original form, and the engine control unit must adapt
it for posterior applications. The signal is needed for, for example,
the automatic gearbox control unit to calculate when to shift
gears, and the rev counter in the instrument panel.
♦ Test box -V.A.G. 1598/31-

Arosa 1997 ➤

C-
1715-
♦ Wiring diagram
3.3.1 Test process

the control unit.
– Following the wiring diagram, test the wiring from contact 27
of the test box to the instrument panel for open circuits. ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
3.4 Data bus: testing
3.4.1 Functioning
The engine control unit communicates with the ABS control unit
via a data bus CAN.
These control units, designed for data bus, are interconnected by
means of two data bus wires twisted round each other (CAN_High
and CAN_Low) and interchange information (messages). The
lack of information in the data bus is interpreted as a fault by the
engine control unit and by the ABS control unit, interconnected
via the data bus CAN.
In order to function without static problems, the data bus CAN
needs the control units in front of the bus CAN controller to have
a matching resistor of 120 Ω each. These matching resistors are
found at the control units of the engine and of the ABS.
♦ Test box -V.A.G. 1598/21-
♦ Test box -V.A.G. 1598/31-
1715-
C- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Wiring diagram respect to the correctness of information in this document. Copyright by SEAT S.A.

• Consult the fault memory before starting the test. Automatic
test cycle ⇒ Vehicle diagnosis, testing and information system
VAS 5051 .
• A fault has been found in the data bus CAN by means of self-
diagnosis.
• ABS control unit coded to function with data bus.

Arosa 1997 ➤
3.4.3 Test process

system; Rep. Gr. 92 ; Windscreen wipers; Windscreen wipers:
disassembly and assembly
– Free the connectors of the engine control unit and remove
them.
the engine control unit.
– Test the data bus CAN wiring with the matching resistor in‐
corporated in the ABS control unit.
– To do so, measure the resistance between female contacts 6
+ 7 of the test box: Target value: 2.2...2.8 KΩ
If the resistance value is within the tolerance range ⇒ page 154
3.4.4 If the resistance value is outside the tol‐

erance range:
– Free the terminal connector (arrow -1- ) of the ABS control unit
and remove it (arrow -2- ).
Note!
The ABS control unit is located in the hydraulic unit, in the engine
compartment.
– Test the data bus CAN wiring for short circuits between wires:
– To do so, re-measure the resistance between female contacts
6 + 7 of the test box Target value: ∞ Ω
If the target value is not reached (the wiring has a short circuit
between wired):
– Eliminate the wiring fault following the wiring diagram: ⇒ Cur‐
If the target value is reached (theunless
wiring has bynoSEAT
shortS.A. circuit
SEAT S.Abe‐
permitted authorised does not guarantee or accept any liability with
tween wires): respect to the correctness of information in this document. Copyright by SEAT S.A.

Arosa 1997 ➤

ABS control unit.
– Following the wiring diagram, test the data bus CAN wiring
between the female contacts of test box -V.A.G. 1598/21- and
-V.A.G. 1598/31- for open circuits:
-V.A.G. -V.A.G.
1598/21- 1598/31-
female contact female contact
10 female con‐ 6 female con‐
tact 11 tact 7
– Also test the wiring for short circuits to positive, battery and
earth.
– Replace the ABS control unit:
respect⇒ Brake
to the systems;
correctness Rep.in this
of information Gr.document.
45 ; Copyright by SEAT S.A.
Control unit and hydraulic unit: disassembly and assembly
3.4.5 If the resistance is within the tolerance

range:
– Free the terminal connector (arrow -1- ) of the ABS control unit
and remove it (arrow -2- ).
Note!
The ABS control unit is located in the hydraulic unit, in the engine
compartment.
– Test the wiring between the control units of the engine and of
the ABS for short circuits to earth and short circuits to positive.
– Re-attach the connectors in the engine control unit.
ABS control unit.
– Test the matching resistor incorporated in the engine control
unit:
– To do so, measure the resistance between female contacts 10
+ 11 of the test box: Target value: 60...72 Ω
If the resistance value is not within the tolerance range:
– Replace the engine control unit ⇒ page 126

Arosa 1997 ➤
4 Engine control unit: replacing, encod‐

ing and adapting
4.1 Engine control unit: replacing

♦ Fault reader -V.A.G. 1551- with lead -V.A.G. 1551/3B-
4.1.1 Operation sequences

– First, print out the control unit identification and, with it, the
code for the previous control unit, as follows:
– Attach fault reader -V.A.G. 1551- ( -V.A.G. 1552- ) and, via the
corresponding “address code” 01, select the engine electron‐
ics control unit. (Fault reader: connecting and selecting the
engine electronics control unit ⇒ Vehicle diagnosis, testing
and information system VAS 5051 .)
The control unit encoding is shown on the display of fault reader 045906019M 1.4l R3 EDC 0000SG 1043 →
-V.A.G. 1551- , for example: Encode 00002 WSC XXXXX
– Print out the control unit identification pressing Print on the

fault reader.
– Press → .
disassembly
Protected and assembly
– Free the connectors from the
respect to the correctness control inunit
of information and remove
this document. Copyrightthem.
by SEAT S.A.
– Remove the control unit from its support -arrows- .

– Install the new control unit.
– Check the previous code and encode the new control unit
⇒ page 126 .
– Adapt the engine control unit to the electronic immobiliser
⇒ page 126 .
– Finally, consult the fault memory of the new engine control unit
and, if necessary, clear the fault memory ⇒ Vehicle diagnosis,
testing and information system VAS 5051 .
4.2 Engine control unit: encoding

If the code corresponding to the vehicle is not displayed, and after
replacing a control unit, encode the control unit as follows:
1552- with lead -V.A.G. 1551/3B-

4. Engine control unit: replacing, encoding and adapting 157

Arosa 1997 ➤

VAS 5051 .)
– Press → .
Select function XX
– Press 0 and 7 for the function “Encode the control unit” and
Reading on the display: Encode the control unit Q
Enter code XXXXX (0-32000)
– Enter the code corresponding to the vehicle and confirm the

Code Vehicles with

00001 Automatic
gearbox
00002 Manual gear‐
box
00003 Cycle foreseen
in event of col‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
lision and data respect to the correctness of information in this document. Copyright by SEAT S.A.
bus CAN Man‐
ual gearbox
and ABS
00005 Without data
bus CAN
The control unit encoding is shown on the display of fault reader 045906019M 1.4l R3 EDC 0000SG 1043 →
-V.A.G. 1551- , for example: Encode 00002 WSC XXXXX
– Switch off the ignition and switch it on again.
Note!
In switching the ignition off and on again, the encoding entered is

activated. If the ignition is not switched off and on after entering
the valid code, the fault “control unit, Incorrect encoding” cannot
be cleared.
Adapt the engine control unit to the electronic immobiliser

⇒ page 126 .
– Clear the fault memory ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .
4.3 Engine control unit: adapting to the elec‐

tronic immobiliser
1552- with lead -V.A.G. 1551/3B-

• An authorised key is needed

– Attach fault reader -V.A.G. 1551- or systems tester -V.A.G.
1552- using lead -V.A.G. 1551/3B- .

Arosa 1997 ➤
– Operate the fault reader or vehicle systems tester taking into

account the message on the display:
– Press 1 for “Rapid data transmission” .
– Press 2 and 5 for the address code “Immobiliser” and confirm
the entry with the Q button. ⇒ Vehicle diagnosis, testing and
information system VAS 5051
– Press → .
Select function XX
– Press 1 and 0 for function “Adaptation” and confirm the entry

with the Q button.
Reading on the display: Adaptation
Enter channel number XX
– Press 0 twice for “Channel number 0” and confirm the entry

with the Q button.
Reading on the display: Adaptation Q
Clear learning values?

The display reads: Adaptation →
Learning values cleared
– End the adaptation by pressing → .

– Press 0 and 6 for function “End transmission” and confirm the
Note!
When the ignition is switched
permitted on again,
unless authorised theS.A.
by SEAT identification
SEAT S.A does notofguarantee
the or accept any liability with
engine control unit is entered
respect to in
the the immobiliser
correctness control
of information unit. Copyright by SEAT S.A.
in this document.
4. Engine control unit: replacing, encoding and adapting 159

Arosa 1997 ➤
26 – Exhaust system
1 Exhaust system components: remov‐
ing and installing
Note!
♦ Exhaust manifold: removing and installing ⇒ page 106 , Ex‐

haust turbocompressor with accessory parts: removing and
installing.
♦ After doing assembly work on the exhaust system, pay special
attention to avoiding stresses and that there is sufficient clear‐
ance between exhaust pipes and the bodywork. If necessary,
loosen the double and tightening clamps and the silencer and
the exhaust pipe such that it is far enough from the bodywork
and that the mounts are uniformly placed.
♦ Replace the self-locking nuts.
1.1 Exhaust pipe front with catalyst and accessory parts
1 - Of the turbocompressor
2 - Gasket
❑ Replace
3 - 25 Nm
4 - Fixing ring
❑ Replace if worn
5 - Front exhaust pipe with cat‐
alyst
6 - Towards the presilencer
160 Rep. Gr. 26 - Exhaust system

Arosa 1997 ➤
1.2 Silencer with holders

alyst
2 - Mark
3 - Double clamp
4 - Dimension -a- = approx. 5
mm
5 - 40 Nm
6 - Middle silencer
7 - Fixing ring
❑ Replace if worn
position ⇒ page 162
8 - Union brace
9 - 15 Nm
10 - Hanger
❑ With fixing ring
❑ Replace if worn
11 - 20 Nm + 1/4 turn (90°)
❑ Replace
12 - Rear silencer
13 - Mark
❑ For double repair clamp,
14 - Cutting point
❑ In the event of repara‐
tion
❑ Marked with three
marks stamped on the
circumference of the ex‐
haust pipe
❑Protected
The by middle
copyright.silencer
Copying forand
privatethe rear silencer
or commercial purposes,come
in part oras a unit.
in whole, is notFor repairs the middle silencer and the rear
silencer
permitted are supplied
unless authorised separately,
by SEAT S.A. SEAT S.A doeswith a double
not guarantee clamp
or accept to hold
any liability with them together.
– Cut the exhaust pipe perpendicularly along the marked area with the -U-40075- .
15 - Double repair clamp

❑ Should fit up to the marks, ⇒ Item 13 (page 161)
1. Exhaust system components: removing and installing 161

Arosa 1997 ➤
Align the exhaust system

• The engine must be cold
– Align the exhaust system bearing in mind the dimension -a-
on the fixing ring, ⇒ Item 7 (page 161) .
The arrow points forward.
Dimension -a- = 5 ± 2 mm
1.3 Exhaust recirculation system

Note!
♦ The exhaust recirculation system is activated by the control

unit of the direct diesel injection system -J248- via the exhaust
recirculation valve -N18- , until the mechanical exhaust recir‐
culation valve.
♦ The mechanical exhaust recirculation valve with conical plung‐
er permits different openings via different valve strokes.
♦ The cadenced activation permits any valve position.
♦ Replace the self-locking nuts.
1.4 Exhaust recirculation system components: removing and installing

Arosa 1997 ➤
1 - Intake manifold
2 - O-ring
❑ Replace
3 - Intake hole
❑ With exhaust recircula‐
tion valve and intake
manifold flap
4 - Mechanical exhaust recir‐
culation valve
intake hole
❑ Can only be replaced
along with the intake
hole
❑ Test the activation ⇒ Ve‐
hicle by
Protected diagnosis, testing
and information system
VAS 5051
5 - 10 Nm
6 - From the intercooler
7 - Gasket
❑ Replace
8 - 25 Nm
10 - Connection line

Arosa 1997 ➤
1.5 Vacuum hose connection diagram
1 - Intake manifold flap switch‐

ing valve -N239-
-N18-
3 - Supercharging pressure
control sol-enoid valve -N75-
❑ Test the supercharging
pressure control
⇒ page 113
4 - Connecting part
5 - Towards the power brake
6 - Retaining valve
7 - Pressure unit
sure control
9 - Intercooler
10 - Intake manifold Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Tandem pump respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ For the fuel supply and

the vacuum
12 - Cylinderhead
13 - Vacuum unit for intake
manifold switching
14 - Mechanical exhaust recir‐
culation valve
intake hole
❑ Can only be replaced along with the intake hole
❑ Test the activation ⇒ Vehicle diagnosis, testing and information system VAS 5051
15 - Air filter
1.6 Mechanical exhaust recirculation valve:

test

Arosa 1997 ➤
♦ Hand vacuum pump -SAT 1390-
1.6.1 Test process

– Remove the soundproofing cover of the engine.
– Remove the connection hose, supercharging air line/intake
line.
– Remove
Protected theCopying
by copyright. vacuum hose
for private from the
or commercial exhaust
purposes, in partrecirculation
or in whole, is not
permittedvalve.
– Attach hand vacuum pump -SAT 1390- to the valve.
– Operate the vacuum pump and check the membrane rod. The
membrane rod should move in the direction of the arrow.
– Remove the vacuum pump hose from the exhaust recircula‐
tion valve.
The membrane rod return to its original position (moving in the
opposite direction of the arrow).
1.7 Exhaust recirculation: testing

Arosa 1997 ➤

equipment required
ter -V.A.G. 1715-
-V.A.G. 1594 A- or -V.A.G.
1594 C-
♦ Test box -V.A.G. 1598/31-
V.A.G. 1551/3B-
♦ Wiring diagrams
1.7.1 Test process

The functioning the exhaust recirculation is tested with function
04 (basic settings). In this procedure, every 10 seconds the ex‐
haust recirculation valve is timed, such that in the measured value
block 003 the extreme values for exhaust recirculation (air mass
meter) can be read, with the reading in field 3.
Select function XX
– Press 0 and 4 for the function “Start basic settings” and press
Reading on the display: Start basic settings



Arosa 1997 ➤
Note!
After selection display group number 3 and confirming with the

Q button, the engine control unit increases the idling revs in dis‐
play field 1 to 1350...1450 rpm.
Reading on the display: (1...4 = Display fields) System in basic settings 3 →

1400 rpm EGR inact 500 mg/H 20 %
The message in field 2 should oscillate every 10 s between EGR

activ. and EGR inact.
The values in display fields 3 and 4 should oscillate within the
following control range:
Note!
♦ If a constant value of 539 mg/H appears in display field 3, test

the air mass meter
♦ ⇒ page 119
EGR inact.
– Target value display field 3 420...600 mg/H (stroke)
– Target value display field 4 20 %
EGR activ.
– Target value display field 3 160...310 mg/H (stroke)
– Target value display field 4 65 %
If target values are not reached:
– Test the mechanical exhaust recirculation valve ⇒ page 164
– Test the vacuum hoses ⇒ page 164
– Test the exhaust recirculation valve -N18- as follows:
– Press → . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Remove the connector from the exhaust recirculation valve.
– Measure the resistance at the valve Target value: 14...20 Ω
– Replace the exhaust recirculation valve -N18- .
Note!
At ambient temperature, the resistance is within the lower toler‐

ance range; with the engine at running temperature, in upper
tolerance range.


Arosa 1997 ➤
– Test the voltage supply of the valve at contact 1 of the con‐

nector and earth engine. Target value: approx. battery voltage

the control unit.
Contact 1 + female contacts 1 and 2
earth and to battery positive.
Targetpermitted
value: ∞ Ωauthorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless
J248- ⇒ page 119

Arosa 1997 ➤
28 – Glow plug system

1 Pre-heating system: testing
♦ Hand-held multimeter -V.A.G. 1526-
♦ Auxiliary measurement set -V.A.G. 1594-
Test conditions
• Battery voltage, 11.5 V minimum
• Ignition off
• Direct diesel injection system control unit -J248- , OK
• Glowplug fuse -S163- , OK
Test process
– Remove the connector from the coolant temperature sender
⇒ page 120 , Location of components
1. Pre-heating system: testing 169

Arosa 1997 ➤
Note!
When the connector is removed from the sender, “engine cold” is

simulated. When the ignition is switched on, the corresponding
pre-heating process is carried out.
– Remove the connectors from the glow plugs.

– To measure the voltage, attach the multimeter between one
glow plug connector and vehicle earth.
– Switch on the ignition. During roughly 20 seconds approx. bat‐
tery voltage should be displayed.
– If there is no voltage: ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
1.1 Glowplugs: testing

♦ Auxiliary measurement set -V.A.G. 1594 A-
♦ Glowplug spanner -U-40082-
♦ Torque spanner -SAT 8010- (5...50 Nm)

♦ Diode test lamp -V.A.G. 1527-

• Ignition off
1.1.2 Test process

– Remove the connectors from the glow plugs.
170 Rep. Gr. 28 - Glow plug system

Arosa 1997 ➤
– Connect the diode lamp wire to l battery positive battery (+)

with auxiliary clamps of the auxiliary measurement set.
– Apply the diode lamp test point to each glow plug successively.
The diode lights up: glow plug OK The diode does not light up:
replace the glow plug
– Remove and install the glow plugs with the tool -U-40082-
1. Pre-heating system: testing 171

Service
Workshop Manual
Arosa 1997 ➤
4 cyl. injection motor (push rods), mechanics
Engine ID AHT
Edition 10.99

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling system
24 - Fuel preparation, injection
26 - Exhaust system
28 - Ignition system

Copyright © 2015 Seat S.A S01AAHT8620

Arosa 1997 ➤
4 cyl. injection motor (push rods), mechanics - Edition 10.99
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Engine: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Fitting: details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Drivetrain supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Vehicles with air conditioner: additional indications and fitting work . . . . . . . . . . . . . . . . . . 8
1 Engine: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Poly-V belt: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Poly-V belt routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Engine block, crankshaft, and flywheel: removing and installing . . . . . . . . . . . . . . . . . . . . 13
3 Crankshaft retainer -pulley side-: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Piston, connecting rod, and casing: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . 18

1 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.1 Cylinder head: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Valve guides: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Valve seats: re-cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Basic adjustment of hydraulic valve play compensation . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Compression: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Valve control unit: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Hydraulic tappets: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Lubrication system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Oil pressure and
permitted unless oil pressure
authorised switch:
by SEAT S.A. SEAT S.A test . .guarantee
does not . . . . . or. accept
. . . .any
. . liability
. . . .with
.................... 40
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Cooling system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Cooling system components, bodywork side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Cooling system components, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Cooling system components, coolant pump side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.4 Coolant liquid: bleed and fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.5 Radiator: removing and install - ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.6 Coolant pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1 Fuel supply system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Fuel tank with accessory parts and fuel filter: removing and installing . . . . . . . . . . . . . . . . 54
1.2 Safety measures for working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.3 Rules for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.4 Fuel supply unit: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.5 Fuel tank: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.6 Fuel pump: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents i
Arosa 1997 ➤
2 Accelerator control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2.1 Accelerator control unit: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Accelerator control cable: adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Components of the activated carbon filter system: removing and installing . . . . . . . . . . . . 68
2.4 Deaeration of fuel tank: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
24 - Fuel preparation, injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1 Injection system: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 General indications relating to injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Injection system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.3 Intake manifold: disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.4 Fuel distributor: disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.5 Air filter: disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.6 Air filter: installing and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.7 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.8 Rules for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2 Testing of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Lambda probe heating: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Throttle control unit: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.3 Coolant temperature pressure transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.4 Intake manifold pressure transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.5 Intake air temperature transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.6 Engine speed transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.7 Injectors: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.8 Fuel and retention pressure regulator: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.9 Intake system: check the airtightness (undue air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.10 Intake air preheating: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.11 Test of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.12 Lambda regulation: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.13 Engine load states: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.14 Dynamic behaviour after a cold start: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.1 Control unit voltage supply: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Engine control unit: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5 Control unit: encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
5.1 Engine control respectunit: adapt toofthe
to the correctness throttle
information in thiscontrol
document.unit . . by. .SEAT
Copyright . . .S.A.
....................... 116
5.2 Engine control unit: adapt to the electronic immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6 Supplementary signals: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.1 Signal to/from the air conditioner: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2 Speed signal: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.3 Engine speed signal: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1 Exhaust system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1 Ignition system: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 General indications relative to the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Ignition system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.5 Ignition coils with final power stage: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.6 Pinking sensor: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
ii Contents
Arosa 1997 ➤
1 Technical data
1.1 Engine number

The engine number (“code letters” and “serial number” ) is en‐
graved on the distribution side of the engine block, next to the
cylinder head.
There is also an adhesive with the “engine code letters” and “se‐
rial number” on the cylinder head cover.
The engine code letters also appear on the vehicle data plate.
1.2 Engine
Protected characteristics
Code letters AHT
Capacity cm³ 997
Valves per cylinder 2
Output kW at 1/rpm 37/5000
Engine torque Nm at 1/rpm 84/3250
Cylinders ∅ mm 72.0
Stroke mm 61.2
Compression 10.0
RON (fuel quality) min. 95 unleaded
Injection Simos 2P
Ignition Simos 2P
Pinking regulation Yes
Self-diagnosis Yes
Lambda control Yes
Catalyst Yes
Exhaust emissions according to Standard D3
Exhaust gas recirculation No
Turbocharged No
1. Technical data 1
Arosa 1997 ➤

1 Engine: removing and installing

equipment required
♦ tray -V.A.G. 1306-
♦ pliers for opening spring-
type clips -T20029-
♦ suspension device -
U-30034-
♦ workshop derrick -V.A.G.
1202 A-
♦ lubricating grease -G 000 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
100- respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ torque wrenches -SAT

8010-
♦ Cable holder
If engine disassembly is required:

Arosa 1997 ➤
♦ engine support -Ar-2204 A-

♦ fastening clamps -T20082-
1.1 Removing: instructions
Note!
In order to carry out these operations, it is necessary to discon‐

nect the earth strap. Because of this, check whether the vehicle
has a coded radio installed, and if so, check the anti-theft coding.
– The engine is removed forwards together with the gearbox.

– With the ignition switched off, disconnect the earth strap from
the battery and remove the battery.
All cable holders that were loosened or cut while removing the
engine, must be installed in the same place as before when in‐
stalling the engine.
– Remove sealing cap -1- and loosen securing nut -2- for engine
cover.
– Remove engine cover and close filler plug drilling with the cap
-3- that is on the lower part of the cover.

Arosa 1997 ➤
– Remove air filter. To do so, loosen the securing screw -1-

(tightening torque 8 Nm).
– Loosen the screws -2- on the top side of the air filter.
Note!
♦ When loosening or tightening the securing screws with an

electric/pneumatic screwdriver, the threads in the intake tube
may be damaged. Therefore, only use an electric/pneumatic
screwdriver under the following conditions:
♦ Maximum screwdriver revoloutions, 200/min
♦ Maximum tightening torque of 3 Nm
– Remove the fuel supply hose by the connection next to the

suspension turret and the return hose by the fuel distributor.
Caution
The fuel supply hose is under pressure. Before opening the

system, place a cloth around the point of connection. Next,
eliminate the pressure by carefully separating the connection.
– Plug the hoses to prevent grime from entering the fuel system.
– Remove all electrical cables from gearbox, alternator and
starter motor, and leave them in the open.
– Remove from the engine the accelerator cable, flexible con‐
nection hoses, coolant hoses, and vacuum and intake hoses.
– Remove the connector from the temperature switch and from
the radiator cooling fan.
– Disconnect all necessary electrical cables from the engine and
leave them in the open.
– Remove the front exhaust pipe from the exhaust manifold
⇒ page 124 , exhaust manifold, front exhaust pipe with cata‐
lyst and accessory parts.
– Remove the the prop shafts from the gearbox and fasten them
to the bodywork.

Arosa 1997 ➤
– Remove the pendular support arm -arrows- .

– Remove the gear shift actuator from the gearbox: ⇒ 5-speed
manual gearbox 002; Rep. Gr. 34 ; Shift control: repair.
– Unhook the clutch control cable: ⇒ 5-speed manual gearbox
002; Rep. Gr. 30 ; Clutch control: repair Clutch cable: remov‐
ing and installing.
Vehicles with air conditioner
– Observe the additional indications and fitting work
⇒ page 8 .
Continued for all vehicles
– Remove the power steering fluid reservoir and place it on its
side.
– Remove the lock support and subsequently fitted elements: ⇒
Bodywork-fitting work; Rep. Gr. 50 ; Bodywork, front Remov‐
ing and fitting the lock support and subsequently fitted ele‐
ments
– Remove the ribbed belt ⇒ page 10 .
– Remove the screws that secure the P.A.S. vane pump and
fasten it to the engine support or to the engine unit carrier; the
flexible hoses remain connected: ⇒ Running Gear; Rep. Gr.
48 ; Fitting synoptic chart: vane pump, filler reservoir, hydraulic
hoses.
– Attach suspension device -U-30034- as shown and lift slightly

using the workshop derrick.
– Loosen the screws that secure the drivetrain to the engine and
gearbox supports (it is only necessary to remove the 2 screws
that secure the supports to the metal-rubber bearings).
– Lower the drivetrain until it is out of the gearbox housing.
– Withdraw the drivetrain by pulling it forward while turning it.
Note!
The drivetrain should be steered very carefully while being with‐

drawn from the vehicle, in order to avoid damage to the bodywork.
– In order to carry out fitting work, the engine should be secured
to the fitting trestle using engine support -Ar-2204A- , together
with clamps -T20082- .
1.2 Fitting: details

Carry out the aforementioned removal operations in reverse or‐
der, taking into account the following:

Arosa 1997 ➤
– Check the wear of the disengagement collar and, if necessary,

renew it.
– Using -G 000 100- , lightly grease the disengagement collar,
the collar guide hose, and the primary shaft spline.
– Check whether the drivetrain centring bushings are aligned,
and if necessary align them.
– While installing the drivetrain, make sure the prop shafts have
freedom of movement.
– Align the engine using shaking movements so that the sup‐
ports rest without being under strain; if necessary, loosen the
engine supports from the bodywork as well
– When fitting the engine supports, special attention must be
paid so that the projections on the metal-rubber bearings sink
into the engine supports -arrows- .
Note!
First insert the drivetrain bolt on the engine side, and then lift the
drivetrain assembly slightly on the gearbox side and insert the
remaining bolt.
– Install the power assisted steering vane pump: ⇒ Running

gear; Rep. Gr. 48 ; fitting synoptic chart: vane pump, filling
reservoir hydraulic hoses.
– Install the air conditioner compressor: ⇒ Heating, air condi‐
tioner; Rep. Gr. 87 ; Compressor support: installing and
removing, engine code letter: AHT
– Install the prop shafts: ⇒ Running gear; Rep. Gr. 40 ; prop
shafts: removing and installing
– Install the lock support along with the subsequently fitted ele‐
ments: ⇒ Bodywork-fitting work; Rep. Gr. 50 ; Bodywork, front
Removing and fitting the lock support and subsequently fitted
elements
– Install the clutch control cable: ⇒ 5-speed manual gearbox
002; Rep. Gr. 30 ; Clutch control: repair Clutch cable: remov‐
ing and installing.
– Install the gearbox shift control: ⇒ 5-speed manual gearbox
002; Rep. Gr. 34 ; Shift control: repair.
– Renew the pointed screw that fastens the shift finger (clean
the threads on the shift finger).
– Install the front exhaust pipe ⇒ page 124 , Exhaust manifold,
front exhaust pipe with catalyst and accessory parts.
– Electrical connections and wiring layout: ⇒ Electrical system;
Rep. Gr. 97
– Re-secure all cables and flexible hoses with cable holders and
clips, paying attention to the coloured markings.
– Load coolant ⇒ page 46 .
– Adjust the accelerator cable ⇒ page 67by .copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– Fit the control unit to the engine's electronics: ⇒ page
respect to the correctness 71
⇒ page 71
– Carry out a road test and check the fault memory: ⇒ Vehicle

Arosa 1997 ➤

Connection to bolts Tightening tor‐
que
M8 20 Nm
M10 45 Nm
Different tightening torques
Front exhaust pipe with catalyst, to 25 Nm
exhaust manifold
1.4 Drivetrain supports
Note!
The bolts cannot be used again.

Drivetrain supports, engine permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
A = 30 Nm + 1/4 turn (90°)
B = 25 Nm + 1/8 turn (45°)
C = 20 Nm + 1/8 turn (45°)
Drivetrain supports, gearbox

A = 30 Nm + 1/4 turn (90°)
B = 20 Nm + 1/8 turn (45°)
C = 40 Nm + 1/4 turn (90°)
Pendular support arm

A = 50 Nm (tighten by nut)
B = 60 Nm 1/4 turn (90°)

Arosa 1997 ➤
1.5 Vehicles with air conditioner: additional

indications and fitting work
Caution
The air conditioner cooling agent circuit must not be opened.
Note!
In order to avoid damage to the condenser and to the cooling

agent hoses, care should be taken not to bend, twist, or exces‐
sively stretch the hoses.
To remove and install

to the the engine withoutin having to open theby cool‐
respect correctness of information this document. Copyright SEAT S.A.
ing agent circuit:
– Remove the screws that secure the air conditioner liquid re‐
serve tank and allow it to hang freely.
– Unscrew the strip clamps on the cooling agent flexible hoses.
– Remove the air conditioner compressor: ⇒ Heating, air con‐
ditioner; Rep. Gr. 87 ; Compressor support: removing and
installing, engine code letters: AHT.
– Remove the lock support and subsequently fitted elements: ⇒
Bodywork-assembly tasks; Rep. Gr. 50 ; Bodywork, front Re‐
moving and installing the lock support and subsequently fitted
elements.
– Place the lock support together with the radiator and condens‐
er to one side in such a way that the cooling agent hoses are
not under strain -arrows- .
– Fasten the compressor to the bodywork in such a way that the
cooling agent hoses are not under strain.

Arosa 1997 ➤
1 Engine: disassembly and assembly
Cylinder head: disassembly and assembly ⇒ page 22
Note!
Clutch repairs: ⇒ 5-speed transmission 002; Rep. Gr. 30 ; Clutch: repair
1 - Cylinder head gasket

❑ Renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Assembly position: The respect to the correctness of information in this document. Copyright by SEAT S.A.
inscription must be read
from above
❑ After replacing it, renew
the all of the coolant
2 - Engine block
❑ Engine block, crank‐
shaft and flywheel: re‐
moval and installation
⇒ page 13
❑ Piston, connecting rod
and casing: disassem‐
bly and assembly
⇒ page 18
3 - Tensioner element
❑ Only on vehicles with
power assisted steering
and/or air conditioner
compressor
4 - Support
❑ For the power assisted
steering vane pump, air
conditioner compressor,
and alternator
5 - Oil filter
❑ Loosen with -U-40078-
or a uninversal extractor
❑ Tighten by hand
❑ Observe the fitting in‐
structions printed on the

Arosa 1997 ➤
filter
6 - 45 Nm
7 - 25 Nm
8 - 10 Nm
9 - Support
❑ For the coolant hose
10 - O-ring
❑ Renew
11 - Oil bleed screw, 30 Nm
12 - Oil sump
❑ Before assembly, clean the watertight surface
❑ Securing bolt tightening order ⇒ page 38 , figure 2
13 - Gasket
❑ Renew
❑ Before fitting, apply -AMW 188 001 02- to the contact zone between the watertight clamp and the engine
block
❑ For Poly-V belt
15 - 25 Nm
❑ Left turning
❑ Cannot be loosened
❑ Fastened with -AMW 185 101 A1-
16 - Guide bolt, 45 Nm
❑ Left turning
❑ For the second idle pulley
❑ On vehicles without power assisted steering or air conditioner compressor, locking bolt without a threaded
bore
Note!
The second idle pulley only on ve‐

hicles with power assisted steering

and air conditioning compressor
17 - Poly-V belt
❑ Before removing it, mark the turning direction
❑ Do not twist
❑ Check the wear
18 - Push rod
❑ Observe the fitting position: cup facing up
1.1 Poly-V belt: removing and installing
1.1.1 Engines with tensioning roller

Working procedure
– Mark the Poly-V belt's turning direction.

Arosa 1997 ➤
– Place a 14 interface wrench on the tensioning roller's flat sur‐

faces -arrow A- .
Note!
A better position for the wrench is obtained by inclining it slightly

towards the oil filter.
– Relieve Poly-V belt tension using the wrench to turn the ten‐
sioning roller in the direction shown -arrow B- .
Note!
♦ Pay special attention while relieving tension so as not to dam‐

age the radiator.
♦ Turn the tensioning roller just enough to be able to remove the
belt Poly-V.
– Remove the Poly-V belt.
1.1.2 Install
Note!
♦ Poly-V belt routing ⇒ Item 12 (page 14) .

♦ Before removing the Poly-V belt, mark its turning direction.
When fitting the belt, make sure it lies on the pulleys.
♦ Check for correct operation of the tenioning and idle rollers,
and that they turn freely.
– Relieve Poly-V belt tension using the wrench to turn the ten‐
sioning roller in the direction shown -arrow B- .
Note!
♦ Pay special attention while relieving tension so as not to dam‐

age the radiator.
♦ Turn the tensioning roller just enough to be able to remove the
belt Poly-V.
– Place the Poly-V belt on allpermitted
the pulleys and finally on the ten‐
sioning roller.
– Remove the fixed spanner and start the engine, check that the
Poly-V belt functions properly.

Arosa 1997 ➤
1.2 Poly-V belt routing

Belt routing with air conditioner compressor.
Belt routing with power assisted steering vane pump.
Belt routing with air conditioner compressor and power assisted

steering vane pump.

Arosa 1997 ➤
2 Engine block, crankshaft, and flywheel: removing and installing
1 - 75 Nm
2 - Caps
❑ Cap 1: pulley side
❑ Cap 2: with holes for
driving washers
3 - Driving washer
❑ For cap 2
❑ Observe fitting
4 - 5 Nm
❑ Fit with -AMV 188 001
02-
5 - Flywheel
❑ Befor removal, mark the
fitting position with the
crankshaft
the flywheel, immobilise
it with special tool -
T20075- and axle -
T20075/1-
❑ When renewing, check
the fitting position
⇒ page 15
6 - 30 Nm + 1/4 turn (90°)
❑ Renew
7 - O-ring
❑ Renew
❑ Remove the sealing
flange and separate the
retainer on the work‐
2. Engine block, crankshaft, and flywheel: removing and installing 13

Arosa 1997 ➤
bench
❑ Before fitting, apply oil
on the sealing lip and the outer edge
❑ Insert in the sealing flange to the limit with -U-40052-
❑ Fit sealing flange with hose -T20097-
8 - Sealing flange
❑ Not supplied as a replacement part
❑ Before fitting, apply -AMV 188 001 02- to it
9 - Engine block
❑ Piston, connecting rod, and casing: removing and installing ⇒ page 18
10 - 8 Nm
11 - Distribution cover
❑ TDC mark ⇒ page 15
12 - Retainer
❑ Renew ⇒ page 16
13 - Pulley
❑ Poly-V belt: removing and installing ⇒ page 10
14 - 100 Nm
15 - 5 Nm
❑ Fit with -D 000 600 A2-
16 - Double chain
❑ Mark the turning direction (fitting position) before removing
17 - 25 Nm
❑ Fit with unless
-D 000 600 byA2-
permitted authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
18 - Drive pinion
❑ For driving oil pump
19 - Camshaft pinion
❑ Camshaft adjustment ⇒ page 34
20 - Gasket
❑ Renew
21 - Half bearings
❑ For engine block with lubrication groove
❑ Do not interchange the used half bearings (mark them)
22 - Crankshaft pinion
❑ Camshaft adjustment ⇒ page 34
23 - Cotter pin
❑ Make sure it lies properly
24 - Crankshaft
❑ ∅ Bed plate bearing journals: 60 mm ∅ Connecting rod bearing journals: 42 mm
❑ Axial play, new: 0.03...0.13 mm Wear limit: 0.26 mm
❑ Measure the radial play with Plastigage New: 0.02...0.07 mm Wear limit: 0.13 mm
❑ Do not turn crankshaft while measuring radial play
25 - Half bearing
❑ For cap without lubrication groove
❑ Do not interchange the used half bearings (mark them)

Arosa 1997 ➤
Flywheel fitting position

• Crankshaft is in TDC for cylinder 1
– Install the flywheel in such a way that the lowered portion -A-
and the ledge -B- are facing the oil sump.
TDC mark
• Crankshaft is in TDC for cylinder 1
– In order to place the crankshaft in TDC, the mark on the pulley
must coincide with the mark on the distribution cover.
2. Engine block, crankshaft, and flywheel: removing and installing 15

Arosa 1997 ➤
3 Crankshaft retainer -pulley side-: renew

equipment required
♦ Exterior extractor -
U-40100-
♦ Pressure part No. 5 from kit
-U-40200-
♦ Guide hose -T10041-
♦ Blocking tool -T10043-
♦ Blocking tool -T20075- and
axle -T20075/1-
♦ Dynamometric spanner -
SAT 8010-
Remove respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove the right front wheel arch protector.
– To block the crankshaft, remove the rpm sender and fit block‐
ing tool -T10043- in its place.
– Turn the crankshaft carefully using the centre bolt, until the
blocking tool becomes lodged in one of the flywheel's lowered
sections.
– Press the blocking tool by hand until it rests firmly on the fly‐
wheel.

Arosa 1997 ➤
Note!
If the engine is removed, use blocking tool -T20075- together with

axle -T20075/1- to block the crankshaft.
– Loosen the centre bolt and remove the pulley from the crank‐
shaft.
– Remove the retainer with the exterior extractor -U-40100- , fit

the pressure piece No. 5 from kit -U-40200- , to prevent dam‐
age to the crankshaft.
Install
• Crankshaft blocked with blocking tool -T10043- or -T20075-
– Lightly oil the sealing retainer's lip.
– Fit the retainer in guide hose -T10041- and fit this ensemble
over the crankshaft journal.
– Press the guide hose-retainer ensemble to the limit. To do this,

use the old crankshaft pulley securing bolt.
– Remove the guide hose -T10041- .
– Install the crankshaft pulley and tighten the center bolt with a
torque of 100 Nm.
– Remove the -T20075- or blocking tool -T10043- . In the case
of the -T10043- , fit the rpm sender back in its place and tighten
with a torque of 10 Nm.
Caution
Do not start the engine while special tool -T10043- is fitted in

the gearbox housing.
3. Crankshaft retainer -pulley side-: renew 17

Arosa 1997 ➤
4 Piston, connecting rod, and casing: removing and installing
1 - Safety cotter pin

2 - Piston pin
❑ If movement is sluggish,
heat the piston to 60 °C
-T20019-
3 - Piston
❑ Mark the fitting position
and correspondence
with respective casing/
cylinder
❑ The arrow on the piston
head indicates the en‐
gine's turning direction
(towards the camshaft
side)
❑ Install with casing to fit
rings
❑ Only install pistons of
the same weight cate‐
gory (+ or - on the piston
head)
❑ Only available as a re‐
placement part together
with the casing
4 - Piston rings
❑ Stagger the cuts by 120°
❑ Remove and install the
compression rings us‐
ing ring pliers
❑ Carefully remove and
install by hand the 3
piece oil scraper rings
❑ The inscription “TOP”

Arosa 1997 ➤
should must indicate the

piston head
❑ Check the play between the ends of the rings ⇒ page 19
❑ Check the coupling play between the rings and the grooves in the piston ⇒ page 20
5 - Connecting rod
❑ Replacement part only available as a complete set (four rods)
❑ Mark correspondence to cylinder ⇒ Item 1 (page 18)
❑ Fitting position: The marks -B- must point towards the distribution
❑ Axial guidance by piston
6 - Connecting rod caps
❑ In the case of fractured or “cracked” connecting rods, the cap can only be fitted in one position and only
on its corresponding connecting rod
7 - Connecting rod bolt, 20 Nm + 1/4 of turn (90°)
❑ Renew
❑ Lubricate the threads and the contact surface
❑ In order to measure radial play, tighten to 20 Nm, without retightening
8 - Engine block
❑ The surfaces where the casings will go must be clean and even
❑ Remove dirt and grime from the surfaces only by cleaning; do not use sandpaper, scraper or the like
9 - Half bearings
❑ Fit the centred half bearings
❑ Do not interchange the used half bearings
❑ Measure pre-tension ⇒ page 20
❑ Measure radial play with Plastigage: New: 0.020...0.061 mm Wear limit: 0.091 mm When measuring
radial play do not turn crankshaft
10 - Washer
❑ Renew
❑ To correct the casing's pre-tension
11 - Casing
❑ Observe the weight category (+ or - on the piston head)
❑ Only available as a replacement part together with the the piston
❑ Measure the pre-tension ⇒ page 21
Check the play between the ends of the piston rings

♦ Gauge
– Fit the ring from above in such a way that it forms a right angle
with the top casing/cylinder opening, and at a distance of ap‐
proximately 15 mm from the edge of the casing/cylinder.
4. Piston, connecting rod, and casing: removing and installing 19

Arosa 1997 ➤

Dimensions in mm
Scraper ring 0.40...1.40 --1)
1) It is not possible to provide an indication regarding the wear limit.
Check the coupling play between the rings and the grooves in the
piston

♦ Gauge
First cleanProtected
the piston ring Copying
by copyright. grooves
Piston ring respect to the correctness of information
New in this document.
Wear limitby SEAT S.A.
Copyright
Dimensions in mm
Scraper ring not measured
Measure the pre-tension of the the half bearings

♦ Gauge
The half bearing's pre-tension is calculated in the following way:
Dimension -a- of half bearing
diameter of the connecting rod -b- = pre-tension
Minimum diemension: 1.5 mm
If pre-tension is not reached:

Arosa 1997 ➤
– Renew the half bearing.

Measure the casing's pre-tension

♦ Setting bar for dial gauge -T20026- support
– Place a wood or plastic wedge over the casing to be checked
and eliminate any projections using a plastic hammer.
– Fit the support setting bar -T20026- so that the point of the
comparison gauge works on the upper edge of the casing
-arrow A- (make a note of the measurement taken), then work
on the upper edge of the engine block -arrow B- .
– The difference between the two values obtained (pre-tension)
must be between 0.07...0.12 mm. respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!
♦ During measurement, the casing must be correctly placed (not

askew) over the engine block's resting surface.
♦ Compensating washers measuring 0.10 mm, 0.12 mm, and
0.14 mm are available for this purpose.
♦ The difference between each casing may be a maximum of
0.4 mm.
4. Piston, connecting rod, and casing: removing and installing 21

Arosa 1997 ➤

1 Cylinder head: removing and instal‐
ling
Check the compression ⇒ page 31
Note!
♦ Removing and installing the intake manifold: ⇒ page 71

♦ Exhaust manifold: removing and installing ⇒ page 124 .
♦ After renewing the cylinder head, the coolant liquid must be
changed.
1 - 3 Nm
2 - Sealing washer
❑ Renew
3 - Cylinder head bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Loosening and tighten‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
ing order ⇒ page 24
4 - Washer
❑ Not on all of the cylinder
head's stud bolts
⇒ page 24
5 - Support
6 - Rockers
⇒ page 35
❑ Basic adjustment of
valve-play hydraulic
compensation
⇒ page 30
❑ Tighten only after hav‐
ing tightened the cylin‐
der head's bolts
8 - Support
❑ For the ignition wiring
strip
❑ Interlock
❑ Tighten only after hav‐
ing tightened the cylin‐

Arosa 1997 ➤
der head's bolts

❑ Fit with -D 000 600 A2-
❑ Tighten only after having tightened the cylinder head's bolts
11 - Support
❑ For the alternator
12 - Cylinder head
❑ Check for deformation ⇒ page 23
❑ After replacing it, renew the all of the coolant
13 - Oil separator
14 - 25 Nm
15 - Support
❑ Renew if deteriorated
17 - Cylinder head cover
18 - Plug
❑ Fit during installation work
❑ Renew gasket if it is deteriorated
Check the cylinder head for deformation

Maximum allowable deformation: 0.05 mm
1. Cylinder head: removing and installing 23

Arosa 1997 ➤
2 Cylinder head: removing and installing

equipment required
♦ dynamometric spanner -
SAT 8010-
type clips -T20029-
♦ tray -V.A.G. 1306-
♦ Flat scraper
♦ sealant -D 000 600 A2-
Premises
• Engine at warm temperature, maximum.
• The pistons must not be at TDC.
Remove
– First check whether the vehicle has a coded radio, in which
case, check the anti-theft coding.
– With the ignition switched off, disconnect the battery's earth
strap.
– Remove the engine and air filter guard ⇒bypage
Protected 2 ,Copying
copyright. Engine: for private or commercial purposes, in part or in whole, is not
removing and installing. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove the fuel supply and return hoses from the connection
that is next to the suspension turret. The fuel system is under
pressure. Therefore, place a cloth over the points of connec‐
tion before removing the hoses.
– Plug the hoses to prevent grime from entering the fuel system.
– Bleed the coolant liquid ⇒ page 46 .

Arosa 1997 ➤
– Unfasten the clamps and remove the flexible hoses from the
thermostat housing.
– Separar el cable de mando del acelerador del soporte y de la
unidad de mando de la mariposa (no quitar la grapa de fijación
-flecha-).
– Remove the following components from their mounts:
♦ The flexible aeration hose that goes from the cylinder head to
the throttle valve control unit
♦ The flexible hose that goes to the activated carbon tank
♦ The vacuum pipe that goes to the brake servo from the intake
manifold
– Remove and mark all of the cylinder head/manifold cables, as
well as the ignition wiring strip.
– Remove the Lambda probe's connector.
– Remove the screws from the ignition wiring strip and separate
it from the spark plugs.
– Remove the dipstick guide tube.
– Separate the front exhaust pipe from the exhaust manifold.
– Remove the cylinder head cover.

Arosa 1997 ➤
– Loosen the cylinder head's nuts and bolts in the order shown
(do not remove them).
– Loosen the rocker arm bolts and remove the rocker arm.
– Remove the bolts/nuts from the cylinder head.
– Remove the push-rods and place them taking into account
their fitting position.
– Carefully remove the cylinder head.
Assembly
Note!
♦ Do not remove the new cylinder head gasket from its packag‐
ing until just before fitting it. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Treat the new gasket with extreme care. If it is damaged, leaks
may occur.
– Plug the cylinders and the push-rod openings with clean cloths
in order to prevent dirt and abrasive particles from penetrating
between the interior cylinder wall, the piston, or the tappet.
– Prevent grime or abrasive particles from entering the coolant
liquid.
– Carefully clean the cylinder head and engine block contact
surfaces. Pay attention that no large marks or gouges are left
(if sandpaper is used, it should be at least 100 grain).
– Carefully eliminate the abrasive particles and remove the
cloths.
– Place Cylinder 1 piston at TDC and turn the crankshaft slightly
backwards.
– Fit the new cylinder head gasket in such a way that the lettering
can be read.
Note!
Before installing the cylinder head, make sure that all casings lie
correctly on their respective engine block resting surfaces (check
that they are not askew).
– Fit the cylinder head.

– Fit the push-rods in the same order that they were in when
disassembled, with the cup facing up.
Note!
Make sure when installing the push-rods that they are fitted with
care into the tappet cup and the adjustment screw swivel joint. If
the rods are fitted on the edges of the tappet or adjustment screw,
valve operation will become unadjusted, and damage could occur
during acceleration.
– Fit the rocker arm and tighten the securing bolts by hand.

Arosa 1997 ➤
– Fit the cylinder head's nuts and bolts and tighten by hand. To
do this, observe the following indication regarding length of
bolts and assembly with/without washer:
Numbering Approximate length with/without wash‐
of position of bolt er
1, 2, 3, 6, 7 168 mm with
4, 5, 8, 9 185 mm without
10 132 mm with
– Tighten the cylinder head bolts/nuts according to the following
tightening order:
Position number Tightening pro‐
cedure
1...10 Phase I 20 Nm
Phase II 1/4
turn (90°) con‐
tinue turning
with
wrench fixed
Phase III 1/4
turn (90°) con‐
tinue turning
with
wrench fixed
11...14 20 Nm
– Next, tighten the rocker arm bolts diagonally with torque of 25
Nm.
– Carry out the basic adjustment of valve play hydraulic com‐
pensation ⇒ page 30 .
Continue assembly in reverse order of what was established for
disassembly, taking the following indications into account:
– Install the front exhaust pipe ⇒ page 124 , Exhaust manifold,
front exhaust pipe with catalyst and accessory elements.
– If necessary, adjust the accelerator cable ⇒ page 67 .
– Electrical connections and cabling harnesses: ⇒ Current flow
– Carry out a road test and check the fault memory: ⇒ Vehicle
2.1 Cylinder head: repair

Arosa 1997 ➤
1 - Half cones
2 - Valve spring disc
3 - Valve spring
❑ Removing and instal‐
ling:
❑ Cylinder head removed
with -T20034/1- , -
T20034/2- , and -
T20034- ∅34
4 - Washer
5 - Valve stem seals
❑ Fit with -T20058-
❑ Fit with -T20039-
6 - Cylinder head
❑ Repair the valve seats
⇒ page 29
❑ Check the valve guide
⇒ page 28
7 - Valves
❑ Do not re-cut them, they
may only be ground
❑ Valve dimensions
⇒ page 28
Valve dimensions
Note!
Valves may not be re-cut, they may only be ground.
Dimension Intake valve Exhaust valve

∅ a mm 31.5 27.0
∅ b mm 7.0 7.0
c mm 104 104
α ∠° 45 45
2.2 Valve guides: check


Arosa 1997 ➤
♦ Universal support for dial gauge -T20020-
♦ Dial gauge
2.2.1 Testing process

– Fit a new valve in the guide. The end of the valve stem must
be even with the guide.
– Measure the tilting play. Intake valve guides = 0.5 mm Exhaust
valve guides = 0.6 mm
2.3 Valve seats: re-cut

♦ Depth gauge Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Valve seat grinder respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!
♦ When re-cutting engines with valves that are not airtight, it is

not enough to re-cut the valve seats, grind the valves or renew
both. It is especially important to check valve guide wear on
engines with high mileage ⇒ page 28 .
♦ Only re-cut the valve seats until a perfect contact is achieved.
Before re-cutting, the maximum re-cutting dimension must be
calculated. If the re-cutting dimension is exceeded, the valve
play hydraulic compensation function is not guaranteed, and
therefore, the cylinder head will need to be renewed.
2.3.1 Calculate the maximum re-cutting di‐

mension
– Insert the valve and push it firmly against the seat.
Note!
In case the valve is renewed during the repair, use the new valve
for measurement.
• Washer for disassembled valve spring.

Arosa 1997 ➤
– Measure the distance -a- between the end of the valve stem
and the valve spring's resting surface.
– Calculate the maximum re-cutting dimension based on the
measured distance -a- and the maximum dimension.
Maximum dimensions:
Intake valve 43.5 mm
Exhaust valve 43.4 mm
Maximum dimension less measured distance = maximum allow‐
able re-cutting dimension.
Example:
Maximum dimension 43.4 mm
Distance measured 42.7 mm
= Maximum allowable re-cutting dimension2) 0.7 mm
2) The maximum allowable re-cutting dimension is referenced in the figures as
dimension “b” .
Intake valve seat: re-cut

a = ∅ 30.3 mm
b = maximum allowable re-cutting dimension2)
c = 1.6 mm max.
Z = lower edge of the cylinder head
α = 45° valve seating angle
β = 30° top correction angle
γ = 60° lower correction angle
Exhaust valve seat: re-cut

a = ∅ 25.8 mm
b = maximum allowable re-cutting dimension2)
c = 1.8 mm max.
Z = lower edge of the cylinder head
α = 45° valve seating angle
β = 30° top correction angle
γ = 60° lower correction angle
2.4 Basic adjustment of hydraulic valve play

compensation
Hydraulic valve play compensation does not require maintai‐
nance, the adjustment should not be modified.
After carrying out repair work on the cylinder head/valve opera‐
tion, hydraulic valve play compensation must bepermitted
adjusted as
follows: respect to the correctness of information in this document. Copyright by SEAT S.A.

Arosa 1997 ➤
♦ torque wrenches -SAT 8010-
2.4.1 Sequence of operations

– Turn the crankshaft until the valves of the 4th cylinder coincide
(intake valve opens and exhaust valve closes).
– Loosen the counter-nuts on cylinder 1's rocker arm adjustment
screws.
– Re-tighten the rocker arm adjustment screws until play is ob‐
served between the rocker arm and the valve.
– Gently turn the adjustment screws on the two rocker arms until
there is slight contact between the valves and the rocker arm
(free valve operation).
– From this point, turn two more times
permittedand
unlessthen tighten
authorised by SEATtheS.A. SEAT S.A does not guarantee or accept any liability with
counternut to 13 Nm. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Carry out the adjustment of the other cylinders following the

order marked on the following table:
Adjust Valve coincidence
Cylinder 1 Cylinder 4
2.5 Compression: check

Arosa 1997 ➤

equipment required
♦ Spark plug wrench -
U-30037- or -T20028-
SAT 8010-
♦ Compression recorder -
V.A.G. 1763- or -V.A.G.
1381-
Test conditions
• Engine oil temperature, at least 30 °C

– Remove the engine and air filter guard ⇒ page 2 , Engine:
removing and installing. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Arosa 1997 ➤
– Withdraw the 4 pole connector -arrow- from the ignition wiring

strip.
– Remove the securing screws from the ignition wiring strip and
separate it from the spark plugs.
– Unscrew the spark plugs using the spark plug wrench -
T20028- or -U-30037- .
– Have a second mechanic step on the accelerator pedal to the
limit.
– Test the compression with the -V.A.G. 1381- or compression
recorder -V.A.G. 1763- .
Note!
Use of testing device ⇒ operating instructions .
– Operate the starter motor until the testing device no longer

indicates increasing pressure.
2.5.2 Compression values:

Allowable difference between all cylinders: 3 bar
2.6 Valve control unit: repair

Camshaft: removing and installing

Arosa 1997 ➤
1 - Push rod
❑ Observe the fitting posi‐
tion: cup facing up
2 - Tappet
❑ With hydraulic valve
play compensation
❑ Withdraw from the en‐
gine block using a bent
wire, do not use a mag‐
net
❑ Do not interchange
them
❑ Place with the sliding
surface facing down
❑ Lubricate the sliding
surface.
3 - Engine block
❑ Cylinder head: remov‐
ing and installing
⇒ page 24
❑ Engine block, crank‐
shaft, and flywheel: re‐
⇒ page 12
4 - Camshaft
❑ Maximum eccentricity:
0.01 mm
❑ Camshaft adjustment
⇒ page 34
❑ Distribution timing
⇒ page 35
5 - Cotter pin
❑ Make sure it lies properly
6 - Securing plate
7 - 5 Nm
Camshaft adjustment
– Fit pinions -2- and -3- on the chain -1- , so that the distance
-a- between the marks -arrows- is of 12 links in the chain.

Arosa 1997 ➤
Distribution timing for 0.2 mm of valve stroke

Engine code letters AHT
Intake before TDC 10°
Intake closes after BDC 46°
Exhaust opens before BDC 40°
Exhaust closes after TDC 5°
Rockers: removing and installing
1 - Rocker arm
⇒ page 22
2 - Safety ring
3 - Rocker support
❑ For M11 screw with cy‐
lindrical head
❑ Take the different ver‐
sions into account
⇒ page 34
4 - Elastic washer permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 - Rocker
❑ Take the different ver‐
sions into account
⇒ page 34
6 - Adjustment screw
❑ Basic adjustment of
valve play hydraulic
compensation
⇒ page 30
7 - Counter-nut, 13 Nm
8 - Rocker support
❑ For bolt M8
9 - Securing ring
10 - Rocker support
❑ For bolt M8
❑ With opening for oil
❑ Do not interchange the
initial position
11 - Spring

Arosa 1997 ➤
Arrangement of rockers and rocker supports

A - Right rocker (seen in direction of travel)
B - Left rocker
C - Rocker support for M11 bolt
D - Rocker support for M8 bolt
E - Rocker support for M8 bolt, with opening for oil
F - Outer rocker
Note!
Rocker supports D can be renewed with rocker supports E with

opening for oil.
2.7 Hydraulic tappets: test

♦ Gauge
♦ Wood or plastic wedge
Note!
♦ Hydraulic tappets must be renewed entirely (they cannot be
adjusted or repaired individually).
♦ The noises made by irregularly by the valves during starting
are normal.
Testing process
– Start the engine and run it until the radiator cooling fan starts
once.
– Increase engine speed to approx. 2,500/min during 2 minutes.
If the hydraulic tappets continue to make noise, determine the
faulty tappet in the following way:
– Remove the cylinder head cover.
– Turn the crankshaft until the valves of the 4th cylinder coincide
(intake valve opens and exhaust valve closes).
– Determine the play between the rockers and the valves.
– Press the rocker slightly downward from the tappet side, using
a wood or plastic wedge. The hydraulic tappet must not flex.
To the contrary, it must be renewed.
Note!
After having fitted the new tappets, the engine must not be starte
for approx. 30 minutes. The hydraulic compensation elements
must become settled (the valves could lie on the piston).

Arosa 1997 ➤
17 – Lubrication
1 Lubrication system components: re‐
Note!
Oil level must not be above the max. mark - risk of damaging the
catalyst! Marks ⇒ page 39 .
Check oil pressure ⇒ page 40

Oil capacities:
4.4 l with oil filter
Engine oil specification:
Use oils that comply with the VW 50000, VW 501 01 or VW 50200
rule.
Only in exceptional cases: multigrade oils that comply with API-
SF or SG rules.
1 - Plug
❑ Fit during installation
work
2 - Gasket
❑ Renew if deterioarated
F1- , 50 Nm
❑ In case of leak, cut and
renew the flange O-ring
4 - Oil filter
❑ Loosen using special
tool -U-40078- or a uni‐
versal extractor
5 - Pin
6 - Ball Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For overpressure
permitted valve
❑ When installing, give a
litht tap with an alumini‐
um punch, in order to

Arosa 1997 ➤
smoothen the ball's seat

❑ For overpressure valve
8 - 5 Nm
9 - Support
❑ For coolant hose
10 - O-ring
❑ Renew
11 - Oil bleed screw, 30 Nm
12 - 10 Nm
❑ Tightening order ⇒ page 39
13 - Oil sump
❑ Clean the gasket's surface before fitting
❑ Tightening order of the bolts ⇒ page 39
14 - Gasket
❑ Renew
❑ Before fitting, apply -AMV 188 001 02- to the contact surface between sealing flange and engine block
15 - Oil pump cover with discharge valve
❑ Aperture pressure: approx. 4.6 bar
❑ Clean the strainer if dirty
16 - Gasket
❑ Renew
❑ Fit only when there is not sufficient axial play in the oil pump pinions
17 - Pinions
❑ Check the axial play ⇒ page 39
18 - Guide tube
19 - Oil level dipstick
❑ Oil leve must no be above the max. mark!
❑ Marks ⇒ page 39
Guide tube for oil dipstick: remove

♦ Dynamometric spanner -SAT 8010-
– Loosen the exhaust manifold securing screw -1- and withdraw
the guide tube -2- upwards.

Arosa 1997 ➤
– Renew the O-ring -3- when fitting.

– Tighten the securing bolt -1- to a torque of 20 Nm.
Oil sump: tightening order
Special tools and workshop equipment permitted

required
♦ Dynamometric spanner -SAT 8010- respect to the correctness of information in this document. Copyright by SEAT S.A.
– Tighten the securing bolts in the order shown, to a torque of

10 Nm.
Oil dipstick marks
1 - Max. mark
2 - Min. mark
a - Area between the upper edge of the marked zone and the max.
mark: do not add oil.
b - The level is within the marked zone: oil may be added.
c - Area between the minimum mark and the lower edge of the
area marked: oil must be topped up with a maximum of 1.5 l.
Oil pump, check axial play

♦ G auge
♦ Auxiliary setting bar
New axial play: 0.02 ... 0.10 mm Wear limit: 0.13 mm
Note!
♦ If the wear limit is reached, the distribution cover will need to

be renewed ⇒ page 15 , Engine block, crankshaft and fly‐
wheel: removing and installing.
♦ If there is no axial play, fit the gasket ⇒ Item 16 (page 38) .
♦ Once the distribution cover is fitted, check that the pump turns
freely.

Arosa 1997 ➤
1.1 Oil pressure and oil pressure switch: test

equipment required
♦ oil pressure gauge -V.A.G.
1342-
♦ Diode lamp -V.A.G. 1527-
♦ Auxiliary measuring set -
V.A.G. 1594-
Note!
♦ Operation inspection and repair of visual and acoustic oil pres‐

sure indicators:
cations

Arosa 1997 ➤
Testing process
– Remove the oil pressure switch -F1- and screw it into the test‐
er.
– Screw the tester into the engine block, in the oil pressure
switch's location.
– Connect the brown tester cable to earth (-).
– Attach the diode lamp -V.A.G. 1527 B- with the auxiliary cables
-V.A.G. 1594 A- to battery positive (+) and to the oil pressure
switch. The diode must not light.
– If the diode lights, renew the 0.9 bar oil pressure switch -F1- .
If the diode does not light:
– Start the engine and gradually increase engine speed. Be‐
tween 0.75 ... 1.05 bar overpressure the diode should light, to
the contrary, renew the 0.9 bar oil pressure switch.
– Continue increasing engine speed. At 2,000/min and being at
a temperature of 80 °C, the oil pressure should be at least 2.0
bar.

Arosa 1997 ➤
1 Cooling system components: remov‐
ing and installing
Note!
♦ The cooling system is under pressure when the engine is hot.

Therefore the pressure must be reduced before repair.
♦ The flexible hose joints are secured with strip clamps. In case
of repair, only strip clamps must be used.
♦ pliers -T20029- are recommended for fitting the strip clamps.
♦ The flexible coolant hoses should be fitted without being tense
and without coming into contact with other components during
the procedure.
Bleeding and filling coolant liquid ⇒ page 46 .

Indications concerning the coolant liquid mixture ⇒ page 46 ,
Coolant liquid: bleeding and filling.
Carry out the cooling system test for watertightness with the -
V.A.G. 1274- and the adapter -V.A.G. 1274/3- .
1.1 Cooling system components, bodywork side

Arosa 1997 ➤
1 - Radiator
⇒ page 48
❑ After renewing it,
change all of the coolant
liquid
2 - Lock support
⇒ Bodywork, assembly
tasks; Rep. Gr. 50 ;
Bodywork, front, Re‐
the lock support and
subsequently fitted ele‐
ments
3 - Radiator cooling fan
4 - 10 Nm
5 - Support
❑ For cooling fan
6 - Connector
7 - Lower coolant liquid flexible
hose
❑ To the front coolant
hose
8 - Upper coolant liquid flexible
hose
❑ To the thermostat hous‐
ing
9 - Expansion tank
10 - Plug
❑ Test with the tester -V.A.G. 1274- along with 1274/4
❑ Testing pressure 1.4...1.6 bar
11 - Cover
12 - Towards the thermostat housing
❑ ⇒ Item 2 (page 44)
13 - Towards the coolant liquid hose
❑ ⇒ Item 14 (page 44)
14 - Temperature switch -F18- , 35 Nm
❑ For cooling fan
❑ Switching temperatures: 1st speed connects: 92...97 °C disconnects: 84...91 °C 2nd speed connects:
99...105 °C disconnects: 91...98 °C

Arosa 1997 ➤
1.2 Cooling system components, engine side

Thermostat side
1 - Bolt with cutting thread

2 - Towards the expansion
tank
❑ ⇒ Item 12 (page 43)
3 - Towards the flexible coolant
liquid hose, upper part
4 - Coolant liquid thermostat
❑ Test function: Heat the
thermostat in water. The
tip of the heat element
should emerge. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Temperature test: Be‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
ginning of aperture (ap‐
prox. 84 °C) and end
(approx. 98 °C) not pos‐
sible
5 - O-ring
❑ Renew
6 - Thermostat housing
7 - Coolant liquid temperature
sender -G62-
❑ With sender to indicate
coolant temperature -
G2-
8 - Fastening clip
9 - Towards the heat exchang‐
er
10 - 20 Nm
11 - From the heat exchanger
12 - Towards the front coolant
hose
13 - 10 Nm
14 - Coolant liquid hose
15 - From the expansion tank
❑ ⇒ Item 13 (page 43)
16 - Bleed screw, 25 Nm
❑ According to versions
❑ Renew the O-ring
❑ Fit with -D 000 600 A2-
17 - Support

Arosa 1997 ➤
1.3 Cooling system components, coolant pump side
1 - Gasket
❑ Renew
2 - Coolant liquid pump
❑ Check whether it turns
smoothly
❑ In case of fault or leak:
renew completely
⇒ page 50
3 - 20 Nm
4 - Pulley
❑ For Poly-V belt
5 - 10 Nm
6 - Poly-V belt
❑ Before removing it,
mark the turning direc‐
tion
❑ Do not twist
❑ Check the wear
⇒ page 10
7 - Coolant liquid flexible hose
❑ On coolant pump side,
only use clamps
❑ Tighten the clamp to a
torque of 3 Nm
8 - 20 Nm
9 - Front coolant hose
10 - Bleed screw, 20 Nm
❑ Fit with -D 000 600 A2-
11 - O-ring permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Renew
12 - Towards the front flexible coolant hose

Arosa 1997 ➤
1.4 Coolant liquid: bleed and fill

equipment required
SAT 8010-
type clips -T20029-
♦ Tray -V.A.G. 1306-
♦ Anti-freeze protection test‐
er -T10007-
♦ sealant -D 000 600 A2-
1.4.1 Bleed
– Open the coolant expansion tank plug.
– Bleed the coolant, removing the bleed screw from the front
coolant liquid hose -arrow- .

Arosa 1997 ➤
– Remove the bleed screw, if there is one, from the engine block
-arrow- , located above the oil pressure switch.
Note!
Observe disposal regulations!
1.4.2 Fill
– Fit the bleed screws in the engine block (according to versions)
and on the new coolant hose, using sealant -D000 600- and a
new O-ring. Tightening torque:
in the engine block 25 Nm
in the coolant hose 20 Nm
Note!
♦ The anti-freeze additive -G12- can only be used according with

rule TL VW 774 D. It can be identified by its red colour.
♦ In no case may -G12- be mixed with other anti-freeze addi‐
tives.
♦ If the liquid in the expansion tank is brown, it means that the -
G12- has been mixed with another anti-freeze additive, in
which case all of the coolant liquid must be changed.
♦ -G12- and other anti-freeze additives with the indication “ac‐
cording to TL VW 774 D” prevent damage due to corrosion,
freezing, or scale, also increasing the boiling temperature of
the coolant. It is for these reasons that the cooling system must
always be filled with the proper mixture of anti-freeze and anti-
corrosive
Protected byproduct.
♦ The anti-freeze, thanksof to
respect to the correctness its high
information boiling
in this temperature,
document. con‐
tributes to guaranteeing safe operation of the engine when
under great strain, especially in countries with tropical cli‐
mates.
♦ Frost protection must be guaranteed to approx. -25 °C (in
countries with arctic climates to approx. -35 °C).
♦ The coolant liquid's concentration must not be reduced by
adding water during hot seasons or in countries with hot cli‐
mates. The percentage of anti-freeze additive must be, at
least, 40%.
♦ If greater anti-freeze protection is needed due to climactic rea‐
sons, the percentage of -G12- may be increased, but only to
60% (frost protection to -40 °C). If a higher proportion is used,
cooling capacity and anti-freeze protection decrease.
♦ Do not reuse the used coolant liquid in case any of the follow‐
ing have been renewed: radiator, heat exchanger, cylinder
head, or cylinder head gasket.
Recommended mixture proportions:

Frost protection Anti-freeze pro‐ -G12- 3) Water3)
up to portion

Arosa 1997 ➤
-25 °C 40 % 2.25 l 3.35 l

-35 °C 50 % 2.8 l 2.8 l
3) The amount of coolant liquid may vary according to the vehicle's equipment.
Note!
If the following filling procedure is not followed, the cooling system

will no be completely filled with coolant and the engine could be
damaged.
– Remove the plastic safety -1- and withdraw the coolant tem‐
perature sender -2- from the thermostat housing.
– Slowly fill the expansion tank with coolant until the liquid be‐
gins to emerge from the temperature sender's housing.
– Refit the coolant temperature sender and secure it with the
plastic safety.
– Run the engine until the cooling fan starts.
– Refill coolant. With the engine hot, the liquid level must reach
the “max.” mark; with the engine cold, it should be between
the “min.” and “max.” marks.
1.5 Radiator: removing and install - ing

Arosa 1997 ➤

equipment required
♦ dinamometric spanners -
SAT 8010-
♦ Pliers for strip clamps -
T20029-
♦ tray -V.A.G. 1306-
er -T10007-
1.5.1 Remove
– Remove the radiator grill and the visor frame: ⇒ Bodywork-
assembly tasks; Rep. Gr. 66 ; Removing and installing the
radiator grill with visor frame.
– Remove the front bumper cover and the bumper support. ⇒
Bodywork-assembly tasks; Rep. Gr. 63 ; Front bumper.
– Remove the flexible coolant hoses from the radiator.
– Remove the temperature switch and cooling fan motor con‐
nectors
– Withdraw the bolts that secure the radiator and remove the
radiator.
Vehicles with air conditioner:
– Follow the additional indications and the assembly work se‐
quences ⇒ page 50 .
1.5.2 Assembly
Carry out assembly in reverse order and observe the following:
– New coolant filling ⇒ page 46 .

Arosa 1997 ➤
– Electrical connection and cabling harness: ⇒ Current flow di‐

agrams, Electrical fault finding and Fitting locations
1.5.3 Additional indications and assembly

work sequences for vehicles with air
conditioner
Caution
The air conditioner cooling agent circuit must not be opened.
Note!
In order to avoid damage to the condenser and to the cooling

agent hoses, care should be taken not to bend, twist, or exces‐
sively stretch the hoses.
– Unscrew the clamp(s) from the cooling agent hoses.

– Remove the screws that secure the air conditioner liquid re‐
serve tank and allow it to hang freely.
– Remove the condenser from the radiator and move it forward
as far as possible.
– Withdraw the radiator carefully.
1.6 Coolant pump: removing and installing

Arosa 1997 ➤

equipment required
♦ Fastening cross-member -
U-30025-
SAT 8010-
type clips -T20029-
♦ Tray -V.A.G. 1306-
er -T10007-
1.6.1 Remove
–respect
Remove the engine and air filter guard ⇒ page 2 , Engine:
removing and installing.


– Remove the clamp that fastens the flexible coolant hose to the
coolant pump.
– Remove the Lambda probe's connector and withdraw the sup‐
port.
– Separate the front exhaust pipe from its connection to the ex‐
haust manifold.

Arosa 1997 ➤
– Remove the screws -arrows- that secure the front coolant

hose.
– Fit fastening cross-member -U-30025- as shown, secure the -

U-30025- 's tensioner on the support next to the distribution
-arrow- .

Arosa 1997 ➤
– Remove the securing screws from the engine unit's front sup‐
port -arrows- .
– Remove the coolant pump pulley. To do so, it is necessary to
lift the engine unit slightly by working the -U-30025- 's ten‐
sioner.
– Remove the pulley's securing bolts (block by inserting a punch
in one of the holes on the pulley).
– Withdraw the coolant pump's securing nuts and bolts and re‐
move the pump.
Note!
♦ In order to remove or install the coolant pump, lift the engine

unit slightly using special tool -U-30025- , and slightly press
towards the rear.
♦ When fitting the coolant pump, make sure that the gasket is
not damaged.
Install
Carry out assembly in reverse order and observe the following:
– Renew the coolant pump gasket.
– Tighten the coolant pump's securing bolts/nuts to a torque of
20 Nm.
– Tighten the belt pulley's securing bolts to a torque of 10 Nm.
– Tighten the engine unit's securing bolts ⇒ page 7 , Tightening
torques.
– Tighten the securing bolts on the coolant hose to a torque of
20 Nm.
– Fill coolant liquid ⇒ page 46 .

Arosa 1997 ➤

1 Fuel supply system components: re‐
Note!
♦ The flexible hose connections are fastened by strip clamps.

♦ Always renew the strip clamps with screw-type clamps.
♦ For the fitting of the flexible fuel hoses to the engine, only
spring clamps may be used, screw clamps not being allowed.
♦ pliers -T20029- are recommended
Protected by copyright. Copying for privatefor fitting the
or commercial stripinclamps.
purposes, part or in whole, is not
Observe safety measures ⇒ page 57 .
Follow the rules for cleaning ⇒ page 57 .
Removing and installing the fuel tank with accessory parts and
fuel filter ⇒ page 54 .
Adjust the accelerator control cable ⇒ page 67 .
Repair the accelerator control cable ⇒ page 67 .
Removing and installing the activated carbon tank components
⇒ page 54 8.
1.1 Fuel tank with accessory parts and fuel filter: removing and installing

Arosa 1997 ➤
1 - Plug
2 - Tank cover unit
3 - Gravity/safety valve
❑ To remove it, free the
safety clip and remove
the valve from the filler
hole, upwards
❑ Check the continuity
from the flow valve Per‐
pendicular valve: open
Valve inclined 90°:
closed
4 - O-ring
6 - Connection nut, 75 Nm
-U-40055 A-
7 - Flexible hose/return hose
❑ From the fuel distributor
⇒ page 71
8 - Fuel supply unit
⇒ page 57
❑ Check the fuel pump
⇒ page 60
❑ Observe the fuel tank fit‐
ting position

Arosa 1997 ➤
⇒ page 56
9 - Fuel level indication sender
❑ Adjust: ⇒ Current flow
10 - O-ring
❑ Wet with fuel for fitting
❑ Renew in case of fault
11 - Fuel filter
❑ Fitting position: the arrow indicates the direction of flow
12 - 3 Nm
13 - Fuel tank
14 - 25 Nm
15 - Strip fastener
❑ Observe the different lengths
16 - Deaeration tube
❑ To the activated carbon tank ⇒ Item 5 (page 68)
17 - Feed hoses
❑ Black
❑ To the fuel distributor ⇒ page 71
18 - Spacer bushing
19 - 12 Nm
20 - Deaeration valve
❑ For removal, lightly press the clips inward and withdraw the valve
Fuel supply unit clamp's fitting position

The marks on the clamp and the fuel tank should meet.
Test the deaeration valve

Lever in rest position: closed
Lever pressed in direction of arrow: open
Note!
Before fitting the deaeration valve, remove the plug from the fuel
tank.

Arosa 1997 ➤
1.2 Safety measures for working on the fuel

supply system
Caution
The fuel supply hose is under pressure. Before opening the

system, place a cloth around the point of connection. Next,
eliminate the pressure by carefully separating the connection.
When removing or installing the fuel level indicator sender or the

fuel pump (fuel supply unit), the following should be observed if
the fuel tank is full or partially full:
♦ Before beginning work, the vacuum tube of a working extractor
must be close at hand, near the fuel tank assembly opening,
to absorb the gases given off by the fuel. If an extractor is not
available, a radial fan can be used (the engine must not be in
the flow of air) with an air flow above 15 m³/h.
♦ Avoid fuel coming into contact with the skin, always use fuel-
resistant gloves!
1.3 Rules for cleaning

For work on the fuel supply/injection system, the following “5
rules” for cleaning must be observed:
♦ Thoroughly clean the connections and their surrounding areas
before releasing them.
Do not use cloths that release fibers!
♦ If repair work is not carried out immediately, the opened com‐
ponents must be covered or carefully stored.
♦ Only fit clean components: Remove the replacement parts
from their packaging just before fitting. Do not fit components
which have been stored without packaging (for instance, in the
toolbox, etc.).
♦ The system is open: If possible, avoid using compressed air.
If possible, do not move the vehicle.
1.4 Fuel supply unit: removing and installing
Note!
In order to carry out these tasks, the earth strap must be removed
from the battery. Therefore, check whether the vehicle has a co‐
ded radio and if so, check the anti-theft coding.


Arosa 1997 ➤
♦ Connection-nut spanner -U-40055 A-
♦ dynamometric spanner -SAT 8010-
1.4.1 Remove
– Observe safety measures before beginning assembly work
⇒ page 57 .
strap.
– Tilt the rear seat forward.
– Remove the fuel supply unit's cover.
Caution
The fuel system is under pressure. Before opening the system,

place a cloth around the connecting joints. Next, bleed the
pressure by carefully loosening the connection.
– Remove from the clamp: the connector -1- , as well as the

supply -3- and return -2- hoses.
Note!
To do so, the press the connection keys on the hoses.
– Unscrew the connection-nut using special tool -U-40055 A- .

– Withdraw the fuel supply unit and the retainer through the
opening in the fuel tank.
Note!
In case of renewal, empty the old unit before discarding it.

Arosa 1997 ➤
1.4.2 Install
– Fitting of the supply unit must be done by reversing the order
of the removal procedure.
Note!
♦ When fitting the fuel supply unit, make sure that the fuel level
indication sender is not bent.
♦ Before fitting, wet the clamp retainer with fuel.
♦ Fuel supply unit clamp's fitting position ⇒ page 56 .
1.5 Fuel tank: removing and installing
Note!

♦ Engine and gearbox bridge lifter -SAT 1001-
1.5.1 Remove
– Observe safety measures before beginning assembly work
⇒ page 57
strap.
– Empty the fuel tank and clean around the fuel filler hole.
– Remove the securing bolt and remove the tank cover unit.

Arosa 1997 ➤

– Remove the flexible return hose -2- and the connector -1- from
the clamp.
– Remove the fuel supply hose and the deaeration hose from
their fixtures on the bodywork.
Note!
To do so, press the fastening keys on the flexible hoses.
– Remove the fuel filler from the bodywork.

– Remove the right rear wheel.
– Remove the rear axle from its fixture:
♦ The hand brake Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Electrical installation for ABS sensors respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Brake lines and flexible tubes ⇒ Running gear; Rep. Gr. 42 ;

rear suspension Rear axle: removing and installing.
– Put the engine and gearbox bridge lifter -SAT 1001- in place
and remove the screws that secure the rear axle to the body‐
work. Lower the lifter until there is enough room to remove the
tank.
– Remove the fastening clamps and then remove the fuel tank.
1.5.2 Install
Assembly is carried out in the reverse order of removal, while ob‐
serving the following:
♦ Fit the flexible fuel supply and deaeration hoses without any
bends.
♦ Do not mix up the supply hose with the return hose (return
hose blue or with blue marking, supply hose, black).
♦ Install rear axle: ⇒ Running gear; Rep. Gr. 42 ; rear suspen‐
sion Rear axle: removing and installing.
1.6 Fuel pump: test

Arosa 1997 ➤

equipment required
♦ Remote control -V.A.G.
1348/3A-
♦ Adapter cable -V.A.G.
1348/3-2-
♦ Diode lamp tester -V.A.G.
1527 B-
-V.A.G. 1594 A-
♦ Multimeter -V.A.G. 1715-
♦ Spanner for connecting-
nuts -U-40055 A-

Arosa 1997 ➤
♦ Pressure gauge -V.A.G.

1318-
♦ Adapter -V.A.G. 1318/1-
♦ Adapter -V.A.G. 1318/7-
♦ Adapter -V.A.G. 1318/11-
♦ Adapter -V.A.G. 1318/13-
♦ Adapter -V.A.G. 1318/17-
♦ Measuring glass
♦ Current flow diagram

Arosa 1997 ➤

• Battery voltage, 11.5 V at least.
• Fuse 32, correct.
1.6.2 Test operation and battery supply
Note!

– Switch ignition on, the fuel pump should be heard as it starts
briefly -approx. 1 second- (in case the check is repeated, wait
for at least 10 seconds).
In case the fuel pump does not start:
– Switch off the ignition and withdraw the fuel pump relay -J17-
from the relay plate (position 4). To do so, it is necessary to
move the fuse holder unit to one side.
– Attach the remote control -V.A.G. 1348/3A- using adapter ca‐
ble -V.A.G. 1348/3-2- to contact 16 on the relay plate and to
the battery's positive (+) terminal.
– Operate the remote control.
The fuel pump works:
– Check the excitation of the fuel pump relay according to cur‐
rent diagram: ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
The fuel pump does not work:

Arosa 1997 ➤
– Withdraw the 4 pole -1- connector from the fuel tank clamp
-2- .
– Attach the diode lamp -V.A.G. 1527B- to the connector's ex‐
terior contacts, using auxiliary cables -V.A.G. 1594- .
– Operate the remote control The diode does not light:
The diode does not ligth:
– Locate and eliminate the cables according to the wiring dia‐
grams: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
The diode lights (voltage supply correct):
– Remove the connection-nut with spanner -U-40055 A- .
– Check the connection of the cables between the flange and
the fuel pump.
If no break is found in the cables:
– Fuel pump faulted, renew the fuel supply unit ⇒ page 57 ; Fuel
supply unit; removing and installing.
1.6.3 Test fuel flow

Test conditions
• Voltage supply, correct.
• Remote control -V.A.G. 1348/3A- , connected.
Testing process
– Remove the plug from the fuel filler hole.
Caution

place a cloth around the connecting joints. Next, bleed the
pressure by carefully loosening the connection.
– Remove the supply hose (black colour) and use a cloth to col‐
lect the fuel that comes out.
– Attach the pressure tester -V.A.G. 1318- to the fuel supply
hose using the adapter -V.A.G. 1318/1- .
– Attach the -V.A.G. 1318/13- with adaptor -V.A.G. 1318/7- to
the pressure tester and place the end in a measuring glass.
– Open the pressure tester flow valve. The lever will indicate the
direction of flow -A- .
– Operate the remote control -V.A.G. 1348/3A- , slowly closing
the flow valve until the pressure gauge shows arespect

reading of 3
bar. From that moment on, do not move the flow valve's posi‐
tion.
– Empty the measuring glass.
– The fuel pump's flow depends on battery voltage. Therefore
the multimeter must be attached to the vehicle's battery using
auxiliary cables -V.A.G. 1594- .
– Operate the remote control for 30 seconds, while measuring
battery voltage.

Arosa 1997 ➤
– Compare the flow obtained with the theoretical value.

-*- Minimum flow cm³/30 s
-**- Voltage of the fuel pump while the engine is stopped and the
pump operates (approx. 2 volts less than battery's voltage).
Reading example:
During testing, a voltage of 12.5 volts is measured. Since the
pump's voltage is 2 volts less than the battery's, a minimum flow
of 540 cc/30 s results.
If the minimum flow is not obtained:
– Check the fuel hoses for possible kinks or clogging.
– Remove the flexible supply hose -1- from the fuel filter intake.
– Attach pressure tester -V.A.G. 1318- to the flexible hose, using
the adapter -V.A.G. 1318/17- .
– Check the flow again.
If maximum flow is now reached:
– Renew fuel filter.
If once again the minimum flow is not reached:
– Remove the fuel supply unit and check whether the filter is
dirty.
Only if no fault has been detected to this time:
– Renew the fuel supply unit.
The fuel flow has been attained, but, in spite of this, there is rea‐
son to believe that there is a fault in fuel supply (for instance: a
momentary fault in fuel supply):
– Test the fuel pump's current consumption, proceeding as fol‐
lows:
– Reattach the fuel hoses that were removed.
– With a current detector, attach the multimeter -V.A.G. 1715-

to one of the fuel pump's supply cables (clamp connector's
exterior contacts).
– Start the engine and allow it to idle.
– Measure the fuel pump's current consumption. Theoretical
value: 8 amperes max.
Note!
If it is a temporary fuel system fault, the test can also be carried
out during a road test, in which case, an additional person's help
is required.
If the power consumption is surpassed:

– Fuel pump faulty, renew the fuel supply unit ⇒ page 57 ; Fuel
supply unit: removing and installing.
1.6.4 Check the fuel pump non-return valve

Test conditions
• Remote control -V.A.G. 1348/3A- , connected.
• Pressure measuring device -V.A.G. 1318- , connected.

Arosa 1997 ➤
Testing process
Note!
This test also checks the watertightness of the fuel supply hose
connections, from the supply unit to the point of connection for
the pressure measuring device -V.A.G. 1318- .
– Close the measuring device's flow valve (lever perpendicular

to flow).
– Operate the remote control in successive short bursts, until the
pressure gauge shows a reading of 3 bar.
Caution
Danger of splashing when the flow valve is openend; place a

receptacle in front of the open connection on the pressure test‐
er.
– Drain any possible excessive pressure by carefully opening

the flow valve.
– Observe the pressure drop on the pressure gauge. After 10
minute, pressure must not fall below 2 bar.
If pressure continues to drop:
– Check the watertightness of the connections.
If no fault is found in the cables:
– Fuel pump faulted, renew the fuel supply unit ⇒ page 57 ; Fuel
supply unit: removing and installing.

Arosa 1997 ➤
2 Accelerator control unit
2.1 Accelerator control unit: repair
1 - Accelerator cable
❑ If the accelerator cable
is damaged, it must be
renewed and not used
again
2 - Fastening clip
❑ Adjust the accelerator
control cable
⇒ page 67
3 - Accelerator pedal
4 - Spacer bushing
5 - Securing nut
❑ Renew (interlock)
❑ 20 Nm
6 - Bearing bushing
7 - Stop screw
8 - Washer
2.2 Accelerator control cable: adjust
– Adjust accelerator cable modifying the position of the regula‐

tion element in the clip in the clip fastener so that the buterfly
valve reaches the full throttle position.
2. Accelerator control unit 67

Arosa 1997 ➤
2.3 Components of the activated carbon filter system: removing and installing
1 - Support ring
2 - Support
❑ On the bodywork, right
front
3 - Electrovalve 1 -N80-
❑ When the ignition is dis‐
connected, the valve is
closed
❑ The valve is activated by
the Simos -J361- control
unit, with the engine hot
❑ Test ⇒ Vehicle diagno‐
sis, testing and informa‐
tion system VAS 5051
4 - Connector
5 - Deaeration tube
❑ From the fuel tank grav‐
ity/safety valve
J338-
7 - To the cylinder head cover
8 - Activated carbon tank
❑ Location: in the right
front wheel arch
❑ “MOTOR” connection to
electrovalve 1
❑ “TANK” connection to
vacuum closing valve
❑ To remove: release the
safety catch -arrow- and
push the tank upwards
2.4 Deaeration of fuel tank: check


Arosa 1997 ➤
♦ Vacuum testing device -V.A.G. 1368-
2.4.1 Testing process

• Ignition switched off
– Remove from electrovalve -2- the activated carbon tank's -1-
flexible deaeration tube -1- .
– Attach to tube -1- the manual vacuum pump -SAT 1390- and
the vacuum tester -V.A.G. 1368- , as shown in the figure.
– Place the vacuum tester in position -A- /-B- .
– Work the manual vacuum pump -SAT 1390- several times. No
vacuum should be produced.
If vacuum is produced:
– Check the aeration connection -3- on the lower part of the ac‐
tivated carbon tank -4- for dirt; if necessary, clean it.
If vacuum is not produced:
– Plug the aeration opening -3- and work the -SAT 1390- several
times. Vacuum must be produced (the activated carbon filter's
closing valve must shut).
If vacuum is not produced:
– Renew the activated carbon tank.
2. Accelerator control unit 69

Arosa 1997 ➤
2.4.2 Check the hose towards the fuel tank

and plug
– Withdraw from the activated carbon tank -2- the fuel tank's
flexible deaeration tube -1- .
– Attach to tube -1- the manual vacuum pump -SAT 1390- and
the vacuum tester -V.A.G. 1368- , as shown in the figure.
– Place the vacuum tester in position -A- /-B- .
– Unscrew the fuel filler's plug.
– Work the -SAT 1390- several times. No vacuum should be
produced.
– Test the gravity/safety valve ⇒ Item 3 (page 55)
– Check the continuity flow in fuel tank hose -1- .
If vacuum is not created:
– Screw on the fuel filler plug.
– Work the manual vacuum pump -SAT 1390- several times. No
vacuum must be produced.
Note!
If the fuel level in the tank is low, the manual pump will have to be
worked 20...30 times.
– Renew the fuel filler's plug.

Arosa 1997 ➤
24 – Fuel preparation, injection

1 Injection system: repair
Location of the components
1 - Electrovalve 1 for the acti‐

vated carbon tank -N80-
❑ Activated carbon tank
system: ⇒ page 54
2 - Air filter
❑ Disassembling and as‐
3 - 4 contact connector
❑ For Lambda probe and Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Lambda probe heating permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 - Butterfly valve control unit -
J338-
5 - Simos -J361- control unit for
injection and ignition system
6 - Intake manifold pressure
transmitter -G71- with intake
air temperature transmitter -
G42-
7 - Fuel distributor with injec‐
tors
8 - Lambda probe -G39- , 50
Nm
❑ Location: in the front ex‐
haust pipe
❑ Only grease the threads
with -G 052 112 A3- . -G
052 112 A3- must not
reach the groove in the
body of the probe
special tool -U-40080-
9 - Pinking sensor 1 -G61-
❑ With thermal protection shield ⇒ Item 6 (page 127)
10 - Engine speed sensor -G628-
❑ Location: clutch housing, upper part
11 - Coolant liquid temperature transmitter -G28-
❑ With transmitter for coolant liquid temperature indicator -G2-
12 - Igition transformer -N152-
13 - Fuel pressure regulator
14 - Activated carbon tank
❑ Activatd carbon tank system: ⇒ page 54
1. Injection system: repair 71

Arosa 1997 ➤
1.1 General indications relating to injection

Ignition unit: repair
⇒ page 126
♦ The injection and ignition system control unit is capable self-
diagnosis. Before carrying out repairs and in order to locate
faults, the fault memory should be checked first. The flexible
vacuum hoses and connections should also be checked (air
leaking in).
♦ The flexible fuel hoses in the engine compartment must be
secured with spring clamps, tightening clamps and screw
clamps not being acceptable.
♦ Before disconnecting and connecting the battery, the ignition
must be disconnected; if this precaution is not observed, the
engine control unit may be damaged.
♦ The components marked with * are tested through self-diag‐
nosis ⇒ Vehicle diagnosis, testing and information system
VAS 5051 , Fault memory: consulting and erasing
♦ The components marked ** are tested through actuator self-
diagnosis ⇒ Vehicle diagnosis, testing and information system
VAS 5051 .
♦ For faultless operation of electrical components, a minimum
voltage of 12.4 V is required.
♦ Do not use silicone based sealant products. Silicone particles
that enter the are notProtected
burned and harm
by copyright. theforLambda
Copying probe.purposes, in part or in whole, is not
private or commercial
♦ If after locating faults, repairing or correctness
respect to the testing components,
of information in thisthe en‐ Copyright by SEAT S.A.
document.
gine starts for an instant and then stops, the immobiliser may
be blocking the engine control unit. In such a case, the fault
memory must be consulted, followed by adaptation of the con‐
trol unit, if necessary ⇒ page 118 .
♦ On some tests, the control unit may detect and memorise a
fault. Therefore, after all tests and repairs are concluded, the
fault memory must be consulted, erasing it if necessary ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051 ,
fault memory: consulting and erasing
Safety measures ⇒ page 78
Rules for cleaning ⇒ page 79
Technical data ⇒ page 79
Check the intake system's airtightness (air leaking in)
⇒ page 100
Test the engine's load states ⇒ page 108
1.2 Injection system components: removing and installing
72 Rep. Gr. 24 - Fuel preparation, injection

Arosa 1997 ➤
1 - 8 Nm
2 - Intake duct with regulating
flap
❑ Test intake air preheat‐
ing ⇒ page 101
3 - Goes to the cylinder head
cover
4 - Air filter
5 - Securing bolts
❑ For securing the intake
manifold, the air filter's
upper element and the
air filter
❑ If using an electrical/
pneumatic screwdriver:
200/min. max.
6 - ConnectorProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 8 contactsrespect to the correctness of information in this document. Copyright by SEAT S.A.
❑ For butterfly valve con‐

trol unit -J338-
7 - Connector
❑ 4 contacts
❑ For intake manifold
pressure transmitter -
G71- with intake air tem‐
perature transmitter -

Arosa 1997 ➤
G42-
8 - Comes from the fuel filter
❑ Secure with clamps
9 - Connector
❑ Black, 2 contacts
❑ For injector -N30- ... -N33- )
10 - Connector
❑ 4 contacts
❑ Coolant temperature transmitter -G62-
11 - 10 Nm
12 - Fuel distributor with injectors
❑ Disassembling and assembling ⇒ page 76
13 - Towards the brake servo
❑ Disassembling and assembling ⇒ page 75
15 - 20 Nm
16 - Support
❑ Between the intake manifold and the engine block
17 - Joint
❑ Renew
19 - O-ring
20 - Staple
❑ Check firm seating
21 - Coolant liquid temperature transmitter -G62- *
❑ With transmitter for coolant liquid temperature indicator -G2-
❑ Tester ⇒ page 87
❑ Before removing, reduce the cooling system's pressure
❑ For Lambda probe and Lambda probe heating
❑ Contacts 3 and 4, golden
❑ Location ⇒ page 71 , engine compartment's synoptic chart
23 - Lambda probe -G39- , 50 Nm
❑ Only grease the threads with -G 052 112 A3- . -G 052 112 A3- must not reach the groove in the body of
the probe
❑ Test the Lambda probe and Lambda regulation ⇒ page 103
❑ Voltage supply for probe heating through fuel pump relay -J17-
❑ Test Lambda probe
permitted unless heating
authorised by SEAT⇒S.A.
pageSEAT80S.A does not guarantee or accept any liability with
❑ Location ⇒ page 71 , engine compartment synoptic chart
❑ Withdraw or attach the connector with the ignition switched off
❑ Release in order to withdraw
❑ Withdraw or attach the connector with the ignition switched off
❑ Release in order to withdraw

Arosa 1997 ➤
26 - 25 Nm
27 - To the cylinder head cover
28 - It comes from the activated carbon tank electrovalve -N80- */**
29 - Engine control unit*
(Simos -J361- control unit for injection and ignition system)
❑ Location: in the water box
❑ Secured to the support with clips
❑ Test voltage supply ⇒ page 112
30 - It goes towards the fuel supply unit in the tank
❑ Secure with clamps
31 - Flexible intake hose
1.3 Intake manifold: disassembling and assembling
1 - Butterfly valve control unit -

J338- *
❑ Butterfly valve control
unit components -
J338- : Butterfly valve
actuator -V60- *, butter‐
fly valve acutator poten‐
tiometer -G88- *, butter‐
fly valve potentiometer -
G69- * and idle switch -
F60- *
❑ In case of renewal,
adapt the engine control
unit ⇒ page 116
2 - 10 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Joint respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Renew
4 - Support
5 - 10 Nm
transmitter -G71- * with intake
air temperature transmitter -
G42- *
❑ Test the intake manifold
pressure transmitter
⇒ page 89
❑ Test the intake manifold
temperature transmitter
⇒ page 90
❑ Intake air transmitter re‐
sistance values

Arosa 1997 ➤
⇒ page 78
7 - 3 Nm
8 - Flexible vacuum hose
❑ It goes towards the brake servo
9 - Intake manifold
❑ Removing and installing ⇒ page 72 , Injection system components: removing and installing
❑ It comes from the fuel pressure regulator ⇒ Item 6 (page 76)
11 - It comes from the cylinder head cover
12 - It comes from the activated carbon tank electrovalve -N80- */** ⇒ page 54
1.4 Fuel distributor: disassembling and assembling
1 - Fuel distributor
2 - 5 Nm
3 - Securing washer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Observe the fitting posi‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
tion respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Test ⇒ page 97 , Fuel
and retention pressure
regulator: test
5 - O-ring
❑ It goes towards the in‐
take manifold
7 - Injector -N30- ... -N33- )*
8 - Securing clip
❑ Ensure that it seats cor‐
rectly in the injector and
the fuel distributor

Arosa 1997 ➤
1.5 Air filter: disassembling and assembling

Removing and installing air filter ⇒ page 78
1 - Securing bolts
❑ For air filter's element
upper element
200/min. max.
2 - Securing bolts
❑ For securing the intake
manifold, the air filter's
upper element and the
air filter
200/min. max.
3 - Air filter's upper element
4 - Filter cartridge
5 - Temperature regulator
❑ For intake air preheating
❑ Observe the fitting posi‐
tion
6 - Joint
7 - Vacuum hoseProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ It goes permitted
towards the
unless re‐ by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
tention valverespect
in the flex‐
ible vacuum hose be‐

tween the intake mani‐
fold and the brake servo
8 - Air filter's lower element
9 - O-ring
❑ Ensure firm seating
10 - Staple
11 - Tube for oil sump deaeration
12 - Hose for hot air intake
❑ From the hot air collecting plate on the exhaust manifold
13 - Intake air duct with regulating flap
❑ Test intake air preheating ⇒ page 101
14 - 8 Nm

Arosa 1997 ➤
Resistance values
The diagram refers to the coolant temperature transmitter -G62-
and to the intake air temperature transmitter -G42-
The diagram is subdivided into two temperature ranges:
A - from 0...50 °C
B - from 50...105 °C
Examples:
♦ 30 °C is within range A and corresponds to a resistance of
1.5...2.0 kΩ
♦ 80 °C is within range B and corresponds with a resistance of
275...375 Ω
1.6 Air filter: installing and removing
1.6.1 Removing
– Remove the oil sump's flexible deaeration tube from the lower
element of the air filter.
– Remove the flexible hot air intake tube from the hot air col‐
lecting plate.
– Withdraw the preheating heat sensor's flexible tube from the
intake manifold.
– Loosen the securing screw -1- of(tightening torque: 8 Copyright
Nm). by SEAT S.A.
respect to the correctness information in this document.
– Loosen the screws -2- on the upper part of the air filter.
Note!
♦ When using an electric/pneumatic screwdriver to loosen or

tighten the screws -2- , the following conditions must be met:
♦ Maximum number of electric/pneumatic screwdriver revolu‐
tions: 200/min.
♦ Maximum tightening torque: 3 Nm.
– Removing air filter.
1.6.2 Installing
– Air filter installation must be carried out by reversing the order
of removal
1.7 Safety measures
Caution

place a cloth around the connecting joint. Next, eliminate the
pressure by carefully releasing the connection.
In order to prevent injury to persons and/or damage to the injec‐

tion and ignition system, the following must be observed:

Arosa 1997 ➤
♦ Remove and connect the injection and ignition system cables,

including measuring equipment cables, only with the ignition
switched off.
If during a road test the use of testing and measurement equip‐
ment is required, the following must be taken into account:
♦ The testing and measurement equipment must always be
placed on the rear seat, so that they can be managed from
there by a second mechanic.
If the testing and measurement equipment is managed from the
front passenger seat, the person occupying the seat could be in‐
jured by the airbag in the event of an accident.
♦ In order to make the engine turn at starting speed, without
starting it:
– Withdraw the 4 contact connector -arrow- from the ignition
coils' final power stage. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.8 Rules for cleaningrespect to the correctness of information in this document. Copyright by SEAT S.A.
For work carried out on the fuel supply/injection system, the “5

rules” for cleaning must be carefully followed:
before opening them.
¡Do not use cloths with loose fibres!
♦ If repairs are not carried out immediately, the removed com‐
ponents must be covered or stored with great care.
♦ Only fit clean components: Remove replacement parts from
their packaging just before fitting them. Do not fit components
which were stored without packaging (for instance, in the tool‐
box, etc.).
♦ The system is open: If possible, avoid using compressed air.
If possible, do not move the vehicle.
1.9 Technical data

Testing of idle
Idling speed4) 1/min 590...790
Engine control unit5)
System Simos 2P
Code6) 047 906 027
Engine speed limitation 1/min starting at approx. 5750
4) Not adjustable
5) Renew the engine control unit ⇒ page 114

6) Actual engine control unit code: ⇒ Replacement parts microfiche

Arosa 1997 ➤
2 Testing of components
2.1 Lambda probe heating: test

♦ Manual multimeter -V.A.G. 1526- or multimeter -V.A.G. 1715-
♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams
2.1.1 Testing conditions

• Fuse number 8, correct
• Fuel pump relay, correct
• Vehicles with airbag: the fuel cut-off control unit must be in
order
2.1.2 Testing procedure
– Detach the 4 contact connector -arrows- towards the Lambda

probe -G39- .
– To check the continuity of flow, attach the multimeter to con‐
tacts 1+2 from the connector to the Lambda probe, using
auxiliary cables -V.A.G. 1594- .
Note!
At ambient temperature, the heating element's resistance is ap‐

prox. 1...5 Ω. If the temperature rises slightly, resistance increa‐
ses considerably.
If a break in probe heating is detected:

– Replace the Lambda probe -G39- .
If the probe's heating has flow:

Arosa 1997 ➤
– Switch the multimeter to voltage measurement and connect it

to contacts 1+2 from the connector towards the control unit.
– Start the engine and run it at idling speed. Theoretical value:
11...15 V
– Attach the test box -V.A.G. 1598/22- to the control unit cabling
harness.
– Using the wiring diagram, test for a break in the cable between
the test box and the 4 contact connector, towards the control
unit. Contact 2 + female socket 27 Cable resistance: 1.5 Ω
max.
If the theoretical value is reached:
– Test the wiring from contact 1 towards the fuel pump relay -
J17- , according to the wiring diagram. ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations
2.2 Throttle control unit: test

Throttle control unit -J338- components: Butterfly
permitted valvebyactuator
unless authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
-V60- , throttle valve actuator potentiometer -G88-
respect , butterfly
to the valve
potentiometer -G69- and idle switch -F60- .
Note!
After renewing, or after removing and installing, the engine control

unit must be adapted to the throttle control unit ⇒ page 116 .

♦ Fault finder -V.A.G. 1551- or vehicle system tester -V.A.G.
1552- with cable -V.A.G. 1551/3-
♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams
2. Testing of components 81
Arosa 1997 ➤

• Throttle valve not damaged or dirty
2.2.2 Test the idle switch

– Attach the V.A.G. unit ( -V.A.G. 1552- ). Connect the ignition
and enter “direction code” 01 in order to select the engine
control unit. (Fault finder: Connect and select the engine con‐
VAS 5051 .)
Display reading: Rapid data transfer HELP
Select function XX
– Press buttons 0 and 8 for the function “Read the measure‐

ment values block” and confirm the entry with the Q button.
Display reading: Read measurement values block HELP
Enter display group number XXX
– Press buttons 0 , 9 , and 8 for “Display group number 98”

Display reading: (1...4 = display fields) Read measurement values block 1 →
1 2 3 4
– Observe the 4 digit numerical block on display field 3:

When the throttle valve is closed, the 4th digit from the left must
be a 0 Value displayed: 0000
– Open the throttle valve slowly. After an empty run a limit is
reached. By continuing to open the throttle valve, the 4th digit
from the left should change to 1. Value displayed: 0001
If the theoretical values are not reached:
– Remove the air filter ⇒ page 78
Value displayed Cause Continue testing
Always 1 Break or short circuit to ⇒ page 83
positive
Always 0 Short to earth ⇒ page 83

Arosa 1997 ➤
2.2.3 If the screen always displays: 1, contin‐

ue testing as follows:
– Detach connector -1- from the throttle control unit -2- .
– Jumper contacts 3+7 of the connector with auxiliary cables -
V.A.G. 1594- and observe the display.
Value displayed 0:
– Press the button → .
– Press buttons 0 and 6 for the function “End data transmis‐
sion” and confirm the entry with the Q button.
– Replace the throttle control unit ⇒ page 75
Value displayed 1:
– Test throttle control unit voltage supply and the cables in the
direction of the control unit ⇒ page 86 .
If voltage supply and the cables are not faulted:
– Renew the engine control unit ⇒ page 114
2.2.4 If the display always reads: 0, continue

testing as follows:
Value displayed 1:
– permitted
Switch off the ignition.
– Renew the throttle control unit ⇒ page 75

Value displayed 0:
If voltage supply and the cables are not faulted:
– Renew the engine control unit ⇒ page 114
2.2.5 Check the operating state

– Attach the unit -V.A.G. 1551- ( -V.A.G. 1552- ). Switch on the
ignition and enter “direction code” 01 to select the engine con‐
trol unit. (Fault finder: Connect and select the engine control
Arosa 1997 ➤
unit ⇒ Vehicle diagnosis, testing and information system VAS

5051 .)
Select function XX


1 2 3 4
– Check the throttle valve control unit's operating state in display

field 3.
Meaning of the numbers in the 4 digit numerical block regarding
the throttle control unit's operating state
x x x x Meaning in case of digits = 1
1 Fault detected during throttle valve adaptation
(consult the fault memory ⇒ Vehicle diagnosis, test‐
ing and information system VAS 5051 )
1 Throttle control unit, without current (proportion of
the period = 0)
1 Adaptation interrupted due to insufficient battery
voltage (less than 8 V)
1 Idle switchProtected
open (switch consultation)
– Adapt the engine control unit to the throttle control unit

⇒ page 116 .
– Repeat the test.
If once again the theoretical values are not reached:
– Test the throttle control unit's voltage supply as well as the
cables towards the control unit ⇒ page 86 .
2.2.6 Check the throttle valve's potentiometer

Test condition
• Coolant liquid temperature, 80 °C at least
Testing procedure
5051 .)
Select function XX

– Press buttons 0 , 0 and 1 for “display group 1” and confirm


Arosa 1997 ➤

1 2 3 4
– Check in display field 2 whether the coolant temperature is

above 80 °C.
– Change to display field 3 proceeding as follows:
– Press the C button.
– Press buttons 0 , 0 and 3 for “Display group number 3” and

1 2 3 4
– Read the throttle valve angle in display field 3. Vehicles with

power assisted steering, air conditioner: Theoretical value:
3.0...8.0 ∠° Vehicles withoutrespect

powerto theassisted steering
informationor airdocument. Copyright by SEAT S.A.
correctness of in this
conditioner: Theoretical value: 2.7...7.0 ∠° Open the throttle
valve slowly, all the way, observing the angle reading in field
3. The numerical value must increase uniformly throughout the
range.
Note!
The value displayed depends on the throttle valve potentiometer's

tolerance, and does not correspond to the real angle of aperture.
If the numerical value does not increase uniformly:

– Replace the throttle control unit ⇒ page 75
If the reading remains constant:
2.2.7 Test the throttle valve actuator and the

actuator's potentiometer
Test condition
Testing procedure
5051 .)
Select function XX
– Press the 0 and 8 buttons for the function “Read measure‐

Arosa 1997 ➤

1 2 3 4

above 80 °C.
– Change to display group 6, proceeding as follows:

1 2 3 4
– Check display field 2 for the voltage value of throttle valve

aperture, supplied by the throttle valve actuator's potentiom‐
eter. Theoretical value: 2.28...4.75 V
If the theoretical value is not reached:
– Remove the air filter ⇒ page 78 .
– Measure the throttle valve actuator's resistance between ter‐
minal contacts 1+2 Theoretical value: 3...200 Ω
– Renew the throttle control unit ⇒ Item 1 (page 75)
2.2.8 Test voltage supply and the cables to‐

wards
Protected the control
by copyright. unitor commercial purposes, in part or in whole, is not
Copying for private
– Detach connector
respect to -1- from theof throttle
the correctness information control unit -2-
in this document. . by SEAT S.A.
Copyright
– Attach the multimeter for voltage measurement to connector

contacts 4+7.
– Switch on the ignition Theoretical value: 4.5 V minimum
– To measure voltage, attach the multimeter to connector con‐
tacts 3+7
– Switch on the ignition Theoretical value: 9 V minimum

Arosa 1997 ➤
harness.
– Test for a break in the cables between the test box and the
connector, using the wiring diagram. Contact 1 + female sock‐
et 59 Contact 2 + female socket 66 Contact 3 + female socket
69 Contact 4 + female socket 62 Contact 5 + female socket
75 Contact 7 + female socket 70 Contact 8 + female socket
74 Cable resistance: 1.5 Ω max.
– Also test the cables for a short circuit between each other.
Theoretical value: ∞ Ω.
If no fault is detected in the cables:
– Test the engine control unit's voltage supply ⇒ page 112 .
2.3 Coolant temperature pressure transmit‐

ter: test
1552- with cable -V.A.G. 1551/3-
♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams

• Engine cold.

5051 .)
Select function XX

ment values block” andpermitted
confirm the entrybywith
SEATthe Q button.
unless authorised S.A. SEAT S.A does not guarantee or accept any liability with

Arosa 1997 ➤

1 2 3 4
Functional test of the transmitter

– Observe the value of the coolant liquid temperature in display
field 2. The value must increase uniformly, without interrup‐
tion.
If the temperature indicated differs much from the transmitter's
ambient temperature, test the transmitter cables with respect to
resistance.
Note!
♦ The value that is displayed in the fault finder may increase in

steps of 2 °C.
♦ If temperature increases uniformly and, in spite of this, a fault
in the coolant temperature transmitter is indicated, it means
that the engine control is in emergency operation, and that it
is calculating coolant temperature.

If the numerical value does not increase uniformly:
– Renew the coolant temperature transmitter -G62-
⇒ Item 21 (page 74) .
If the numerical value increases uniformly and, nevertheless, a
fault in -G62- appears in the fault memory:
Switch off the ignition.
– Attach the test box -V.A.G. 1598/22- to the control unit's ca‐
bling harness.
– Remove the 4 contact connector -1- , from the -G62- coolant

temperature transmitter -2- .
– Check for a break in the cables between the test box and the
4 contact connector, following the wiring diagram. Contact 1 +
female socket 70byContact
Protected 3 + female
copyright. Copying socket
for private 53 Cable
or commercial purposes,resist‐
in part or in whole, is not
ance: 1.5permitted
Ω max. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Check the cable between the control unit connector and con‐
tact 3 on the 4 contact connector, for a short with contact cable
1 and vehicle earth, following the wiring diagram. Theoretical
value: ∞ Ω.
Additionally, test the cables short to battery positive.
If no fault is found in the cable:

Arosa 1997 ➤
– Test the resistance between transmitter contacts 1 (earth) and

3 (signal).
Zone A shows the resistance values for temperature range 0...50

°C, and zone B, the values for temperature range 50...100 °C.
Examples:
1.5...2.0 kΩ
♦ 80 °C is within range B and corresponds with a resistance ofç
275...375 Ω
– Renew the coolant temperature transmitter -G62-
⇒ Item 21 (page 74) .
2.4 Intake manifold pressure transmitter:

test
♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams

• Fault “00519 Intake manifold pressure transmitter (G71)” de‐
tected by the self-diagnosis.
Note!
In case ofpermitted
a defect inauthorised
unless the transmitter
by SEAT S.A.or in S.A
SEAT thedoeswiring, the control
unit operates with a supplemental value.
Arosa 1997 ➤

– Remove connector -1- from the intake manifold's pressure
transmitter -G71- with intake air temperature transmitter -G42-
-2- .
harness.
– Test for a break in the cable between the test box and the
connector, following the wiring diagram. Contact 3 + female
socket 62 Contact 4 + female socket 13 Cable resistance: 1.5
Ω max.
In addition, test the cables for a short between each other, both
to vehicle earth and to battery positive. Theoretical value: ∞ Ω
– Renew the intake manifold's pressure transmitter -G71- with
the intake air temperature transmitter -G42-
2.5 Intake air temperature transmitter: test

1552- with cable -V.A.G. 1551/3-
♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams
♦ Cooling spray (commercial)

5051 .) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Display reading: respect to the correctness of information inRapid
data transfer HELP
Select function XX



Arosa 1997 ➤

1 2 3 4
Functional test of the transmitter

– Read the value for the intake air temperature that appears in
field 4.
approx. -33 °C Break or short circuit to ⇒ page 91
positive
approx. 118 °C Short circuit to earth ⇒ page 92
Approximate ambi‐ --- ⇒ page 93
ent
temperature7)
[amp ]sup1;)[amp ]tab;If a temperature is displayed that is lower
than the transmitter's ambient temperature, the transmitter cables
should first be checked with respect to contact resistance. Bear
in mind that the transmitter may become heated by radiated heat
while the vehicle is stopped. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7) Hier hat der Redakteur keine Fussnote eingegeben.
2.5.2 If approximately -33 °C is displayed, pro‐

ceed as follows:
– Remove connector -1- from the intake air temperature trans‐
mitter -G42- with the intake manifold pressure transmitter -
G71- -2- .
– Jumper connector contacts 1+2 with auxiliary cables -V.A.G.
1594- and observe the display.
Value displayed approximately 118 °C:
– Renew the intake manifold pressure transmitter -G71- with the
intake air temperature transmitter -G42- ⇒ Item 6 (page 75) .
Approximate value displayed -33 °C:
Arosa 1997 ➤
harness.
– Check for a break in the cable between test box female socket
54 and 4 contact connector contact 2, following the wiring di‐
agram. Cable resistance: 1.5 Ω max.
Also test the cable for a short to battery positive. Theoretical val‐
ue: ∞ Ω.
Check for a break in the cable between test box female socket 70
and 4 contact connector contact 1, according to the wiring dia‐
gram.
Cable resistance: 1.5 Ω max.
If no fault is found in the cable:
– Renew the engine control unit ⇒ page 114 .
2.5.3 If approximately 118 °C, continue as fol‐

lows:
– Remove connector -1- from the intake air temperature trans‐
mitter -G42- with the intake manifold pressure transmitter -
G71- -2- .
Value displayed approximately -33 °C:
– Renew the intake manifold pressure transmitter -G71- with the
intake manifold air temperature transmitter -G42-
Value displayed approximately 118 °C:
– Remove the connector from the engine control unit.
– Test whether the cables towards the control unit connector, on
4 contact connector contact 2, are shorted with contact cable
1, as well as with vehicle earth. Theoretical value: ∞ Ω.

Arosa 1997 ➤
2.5.4 If the ambient temperature is displayed,

proceed with the test as follows:
– Remove the air intake temperature sender with the intake
manifold's pressure sender (the connector remains attached).
– Memorize the value for the intake air temperature that appears
in display field 4.
– Apply an ordinary cooling spray to the transmitter, observing
the temperature reading. The temperature reading must drop.
2.6 Engine speed transmitter: test
Note!
The engine speed transmitter is a speed transmitter and refer‐

ence mark.

♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams

– Detach the engine speed transmitter's connector -arrow- .
– Attach the manual multimeter -V.A.G. 1526- , using the -

V.A.G. 1594- 's measurement cables, to contact 1 (positive),
and 3 (earth) on the engine speed transmitter's connection.
– Switch on the ignition Theoretical value: 4.5 V minimum
Arosa 1997 ➤
harness.
3 contact connector, following the wiring diagrams. Contact 1
+ female socket 62 Contact 2 + female socket 76 Contact 3 +
female socket 70 Cable resistance: 1.5 Ω max.
Also test the cables for a short circuit between each other. The‐
oretical value: ∞ Ω.
If no fault is detected in the cables and there is no voltage between
contacts 1 + 3:
– Renew the engine speed transmitter -G28- .
– Remove the transmitter and check whether the generator
wheel (inertial flywheel) is damaged or does not turn concen‐
trically.
Note!
The impulse generator wheel has a notch in its teeth. This notch
is not a defect but a reference mark.
If no fault is detected on the generator wheel (inertial flywheel):

2.7 Injectors: test

Check the excitation

Arosa 1997 ➤

equipment required
♦ Test box -V.A.G. 1598/22-
♦ Manual multimeter -V.A.G.
1526- or multimeter -V.A.G.
1715-
-V.A.G. 1594-
♦ Diode testing lamp -V.A.G.
1527-
♦ Wiring diagrams
Testing conditions
• Fuse number 8, correct.
• Earth connections between engine (gearbox housing) and
bodywork (beneath the battery), correct.
• Battery voltage, 12.4 V minimum.
• Engine speed transmitter, correct; test ⇒ page 93 .
• Fuel pump relay, correct.

Arosa 1997 ➤
– Detach the connectors -1- from the injectors -2- .

– Attach diode lamp -V.A.G. 1527- , using auxiliary cables -
V.A.G. 1594- , to the contacts on cylinder 1's connector.
– Operate the starter motor. The diode should blink.
– Repeat the test on the injector connectors corresponding to
cylinders 2...4.
If the diode does not blink:
harness.
injection connector, following the wiring diagram. Connector
cyl. 1, contact 2 + female socket 73 Connector cyl. 2, contact
2 + female socket 80 Connector cyl. 3, contact 2 + female
socket 80 Connector cyl. 4, contact 2 + female socket 73 Cable
– Also test whether the cables are shorted between each other.
– Check the cables between injector connector contacts 2 for a
break. Cable resistance: 1.5 Ω max.
2.7.2 Test injector resistances

– Test the resistance of the injectors between the contacts. The‐
oretical value: 14...20 Ω.
– Renew the injector(s).
2.7.3 Check the jet form and watertightness

♦ Measuring glass

Arosa 1997 ➤

– Remove the 4 contact connector from the ignition cable strip.
– Remove the entire fuel distributor, including injectors (the flex‐
ible fuel hoses remain attached) from the intake manifold.
– Place a small receptacle beneath the injector to be checked
and remove the connectors from the other injectors.
– Ask a second person to operate the starter motor. The injector
must send out a pulsating jet.
– Repeat the test on the other injectors, making sure that only
the injector to be tested is connected.
– Next, test the watertightness of the injectors. No more than 2
drops/min should come out.
If fuel loss is greater
– Replace the faulty injector ⇒ Item 7 (page 76) .
Note!
When installing the injectors, make sure the O-rings are not dam‐
aged.
2.8 Fuel and retention pressure regulator: check

The fuel pressure regulator regulates fuel pressure according to
intake manifold pressure.
The theoretical value for this test depends on the fuel pump's
working pressure, which goes up to approx. 3.0 bar
Arosa 1997 ➤

equipment required
1318-
♦ Adapter -1318/10-
♦ Adapter -1318/11-
♦ Adapter -1318/16-

• The fuel pump's flow must be correct; Check the flow
⇒ page 60
Caution

place a cloth around the connecting joint. Next, eliminate the
pressure by carefully releasing the connection.

Arosa 1997 ➤
– Remove flexible fuel supply tube (with white mark) -1- from the
supply hose -2- .
– Attach the pressure gauge -V.A.G. 1318- to the flexible tube
using the adapter -1318/10- , and to the supply hose with
adapters /11 and /16.
– Open the pressure tester's flow valve. The lever shows the
direction of flow -arrow- .
– Measure the fuel pressure Theoretical value: approx. 2.5 bar
– Withdraw the flexible vacuum hose from the fuel pressure reg‐
ulator -1- from the intake manifold side -2- . The fuel pressure
should increase to approx. 3,0 bar
– Test the fuel pump's flow. ⇒ page 54
– Test airtightness and retention pressure, observing the pres‐
sure drop on the gauge. After 10 minutes, a pressure of at least
2 bar should remain.
If retention pressure drops below 2 bar:
– Observe the pressure drop on the gauge.
– As soon as pressure has been produced, switch off the igni‐

tion, while at the same time closing the flow valve on the
pressure tester -V.A.G. 1318- (lever perpendicular to direction
of flow -arrow-permitted
).Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If pressure does not drop:
– Check the fuel pump's retention valve. ⇒ page 54

If pressure drops again:
– Open the pressure gauge -V.A.G. 1318- 's flow valve (lever
turned in direction of flow -arrow- ).
Arosa 1997 ➤
– As soon as pressure has been produced, switch off the ignition

while strangulating the flexible return hose (with blue mark)
-3- at the same time.
If pressure does not drop:
– Renew the fuel pressure regulator ⇒ Item 4 (page 76) .
If pressure drops again:
– Check the airtightness of the hose connections, as well as the
fuel distributor and injector O-rings.
– Check the airtightness of the pressure tester.
Note!
Before removing the pressure tester, place cloths around the

point of connection.
2.9 Intake system: check the airtightness

(undue air)
2.9.1 Test with leak detection spray -G 0010
800 A1-
1552- with cable -V.A.G. 1551/3-
♦ Leak detection spray -G 0010 800 A1-

• Coolant liquid temperature, 85 °C at least ⇒ display group 1,
display field 2.
Note!
♦ Due to the vacuum in the intake system, the leak detecting

spray is sucked in together with the undue air. The spray re‐
duces the flammability of the fuel mixture. This way, a drop in
engine speed occurs, as well as a variation in Lambda probe
voltage.
♦ Follow the safety rules on the container unconditionally.
– Attach the unit -V.A.G. 1551- ( -V.A.G. 1552- ). Start the engine
and enter “direction code” 01 to select the engine control unit.
(Fault finder: Connect and select the engine control unit ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051 .)
Select function XX


Arosa 1997 ➤

1 2 3 4
Proceed with testing only when the following are complied with:
• Coolant temperature, 85 °C display field 2.
– Observe engine speed in display field 1 and Lambda probe
voltage in display field 3.
– Systematically apply leak detecting spray to all intake system
components.
If engine speed drops or Lambda probe voltage varies:
– Switch off the ignition. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Check whether the area sprayed has any leaks and eliminate
any that that are detected.
If the engine speed and the Lambda probe voltage do not change:
2.10 Intake air preheating: check

♦ Cooling spray (commercial)
2.10.1 Check the regulating flap

– Remove the air filter intake tube.
– Check the position of the regulating flap in the intake tube.
♦ Above +23 °C, the regulating flap must close the hot air intake
♦ Below +10 °C, the regulating flap must open the hot air intake
Note!
The operation of the heat element may be checked by spraying

the end of the intake tube with normal cooling spray.

Arosa 1997 ➤
2.11 Test of functions
2.11.1 Testing of idle
Note!
♦ Idling speed, ignition timing, and CO content are not adjusta‐

ble.
♦ CO content is adjusted to the theoretical value through Lamb‐
da regulation. By means of the self-diagnosis, possible faults
in Lambda regulation are detected and recorded in the fault
memory.

1552- with cable -V.A.G. 1551/3-

• Exhaust system, no leaks between the cylinder head and the
catalyst.
• Coolant liquid temperature, 80 °C at least.
• All electrical loads, such as lights and heated rear window,
must be disconnected.
• On vehicles with air conditioner, it must be switched off.
• The accelerator control cable must be correctly adjusted,
check ⇒ page 54

5051 .)
– Consult the fault memory; if necessary, eliminate the fault and
erase the memory ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051 , Fault memory: consult and erase
– Next:
♦ Leave the fault connector -V.A.G. 1551- connected.
♦ Keep the engine idling.
Select function XX


1 2 3 4
Do not proceed with testing until 00000010 appears in the 4th

display field -8 digit numerical block-.

Arosa 1997 ➤
– Run the engine at idling speed for at least 1 minute.

– Check the idling speed in display field 1. Theoretical value:
590...790/min
If idling speed is not attained:
– Adapt the engine control unit to the throttle control unit
⇒ page 116 .
– Carry out a road test.
– Consult the control unit's fault memory again.
Repeat the idling test.
If once again the theoretical value is not attained:
– Test the throttle control unit ⇒ page 81 .
2.12 Lambda regulation: test

equipment required
♦ Fault finder -V.A.G. 1551-
or vehicle system tester -
V.A.G. 1552- with cable -
V.A.G. 1551/3-
♦ Test box -V.A.G. 1598/22-
1715-
-V.A.G. 1594-
♦ Protected
Wiring by diagrams

Arosa 1997 ➤
Testing conditions
• Coolant liquid temperature, 80 °C at least.
• Exhaust system, no leaks between the catalyst and the cylin‐
der head.
2.12.1 Function test

5051 .)
Select function XX


1 2 3 4

above 80 °C.
– Change to display group as follows:

1 2 3 4
– Check the operating state of Lambda regulation in display field

4: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Indication of Lambda regulation's operating state:
♦ Fault in the fault memory:

The 1st digit from the left must be a 0
Value displayed: 00000000
♦ Lambda regulation at limit:
The 4th digit from the right must be a 0
♦ Lambda regulation active:
The 3rd digit from the right must be a 1
♦ Lambda probe ready for operation:
The 2nd digit from the right must be a 1
♦ Mixture:

Arosa 1997 ➤
The 1st digit from the right must change back and forth between
0 and 1
Value displayed: 00000001 (1 = mixture rich)
Value displayed: 00000000 (0 = mixture lean)
Note!
The remaining digits may be either 1 or 0.

1 2 3 4
– Observe Lambda probe voltage
permitted in display
unless authorised field
by SEAT S.A.3. The
SEAT S.Avoltage
must oscillate at least 30 times per minute, within the following

range: 0.0...1.0 V
If the reading remains constant at one value:
approx. 5.0 V Short to positive ⇒ page 105 test
basic
voltage
1,50... 1,60 V Break ⇒ page 106
check cables
approx. 0.0 V Short to earth
Short to cable 2
oscillates Regulation correct ---
between
0.0...1.0 V
If the theoretical values for the operating state of Lambda regu‐
lation are not reached, or if probe voltage does not oscillate as
indicated:
– Test Lambda probe heating ⇒ page 80 .
– Check whether the Lambda probe has soot; renew if neces‐
sary.
2.12.2 Check the basic voltage

– Remove the 4 contact connector -arrows- towards the Lambda
probe -G39- .

Arosa 1997 ➤
– To measure voltage, attach the multimeter to contacts 3+4

(connector towards the engine control unit), using auxiliary
cables -V.A.G. 1594- .
– Switch on the ignition and measure the basic voltage. Theo‐
retical value: 1.50...1.60 V
– Check the Lambda probe's cables ⇒ page 106
2.12.3 Check the Lambda probe's cables

– Attach the test box -V.A.G. 1598/22- to the control unit's ca‐
bling harness.
4 contact connector (towards the control unit), following the
wiring diagram. Contact 3 + female socket 25 Contact 4 + fe‐
male socket 26 Cable resistance: 1.5 Ω max.
– Test the connector cables, contacts 3 + 4 for short circuits with
contacts 1 + 2, following the wiring diagram. Theoretical value:
∞ Ω.
2.12.4 Check mixture adaptation

5051 .)
Select function XX


Display reading: Read measurement values block 99 →
1 2 3 4

Arosa 1997 ➤
The Lambda probe's operating state is indicated in display field

4.
– Check the operating state of Lambda regulation in display field
4:
Meaning of the figures in the 8 digit numerical block for the Lamb‐
da regulator's operating state.
x x x x x x x x Meaning in case of digits = 1
1 Fault detected by self-diagnosis
0 Not occupied
0 Not occupied
1 Lambda control limited dynamism, active
1 Lambda regulator at limit
1 Lambda regulator activated
1 Lambda probe ready
1 State of mixture:
Message = 1: Rich mixture
Message = 0: Lean mixture

1 2 3 XXXX111X
If the Lambda regulator ispermitted
at theunless
limitauthorised
(indication
by SEATforS.A.Lambda reg‐
ulator at the limit at “1” ), it can respect
be determined through
to the correctness theinmixture
of information this document. Copyright by SEAT S.A.
state indicator whether the Lambda regulator is at the limit of
leaning or enrichment.
1 2 3 XXXX1111
If the Lambda regulator is at the limit and the mixture state indi‐
cation remains constant at “1” , it means that Lambda regulation
has reached the limit with respect to “leaning” , however the
Lambda probe continues to detect “very rich mixture” .
1 2 3 XXXX1110
If the Lambda regulator is at the limit and the mixture state indi‐
cation remains constant at “0” , it means that Lambda regulation
has reached the limit with respect to “enrichment” , however the
Lambda probe continues to detect “very lean mixture” .
Note!
If the Lambda regulator remains at the limit for a certain time,

either for “enrichment” or “leaning” , a fault is recorded in the fault
memory.
– If the Lambda probe functions perfectly, the self-adaptive

Lambda values must be checked
– Press buttons 0 , 1 , and 1 for “display group number 11” and
confirm the entry by pressing the Q button.
Mixture adaptation is subject to self-adaptation, that is, Lambda
regulation detects differences between the engines (injector noz‐
zle flow, compression, fuel pressure, etc.) and compensates for
them by adaptation of the basic injection times programmed in

Arosa 1997 ➤
the map of characteristics. Injection times are increased or re‐

duced until a mixture with l = 1.
1 2 3 4
The value for Lambda self-adaptation at idling speed appears in

display field 2.
♦ Self-adaptive value positive (+...ms): basic injection time pro‐
grammed very brief; the effective injection time ...ms longer in
order to attain l = 1.
♦ Self-adaptive value negative (-...ms): basic injection time pro‐
grammed, very long; the effective injection time is ...ms shorter
in order to attain l = 1.
The Lambda self-adaptation value at partial load is indicated in
display field 3.
♦ Values above 1: basic injection time programmed, very brief;
effective injection time longer in order to attain l = 1.
♦ Values below 1: basic injection time programmed, very long;
effective injection time shorter in order to attain l = 1.
Theoretical values: ⇒ Vehicle diagnosis, testing and information
system VAS 5051 , Read measurement values block, display
group 11.
2.13 Engine load states: check
Note!
The Simos engine control unit -J361- is tested for identification of

engine load states.

1552- with cable -V.A.G. 1551/3-

• The accelerator control cable must be correctly adjusted,
check ⇒ page 54

ignition and enter “direction
Protectedcode” 01 to
by copyright. select
Copying the engine
for private con‐purposes, in part or in whole, is not
or commercial
trol unit. (Fault finder:permitted
Connect and select the engine control
5051 .)
Select function XX


1 2 3 4

Arosa 1997 ➤

above 80 °C.
– Change to display group 7 by proceeding as follows:
– Press buttons 0 , 0 , and 7 for “Display group number 7” and
1 2 3 4
Engine load state (display field 4):

♦ Deceleration:
– Increase the engine speed to more than 3,000/min.
– Close the throttle valve suddenly.
While the engine speed is greater than 1,500/min., the 1st digit
from the left must be a 1.
Value displayed: 1000 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Idle:
The 2nd digit from the left must be a 1
♦ Partial load:
– Accelerate uniformly.
The 3rd digit from the left must be a 1
♦ Full load:
– Accelerate at full throttle (to the butterfly valve's limit)
The 4th digit from the left must briefly be a 1
Note!
It could be necessary to carry out a road test in order for “full load”
to be displayed. A second person is required for the road test.
Caution
The fault finder must be secured in the back seat and operated
from there.

– Consult the fault memory; eliminate possible faults and erase
the memory ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051 , Fault memory consulting and erasing.
– Test smoothness of accelerator control operation.

Arosa 1997 ➤
– Test the throttle valve's potentiometer ⇒ page 81 , Throttle

control unit: test.
2.14 Dynamic behaviour after a cold start:

test
If faults appear after the cold start, check whether the problem
begins before or after Lambda regulation begins operation.
Lambda regulation begins to operate when the probe has reached
the necessary temperature of approx. 300 °C.
The time required for reaching this temperature is mainly influ‐
enced by the following factors:
♦ Ambient temperature (summer/winter)
♦ Operating conditions after starting
♦ Lambda probe heating operation
1552- with cable -V.A.G. 1551/3-

• No fault in Lambda regulation should be recorded ⇒ Vehicle
diagnosis, testing and information system VAS 5051 , Consult
fault memory.

Check the vehicle under cold start conditions during a road test.
Note!
A second person is required for the road test.
Caution
from there.

5051 .)
Select function XX

– Press buttons 0 , 9 and 9 for “Display

respect to thegroup number 99” and
1 2 3 4
The Lambda probe's operating state is indicated in display field

4.

Arosa 1997 ➤
Meaning of the figures in the 8 digit numerical block for the Lamb‐
da regulator's operating state.
x x x x x x x x Meaning in case of digits = 1
1 Fault detected by self-diagnosis
0 Not occupied
0 Not occupied
1 Lambda control limited dynamism, active
1 Lambda regulator at limit
1 Lambda regulator activated
1 State of mixture:
Message = 1: Rich mixture
Message = 0: Lean mixture
– Carry out the road test. During the road test, observe the op‐
erating state of Lambda regulation as it appears in display field
4.
1 2 3 XXXXX00X
When Lambda regulation begins to operate, the Lambda probe Read measurement values block 99 →
must be in operating condition and the Lambda regulator must be 1 2 3 XXXXX11X
activated.
If the faults in vehicle operating behaviour begin before Lambda
regulation starts:
Lambda
Protected regulation
by copyright. cannot
Copying be
for private the cause
or commercial of the
purposes, fault.
Note!
If behaviour improves after Lambda regulation begins, it means

that regulation intervenes by compensating for the fault's cause
(for example: undue air, faulty injector, etc.). This can be detected
by consulting the adaptive Lambda values.
If the fault in the vehicle's operating behaviour begins after Lamb‐

da regulation begins:
– Test Lambda regulation ⇒ page 103 .

Arosa 1997 ➤
3 Engine control unit
3.1 Control unit voltage supply: test

1552- with cable -V.A.G. 1551/3-
♦ Test box -V.A.G. 1598/22-
♦ Wiring diagram

• Battery voltage, at least 12.4 V Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Fuses 1 and 2, correct
• Alernator correct, check: ⇒ Current flow diagrams, Electrical

fault finding and Fitting locations

5051 .)
Select function XX


and confirm the entry by pressing the Q button.
1 2 3 4
– Read the value displayed in field 2. Theoretical value: 11.5 V

at least
If the theoretical value is not attained

Arosa 1997 ➤
harness.
3.1.3 Test terminal 30 voltage supply

– MeasureProtected
voltage supply with a multimeter and auxiliary cables
-V.A.G.permitted
1594-unless
between
authorisedtest boxS.A.
female sockets 2 + 3:orTheo‐
by SEAT SEAT S.A does not guarantee accept any liability with
retical value: 11.5
respect V at
to the least of information in this document. Copyright by SEAT S.A.
correctness

– Test the wiring towards the relay plate, according to the wiring
diagram. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
3.1.4 Test terminal 15 voltage supply

– Measure voltage supply with a multimeter and auxiliary cables
-V.A.G.1594- between test box female sockets 1 + 2:
– Switch on the ignition Theoretical value: 11.5 V at least
If the theoretical value is not attained
– Test the wiring towards the relay plate, according to the wiring
diagram. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
3. Engine control unit 113

Arosa 1997 ➤
4 Engine control unit: renew

The engine control unit governs injection, throttle control unit,
Lambda regulation, ignition, pinking regulation, electrovalve 1 for
the activated carbon tank, engine speed regulation through the
injectors or the fuel pump relay, and self-diagnosis.
♦ fault finder -V.A.G. 1551- with cable -V.A.G. 1551/3-
Sequence of operations
– First, print the control unit's identification and along with it, the
previous control unit's code, proceeding as follows:
– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ). Switch on the ig‐
nition and enter “direction code” 01 to select the engine control
unit. (Fault finder: Connect and select the engine control unit
⇒ Vehicle diagnosis, testing and information system VAS
5051 .)
Display message; the control unit's identification and the coding 047 906027 Simos 2.3P HS7023 →
appear, for example: Encode 04800 WSC XXXXX
Print the engine control unit's identification by pressing the

Print button on the fault finder.

Select function XX

– Remove the wiper arms and the water box cover: ⇒ Electrical
system; Rep. Gr. 92
– Release the control unit connectors and remove them.
– Release the safety catchespermitted
-arrows- that secure the control
unit. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Fit the new control unit and secure with the safety catches.
– Check the previous coding and encode the new control unit
⇒ page 115
– Adapt the new control unit to the throttle control unit
⇒ page 116
– Adapt the new control unit to the electronic immobiliser
⇒ page 118
– To finish, consult the new engine control unit's fault memory,
and if necessary, erase it.

Arosa 1997 ➤
5 Control unit: encoding
Note!
♦ During control unit identification, a 5 digit code must always

be indicated.
♦ If the coding corresponding to the vehicle is not indicated, or
if the control unit has been renewed, the control unit must be
encoded in the following way:

♦ fault finder -V.A.G. 1551- with cable -V.A.G. 1551/3-
Sequence of operations
5051 .)
Display reading:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, isRapid
not data transfer HELP
Select
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with function XX
– Press buttons 0 and 7 for the “Control unit encoding” function
Display reading: Encode the control unit Q
– Enter the coding corresponding to this vehicle and confirm the

Code For vehicles with

04000 Manual gearbox
04800 Power assisted steering or air conditioner
If this message appears in the display, it means that an unau‐ Unknown function or cannot →
thorised code has been entered. be carried out at this time
The control unit's identification and its coding appear in the dis‐ 047 906027 Simos 2.3P HS7023 →
play, for example: Encode 04800 WSC XXXXX

Note!
♦ The engine control unit will not apply the code that has been
entered and which appears on the display until the ignition has
been switched off for more than 15 seconds
♦ Incorrect encoding would cause:
♦ Faults in running behaviour
♦ Fuel consumption somewhat high
♦ Emission of pollutants somewhat high
♦ Non-existent faults recorded in the fault memory
♦ Reduced gearbox life
5. Control unit: encoding 115

Arosa 1997 ➤
5.1 Engine control unit: adapt to the throttle

control unit
When carrying out the adaptation, with the ignition switched off
and the engine stopped, the engine control unit self-adapts the
limit positions of the throttle control unit and a characteristic com‐
parison curve between the throttle valve potentiometer, and the
throttle valve actuator's transmitter.
Adaptation should be carried out in the following cases:
♦ After removing and installing the throttle control unit
♦ After renewing the throttle control unit
♦ Renewal of the throttle control unit due to engine renewal
1552- with cable -V.A.G. 1551/3-

• No fault should be recorded in the memory ⇒ Vehicle diagno‐
sis, testing and information system VAS 5051 , Fault memory:
consult.
• Battery voltage at least 12.4 V
• All electrical loads, for instance lights and heated rear window,
should be disconnected.
• The throttle valve should be in the idle position.

5051 .)
Select function XX
– Press the 0 and 4 buttons for the “Begin basic adjustment”

function and confirm theProtected
entrybywith the Copying
copyright. Q button.
Display reading:
Basic adjustment HELP

Display reading: System at basic adjustment 98 →
x,xx V x,xx V 0000 01
After pressing the Q button, the throttle valve actuator moves from
min. to max. and five intermediate positions, and the control unit
memorises the respective angles in its permanent memory. This
process lasts a maximum of 10 seconds. Next, the throttle valve
stops briefly in the starting position and then closes.
Display reading: System at basic adjustment 98 →
x,xx V x,xx V 1000 00
The adaptation of the engine control unit to the throttle control unit
has been successfully completed.

Arosa 1997 ➤
Note!
If one of the messages appears in the display, it means that self‐

adaptation was not completed with a positive result.
Note!
♦ Note relative to display field 3:

♦ Meaning of the figures in the 4 digit numerical block for the
throttle control unit's operating state:
x x x x Meaning in case of digits = 1

1 Fault during a throttle valve adaptation (consult the fault memory
⇒ Vehicle diagnosis, testing and information system VAS 5051 )
1 Throttle control unit, without current (proportion of period = 0)
1 Adaptation interrupted due to insufficient battery voltage (less than
8 V)
1 Idle switch open (switch consultation)
Note!
♦ Note relative to display field 4:

♦ Meaning of the figures in the 2 digit numerical block for the
throttle control unit's state of adaptation:
Meaning in case of digits = 1

x x State of throttle control unit's adaptation
1 Fault during a throttle valve adaptation (consult the fault memory
⇒ Vehicle diagnosis, testing and information system VAS 5051 )
1 Adaptation of the throttle control unit, under way
Display reading: Basic adjustment not carried out

Signal not plausible

Arosa 1997 ➤
Note!
♦ If the control unit interrupts adaptation, it could be due to dif‐

ferent reasons:
♦ Necessary conditions for adaptation of engine control unit to
the throttle control unit are not met; conditions for adaptation
⇒ see fault table, fault code 01087 ⇒ Vehicle diagnosis, testing
and information system VAS 5051 .
♦ The throttle valve does not reach the mechanical idle limit be‐
cause it is dirty (burnt oil residue for example) or because the
accelerator control cable is not properly adjusted.
♦ Throttle valve control unit or wiring, faulty.
♦ After the interruption, “Basic adjustment not carried out, signal
not plausible” is recorded in the fault memory.
♦ When the ignition is switched on again, the engine control unit
will once again try to carry out the adaptation.
– Finish the basic adjustment of the engine by pressing button

→ .

Note!
The ignition must remain switched off for at least 15 seconds in

order to memorise the basic adjustment.
– Check the throttle valve's operating state ⇒ page 83 .
5.2 Engine control unit: adapt to the elec‐

tronic immobiliser
1552- with cable -V.A.G. 1551/3-
5.2.1 Condition
• There must not be an authorised key

Arosa 1997 ➤

– Remove the cover located in front of the fuse box.
– Attach the fault finder -V.A.G. 1551- or vehicle system tester -
V.A.G. 1552- , using cable -V.A.G. 1551/3- .
Operate the fault finder or vehicle system tester while taking into
account the display's message:
– Press button 1 for the “Rapid data transfer” function mode.
– Press buttons 2 and 5 for the “immobiliser” direction code and
Display reading:
Select function XX
– Press buttons 1 and 0 for the “Adaptation” function and con‐

Display reading:
Adaptation
– Press the 0 button twice for the “Channel number 0” function

Display reading:
Adaptation Q
Erase adaptive values?

Display reading:
Adaptation →
The adaptive values are erased
– Finish the adaptation by pressing the → button.

Note!
When the ignition is switched back on, the engine control unit's
identification will be entered in the immobiliser control unit.

Arosa 1997 ➤
6 Supplementary signals: check
6.1 Signal to/from the air conditioner: check

Signal from the air conditioner compressor: Shortly before air
conditioner compressor activation, voltage is applied to the en‐
gine control unit. This engine control unit signal maintains idling
speed constant, even in the event of fluctuations in air conditioner
system power consumption.
Air conditioner compressor deactivation: In order to make the en‐
gine's full power available during acceleration, the engine control
unit deactivates the air conditioner compressor for approx. 6 sec‐
onds upon acceleration from a complete stop or at low speeds
(first gear). If the accelerator pedal is released during this time
period, the time is reduced to a minimum of 3 seconds.
1552- with cable -V.A.G. 1551/3-
♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams

• Air conditioner operation, correct.
• The air conditioner must be switched off.
• No fault should be recorded in the memory ⇒ Vehicle diagno‐
sis, testing and information system VAS 5051 , Fault memory:
consult.
• The vehicle must be at ambient temperature (above + 15 °C).

5051 .)
Select function XX


1 2 3 4
Observe the value that appears in field 3. It must be respect to the correctness of information in this document. Copyright by SEAT S.A.
0
– Observe the value that appears in field 4. The 1st digit from
the right must be 00

Arosa 1997 ➤
– Switch on the air conditioner.

– Set the lowest temperature and the maximum turbine speed.
The value in field 3 must change to 1
The 1st digit from the right in display field 4 must change to
01
If the message does not change:
harness.
8 and the air conditioner, following the wiring diagram. Cable
10 and the air conditioner, following the wiring diagram. Cable
If there is no fault in the wiring:
– Test the operation of the air conditioner control unit. ⇒ Vehicle
6.2 Speed signal: check

1552- with cable -V.A.G. 1551/3-
♦ Test box -V.A.G. 1598/22-
♦ Diode testing lamp -V.A.G. 1527-
♦ Wiring diagrams

• The speedometer must be OK. Check the speedometer: ⇒
Electrical system; Rep. Gr. 90
Note!
In order to test the speed signal, the vehicle must be in motion.

To do so, the help of a second person is required.
Caution
from there.


5051 .)
Select function XX
6. Supplementary signals: check 121

Arosa 1997 ➤

– Press buttons 0 , 0 , and 2 for “Display group number 2” and

confirm the entry by pressing the Q button.
1 2 3 4
Carry out a road test, during which a second person must observe
the values that appear on the display.
– Observe the value displayed in field 3: Theoretical value: ap‐
proximate vehicle speed
If no speed appears in the display:
harness.
– Attach the diode lamp between female sockets 3 (positive) and
20 (speed signal).
– Lift the front left part of the vehicle.
– Switch on the ignition
permitted and turn
unless authorised by the
SEATfront leftS.A
S.A. SEAT wheel
does notby hand.or accept any liability with
guarantee
– The diode lamp must blink (very brief intermittent signal).
Note!
During the procedure, the right front wheel must not turn; if nec‐
essary, restrain its motion.
– If the diode lamp does not blink, check for a break or short in
the cable that goes from engine control unit contact 20 to the
instrument panel. ⇒ Current flow diagrams, Electrical fault
6.3 Engine speed signal: check

♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams
Note!
The engine speed signal is sent by contact 6 on the engine control

unit. This signal is needed for the revolution counter in the instru‐
ment panel, among others.

Arosa 1997 ➤
harness.
– Check for a break in the wiring that goes from test box contact
6 to the instrument panel, following the wiring diagram. ⇒ Cur‐
6. Supplementary signals: check 123

Arosa 1997 ➤
1 Exhaust system components: remov‐
ing and installing
Note!
♦ After carrying out fitting work on the exhaust system, carefully

ensure that there are no stresses and that there is sufficient
separation from the bodywork. If necessary, release the dou‐
ble clamp(s) and align the silencer and the exhaust pipe so
that there is sufficient distance between them and the body‐
work and that the supports are uniformly employed.
♦ Renew the self-locking nuts.
Exhaust manifold, front exhaust pipe with catalyst and accessory

parts
1 - Gasket
❑ Renew
2 - Gasket
❑ Renew
❑ Fitting position: notch
facing down
3 - 25 Nm
❑ For disassembly, re‐
move the exhaust mani‐
fold: ⇒ page 71
5 - 20 Nm
6 - Hot air pick up plate
7 - Guide tube
❑ For the oil dipstick tube
alyst
9 - Toward the presilencer
10 - Mark
❑ Three times around the
perimeter
11 - Lambda probe, 50 Nm
❑ Only grease the threadsProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
with -G5- . -G5- must not respect to the correctness of information in this document. Copyright by SEAT S.A.
reach the grooves in the
probe
-U-40080-
❑ Test: ⇒ Vehicle diagno‐

Arosa 1997 ➤
tion system VAS 5051

❑ Test Lambda regulation: ⇒ page 71
❑ Test the Lambda probe's heating: ⇒ page 71
12 - 25 Nm
Silencer with fasteners

alyst
2 - Mark
❑ Three times around the
perimeter
3 - Double clamp
4 - Dimension -a- = approx. 5
mm
5 - Crushed bolt
6 - 23 Nm
7 - Presilencer8)
❑ Insert the double clamp
up to the mark
8 - Fastening element
9 - Union brace
10 - 15 Nm
11 - Suspension element
❑ Renew if deteriorated Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - 22 Nm + 1/4 turn (90°) respect to the correctness of information in this document. Copyright by SEAT S.A.
13 - Rear silencer8)
14 - Mark
❑ Visible from below
❑ For double repair clamp
15 - Cutting point
❑ For repairs 8)
❑ With three marks

around the perimeter of the joining tube
16 - Double repair clamp
❑ It should be inserted up to the marks ⇒ Item 14 (page 125)
8) In the stock vehicle, the presilencer and the rear silencer are made up of a
single part. For repair, the presilencer and silencer are supplied separately with a
double clamp, ⇒ Item 16 (page 125) . Cut the joining tube at the cutting point
⇒ Item 15 (page 125) with -U-40075- .

Arosa 1997 ➤
28 – Ignition system
1 Ignition system: repair
1.1 General indications relative to the igni‐

tion system
♦ Only ignition related components are dealt with in this group.
The remaining injection and ignition components ⇒ page 71
♦ Before disconnecting or connecting the battery, the ignition
must be switched off; if this instruction is not observed, the
engine control unit may be considerably affected.
♦ The engine control unit is capable of self-diagnosis.
♦ The components marked * are tested by self-diagnosis.
♦ For perfect operation of electrical components, a minimum
voltage of 12.4 V is required.
♦ Before carrying out a repair or for fault finding, the fault mem‐
ory must be consulted ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 , Fault memory: consult and erase.
♦ On some tests it is possible that the control unit will detect and
record a Protected
fault. Therefore, onceforallprivate
by copyright. Copying tests and repairs
or commercial arein finish‐
ed, the permitted
fault respect
memory must be consulted and erased if neces‐
sary.
♦ If the engine starts briefly and then stops after fault finding,
repair or testing of components has been carried out, it could
be due to the immobiliser blocking the engine control unit. In
such a case, the fault memory must be consulted, adapting
the control unit if necessary ⇒ Vehicle diagnosis, testing and
information system VAS 5051 , Fault memory: consult and
erase.
Safety measures ⇒ page 83 .
Test data, spark plugs ⇒ page 128 .
1.2 Ignition system components: removing and installing
Note!
Simos -J361- * control unit with connector ⇒ Item 5 (page 71)
126 Rep. Gr. 28 - Ignition system

Arosa 1997 ➤
1 - Spark plug, 30 Nm
spark plug wrench -
U-30037-
❑ Type and separation of
electrodes
⇒ page 128 , test data,
spark plugs
2 - Connector
❑ 4 contacts
❑ For ignition transformer
-N152-
3 - 10 Nm
4 - Protection plate
5 - 20 Nm
❑ Tightening torque af‐
fects the operation of
the pinking sensor
6 -permitted
Pinking sensor
unless 1 -G61-
authorised * SEAT S.A does not guarantee or accept any liability with
by SEAT S.A.
❑ Golden contacts on sen‐
sor and connector
❑ Location ⇒ page 71 , en‐
gine compartment syn‐
optic chart
7 - Connector
❑ 3 contacts
❑ For pinking sensor 1 -
G61-
8 - Engine speed transmitter -
G28- *
9 - 10 Nm
10 - Connector
❑ 3 contacts
❑ For engine speed transmitter -G28-
11 - 7 Nm
12 - Igition transformer -N152-
❑ With final power stage
1.3 Safety measures

In order to prevent injury to persons and/or damage to the injec‐
tion and ignition system, the following must be observed:
♦ Disconnect and connect the injection and ignition system ca‐
bles, including measurement equipment cables, only when the
ignition is disconnected.
♦ In order to make the engine turn at starting speed without it
starting (to test compression for instance), the connectors on
the final power stages must be removed.
1. Ignition system: repair 127

Arosa 1997 ➤

coils' final power stage.
If during a road test the use of testing and measurement equip‐
ment is required, the following must be taken into account:
♦ The testing and measurement equipment must always be
placed on the rear seat, so that they can be managed from
there by a second mechanic.
If the testing and measurement equipment is managed from the
front passenger seat, the person occupying the seat could be in‐
jured by the airbag in the event of an accident.
1.4 Test data, spark plugs

Ignition order 1-3-4-2
Spark plugs
VW/Audi -101 000 049 AD-
Name of manufacturer RC 87 PYC
Electrode separation 0.75...0.85 mm
Tightening torque 30 Nm
1.5 Ignition coils with final power stage: test

Arosa 1997 ➤

equipment required
♦ Test box -V.A.G. 1598/22-
1715-
-V.A.G. 1594-
♦ Diode testing lamp -V.A.G.
1527-
♦ Wiring diagrams
Testing conditions
• Engine speed transmitter, correct, test ⇒ page 93
Note!
The ignition coils and the final power stage are a single piece and
cannot be renewed separately.

• Fuse number 4 correct

Arosa 1997 ➤
1.5.2 Check voltage supply

– Measure supply voltage between contacts 2 + 4 of the re‐

moved connector using the multimeter and auxiliary cables -
V.A.G. 1594-
– Switch on the ignition Theoretical value: 12.4 V at least
– Check for a break in the cable between 4 contact connector
contact 4 and earth, following the wiring diagram. Cable re‐
sistance: 1.5 Ω max.
– Check for a break in the cable between 4 contact connector
contact 2 and the fuse holder plate, following the wiring dia‐
gram. Cable resistance: 1.5 Ω max.
1.5.3 Check the excitation
Caution
During the following test, do not touch the ignition coil terminals
or the test cables.
– Withdraw fuse number 8 from the fuse holder.

Arosa 1997 ➤

– Attach the diode lamp -V.A.G. 1527- with auxiliary cables -

V.A.G. 1594- to the Contacts 1 + 4 (ignition output 1) Contacts
3 + 4 (ignition output 2) of the removed connector
– Operate the starter
Protectedmotor andCopying
by copyright. check the engine
for private control
or commercial unit's
ignition signal. The diode should blink.

If the diode blinks and there is voltage between contacts 2 + 4:
– Renew the ignition transformer ⇒ Item 12 (page 127) .
If the diode does not blink:
harness.
4 contact connector, following the wiring diagram. Contacts 1
+ female socket 71 Contacts 3 + female socket 78 Cable re‐
– Also check whether the cables are shorted between each oth‐
er. Theoretical value: ∞ Ω max.
If no fault is detected in the cables and there is voltage between
contacts 2 + 4:

Arosa 1997 ➤
1.6 Pinking sensor: test
Note!
♦ The tightening torque of 20 Nm must be strictly applied in order

to ensure the perfect operation of the pinking sensor.
♦ Only use golden contacts for the repair of pinking sensor con‐
tacts.

♦ Test box -V.A.G. 1598/22-
♦ Wiring diagrams

• Fault “00524 pinking sensor 1-G61” detected by self-diagnosis
1.6.2 Test operation

– Pinking regulation and pinking sensor function test ⇒ Vehicle
diagnosis, testing and information system VAS 5051 , read
measurement values block, display groups 14 to 17.
1.6.3 Test resistance and cables

– Remove the connector -arrow- from the wiring that goes to
pinking sensor 1 -G61- .
– Measure the resistance between pinking sensor contacts 1 +

2, 1 + 3 and 2 + 3. Theoretical value: ∞ Ω

Arosa 1997 ➤
harness.
– Using the wiring diagram, check for a break in the cables be‐
tween the test box and the triple connector. Contacts 1 +
female socket 68 Contacts 2 + female socket 67 Contacts 3 +
female socket 67 Cable resistance: 1.5 Ω max.
– Also test the cables for a short circuit between each other.
Theoretical value: ∞ Ω
– Loosen the pinking sensor and tighten it again to a torque of
20 Nm.
– Carry out a road test.
The following service conditions must be met during this run:
♦ Coolant liquid temperature must rise above 80 °C.
♦ Once the temperature is reached, the load states must be at‐
tained several times idle partial load full load deceleration
♦ At full load, the engine speed must be increased to more than
3,500/min.
– Consult the control unit's fault memory again.
If the fault persists:
– Renew the pinking sensor -G61- ⇒ Item 6 (page 127) .

Service
Workshop Manual
Arosa 1997 ➤
4-Cyl. Diesel engine, Mechanics
Engine ID AKU
Edition 08.98

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling system Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
20 - Fuel supply system permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

26 - Exhaust system
28 - Glow plug system

Copyright © 2015 Seat S.A S01AAKU8620

Arosa 1997 ➤
4-Cyl. Diesel engine, Mechanics - Edition 08.98
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1 Renewing crankshaft oil seal -belt pulley end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Protected 4.2 Piston
by copyright. Copyingand cylinder
for private dimensions
or commercial . . or
purposes, in part . .in.whole,
. . . .is .not. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.1 Dismantling and assembling intake pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.6 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.1 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Removing and installing coolant pump and compact bracket . . . . . . . . . . . . . . . . . . . . . . 63
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contents i
Arosa 1997 ➤
1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.1 Removing and installing fuel tank with its attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Servicing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.6 Servicing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.7 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.8 Adjusting pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1 Servicing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.4 Servicing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.5 Removing, installing and checking throttle valve housing . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.6 Removing and installing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.7 Dynamically checking and adjusting commencement of injection . . . . . . . . . . . . . . . . . . . . 93
1.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.9 Servicing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.10 Renewing injection timing device cover O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2 Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.1 Checking engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.2 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Checking brake light switch and brake pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.4 Checking clutch pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.5 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
2.6 Checking fuel temperature
respect to the correctnesssender . .in.this
of information . .document.
. . . . . .Copyright
. . . . .by. .SEAT
. . .S.A.
....................... 108
2.7 Checking modulating piston movement sender and meteringadjuster . . . . . . . . . . . . . . . . 110
2.8 Checking needle lift sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.9 Checking injection timing control range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.10 Checking commencement of injection valve N108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.11 Checking throttle valve positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.1 Checking speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.1 Checking control unit voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Replacing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3 Coding engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.4 Adapting (matching) engine control unit to electronic immobilizer . . . . . . . . . . . . . . . . . . . . 123
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.1 Servicing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.2 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.3 Checking exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.4 Checking exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
ii Contents
Arosa 1997 ➤
1 Technical data
1.1 Engine number

The engine number (“Code letters” and “Serial number” ) can be
found between injection pump and exhauster on cylinder block.
Additionally there is a sticker on the toothed belt guard with “En‐
gine code” and “Serial number” .
The engine code is also included on the vehicle data plate.
1.2 Engine data

Code AKU
Manufactured 01.98 ▸
Emissions fulfil D3 standard
Displacement ltr 1.7
Output kW at rpm 44/4200
Torque Nm at rpm 115/2200...3000
Bore ∅ mm 79.5
Stroke mm 86.4
Compression 19.5
CN min. 45
Firing order 1-3-4-2
Catalyst x
Exhaust gas recirculation x
Charged -
Charge air cooling -
1. Technical data 1
Arosa 1997 ➤

1 Removing and installing engine

equipment required
♦ Assembly stand -
AR-2204A-
♦ Engine bracket -U-20000-
♦ Flange adapter -U-30000-
♦ Retainer -U-30017-
♦ Support device -U-30034-
♦ Spring-type clip pliers -
T20029-

Arosa 1997 ➤
♦ Ring bolt -T20068-

♦ Torque wrench -SAT 8010-
(20...100 Nm)
♦ Workshop crane -V.A.G
1202 A-
♦ Grease -G 000 100-
♦ Cable tie
1.1 Notes on removing
Note!
Check whether a coded radio is installed as during the forthcom‐

ing work sequences the battery earth strap must be disconnected.
Obtain radio code first if necessary.
1.1.1 Work sequence Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– With the ignition switched off disconnect the battery earth
strap.
– Remove battery and battery retainer.
– All cable ties which are opened or cut open when removing
engine, must be replaced in the same position when installing
engine.
– Remove noise insulation tray.
– Drain coolant ⇒ page 64 .
– Pull connectors off thermoswitch and radiator fan.
1. Removing and installing engine 3

Arosa 1997 ➤
– Pull radiator coolant hoses off engine using pliers -T20029- for
spring-type clips.
– Remove power assisted steering reservoir from lock carrier
and tie-up.
– Removing lock carrier with attachments: ⇒ General body re‐
pairs; Rep. Gr. 50 ; Body, front Removing and installing lock
carrier with attachments.
– Remove power assisted steering vane pump and lay to side;
hoses remain connected: ⇒ Running gear; Rep. Gr. 48 ; As‐
sembly overview: Vane pump, reservoir, hydraulic lines Re‐
moving and installing power steering vane pump
– Pull vacuum hose off exhaust gas recirculation valve -N18-
-arrow- .
– Pull vacuum and breather hoses off engine.
– Disconnect fuel supply and return pipes at fuel filter -arrows- .
Note!
♦ Hose connections are secured with either screw-type or

spring-type clips.
♦ Always replace clamp-type clips with screw or spring-type
clips.
♦ Cover openings with clean cloths.
♦ Also ensure that no diesel fuel runs onto the coolant hoses. If
necessary hoses must be cleaned immediately. Affected ho‐
ses must be replaced.
– Remove intake hose between air cleaner and throttle valve

housing using pliers -T20029- for spring-type clips.
– Remove cover for intake pipes ⇒ page 36 , Dismantling and
assembling intake pipes.

Arosa 1997 ➤
– Separate 10-pin connector (Connection to injection pump me‐

tering control) -arrow- and unclip connector from retainer.
– Disconnect all other electric wires as necessary from gearbox,
alternator and starter and move clear.
– Pull off/disconnect all other electrical connections as neces‐
sary from engine and lay to one side.
– Disconnecting clutch cable: ⇒ 5-Speed manual gearbox 085;
Rep. Gr. 30 ; Servicing clutch mechanism Removing and in‐
stalling clutch cable.
– Remove front exhaust pipe ⇒ page 127 , Removing and in‐
stalling parts of exhaust system.
– Disconnect selector mechanism from gearbox: ⇒ 5-Speed
manual gearbox 085; Rep. Gr. 34 ; Servicing selector mech‐
anism
– Disconnect drive shafts at gearbox and tie-up: ⇒ Running
gear; Rep. Gr. 40 ; Servicing front suspension Removing and
installing drive shaft
– Remove pendulum support -1- .
– Remove engine mounting securing bolt -1- and fit ring bolt -
T20068- .
– Attach support device -U-30034- with bracket -U-30017- as

follows and lift slightly with workshop crane:
Belt pulley end:
2 - nd hole in hook at position 1
Flywheel end: 1st hole in hook at position 4
Note!
♦ The positions marked 1...2 on the bar must be towards the belt
pulley end.
♦ The holes in the hooks are counted up from the hook.

Arosa 1997 ➤
– Unbolt assembly at gearbox and engine mountings.

– Lower assembly until it is released from the gearbox mounting.
– Pull assembly out forwards. When doing this, if necessary turn
assembly and lower slightly.
Note!
When lifting out the assembly must be carefully guided, to prevent

damage to the bodywork.
1.2 Securing engine to assembly stand

When working on the engine, it should be secured to the assem‐
bly stand AR-2204A using the engine bracket -U-20000- and
flange adapter -U-30000- .
1.2.1 Work sequence

– Remove gearbox.
– Remove compact bracket ⇒ page 63 , Removing and instal‐
ling coolant pump and compact bracket.
– Fit flange adapter -U-30000- with engine bracket -U-20000- to
oil filter side of cylinder block.
– Fit engine bracket -U-20000- to exhaust sideunless
permitted of cylinder block.
– Secure engine to assembly stand AR-2204A with engine

brackets -U-20000- .
1.3 Notes on installing

Installation is carried out in the reverse sequence, when doing this
note the following:
1.3.1 Work sequence

– Check clutch release bearing for wear, renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with -G 000 100- .

Arosa 1997 ➤
– Check whether the dowel sleeves for centralising engine/gear‐

box are in the cylinder block, install if necessary.
– When swinging the assembly in, ensure that clearance exists
between the drive shafts.
– Align engine mountings stress-free by rocking, if necessary
loosen engine mountings to body.
– When installing the engine mounting ensure that the pins on
the bonded rubber mounting engage in the engine mounting
-arrows- .
Note!
Assembly mounting tightening torques ⇒ page 8 .
– Installing drive shafts: ⇒ Running gear; Rep. Gr. 40 ; Servicing

front suspension Removing and installing drive shaft
– Install selector mechanism: ⇒ 5-Speed manual gearbox 085;
Rep. Gr. 34 ; Servicing selector mechanism
– Install front exhaust pipe ⇒ page 127 , Removing and instal‐
ling parts of exhaust system.
– Install clutch cable: ⇒ 5-Speed manual gearbox 085; Rep. Gr.
30 ; Servicing clutch mechanism Removing and installing
clutch cable
– Install cover for intake pipes ⇒ page 36 , Dismantling and
– Install intake hose between air cleaner and throttle valve hous‐
ing using pliers -T20029- for spring -type clips.
– Installing P.A.S. vane pump: ⇒ Running gear; Rep. Gr. 48 ;
Assembly overview: vane pump, reservoir, hydraulic lines Re‐
moving and installing power steering vane pump
– Install lock carrier with attachments: ⇒ General body repairs;
Rep. Gr. 50 ; Body, front Removing and installing lock carrier
with attachments
– Electrical connections and routing: ⇒ Current flow diagrams,
– Filling with coolant ⇒ page 64 .
– Install noise insulation tray.
– Carry out a test drive and interrogate fault memory: ⇒ Vehicle

Bolted joint Tightening tor‐
que
Nuts, bolts
Protected M6 in part or in10
by copyright. Copying for private or commercial purposes, Nmis not
whole,
M8 Copyright by SEAT
20 S.A.
Nm
respect to the correctness of information in this document.
M10 45 Nm
M12 80 Nm
in variation of this
Exhaust pipe to manifold 40 Nm

Arosa 1997 ➤
1.5 Assembly mountings

Engine mounting
A1) = 40 Nm + 1/4 turn (90°) further
B = 50 Nm
C1) = 20 Nm + 1/8 turn (45°) further
1) Renew
Note!
The turning further angle can be measured with protractor -

T20030- .
Gearbox mounting
A2) = 60 Nm + 1/4 turn (90°) further
B2) = 20 Nm + 1/8 turn (45°) further
C = 50 Nm
2) Renew
Note!

T20030- .
Pendulum support
A = 50 Nm (tighten on nut)
B3) = 20 Nm + 1/4 turn (90°) further
3) Renew
Note!

T20030- .

Arosa 1997 ➤
1 Dismantling and assembling engine
Note!
♦ If during repair work, metal shavings or larger quantities of small metal particles are found in the engine oil
(caused, for example, by partial seizure of the crankshaft and conrod bearings) then, it is necessary to
thoroughly clean out the oil passages to prevent further damage.
♦ Defective injectors can cause violent knocking noises in the engine which sound like defective bearings.
When this occurs, run engine at idling speed and slacken off injector pipe unions one after the other. If
knocking stops when a union is loosened, this indicates that the injector concerned is defective.
Servicing injectors:
⇒ page 77
I ⇒ page 9
II ⇒ page 12
Part I
1. Dismantling and assembling engine 9

Arosa 1997 ➤
1 - 45 Nm
2 - Cover cap
3 - Engine bracket
4 - Toothed belt guard - upper
part
5 - Toothed belt
❑ Mark D.O.R. before re‐
moving
❑ Check for wear
❑ Do not kink
❑ Removing, installing
and tensioning
⇒ page 14
6 - 20 Nm
❑ Checking semi-auto‐
matic toothed belt ten‐
sioning roller
⇒ page 20
❑ Tensioning toothed belt
⇒ page 14 , Remov‐
ing, installing and ten‐
sioning toothed belt
8 - 45 Nm
❑ Use counter-hold -
T20018- to loosen and
tighten
9 - Camshaft sprocket
❑ Drive off camshaft taper
with a blow of a hammer
on a drift (6 mm ∅) posi‐

Arosa 1997 ➤
tioned through toothed

belt guard openings
10 - 10 Nm
11 - Idler wheel
12 - Rear toothed belt guard
13 - Clip
14 - Injection pump sprocket
❑ Single part
❑ Removing ⇒ page 20
15 - 55 Nm
❑ Secure injection pump sprocket with pin -U-20003- to loosen and tighten
16 - Intermediate shaft sprocket
17 - Crankshaft toothed belt sprocket
18 - 90 Nm + 1/4 turn (90 °) further
❑ Renew
❑ Threads and shoulder must be free of oil and grease
❑ Use counter-hold -T20018- to loosen and tighten
❑ The quarter
Protectedturn further
by copyright. canforbe
Copying done
private in several
or commercial stages.
❑ The turning further
permitted unless angle
authorised can
by SEAT be
S.A. measured
SEAT with
S.A does not protractor
guarantee -T20030-
or accept any liability with
19 - 25 Nm
20 - Injection pump
❑ Servicing: ⇒ page 81
❑ Removing and installing: ⇒ page 84
21 - Bracket
22 - Console
23 - 25 Nm
❑ Only tighten when injection pump is bolted tightly to the console
24 - Tensioning lever
❑ Grease with -G 000 100-
25 - Bearing bush
26 - Tensioner
❑ Removing and installing ribbed belts ⇒ page 13
27 - Washer
28 - 20 Nm
❑ Left-hand thread
29 - Ribbed belt
❑ Mark D.O.R. before removing
❑ Check for wear
❑ Do not kink
30 - Pulley
❑ For coolant pump
❑ Removing and installing coolant pump and compact bracket ⇒ page 63
31 - 25 Nm
❑ Use counter-hold -U-40011- to loosen and tighten

Arosa 1997 ➤
32 - 25 Nm
❑ Use counter-hold -T20018- to loosen and tighten
33 - Belt pulley/vibration damper
❑ Can only be installed in one position. Holes are off-set
34 - Toothed belt guard - lower part
35 - Spreader clip
Part II
1 - Cylinder block
sealing flange and fly‐
wheel ⇒ page 22
crankshaft ⇒ page 25
bling pistons and con‐
rods ⇒ page 28
2 - O-Ring
❑ Renew if damaged
3 - Exhauster
4 - Clamp
5 - 20 Nm
6 - Gasket
❑ Renew
7 - Oil filter bracket
8 - 25 Nm
9 - Oil filter
❑ Loosen with strap
wrench -U-40078- or
socket -U-30043-
❑ Tighten by hand
❑ Note instructions on fil‐

Arosa 1997 ➤
ter when installing

10 - Cap
11 - 10 Nm
12 - Engine speed sender -
G28-
❑ Checking: ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051
13 - 25 Nm
❑ Note tightening sequence ⇒ page 63
14 - Tensioning element
15 - Sealing ring
16 - Compact bracket
❑ For coolant pump, coolant thermostat, ribbed belt tensioning roller, alternator and P.A.S. vane pump
17 - Tensioning lever
❑ Grease with -G 000 100-
18 - 20 Nm
❑ Remove and install both rear bolts to gearbox with spanner -U-40051- and socket -U-40051/1- or -
U-40051/2-
19 - Sump
❑ Clean sealing surface before installing
20 - Gasket
❑ Renew
❑ Before fitting gasket coat sump flange/cylinder block flange with -D2-
1.1 Removing and installing ribbed belt

Before removing the ribbed belt mark the direction of rotation.

When installing the belt ensure it is correctly seated in the pulley.
1.1.1 Removing
– Mark ribbed belt direction of rotation.
– Swing tensioning roller in direction of arrow using spanner on
tensioning lever.
– Take ribbed belt off alternator belt pulley first.

Arosa 1997 ➤
1.1.2 Installing
– Place ribbed belt on alternator belt pulley first.
1.1.3 Ribbed belt routing

1 - Vibration damper/pulley
2 - Ribbed belt
3 - Tensioner
4 - Pulley - Alternator
5 - Pulley - P.A.S. vane pump
6 - Pulley - Coolant pump
1.2 Removing, installing and tensioning toothed belt

equipment required
♦ Pin -U-20003-
♦ TDC setting device -
U-20010-
♦ Pin wrench -U-30009/A-
♦ Support bracket -U-30025-
with legs
♦ Extension -U-30025/2-
♦ Counter-hold tool -
U-40011-

Arosa 1997 ➤
♦ Setting bar -U-40021-

♦ Counter-hold -T20018- tool
T20029-
(20...100 Nm)
♦ Feeler gauge
♦ Punch, 6 mm ∅
1.2.1 Removing
Note!
Mark the direction of rotation before removing the ribbed belt.

When installing the belt ensure it is correctly seated in the pulley.

housing with pliers -T20029- for spring-type clips.
– Remove cover for intake pipes ⇒ page 36 , Dismantling and
– Remove upper toothed belt guard and cylinder head cover.

Arosa 1997 ➤
– Turn crankshaft to TDC No. 1 cylinder -arrow- .

Engine removed:
– Fit adjustment device -U-20010- as shown.

– Set adjustment device to 38 mm -arrow A- .
– Turn crankshaft until flywheel TDC marking aligns with point
of setting device -arrow B- .
– Lock camshaft with setting bar -U-40021- .

– Centralize setting bar as follows: Turn camshaftProtected
so that one Copying for private or commercial purposes, in part or in whole, is not
by copyright.
end of setting bar contacts the cylinder head. permitted
Using unless
feeler authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
gauge establish the gap at the other end of the setting bar.
Place a feeler gauge corresponding to half the gap between

setting bar and cylinder head. Turn camshaft until the setting
bar contacts the feeler gauge. Place a 2nd feeler gauge, of
same thickness, at the other end between setting bar and cyl‐
inder head.
– Hook extension -U-30025/2- into bracket on lower right of cyl‐

inder block.

Arosa 1997 ➤
– Fit support bracket -U-30025- (with legs) and support engine

in installation position using extension -U-30025/2- .
– Remove pendulum support -1- at body.
– Remove assembly mounting complete on right of engine

-arrows- .
– Remove engine mounting on cylinder block.
– Lock injection pump sprocket with pin -U-20003- .

Arosa 1997 ➤
– Loosen tensioning roller nut -arrow- .

– Relieve tooth belt tension and take off camshaft and injection
pump sprockets.
– Lower engine carefully and evenly as far as possible using
support bracket -U-30025- .
– Remove coolant pump pulley (use counter-hold -U-40011- to
loosen and tighten the securing bolt).
– Remove belt pulley/vibration damper (use counter-hold -
T20018- to loosen and tighten the securing bolt).
– Remove ribbed belt tensioning roller (left-hand thread).
– Take off toothed belt.
1.2.2 Installing respect to the correctness of information in this document. Copyright by SEAT S.A.
– Loosen camshaft sprocket securing bolt a half turn.
Note!
Never use setting bar -U-40021- as a counter-hold to loosen and

tighten the camshaft. Use counter-hold -T20018- .
– Place a punch (6 mm ∅) through hole in the rear of the toothed

belt guard and release the camshaft sprocket from camshaft
taper with a blow from a hammer.
– Check whether TDC mark on flywheel and reference mark are

aligned.
Engine removed:

Arosa 1997 ➤
– Fit adjustment device -U-20010- as shown.

– Fit toothed belt on crankshaft toothed belt sprocket, injection
pump sprocket, intermediate shaft sprocket and tensioning
roller (note direction of rotation).
– Fit camshaft sprocket into toothed belt and secure sprocket so
that the camshaft can still turn.
– Tension toothed belt. To do this, turn pin wrench -U-30009/A-

clockwise until the notch and the raised point align -arrows- .
Note!
If the eccentric has been turned too far the tensioning roller must
be relieved completely and retensioned. The eccentric must nev‐
er be turned back when it has been turned too far.
– Tighten securing nut to 20 Nm.

– Check TDC mark on flywheel again.
– Tighten camshaft sprocket securing bolt to 45 Nm.
Note!

tighten the camshaft.Use counter-hold -T20018- .
– Remove setting bar -U-40021- from the camshaft and remove

pin -U-20003- from injection pump sprocket.
– Turn crankshaft two rotations in engine D.O.R. until crankshaft
is set to TDC No. 1 cylinder again.
– Check if the TDC mark on flywheel the setting bar on camshaft
the pin in injection pump sprocket the tensioning roller setting
(notch/raised mark) align/are fitted correctly.
– If the notch and raised mark are not opposite one another
-arrows- , tension thetensioning roller further. To do this, hold
tensioning roller tight with pin wrench -U-30009/A- , release
securing nut, then turn eccentric clockwise further until the
notch and the raised mark are opposite one another and tight‐
en the securing nut to 20 Nm.
– Repeat check.
– Install toothed belt lower guard, vibration damper/belt pulley
(note fixing), ribbed belt pulley tensioning roller, coolant pump
belt pulley and cylinder head cover.
– Fit engine mounting onto cylinder block and tighten the secur‐
ing bolt to45 Nm.

Arosa 1997 ➤
– Install right-hand assembly mounting to engine complete.

A4) = 40 Nm + 1/4 turn (90°) further
B = 50 Nm
C4) = 20 Nm + 1/8 turn (45°) further
4) Renew
Note!

T20030- .
– Install cover for intake pipes ⇒ page 36 , Dismantling and

– Install intake pipe between air cleaner and throttle valve hous‐
ing using pliers -T20029- for spring-type clips.
– Install upper toothed belt guard.
– Install pendulum support free of stress.

B5) = 20 Nm + 1/4 turn (90°) further
5) Renew
Note!

T20030- .

– Checking injection pump commencement ofProtected
delivery:
⇒ page 77 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1.3 Checking semi-automatic toothed belt

tensioning roller

• Toothed belt installed and tensioned
1.3.2 Test sequence

– Tension toothed belt with firm thumb pressure. Notch and
raised portion -arrows- must move apart.
– Release thumb pressure on toothed belt. The tensioning roller
must move back to its initial position. (Notch and raised portion
align again).
– If notch and raised portion do not align, loosen tensioning roller
and adjust toothed belt tension ⇒ page 14 .
– If the toothed belt tension is adjusted, the commencement of
injection must be checked and adjust if necessary:
⇒ page 77
Removing single part injection pump sprocket

Arosa 1997 ➤
♦ Puller -U-20001-
♦ Pin -U-20003-
1.3.3 Removing

– Remove injection pump sprocket securing nut.
– Pull pin -U-20003- out from injection pump sprocket.
– Loosen puller arms -U-20001- and offer up.

– Locate puller arms through holes in injection pump sprocket
and tighten.
– Place injection pump sprocket under tension with puller.
– Release injection pump sprocket from injection pump taper by
tapping on spindle of puller -arrow- (thereby hold sprocket so
that it does not fall off).

Arosa 1997 ➤
2 Removing and installing sealing flange and flywheel
Note!
♦ Servicing the clutch:

♦ ⇒ 5-Speed manual gearbox 085; Rep. Gr. 30 ; Servicing clutch
1 - Oil seal
❑ Renewing ⇒ page 23
2 - 25 Nm
3 - Front sealing flange
❑ Must be located on dow‐
el sleeves
4 - Gasket
❑ Renew
5 - Cylinder block
crankshaft ⇒ page 25
bling pistons
Protected and con‐
rods ⇒ page
permitted 28
6 - 60 Nm + 1/4 turn (90 °) fur‐
ther
❑ Renew
❑ The quarter turn further
can be done in several
stages.
❑ The turning further an‐
gle can be measured
with protractor -T20030-
7 - Flywheel
hold flywheel with coun‐
ter-hold -T20075-
8 - Intermediate plate
el sleeves
❑ Do not damage/bend
when assembling
9 - 10 Nm
10 - Sealing flange with oil seal
❑ Only renew complete
❑ Lightly oil sealing lip of oil seal
11 - Intermediate shaft
12 - O ring
13 - Sealing flange intermediate shaft
14 - Oil seal
❑ Remove to remove sealing flange

Arosa 1997 ➤
❑ Install with oil seal fitting tool U-30002

❑ Lightly oil sealing lip
2.1 Renewing crankshaft oil seal -belt pulley end-

equipment required
♦ Oil seal fitting tool -
U-40062-
♦ Oil seal extractor -T20031-
(32 mm ∅)
(20...100 Nm)
2.1.1 Removing

– Remove toothed belt ⇒ page 14 .
– Remove crankshaft sprocket. To do this hold sprocket with
counter-hold -T20018- .
– To guide seal extractor, screw securing bolt for crankshaft
toothed belt sprocket into crankshaft onto stop by hand.
– Unscrew inner part of the oil seal extractor -T20031- (32 mm
∅) out of the outer part.
2. Removing and installing sealing flange and flywheel 23

Arosa 1997 ➤
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and exerting firm pressure screw it as far as possible into
oil seal.
– Turn inner part against crankshaft until the oil seal is pulled
out.
2.1.2 Installing
– Lightly oil sealing lip of oil seal.
– Fit guide sleeve from oil seal fitting tool -U-40062- onto crank‐
shaft journal.
– Slide oil seal over guide sleeve.
– Press in oil seal using press sleeve from oil seal fitting tool -
U-40062- onto stop with old securing bolt from crankshaft
toothed belt sprocket.
– Install crankshaft toothed belt sprocket. To do this hold toothed
belt sprocket with counter-hold -T20018- and secure using a
new securing bolt 90 Nm + 1/4 turn (90 °).
Note!

T20030- .
– Install and tension toothed belt ⇒ page 14 .


Arosa 1997 ➤
3 Removing and installing crankshaft
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing caps with‐
out oil groove
❑ For cylinder block with
oil groove
used bearing shells
(mark)
2 - 65 Nm + 1/4 turn (90 °) fur‐
ther
❑ Renew
❑ The quarter turn further
can be done in several
stages.
gle can be measured
❑ To measure radial clear‐
ance tighten to 65 Nm
but not further
3 - Bearing cap
❑ Bearing cap 1: Pulley
end
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs cylinder block/
bearing cap must be on
the same side
4 - Bearing shell 3
❑ For bearing cap without
oil groove
❑ For cylinder block with
3. Removing and installing crankshaft 25

Arosa 1997 ➤
oil groove
5 - Thrust washer
❑ For bearing cap 3
❑ Note fixing arrangement
6 - Sender wheel
❑ For engine speed sender
7 - 10 Nm + 1/4 turn (90 °) further
❑ Renew
❑ The quarter turn further can be done in several stages.
❑ The turning further angle can be measured with protractor -T20030-
8 - Fitted pin
❑ Checking projection from crankshaft ⇒ page 26
9 - Crankshaft
❑ Axial clearance new: 0.07...0.17 mm Wear limit: 0.37 mm
❑ Check radial clearance with Plastigage New: 0.03...0.08 mm Wear limit: 0.17 mm
❑ Do not rotate the crankshaft when checking the radial clearance
❑ Crankshaft dimensions ⇒ page 26
10 - Thrust washer
❑ For cylinder block, bearing 3
Checking dowel pin projection from crankshaft


♦ Depth gauge
Test sequence
– Checking dowel pin projection -a- with a depth gauge when
sender wheel -1- is removed.
1 - Sender wheel
2 - Securing bolt
3 - Dowel pin projection -3- from crankshaft a = 2.5...3.0 mm

(in mm)
Honing Main journal -∅ Conrod journal -∅
dimension
Basic -0.022 -0.022
dimension 54.00 47.80
-0.042 -0.042

Arosa 1997 ➤
1st undersize -0.022 -0.022

53.75 47.55
-0.042 -0.042
2nd undersize -0.022 -0.022
53.50 47.30
-0.042 -0.042
3rd undersize -0.022 -0.022
53.25 47.05
-0.042 -0.042
3. Removing and installing crankshaft 27

Arosa 1997 ➤
4 Dismantling and assembling pistons and conrods
1 - Piston ring
❑ Offset gaps by 120 °
piston ring pliers
❑ “TOP” faces towards
piston crown
❑ Checking ring gap
⇒ page 29
❑ Checking ring to groove
clearance ⇒ page 30
2 - Piston
❑ With combustion cham‐
ber
❑ Mark installation posi‐
tion and cylinder num‐
ber
tion and allocation pis‐
ton/cylinder
⇒ page 31
❑ Arrow on piston crown
points to pulley end
❑ Install using piston ring
clamp
❑ Cracks on piston skirt,
renew piston
❑ Checking piston projec‐
tion at TDC
⇒ page 31
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C

Arosa 1997 ➤
punch -U-20008-
4 - Circlip
5 - Conrod
❑ Only renew as a set
❑ Mark cylinder number -A-
❑ Installation position: Marking -B- faces towards pulley end
6 - Bearing shell
❑ Note installation position
❑ Do not interchange used bearing shells
❑ Ensure retaining lugs fit tightly in recesses
❑ Axial clearance Wear limit: 0.37 mm
❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm Do not rotate crankshaft when checking
radial clearance
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 30
❑ Piston and cylinder dimensions ⇒ page 32
8 - Conrod bearing cap
❑ Note installation position
9 - Oil spray jet
❑ For piston cooling
10 - 25 Nm
❑ Insert without sealant
11 - Conrod bolt, 30 Nm + 1/4 turn (90 °) further
❑ Renewing
❑ Oil threads and contact surface Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ The quarter turn further canpermitted
be done in several stages.
❑ The turning further angle can be measured with protractor -T20030-
❑ To measure radial clearance use old bolts
Checking piston ring gap

♦ Feeler gauge
Test sequence
– Push ring squarely from above down to approx. 15 mm from
bottom end of cylinder.
Dimensions in mm
4. Dismantling and assembling pistons and conrods 29

Arosa 1997 ➤

Oil scraper ring 0.25...0.50 1.0
Checking ring to groove clearance
Special tools andProtected

workshop equipment
by copyright. Copying forrequired
♦ Feeler gauge respect to the correctness of information in this document. Copyright by SEAT S.A.
Test sequence
Clean groove before check.
Dimensions in mm
Oil scraper ring 0.03...0.06 0.15
Checking cylinder bores

♦ Internal dial gauge 50...100 mm
Test sequence
– Take measurements at 3 positions in both lateral -A- and lon‐
gitudinal -B- directions, as illustrated. Deviation from nominal
dimension max. 0.10 mm

Arosa 1997 ➤
Note!
Measuring the cylinder bores must not be done when the cylinder
block is mounted on a repair stand with adapter bracket -VW
540- , as incorrect measurements would then be possible.
Piston installation position and piston/cylinder allocation

Piston in cylinders 1 and 2:
Larger inlet valve chamber towards flywheel -arrows-
Piston in cylinders 3 and 4:
Larger inlet valve chamber towards belt pulley side -arrows- .
Note!
♦ New piston allocation to cylinders is shown by a coloured

marking on piston crown.
♦ Piston for cylinder 1 and 2: marked 1/2
♦ Piston for cylinder 3 and 4: marked 3/4
4.1 Checking piston projection at TDC

♦ Universal dial gauge bracket -T20026-
♦ Dial gauge
4.1.1 Test sequence

Piston projection at TDC must be measured when installing new
pistons or a short engine. Depending upon piston projection, in‐
stall the corresponding cylinder head gasket according to follow‐
ing table:
Note!
Turn engine clockwise to measure piston
permitted unless projection
authorised atSEAT
by SEAT S.A. TDC.S.A does not guarantee or accept any liability with
Piston projection Identification

Holes/notches
0.91 mm ... 1.00 mm 1
1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3

Arosa 1997 ➤
4.1.2 Cylinder head gasket identification

♦ Part No. = arrow -1-
♦ Production control code = arrow -2- (can be disregarded)
Note!
If differing figures are obtained when measuring piston projection,

the highest figure should be taken when selecting the gasket.
4.2 Piston and cylinder dimensions

Honing Piston-∅ Cylinder bore-∅
dimension
Basic dimen. mm 79.47 79.51
1st oversize mm 79.72 79.76
2nd oversize mm 79.97 80.01

Arosa 1997 ➤

1 Removing and installing cylinder
head
Checking compressions ⇒ page 38 .
Note!
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ 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 renewed.
1 - Expanding clip
2 - Toothed belt guard - upper Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
part permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
3 - Toothed belt
moving
❑ Check for wear
❑ Do not kink
and tensioning
⇒ page 14
4 - 45 Nm
tighten
❑ Drive off camshaft taper
with a blow of a hammer
on a drift (6 mm ∅) posi‐
tioned through toothed
1. Removing and installing cylinder head 33

Arosa 1997 ➤
belt guard openings

6 - 10 Nm
9 - Cap
❑ Renew seal if damaged
10 - Upper sealing washer
11 - Dished washer
12 - Cap
13 - Connecting pipe
14 - Gasket
15 - Lower sealing cone
16 - Cylinder head cover gasket
❑ Insert projections into holes on cylinder head
❑ Before fitting gasket coat transition between bearing cap/cylinder head with -D2-
17 - Intake pipes cover
18 - Cylinder head bolt
❑ Renew
❑ Note sequence when loosening and tightening ⇒ page 37 , Removing and installing cylinder head
19 - Intake pipes
20 - Injector pipes
❑ Tighten to 25 Nm
❑ Remove and install with spanner -U-40072-
❑ Always remove pipework complete
❑ Do not alter shape
21 - Cylinder head
❑ Check for distortion ⇒ page 35
❑ If replaced, renew the complete coolant
22 - Injector Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing: ⇒ page 96respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Servicing: ⇒ page 77
23 - Glow plug, 15 Nm
❑ Remove and install with spanner -U-40082-
❑ Checking: ⇒ page 135
❑ Renew
❑ Note marking ⇒ page 35
❑ If replaced renew the complete coolant
25 - Lifting eye

Arosa 1997 ➤
26 - 20 Nm
❑ Checking semi-automatic toothed belt tensioning roller ⇒ page 20
❑ Tensioning toothed belt ⇒ page 14 , Removing, installing and tensioning toothed belt
28 - Idler roller
29 - 20 Nm
Checking cylinder head for distortion

♦ Feeler gauge
♦ Straight edge
Test sequence
Max. permissible distortion: 0.1 mm
Note!
Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification

♦ Part No. = arrow -1-
♦ Production control code = arrow -2- (can be disregarded)
Note!
Different thicknesses of cylinder head gasket are fitted depending

on the piston projection. When replacing the cylinder head gasket,
install a new gasket with the same identification.

Arosa 1997 ➤
1.1 Dismantling and assembling intake pipes
1 - Intake hose
pliers -T20029- for
spring-type clips
2 - Throttle valve housing
❑ Renew complete only
and checking:
⇒ page 82
3 - Seal
4 - Intake pipes cover
5 - Pressure regulating valve
❑ For crankcase breather
6 - 10 Nm
7 - Gasket
8 - 25 Nm
9 - Exhaust gas recirculation
valve
❑ Checking ⇒ page 130
10 - Gasket
❑ Renew
11 - Intake pipes
❑ Note differing Part No's.

Arosa 1997 ➤
1.2 Removing and installing cylinder head

equipment required
♦ Removal tool with guide
pins -T20049- M12
♦ Socket set -U-30022-
(20...100 Nm)
1.2.1 Removing
– Maintain sequence when loosening and tightening cylinder
head bolts.
Note!
Remove and install cylinder head bolts with socket set -U-30022- .

Arosa 1997 ➤
1.2.2 Installing
Note!
♦ Always renew cylinder head bolts.

♦ In cases of repair carefully remove gasket remains from cyl‐
inder head and cylinder block. Ensure that no long grooves or
scratches are created. When using abrasive paper do not use
a grade less than 100.
♦ Carefully remove emery and abrasive remains.
♦ Remove new cylinder head gasket from packaging, just before
installation.
♦ Handle gasket extremely carefully. Damaging the silicone lay‐
er or the indented area will lead to leaks.
– Turn crankshaft to TDC marking before fitting cylinder head.

– Turn crankshaft against engine direction of rotation until all
pistons are approximately equally placed below TDC.
– Place cylinder head gasket on.
– To centralize, screw guide pins M12 from -T20049- into the
outer threaded holes on the intake side.
– Fit cylinder head, screw in 8 remaining cylinder head bolts and
tighten by hand.
– Remove guide pins through threaded holes with removal tool
from -T20049- and install cylinder head bolts.
– Tighten cylinder head in four stages in sequence shown as

follows:
– 1. Tighten initially with torque wrench: Stage I = 40 Nm Stage
II = 60 Nm
– 2. Turn further with normal spanner: Stage III = 1/4 turn (90 °)
Stage IV = 1/4 turn (90 °)
Note!
♦ The turning further angle can be measured with protractor -

T20030- .
♦ Pulling-down the cylinder head after repairs is not necessary.
– After tightening the cylinder head turn camshaft so that the

cams for No. 1 cylinder point evenly upwards. Turn crankshaft,
in engine D.O.R., To TDC before fitting toothed belt.
1.3 Checking compression pressures

Arosa 1997 ➤

equipment required
♦ Spanner -U-40082-
(5...25 Nm)
♦ Adapter -V.A.G 1381/12-
♦ Compression tester -V.A.G
1763-
1.3.1 Check conditions

• Engine oil temperature min. 30 °C. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
• The battery voltage must be at least 11.5 V.
1.3.2 Test sequence

– Separate 10-pin connector for fuel cut-off valve -N109- (con‐
nection to injection pump metering control) -arrow- .
– Pull glow plug connector off glow plug.
– Remove all glow plugs using spanner -U-40082- .

Arosa 1997 ➤
– Screw in adapter -V.A.G 1381/12- in place of the glow plugs.

– Check compression pressure with compression tester -V.A.G
1763- .
Note!
Using the compression tester ⇒ Operating instructions .
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressure:
Permissible difference between all cylinders: 5 bar
– Install glow plugs with spanner -U-40082- Tightening torque:
15 Nm.
– Interrogate fault memory: ⇒ Vehicle diagnosis, testing and in‐
formation Protected
systembyVAS 5051
Note!
Faults will have been stored because the 10-pin connector to in‐
jection pump has been separated. Therefore interrogate and
erase fault memory.

Arosa 1997 ➤
2 Servicing valve gear
Note!
Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the
cracks are small and not more than 0.5 mm wide.
1 - Bearing cap
❑ Installation position
⇒ page 43
❑ Installation sequence
⇒ page 48 , removing
and installing camshaft
2 - 20 Nm
3 - Camshaft
❑ Checking axial clear‐
ance ⇒ page 42
⇒ page 48
❑ Checking radial clear‐
ance with plastigage
Wear limit: 0.11 mm
❑ Run-out: max. 0.01 mm
❑ Identification and valve
timing ⇒ page 43
4 - Bucket tappet
❑ Before installing check
camshaft axial clear‐
ance ⇒ page 42
❑ Use pliers -U-10014- to
remove
❑ With hydraulic valve
clearance compensa‐
tion
❑ Oil contact surface
❑ Store with cam contact
surface downwards on
2. Servicing valve gear 41

Arosa 1997 ➤
storage plate -U-10083-

5 - Cotters
6 - Upper valve spring plate
7 - Valve spring
❑ Store on storage plate -U-10083-
❑ Remove and install with assembly tool -T20034- ⇒ page 46 , Renewing valve stem seals
8 - Valve stem seal
9 - Valve guide
❑ Service version with collar
10 - Oil seal
❑ To remove and install, remove bearing cap
❑ Removing, installing and tensioning toothed belt ⇒ page 14
11 - Cylinder head
❑ See note ⇒ page 41
❑ Reworking valve seats ⇒ page 43
12 - Valves
❑ Store on storage plate -U-10083-
❑ Do not rework only grinding-in
respect is permitted
13 - Lower sealing cone
Checking camshaft axial clearance

♦ Dial gauge
Check with bucket tappets removed and with first and last bearing
caps fitted.

Arosa 1997 ➤

Fitting position of camshaft bearing caps
Note offset. Before installing camshaft fit bearing caps and de‐
termine fitting position.
Valve dimensions
Note!
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 35.950 31.450
∅b mm 6.963 6.943
c mm 96.550 96.350
α ∠° 45 45
Camshaft identification, valve timing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Identification
♦ Cam base diameter: a = 38 mm ∅
♦ Identification by stamped numbers and letters between inlet
and exhaust cams:
Cylinder Identification
Cylinder 1 -arrow A- W
Cylinder 2 -arrow B- 028 H
Valve timing at 1 mm valve lift
Valve Valve timing
Inlet opens after TDC 11 °
Inlet closes after BDC 25 °
Exhaust opens before BDC 40 °
Exhaust closes before TDC 10 °
2.1 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool

Arosa 1997 ➤
Note!
♦ When repairing engines with leaking valves, it is not always

sufficient to reface or renew valve seats and valves. It is also
necessary to check the valve guides for wear. This particularly
important on high mileage engines.
♦ The valve seats should only be reworked just enough to pro‐
duce a perfect seating pattern. The maximum permissible
reworking dimension must be calculated before reworking
commences. If the reworking dimension is exceeded, the func‐
tion of the hydraulic tappets can no longer be guaranteed and
the cylinder head should be renewed.
2.1.1 Work sequence

The max. permissible reworking dimension is calculated as fol‐
lows:
– Insert valve and press firmly against seat.
Note!
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate max. permissible reworking dimension from meas‐
ured distance -a- and minimum dimension.
Minimum dimension: Inlet valve 35.8 mm Exhaust valve 36.1 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
- Measured distance 36.5 mm
= max. perm. rework dimension 0.7 mm
2.1.2 Reworking inlet valve seat

a = 35.7 mm ∅
b = 1.6 mm
45 ° = Valve seat angle
Note!
The 30 ° lower valve seat chamfer is necessary to ensure that the

inlet channel flow characteristics are maintained.

Arosa 1997 ➤
2.1.3 Reworking exhaust valve seat

a = 31.4 mm ∅
b = 2.7 mm
45 ° = Valve seat angle
2.2 Checking valve guides

♦ Dial gauge
2.2.1 Test sequence

– Insert new valve into guide until end of valveunless
stem is flush withS.A. SEAT S.A does not guarantee or accept any liability with
permitted authorised by SEAT
end of guide. Due to the slight difference respect
in stem dimensions,
ensure that only an inlet valve is used in the inlet guide and an
exhaust valve in the exhaust guide.
– Rock: Max. 1.3 mm
2.3 Renewing valve guides


Arosa 1997 ➤
♦ Drift -T20035- (6 mm ∅)
♦ Hand reamer -T20066- and cutting fluid
2.3.1 Removing
– Clean and check cylinder head. Cylinder heads in which the
valve seats can no longer be reworked, or cylinder heads
which have already been machined to the minimum dimen‐
sion, are not suitable for valve guide replacement.
– Press out worn valve guides with drift -T20035- (6 mm ∅) from
the camshaft side (valve guides with shoulder - repair version
- from the combustion chamber side).
2.3.2 Installing
– Press in new guides, moistened with
permitted unless oil, from
authorised by SEATcamshaft
S.A. SEAT S.A side
onto shoulder in cold cylinder head using drift -T20035- (6 mm
∅).
Note!
When the shoulder on guide makes contact, the pressure must

not exceed 1.0 t otherwise shoulder may break off.
– Ream guides out with hand reamer -T20066- , use cutting fluid
when doing this.
– Rework valve seats ⇒ page 43 .
2.4 Renewing valve stem seals

Arosa 1997 ➤

equipment required
♦ Pliers -U-10014-
♦ Storage plate -U-10083-
♦ Fitting tool -U-30007-
♦ Assembly tool -T20034-
(with 35 mm ∅ press piece)
♦ Puller -T20058-
2.4.1 Removing
(with cylinder head fitted)
– Remove camshaft ⇒ page 48 .
– Remove bucket tappet with pliers -U-10014- .
– Place down on storage plate -U-10083- with running (contact)
surface downwards Ensure the tappets are not interchanged
when doing this.
– Set piston of permitted
respective cylinderbyto
unless authorised top
SEAT dead
S.A. centre
SEAT S.A (TDC).
– Fit assembly tool -T20034- (with 35 mm ∅ press piece) and
secure using bearing cap securing nuts.
– Remove cotters and valve springs and place down on storage
plate -U-10083- .
Note!
The valves are supported by the piston crown.
– Pull off valve stem seals with puller -T20058- .

Arosa 1997 ➤
2.4.2 Installing
– Place the plastic sleeve -A- supplied on the appropriate valve
stem. This will prevent the new valve stem seal being dam‐
aged.
– Insert new valve stem seal -B- in fitting tool -U-30007- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
– Install camshaft ⇒ page 48 .
2.5 Removing and installing camshaft

equipment required
♦ Pin -U-20003-
♦ Counter-hold -T20018-
respect tool

T20029-
(20...100 Nm)
♦ Punch 6 mm ∅

Arosa 1997 ➤
2.5.1 Removing
(with cylinder head fitted)
housing using -T20029- for spring-type clips.

pump sprockets. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note!

tighten the camshaft. Use counter-hold -T20018- .

Arosa 1997 ➤
– Place a punch (6 mm ∅) through hole in the rear of the toothed

– Take camshaft sprocket off.
– First remove bearing caps 5, 1 and 3. Then loosen bearing
caps 2 and 4 alternately and diagonally.
2.5.2 Installing
Note!
♦ When installing the camshaft No. 1 cylinder cams must point

upwards.
♦ When installing the bearing cap note offset, before installing
camshaft fit bearing caps and determine fitting position.
– Oil camshaft running surfaces.

– Tighten bearing caps 2 and 4 alternately and diagonally to 20
Nm.
– Install bearing caps 5, 1 and 3 and also tighten to 20 Nm.
– Locate bearing cap 5 by tapping lightly on the end of the cam‐
shaft.
– Install camshaft sprocket.
– Install and tension toothed belt ⇒ page 14 .
Note!
When new tappets have been installed the engine must not be
started for about 30 minutes. Hydraulic compensation elements
must settle (otherwise valves will strike pistons).
2.6 Checking hydraulic bucket tappets

♦ Feeler gauge
♦ Wood or plastic wedge
Note!
♦ Renew Protected
defective tappetCopying
by copyright. complete (cannot
for private be purposes,
or commercial adjusted or orre‐
in part in whole, is not
paired).
♦ Irregular valve noises when starting engine are normal.

• Engine oil temperature min. 80 °C

Arosa 1997 ➤
2.6.2 Test sequence

– Start engine and run until engine oil temperature is min. 80 °
C.
– Increase engine speed to about 2500 rpm for approx. 2 mi‐
nutes.
If the hydraulic tappets are still noisy, locate defective tappets as
follows:
– Remove cylinder head cover.
– Rotate crankshaft clockwise, until cam of the tappet to be
checked is pointing upwards.
– Determine play between cam and bucket tappet.
– If the play is in excess of 0.1 mm, renew bucket tappet. If the
play is less than 0.1 mm or no play, proceed with check as
follows:
– Press tappet down with a wooden or plastic wedge. If free
travel in excess of 1 mm is felt before tappet contacts valve,
renew tappet.
Note!
After installing new tappets thepermitted

engine must
respect not be started
to the correctness for in this document. Copyright by SEAT S.A.
of information
approx. 30 minutes. Hydraulic compensation elements must set‐
tle (otherwise valves will strike pistons).

Arosa 1997 ➤
17 – Lubrication
1 Removing and installing parts of the
lubrication system
Note!
♦ If large quantities of metal particles or other deposits (caused,

for example, by partial seizure of the crankshaft or conrod
bearings) are found in the engine oil when performing repairs,
the oil passages in the oil cooler must be cleaned thoroughly
to prevent further damage.
♦ The oil level must not be
Protected aboveCopying
by copyright. the max. mark
for private - danger
or commercial of in part or in whole, is not
purposes,
damage to catalyst!
Checking oil pressure ⇒ page 55 .

Oil system capacity:
with oil filter 4.7 ltrs.
Engine oil specifications:
Only use engine oil conforming to VW standard 50000, 50101,
50200 or 50500 or multi-grade oil corresponding to API-CD.

Arosa 1997 ➤
1 - Cap
2 - Gasket
3 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 55
4 - Guide tube
5 - 25 Nm
6 - Gasket
❑ Renew
F1- , 25 Nm
❑ Grey
❑ Checking oil pressure
and oil pressure switch
⇒ page 55
❑ If sealing ring is leaking
nip open and replace.
8 - Oil filter bracket
9 - Oil filter
wrench -U-40078- or
socket -U-30043-
❑ Tighten by hand
1. Removing and installing parts of the lubrication system 53

Arosa 1997 ➤
ter when installing

10 - O ring
❑ Renew
11 - 45 Nm
12 - Gears
❑ Checking backlash ⇒ page 54
❑ Checking axial clearance ⇒ page 55
13 - Oil pump cover with pressure relief valve
❑ Opening pressure: 5.7...6.7 bar
14 - Sump
15 - Seal
❑ Renew
16 - Oil drain plug, 30 Nm
17 - 20 Nm
❑ Remove and install both rear bolts at gearbox end with spanner -U-40051- and socket -U-40051/1- or -
U-40051/2-
18 - 10 Nm
19 - Baffle plate
20 - Suction pipe
❑ Clean strainer if soiled
21 - Gasket
❑ Renew
❑ Before fitting gasket coat sump flange/cylinder block flange with -D2-
22 - 25 Nm
❑ Insert without sealant
23 - Oil spray jet
❑ For piston cooling
Checking oil pump backlash
Special tools and workshop equipment respect

required
♦ Feeler gauge
New: 0.05 mm

Arosa 1997 ➤
Wear limit: 0.20 mm

Checking oil pump axial clearance

♦ Feeler gauge
♦ Straight edge
Wear limit: 0.15 mm
Markings on oil dipstick

1 - max. mark
2 - min. mark
a - Area above hatched field up to max. mark: Do not top-up with
engine oil!
b - Oil level within hatched field: can be topped-up with engine oil
c - Area from min. mark up to hatched field: fill with max. 0.5 ltr.
of engine oil!
1.1 Checking oil pressure and oil pressure switch

Arosa 1997 ➤

equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Diode test lamp -V.A.G
1527 B-
♦ Adapter set -V.A.G 1594 A-
Note!
♦ Functional check and servicing the optical and acoustic oil

pressure warning:
cations

• Engine oil temperature min. 80 °C

Arosa 1997 ➤
1.1.2 Test sequence

– Remove oil pressure switch -F1- and screw into tester.
– Screw tester into the oil filter bracket in place of the oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect diode test lamp -V.A.G 1527 B- using aux. cables
from -V.A.G 1594 A- to battery positive (+) and oil pressure
switch.
– Start engine and increase speed slowly. At 0.75...1.05 bar the
LED must light up, otherwise renew oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed 7.0 bar.
If necessary renew oil pump cover with pressure relief valve.

Arosa 1997 ➤
1 Removing and installing parts of cool‐
ing system
Note!
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary release pressure before commencing repair
work.
♦ Hoses are secured with spring-type clips. In cases of repair
only use spring-type clips.
♦ Pliers -T20029- are recommended when installing spring-type
clips.
Perform cooling system leakage test with cooling system tester -

V.A.G 1274- and adapters -V.A.G 1274/3- and -V.A.G 1274/4- .
Parts of cooling system body side ⇒ page 58 .
Parts of cooling system engine side ⇒ page 60 .
Coolant hose connection diagram ⇒ page 62 .
Draining and filling with coolant ⇒ page 64 .
Coolant mixture ratios
permitted ⇒ authorised
unless page 64 , draining
by SEAT S.A. SEATand filling
S.A does with cool‐
ant. respect to the correctness of information in this document. Copyright by SEAT S.A.
1.1 Parts of cooling system body side

Arosa 1997 ➤
1 - Radiator
⇒ page 65
❑ After replacing renew
entire coolant
2 - Lock carrier
3 - Radiator fan
4 - 10 Nm
5 - Bracket
6 - Cable retainer
❑ To thermostat in ther‐
mostat housing
tion diagram
⇒ page 62
❑ Secured to radiator with
retaining clip
8 - From heat exchanger
tion diagram
9 - Connector respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ From connection on cyl‐
inder head
tion diagram
⇒ page 62
❑ Secured to radiator with retaining clip
11 - Expansion tank
❑ Carry out leak test of cooling system with cooling system tester -V.A.G 1274- and adapter -V.A.G1274/3-
12 - O-ring
13 - Cap
❑ Check with cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/4-
❑ Test pressure 1.4...1.6 bar
14 - Cover
15 - From cylinder head
16 - To coolant pipe
17 - Thermo-switch -F18- , 35 Nm
1. Removing and installing parts of cooling system 59

Arosa 1997 ➤
❑ Switching temperatures: 1st speed on: 92...97 °C off: 84...91 °C 2nd speed on: 99...105 °C off: 91...98
°C
1.2 Parts of cooling system engine side
1 - O-ring
❑ Renew
2 - 10 Nm
3 - To upper coolant hose
❑ ⇒ Item 10 (page 59)
tion diagram
⇒ page 62
4 - Retaining clip
❑ Check seated securely Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Coolant temperature send‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
er -G62-
❑ With coolant tempera‐
ture gauge sender -G2-
❑ If necessary release
pressure in cooling sys‐
tem before removing
❑ Checking: ⇒ Vehicle di‐
agnosis, testing and in‐
formation system VAS
5051
6 - To top of expansion tank
❑ ⇒ Item 15 (page 59)
tion diagram
⇒ page 62
7 - Bracket
8 - Coolant pipe
tion diagram

Arosa 1997 ➤
⇒ page 62
10 - To heat exchanger
11 - From bottom of expansion tank
❑ ⇒ Item 11 (page 59)
❑ From bottom of radiator ⇒ Item 7 (page 59)
❑ Secured to radiator with retaining clip
14 - Compact bracket
❑ For coolant pump, coolant thermostat, ribbed belt tensioning roller, alternator and P.A.S. vane pump
15 - 25 Nm
❑ Note tightening sequence ⇒ page 63
16 - Ribbed belt
❑ Check for wear
❑ Do not kink
17 - Pulley

Arosa 1997 ➤
1.3 Coolant hose connection diagram
1 - Intake pipes
2 - Cylinder head/cylinder
block
3 - Heating system heat ex‐
changer
4 - Expansion tank
5 - Coolant pipe
8 - Cooler
9 - Coolant pump/thermostat

Arosa 1997 ➤
1.4 Removing and installing coolant pump and compact bracket
1 - 25 Nm
tighten
2 - Belt pulley
3 - 10 Nm
4 - Coolant pump
❑ Check for ease of move‐
ment
5 - O-ring
❑ Renew
6 - 25 Nm
❑ Do not tighten until the
injection pump is bolted
tightly to the console
❑ Note tightening se‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
quence ⇒ page 63 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7 - Compact bracket
❑ For coolant pump, cool‐
ant thermostat, ribbed
belt tensioning roller, al‐
ternator and P.A.S.
vane pump
8 - 25 Nm
❑ Note tightening se‐
quence ⇒ page 63
❑ Checking: heat-up ther‐
mostat in water
❑ Opening commences
approx. 85 °C
❑ Ends approx. 105 °C
❑ Opening lift min. 7 mm
10 - Connection
Tightening sequence compact bracket to cylinder block

1 - Guide bracket into fitted hole -1-
2 - Tighten bolt -2- , 25 Nm
6 - Tighten bolt -6- , 25 Nm (injection pump must be tightly bolted
to console)

Arosa 1997 ➤
1.5 Draining and filling cooling system

♦ Pliers for spring-type clips -T20029-
♦ Anti-freeze tester
1.5.1 Draining
– Remove cap from coolant expansion tank.
– Drain coolant from bottom
Protected radiator
by copyright. hose.
Note!

Arosa 1997 ➤
1.5.2 Filling
Note!
♦ Only use coolant additive G 12 in accordance with TL VW 774

D. Identification: coloured red
♦ On no account must G 12 be mixed with other coolant addi‐
tives!
with other coolant. In this case the coolant must be changed.
♦ G 12 and coolant additives marked “In accordance with TL VW
774 D” prevent frost and corrosion damage, scaling and also
raise boiling point of coolant. For this reason the system must
be filled all year round with frost and corrosion protection ad‐
ditives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Protected against frost to about -25 °C (in arctic climatic coun‐
tries to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The anti-
freeze ratio must be at least 40 %.
♦ If for climatic reasons a greater frost protection is required, the
amount of G 12 can be increased, but only up to 60 % (frost
protection to about -40 °C), as otherwise frost protection is re‐
duced again and cooling Protected
effectiveness isCopying
by copyright. also reduced.
♦ If radiator, heat exchanger, cylinder head
respect to the or cylinder
correctness head
gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:

Frost protection to Anti-freeze amount G 126) Water6)
-25 °C 40 % 2.60 ltr. 3.90 ltr.
-35 °C 50 % 3.25 ltr. 3.25 ltr.
6) The quantity of coolant can vary depending upon the vehicle equipment.
– Secure coolant hose to lower connection on radiator.

– Fill with coolant up to max. mark on expansion tank.
– Fit expansion tank cap.
– Set heater controls to maximum heat position.
– Start engine and maintain an engine speed of about 2000 rpm
for approx. 3 minutes.
– Run engine until radiator fan cuts-in.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
on the max. mark, when the engine is cold, between the min.
and max. marks.
1.6 Removing and installing radiator

Arosa 1997 ➤

equipment required
♦ Pliers for spring-type clips -
T20029-
(5...25 Nm)
(20...100 Nm)
1.6.1 Removing
– Removing front bumper: ⇒ General body repairs; Rep. Gr.
63 ; FrontProtected
bumper Removing
by copyright. Copyingand installing
for private bumper
– Pull coolant hoses
respect tooff radiator.of information in this document. Copyright by SEAT S.A.
the correctness
– Pull connectors off thermo-switch.

– Remove radiator securing bolts and take radiator out down‐
wards.
1.6.2 Installing
Installation is carried out in the reverse order, when doing this
note the following:
– Filling with coolant ⇒ page 64 .

Arosa 1997 ➤

1 Removing and installing parts of fuel
supply system
Note!

spring-type clips.
clips.
Servicing fuel filter ⇒ page 69 .

Observe safety precautions ⇒ page 69 .
Observe rules for cleanliness ⇒ page 70 .
Servicing accelerator mechanism ⇒ page 71 .
1.1 Removing and installing fuel tank with its attachments
1 - Sealing cap
2 - Securing screw
3 - Tank flap unit
❑ With rubber cup
4 - Gravity/overflow valve
❑ To remove valve unclip
upwards out of support
❑ Check valve for
through-flow valve verti‐
cal: open, valve tilted 45
°: closed
5 - O-Ring
❑ Renew
❑ Check securely seated
7 - Connector
❑ For fuel gauge sender
8 - Union nut respect to the correctness of information in this document. Copyright by SEAT S.A.

spanner -U-40055-
9 - Fuel gauge sender
❑ Note fitting position on
fuel tank ⇒ page 68
10 - Sealing ring
❑ Coat with fuel when in‐
1. Removing and installing parts of fuel supply system 67

Arosa 1997 ➤
stalling
11 - Spacer bush
12 - 15 Nm
13 - Fuel tank
14 - 25 Nm
15 - Securing strap
❑ Note differing length
16 - Supply pipe
❑ To fuel filter ⇒ Item 2 (page 69)
❑ Black
❑ Clipped onto fuel tank
❑ To remove from flange press release button on connecting piece
17 - Return pipe
❑ From fuel filter ⇒ Item 2 (page 69)
❑ Blue or blue markings
❑ Clipped onto fuel tank
❑ Check securely seated Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To remove from flange press release button on connecting
of information inpiece
respect to the correctness this document. Copyright by SEAT S.A.
18 - Vent valve
❑ To remove valve unclip out of side support
❑ Before installing remove sealing cap
Installation position of fuel gauge sender

Marking on sender must align with the marking on fuel tank
-arrows- .
Connections for blue (or with blue marks) return hose -1- and
black supply hose -2- are marked on the flange of the fuel gauge
sender with arrows.
Note!
After installing fuel gauge sender check that the supply pipe -2-
and return pipe -1- are securely clipped onto fuel tank.
Checking vent valve

Lever in rest position: Closed
Lever pushed in direction of arrow: Open
Note!
Before installing vent valve remove fuel tank sealing cover.

Arosa 1997 ➤
1.2 Servicing fuel filter
1 - Return pipe
❑ From injection pump
2 - Supply pipe
❑ Black
❑ To injection pump
3 - O-Ring
❑ Renew
4 - Control valve
❑ Installation position: ar‐
row points towards fuel
tank
❑ When changing filter,
remove securing clip
and take control valve
off complete with fuel
pipes
❑ Below + 15 °C: Passa‐
geway to filter open
❑ Over + 31 °C: Passage‐
way to filter closed
5 - Securing clip
❑ Check seated securely
6 - Return pipe
❑ To fuel tank
7 - Supply pipe
❑ Black
❑ From fuel tank
8 - Fuel filter
❑ Fill with diesel before installing
❑ Flow direction is marked by an arrow
❑ Do not interchange connections
9 - Gasket
10 - Water drain plug
❑ To bleed remove securing clip and take control valve off complete with fuel pipes attached
❑ Loosen and allow
Protected approx.
by copyright. Copying100 cm³orfluid
for private to drain
1.3 Safety precautions when working on the

fuel supply system
When removing and installing the fuel gauge sender from a full or
partly full fuel tank the following must be observed:

Arosa 1997 ➤
♦ Before commencing work, switch on exhaust exctraction sys‐

tem and place an extraction hose close to the sender opening
in the fuel tank to extract escaping petrol fumes. 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 can
be used.
♦ Prevent skin contact with petrol! Wear fuel-resistant gloves!
1.4 Rules for cleanliness

When working on the fuel supply/injection system, pay careful at‐
tention to the following “6 rules” :
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ Place parts that have been removed on a clean surface and
cover. Do not use fluffy cloths!
♦ Carefully cover opened components or seal, if the repair can‐
not be carried out immediately.
♦ Only install clean components: Only unpack replacement
parts immediately prior to installation. 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 if
this can be avoided. Do not move vehicle unless absolutely
necessary.
♦ Also ensure that no Diesel fuel runs onto the coolant hoses. If
1.5 Removing and installing fuel tank

♦ Torque wrench -SAT 8010- (5...25 Nm)
1.5.1 Removing respect to the correctness of information in this document. Copyright by SEAT S.A.
– Note safety precautions before starting work ⇒ page 69 .
Note!


strap.
– Remove rear axle: ⇒ Running gear; Rep. Gr. 42 ; Servicing
rear axle Removing and installing rear axle

Arosa 1997 ➤
– Remove rear right wheel housing liner: ⇒ General body re‐

pairs; Rep. Gr. 66 ; Wheel housing liner Removing and
installing rear wheel housing liner
– Open fuel flap.
– Drain fuel tank, clean fuel filler neck and surrounding area.
– Unscrew securing bolts and remove tank flap unit with rubber
cup.
– Remove securing bolts on filler neck.
– Fold rear seat bench forwards.
– Remove fuel gauge sender cover plate.
– Pull fuel return hose -1- (blue) and fuel supply hose -2- (black)
off flange.
Note!
Press buttons on hose couplings -arrows- to do this.
– Pull off connector -3- .

– Undo tensioning strap and support fuel tank.
– Lower fuel tank.
1.5.2 Installing
Install in reverse order but note following:
♦ Route breather hose kink free.
♦ Clip supply and return pipe onto fuel tank.
♦ Do not interchange supply and return hoseunless
permitted (return hose
authorised blueS.A. SEAT S.A does not guarantee or accept any liability with
by SEAT
or blue markings, supply hose black). respect to the correctness of information in this document. Copyright by SEAT S.A.
Connections for blue (or with blue marks) return hose -1- and
black supply hose -2- are marked on the flange of the fuel gauge
sender with arrows.
1.6 Servicing accelerator mechanism

Arosa 1997 ➤
1 - Bearing bracket
sender -G79-
❑ Adjusting ⇒ page 75
❑ Bearing bracket,
⇒ Item 1 (page 72) must
be removed to remove
and install the sender
3 - 6-pin connector
❑ For accelerator pedal
position sender
4 - 10 Nm
5 - 25 Nm
6 - Accelerator pedal
7 - Adjustment bolt
8 - Spring washer
9 - Cable cam
10 - Hexagon bolt

Arosa 1997 ➤
1.7 Checking accelerator pedal position sender

equipment required
♦ Hand multimeter -V.A.G
1526 A-
♦ Test box -V.A.G 1598/22-
V.A.G 1552- with cable -
V.A.G 1551/3A-
The accelerator pedal position sender is located on accelerator

pedal and passes the driver's requirement (pedal position) on fur‐
ther to the control unit.
1.7.1 Test sequence

– Connect fault reader -V.A.G 1551- ( -V.A.G 1552- ) and with
ignition switched on select engine electronics control unit with
the “Address word” 01: ⇒ Vehicle diagnosis, testing and infor‐
Indicated on display: Rapid data transfer HELP
Select function XX
– Press keys 0 and 8 for the function “Read measured value

block” and confirm entry with Q key.
Indicated on display: Read measured value block HELP
– Press keys 0 , 0 and 2 for “Display group number 2” and

confirm entry with Q key.

Arosa 1997 ➤

0 rpm 0.0 % 0 1 0 18.4 °C
– Check accelerator pedal position display in display zone 2.

The accelerator pedal must not be depressed. Specification:
0.0 %
– Check additionally the idling speed switch display in display
zone 3. The centre position must show 1. Display: 0 1 0
0 rpm 100.0 % 0 0 0 18.4 °C
– Depress accelerator pedal slowly until fully down, and observe

display zones 2 and 3.
♦ Display zone 2: The accelerator pedal position figure must in‐
crease continuously. Specification at full throttle position: 100
%
♦ Display zone 3: The centre position must change to 0. Display:
000
– Press the → key.
– Press permitted
keys 0unless
andauthorised
6 for the function
by SEAT S.A. SEAT“End
S.A doesoutput” andorconfirm
not guarantee accept any liability with
entry with the Q tokey.
respect the correctness of information in this document. Copyright by SEAT S.A.
– Switch off ignition.

End specification value not achieved:
– Adjust accelerator pedal position sender ⇒ page 75 .
Display does not change or is erratic:
– Check accelerator pedal position sender as follows:
– Separate 6-pin connector -1- for accelerator pedal position
sender.
– Measure sender resistance between connector contacts 1+3.

Specification: Accelerator pedal in idling position: 1.0...1.4
kΩ Accelerator pedal in full throttle position: 1.5...2.5 kΩ
– Check idling speed switch -F60- in accelerator pedal position
sender. To do this measure resistance between connector
contacts 4+6. Specification Accelerator pedal in idling posi‐
tion: max. 1.5 kΩ Accelerator pedal depressed: ∞ Ω
If the specifications are not obtained:
– Renew accelerator pedal position sender -G79-
If the specifications are attained:
Gr. 92 ; windscreen wiper system removing and installing
windscreen wiper system

Arosa 1997 ➤
– Connect test box -V.A.G 1598/22- to control unit wiring har‐

ness.
– Check wiring for open circuit between test box and connector
according to current flow diagram. Contact 1+ socket 24 Con‐
tact 2+ socket 11 Contact 3+ socket 23 Contact 4+ socket 12
Contact 5+ socket 8 Contact 6+ socket 25 Wire resistance:
max.
Protected 1.5 Ω Copying for private or commercial purposes, in part or in whole, is not
by copyright.
– respect
Additionally checkof wires
to the correctness forin short
information to one
this document. another,
Copyright toS.A.
by SEAT vehicle
earth and to battery positive. Specification: ∞Ω
If no wiring fault is detected:
– Renew engine control unit: ⇒ page 77
1.8 Adjusting pedal position sender

♦ Fault reader -V.A.G 1551- or vehicle system tester -V.A.G
1552- with cable -V.A.G 1551/3A-
1.8.1 Work sequence

(Accelerator pedal position sender removed)
Adjusting cable cam:

Arosa 1997 ➤
– Install cable cam in position as illustrated.

– Secure cable cam to sender so that the dimensions shown are
adhered to when facing forwards. a = 22 ± 0.05 mm b = 41 ±,
0.05 mm c = Forwards
Note!
The cable cam eye must be parallel to the forward direction.
– Then secure accelerator position sender with preassembled

cable cam to bearing bracket.
– Install bearing bracket.
– Reconnect sender 6-pin connector.
Fine adjustment with sender installed:
Indicated on display:
Select function XX

Read measured value block HELP


0 rpm 0.0 % 0 1 0 18.4 °C
– Check accelerator pedal position display in display zone 2.

The accelerator pedal must not be depressed. Specification:
0.0 %

0 rpm 100.0 % 0 0 0 18.4 °C
– Depress accelerator pedal slowly until fully down and observe

display zone 2. The value for the accelerator pedal position
must increase continuously and shortly before full throttle stop
reach 100 %.
– If necessary adjust accelerator pedal
permitted unless -2- by
authorised turning
by SEAT the S.A
S.A. SEAT ad‐does not guarantee or accept any liability with
justment screw -1- so that whenrespectaccelerator
to the correctnesspedal is not
depressed (idling position) 0.0 % and with accelerator pedal
depressed to just before full throttle position 100 % is dis‐
played.

Arosa 1997 ➤

1 Servicing diesel direct injection sys‐
tem
Diesel is drawn from the fuel tank by the distributor injection
pump, pressurised, and then sprayed into the combustion cham‐
ber onto the crown of the piston by the injector.
The quantity injected is regulated electronically by the diesel di‐
rect injection system control unit. The electronic regulation allows
the quantity injected and the injection characteristics, commence‐
ment of injection and exhaust gas recirculation, to be regulated
flexibly to meet requirements.
The diesel direct injection system control unit is equipped with a
fault memory. Before starting repairs, adjustments and fault find‐
ing, the fault memory must be interrogated ⇒ Vehicle diagnosis,
testing and information system VAS 5051 and final control diag‐
nosis performed ⇒ Vehicle diagnosis, testing and information
system VAS 5051 .
Note!
♦ When making adjustments and performing tests it is possible

that a control unit can recognize and store faults. Therefore
after performing all tests and completing adjustments the fault
memory must be erased ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051 .
♦ Components marked with an * are checked via the self-diag‐
nosis ⇒ Vehicle diagnosis, testing and information system
VAS 5051 , Interrogating fault memory.
♦ Components marked with **can be checked with the final con‐
trol diagnosis ⇒ Vehicle diagnosis, testing and information
system VAS 5051 .
♦ For trouble-free operation of the electrical components, a volt‐
age of at least 11.5 V is necessary.
♦ If the engine starts, runs for a short period and then stops, after
fault finding, repairs or component tests, then the fault may lie
with the immobilizer which is blocking the engine control unit.
The fault memory must be interrogated and if necessary the
control unit matched ⇒ page 123 .
♦ During some checks it is possible that the control unit will rec‐
ognise and store a fault. Therefore after completing all checks
and repairs the fault memory must be interrogated and if nec‐
essary erased ⇒ Vehicle diagnosis, testing and information
system VAS 5051 , Interrogating fault memory.
Safety precautions ⇒ page 77 .

Rules for cleanliness ⇒ page 78 .
1.1 Safetypermitted
precautions
To prevent injuries to persons and/or damage to the injection and
glow plug system, the following must be noted:
1. Servicing diesel direct injection system 77

Arosa 1997 ➤
♦ The ignition must be switched off before connecting or dis‐

connecting injection or glow plug system wiring or tester ca‐
bles.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, separate connector
-arrow- from fuel cut-off valve -N109- (10-pin connection to
injection pump metering control) on injection pump.
♦ Before disconnecting battery, obtain radio code for radios fit‐
ted with anti-theft coding.
♦ Disconnecting and connecting the battery must only be un‐
dertaken when the ignition switched off otherwise the diesel
direct injection system control unit may be damaged.
Observe following if test and measuring instruments are required
during a test drive:
♦ Test and measuring instruments must be secured to rear seat
and operated by a 2nd person from this location.
If test and measuring instruments are operated from front pas‐
senger's seat and the vehicle is involved in an accident, there is
a possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.

disconnecting.
♦ Only install clean components: Only
respectunpack replacement
necessary.
1.3 Fitting locations overview

Components A to C are not shown on the illustration.

Arosa 1997 ➤
A - Brake pedal switch -F47- *

or brake light switch -F- *
♦ Together in one housing, in
footwell on brake pedal
⇒ page 81
♦ Checking ⇒ page 102
B - Accelerator pedal position
sender -G79- *
♦ In footwell on accelerator:
⇒ page 67
C - Clutch pedal switch -F36-
♦ In footwell ⇒ page 81
♦ Checking ⇒ page 104 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - Fuel filter respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Servicing fuel filter:

⇒ page 67
2 - Throttle valve housing
and checking
⇒ page 82
❑ With throttle valve posi‐
tioner -V60- */**
❑ Checking throttle valve
positioner ⇒ page 117
3 - Intake air temperature
sender -G42-
❑ Is displayed as intake
manifold temperature
sender -G72- * if there is

Arosa 1997 ➤
a fault
4 - Diesel direct injection system control unit -J248- *
❑ Checking voltage supply ⇒ page 121
❑ Coding ⇒ page 122
❑ On replacement, the control unit must be matched to the electronic immobilizer ⇒ page 123
5 - Intake pipes
❑ Dismantling and assembling: ⇒ page 36
6 - Exhaust gas recirculation valve -N18- */** ⇒ page 127
7 - Exhaust gas recirculation valve ⇒ page 127
8 - Engine speed sender -G28- *
❑ Inductive sender
❑ Fitting location: Cylinder block
9 - 2-pin connector
❑ Brown for needle lift sender -G80-
10 - 3-pin connector Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Black for engine speed sender -G28- respect to the correctness of information in this document. Copyright by SEAT S.A.
11 - Coolant temperature sender -G62- *

❑ For engine control unit
❑ If necessary release pressure in cooling system before removing
12 - 10-pin connector
❑ Black
❑ For fuel temperature sender -G81- */**
❑ For metering adjuster -N146- *
❑ For modulating piston movement sender -G149- *
❑ For fuel cut-off valve -N109- */**
❑ For commencement of injection valve -N108- */**
13 - Injection pump metering device
❑ With fuel temperature sender -G81- */**
❑ With metering adjuster -N146- *
❑ With modulating piston movement sender -G149- *
14 - Fuel cut off valve -N109- */**
15 - Injector
❑ For 3rd cylinder with needle lift sender -G80- *
16 - Air cleaner
❑ Location: In front right wheel housing

Arosa 1997 ➤
Switches in footwell
1 - Clutch pedal switch -F36-
2 - Brake pedal switch/brake light switch -F47- /F)
Note!
The brake pedal switch -F47- and brake light switch -F- are to‐
gether in one housing.
1.4 Servicing injection pump
1 - 55 Nm
❑ Counter-hold with Pin -
U-20003- to loosen and
tighten
2 - Injection pump sprocket
❑ Single part
⇒ page 84 , Removing
and installing injection
pump
3 - Woodruff key
❑ Protected
Check seatedCopying
by copyright. securely
4 - Pipe respect
unionto the correctness of information in this document. Copyright by SEAT S.A.
❑ For supply pipe
❑ From fuel filter:
⇒ page 69
5 - Seal
❑ Renew
6 - Fuel cut-off valve -N109- */
**, 40 Nm
7 - Pipe union
❑ For return pipe
8 - Return pipe
❑ To control valve/fuel fil‐
ter: ⇒ page 69
9 - 25 Nm
10 - Injector pipes
❑ Tighten to 25 Nm

Arosa 1997 ➤
spanner -U-40072-
❑ Always remove pipework complete
❑ Do not alter shape
11 - 20 Nm
12 - Retainer
13 - Mounting
14 - Injector
❑ Servicing ⇒ page 97
❑ For 3rd cylinder with needle lift sender -G80- *
❑ Checking needle lift sender ⇒ page 113
15 - Heat insulation seal
❑ Renew
16 - 10 Nm
17 - Commencement of injection valve -N108- */**
❑ Checking ⇒ page 115 , Checking injection timing control range
18 - Strainer
19 - O-Ring
❑ Renew
20 - Bracket
21 - Timing control cover
❑ If leaking, replace O-ring ⇒ page 98
22 - Sleeve
❑ Tapered
23 - 25 Nm
❑ Nut with taper
24 - Console
1.5 Removing, installing and checking throt‐

tle valve
Protected housing
At low engine speeds the
respect to the vacuum
correctness in the intake
of information manifold
in this document. is not
sufficient to ensure correct functioning of the exhaust gas recir‐
culation system. Therefore to increase vacuum the throttle valve
remains closed up to 2200 rpm after starting the engine.

Arosa 1997 ➤
♦ Pliers for spring type clips -T20029-
1.5.1 Removing
– Take intake hose -1- off throttle valve housing -2- using pliers
-T20029- for spring-type clips.
– Pull vacuum hose -4- off throttle valve positioner -6- .
– Pull 2-pin -5- off throttle valve positioner -6- .
– Release throttle valve housing -2- by turning to right -arrow-
out of bayonet connection and remove.
– Take O-ring -3- off intake manifold cover-7- .
1.5.2 Installing
Installing the throttle valve housing is carried out in the reverse
order.
Note!
Renew O-ring -3- if damaged.

Arosa 1997 ➤
1.5.3 Functional check of throttle valve posi‐

tioner vacuum unit
– Take intake hose -1- off throttle valve housing -2- using pliers
-T20029- for spring-type clips.
– Start the engine and run at idling speed.
– Connect hand vacuum pump -SAT 1390- to vacuum unit -1-

and create a vacuum.
Specification: The throttle valve must close up to stop and remain
closed.
If the specification is not attained:
– Renew throttle valve housing (complete).
1.6 Removing and installing injection pump

Arosa 1997 ➤

equipment required
♦ Puller -U-20001-
♦ Pin -U-20003-
♦ TDC setting device -
U-20010-
♦ Engine support bracket
with legs -U-30025-
♦ Extension -U-30025/2-

Arosa 1997 ➤

T20029-
♦ Hand vacuum pump -SAT
1390-
(20...100 Nm)
♦ Feeler gauge
♦ Punch ∅ 6 mm
♦ Plastic hose (transparent approx. 1 m)
1.6.1 Removing
housing using pliers -T20029- for spring-type clips.
– Remove throttle valve housing ⇒ page 82 .

Arosa 1997 ➤
– Remove cover for intake pipes: ⇒ page 36

Engine removed:
– Install adjustment device -U-20010- as shown.


– Centralize setting bar as follows: Turn camshaft so that one
end of setting bar contacts the cylinder head. Using feeler
gauge establish the gap at the other end of the setting bar.
Place a feeler gauge corresponding to half the gap between
setting bar and cylinder head. Turn camshaft until the setting
bar contacts the feeler gauge. Place a 2nd feeler gauge, of
same thickness, at the other end between setting bar and cyl‐
inder head.
– Hook extension -U-30025/2- into bracket on lower right of cyl‐

inder block.

Arosa 1997 ➤
– Fit support bracket -U-30025- (with legs) and support engine,

in installation position with extension -U-30025/2- .
– Remove right-hand engine assembly mounting complete

-arrows- .
– Remove engine mounting on cylinder block.


pump sprockets.
– Remove injection pump sprocket securing nut.
– Pull pin -U-20003- out from injection pump sprocket.

Arosa 1997 ➤
– Loosen puller -U-20001- arms and offer up.

– Locate puller arms through holes in injection pump sprocket
and tighten.
– Place injection pump sprocket under tension with puller.
– Release injection pump sprocket from injection pump taper by
tapping on spindle of puller -arrow- (thereby hold sprocket so
that it does not fall off).
– Remove fuel supply and return pipes from injection pump.
– Remove injection pipes with spanner -U-40072- .
Note!
♦ Use spanner -U-40072- to loosen injection pipes.

♦ Always remove pipework complete, do not alter shape.
– Separate 10-pin connector -arrow- (connection to injection

pump metering adjuster) and unclip connetor from retainer.
– Remove securing nuts/bolt from console -arrows- .

Arosa 1997 ➤
– Then remove bolt from rear support -arrow- .

– Take off injection pump.
1.6.2 Installing
Note!

springtype clips.
clips. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Insert injection pump into console and then tighten securing
bolt on rear support with conical nut first.
– Align injection pump to centre position of console elongated
holes and secure hand tight.
Note!
♦ Commencement of injection is set dynamically with fault read‐

er -V.A.G 1551- / -V.A.G 1552- .
♦ Injection pump is tightened to prescribed tightening torque af‐
ter completing adjustments.
– Install injection pump sprocket and lock in position with pin -

U-20003- .
– When installing check woodruff key is fitted correctly.
Note!
Never use setting bar -U-40021- as a counter-hold when loosen‐

ing and tightening the camshaft sprocket. Use counter-hold -
T20018- .

Arosa 1997 ➤
– Place a punch ( 6 mm ∅) through hole in the rear of the toothed

– Take off camshaft sprocket.
– Check whether TDC mark on flywheel and reference mark are

aligned.
Engine removed:
– Install adjustment device -U-20010- as shown.

– Place tooth belt on injection pump sprocket and tensioning
roller.
– Fit camshaft sprocket into toothed belt and secure sprocket so
that the camshaft can still turn.

Arosa 1997 ➤
– Tension toothed belt. Turn eccentric clockwise with pin wrench

-U-30009/A- until the notch and the raised point align
-arrows- .
Note!
If the eccentric has been turned too far the tensioning roller must
be relieved completely and retensioned. The eccentric must nev‐
er be turned back when it has been turned too far.

– Check TDC mark on flywheel again.
– Tighten camshaft sprocket securing bolt to 45 Nm.
Note!
Never use setting bar -U-40021- as a counter-hold when loosen‐

ing and tightening the camshaft sprocket. Use counter-hold -
T20018- .
– Remove setting bar -U-40021- from camshaft and remove pin

-U-20003- from injection pump sprocket.
– Check if the TDC mark on flywheel the setting bar on camshaft
the pin in injection pump sprocket the tensioning roller setting
(notch/raised mark) align/are fitted correctly.
– If the notch and raised mark are not opposite one another
-arrows- , tension the tensioning roller further. To do this, hold
tensioning roller tight with pin wrench -U-30009/A- , release
securing nut, then turn eccentric clockwise further until the
notch and the raised mark are opposite one another and tight‐
en the securing nut to 20 Nm.
– Repeat check.
– Install injector pipework complete and tighten union nuts to 25
Nm.
– Connect fuel pipes to injection pump.
– Reconnect 10-pin connector -arrow- (connection
permitted unless to injection
pump metering control) and clip connector into
respectretainer.

Arosa 1997 ➤
Fill injection pump with diesel as follows:

– Screw adapter -V.A.G 1318/10- into injection pump return
supply opening.
– Connect hand vacuum pump -SAT 1390- with approx. 1 m
transparent plastic hose to adapter.
– Operate hand vacuum pump until fuel flows out of return sup‐
ply opening. Do not draw fuel into vacuum pump.
– Remove adapter and connect return supply pipe.
– Fit engine mounting on to cylinder block and tighten securing
bolts to 45 Nm.
– Fit complete right-hand assembly mounting to engine.

A7) = 40 Nm + 1/4 turn (90°) further
B = 50 Nm
C7) = 20 Nm + 1/8 turn (45°) further
7) Renew
Note!
The turning further

unlessangle can be measured withnotprotractor - any liability with
permitted authorised by SEAT S.A. SEAT S.A does guarantee or accept
T20030- . respect to the correctness of information in this document. Copyright by SEAT S.A.
– Install cover for intake pipes: ⇒ page 36

– Install throttle valve housing ⇒ page 82 .
– Install toothed belt guard, cylinder head cover and intake hose.
– Dynamically check commencement of injection and adjust if
necessary ⇒ page 93 .
– Tighten injection pump securing nuts/bolts to 25 Nm.
1.7 Dynamically checking and adjusting

commencement of injection
Note!
♦ Dynamically checking and correcting commencement of in‐

jection is only possible in function 04 “Engine basic setting” .
♦ The commencement of injection must always be checked after
renewing the toothed belt or loosening the injection pump bolts
or toothed belt sprockets and if necessary adjusted.

Arosa 1997 ➤

Checking and adjustment conditions
• Engine basic mechanical settings (timing) OK.
• Toothed belt tension OK.
1.7.1 Work sequence

– Connect fault reader -V.A.G 1551- ( -V.A.G 1552- ) and select
engine electronics control unit with the “Address word” 01.
When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine electronics con‐
VAS 5051 .)
Select function XX
– Press keys 0 and 4 for the function “Introduction of basic set‐

ting” and confirm entry with Q key.
Indicated on display: Basic setting HELP
– Press key 0 three times for “Display group number 0” and

Indicated on display: (1...10 = Display zones) System in basic setting 0 →
1 2 3 4 5 6 7 8 9 10
– Check coolant temperature in display zone 7. Specification:

less than 73 (equates to 85 °C)
Continue with check only when coolant temperature is attained.
The commencement of injection in display zone 2 is dependent
on the fuel temperature in display zone 9.

Arosa 1997 ➤
A - Display zone 2 commencement of injection B - Display zone

9 fuel temperature C - Specified range for commencement of in‐
jection
Example:
The numerical value 90 in display zone 9 B corresponds to a nu‐
merical value range of 40...79 in display zone 2 A.
Note!
♦ If the commencement of injection is advanced turn injection

pump in engine direction of rotation, if the commencement of
injection is retarded turn against direction of rotation.
♦ If when checking the commencement of injection the specifi‐
cations are within zone -C- then no adjustment is required.
After repairs e.g. removing and installing injection pump, ad‐
justing timing then the commencement of injection is to be set
to the mean value (dashed line) of specification zone -C- .
If the commencement of injection (timing) is outside the specifi‐

cation tolerances, adjust commencement of injection as follows:
– Loosen injection pump securing nuts/bolts approx. one turn,
leaving the easiest to reach nut/bolt till last.
– Hold injection pump by hand under tension in direction to be
adjusted.
– Carefully loosen last securing nut/bolt until the pump can be
turned slightly and then retighten securing nut/bolt.
– Observe figures in zone 2 and respect
if necessary adjust
to the correctness again until
the mean value for specification zone -C- is displayed.
– Tighten injection pump securing nuts/bolts to 25 Nm.
– Check commencement of injection again.
Select function XX
– Press keys 0 and 6 for the function “End output” and confirm
entry with the Q key.
Enter address word XX
Note!
♦ After dynamically adjusting the injection pump, always loosen

injector pipes on injection pump and retighten (25 Nm). This
relieves stress on pipes and prevents fatigue fractures.
♦ Use spanner -U-40072- to loosen and tighten injector pipes.
– Install upper toothed belt guard.

Arosa 1997 ➤
1.8 Removing and installing injectors

Note!
♦ Defective injectors cause the following faults:

♦ Misfiring
♦ Knocking in one or more cylinders
♦ Engine over-heating
♦ Loss of power
♦ Excessive black exhaust smoke
♦ Higher fuel consumption
♦ Excessive blue smoke when starting from cold
Defective injectors can be located by loosening the high pressure

pipe union on each injector in turn with the engine running at a
fast idling speed. If engine speed remains constant after loosen‐
ing a pipe union, this indicates a defective injector.
1.8.1 Removing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove injection pipes with spanner -U-40072- .

Arosa 1997 ➤
Note!
♦ Use spanner -U-40072- to loosen injection pipes.

♦ Always remove pipework complete, do not alter shape.
– Remove securing nut, take off retainer and take out injector.
1.8.2 Installing
Note!
Always renew heat insulating seal between cylinder head and in‐
jectors.
– Insert injector.
– Check mounting is seated correctly in cylinder head.
– Fit retainer.
Tightening torques:
Injection pipes = 25 Nm
Retaining clamp bolt = 20 Nm
1.9 Servicing injectors

This engine is equipped with dual spring injectors. The fuel injec‐
ted therefore occurs in 2 stages. If faults occur with these injectors
then they are to be exchanged as neither servicing nor pressure
setting is possible.
♦ Injector test unit -V.A.G 1322- with pressure pipe -V.A.G
1322/2-

• Pressure gauge on
1.9.2 Checking injection pressure

– Removing injectors ⇒ page 96 .
– Connect injector to injector test unit.
– Press pump lever down slowly. When spray begins, read off
opening pressure. For deviations from specification renew in‐
jector.
Caution
When testing injectors ensure that the jet of fuel does not con‐
tact the hands as the high pressure will cause the fuel to
penetrate the skin and may cause severe injuries.
Specification: New injectors: 190 ... 200 bar Wear limit: 170 bar

Arosa 1997 ➤
1.9.3 Checking for leaks

– Move pump lever down slowly and maintain a pressure of ap‐
prox. 150 bar for 10 seconds. No fuel should leak from the
nozzle tip.
– If injector leaks, replace.
– Installing injectors ⇒ page 96 .
1.10 Renewing injection timing device cover

O-ring
– Place a clean cloth under the injection pump.
– Remove cover screws -1- with commercially available key for
Torx socket head screws, e.g. -Hazet 2115-T30- .
– Remove cover -2- and clean it.
– Renew O-ring -3- and install cover with existing shims -4- .

Arosa 1997 ➤
2 Checking components and functions
2.1 Checking engine speed sender

The engine speed sender -G28- is a speed and reference mark
sender. If the speed signal fails when the engine is running the
engine will stop.
♦ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715-
♦ Adapter set -V.A.G 1594-
♦ Test box -V.A.G 1598/22-
2.1.1 Test sequence

– Separate black 3-pin connector to engine speed sender
-arrow- .
– Measure resistance between connector contacts 1+2. Speci‐

fication: 1.0 ... 1.5 kΩ
If the specification is not obtained:
– Renew engine speed sender -G28- : ⇒ page 9
If specification attained:
windscreen wiper system Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

ness.
2. Checking components and functions 99

Arosa 1997 ➤
– Check wiring for open circuit between test box and 3-pin con‐
nectoraccording to current flow diagram. Contact 1+ socket 69
Contact 2+ socket 67 Contact 3+ socket 71 Wire resistance:
max. 1.5 Ω
– Check wiring at 3-pin connector for short circuit to one another
according to current flow diagram. Specification: ∞ Ω
– Renew engine control unit ⇒ page 121 .
2.2 Checking coolant temperature sender

♦ Test box -V.A.G 1598/22-

• Engine must be cold.
2.2.2 Test sequence

VAS 5051 .)
Select function XX

Indicated on display: 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
HELP
Inputbydisplay
SEAT S.A.group number XXX

Indicated on display: Read measured value block 7 →
15.4 °C 15.9 °C 16.7 °C
– Observe coolant temperature figure in display zone 4. The

temperature figure must Increase uniformly and without inter‐
ruption.
Note!
♦ In cases of a fault the fuel temperature is displayed as an al‐

ternative.
♦ If the display on fault reader jumps by 2...5 °C, it is a control
unit fault and not caused by a defective sender.

Arosa 1997 ➤
– If no realistic display appears in display zone 4 or the fuel

temperature is displayed as a substitute. Check coolant tem‐
perature sender and wiring connections to sender as follows:
– Pull the 4-pin connector off coolant temperature sender -G62-
with coolant temperature gauge sender -G2- -arrow- .
– Measure resistance between sender contacts 1+3.
Specification see diagram

Scale A shows resistance values for temperature range 0...50 °C
and scale B the values for temperature range 50...100 °C.
Examples:
♦ 30 °C corresponds to a resistance from 1500...2000 Ω
– Renew coolant temperature sender -G62- with coolant tem‐
perature gauge sender -G2- ⇒ Item 11 (page 80) .

Arosa 1997 ➤

ness.
nector according to current flow diagram. Contact 1+ socket
70 Contact 3+ socket 54 Wire resistance: max. 1.5 Ω
– Additionally check wires for short to one another, to vehicle
2.3 Checking brake light switch and brake

pedal switch
Because the injection system operates with an accelerator pedal
sender (potentiometer) which may be defective, the engine is
regulated for reasons of safety when the brakes are operated. To
do this the control unit requires signals from the brake light switch
and also the brake pedal switch. This means that if the brakes are
operated when the accelerator pedal is held at a constant position
the engine is immediately reduced to idling speed. Incorrectly ad‐
justed switches may lead to unrequired regulating action
♦ Test box -V.A.G 1598/22- permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

• Fuses 2 and 20 must be OK.

Arosa 1997 ➤
2.3.2 Test sequence
Note!
– Connect the fault reader -V.A.G 1551- ( -V.A.G 1552- ) and

with ignition switched on select engine electronics control unit
with the “Address word” 01. (Connecting fault reader and se‐
lecting engine electronics control unit ⇒ Vehicle diagnosis,
testing and information system VAS 5051 .)
Select function XX


– Observe display in display zone 2.
Specification: 0 0 0 Read measured value block 6 →
0 km/h 0 0 0 000000 255
– Operate brake
unlesspedal slowly.
Specification: 0 1 1 Both displays must simultaneously change Read measured value block 6 →
from 0 to 1. 0 km/h 0 1 1 000000 255
♦ Centre display = Brake pedal switch

♦ Right-hand display = Brake light switch
– Release brake pedal slowly into rest position again.
Both displays must change from 1 to 0 again. Read measured value block 6 →
0 km/h 0 0 0 000000 255
If one or both displays do not change:

– Pull 4-pin connector off brake pedal switch -F47- and brake
light switch -F- -arrow- .

Arosa 1997 ➤
– Measure resistance between switch contacts 1+4. Specifica‐

tion Brakes not operated: ∞Ω Brakes operated: max. 1.5 Ω
– Measure resistance between switch contacts 2+3. Specifica‐
tion Brakes not operated: max.1.5 Ω Brakes operated: ∞Ω
– Renew brake pedal switch -F47- and brake light switch -F- .

ness.
nector according to current flow diagram. Contact 2+ socket 2
Contact 2+ socket 28 Contact 3+ socket 9 Contact 4+ socket
20 Wire resistance: max. 1.5 Ω
2.4 Checking clutch pedal switch

The clutch pedal switch supplies the control unit with information
as to whether the clutch is engaged or disengaged. If the clutch
is being operated the injected quantity is momentarily reduced.
This prevents engine jerks.
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤

• Fuses 2 and 20 must be OK.
2.4.2 Test sequence

– Connect the fault reader -V.A.G 1551- ( -V.A.G 1552- ) and
with ignition switched on select engine electronics control unit
with the “Address word” 01. (Connecting fault reader and se‐
lecting engine electronics control unit ⇒ Vehicle diagnosis,
testing and information system VAS 5051 .) by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
Indicated on display: respect to the correctness of information in this document.
Rapid Copyright by SEAT S.A.
data transfer HELP
Select function XX


– Observe display in display zone 2.
0 km/h 0 0 0 000000 255
– Operate clutch pedal. The left-hand position must change to

1.
0 km/h 1 0 0 000000 255
– Release clutch pedal slowly back to rest position.

Left-hand position of display must change from 1 to 0 again. Read measured value block 6 →
0 km/h 0 0 0 000000 255
If the display does not change:


Arosa 1997 ➤
– Pull 2-pin connector off clutch pedal switch -arrow- .
– Measure resistance at switch contacts. Specification Clutch

not depressed: max. 10 Ω Clutch depressed: ∞ Ω
– Renew clutch pedal switch -F36- .
If the specifications are attained:Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove wiper arms and cowl panel: ⇒respect
Electrical system;
to the correctness Rep. in this document. Copyright by SEAT S.A.
of information

ness.
tact 1+ socket 28 Contact 2+ socket 46 Wire resistance: max.
1.5 Ω
2.5 Checking intake air temperature sender
Note!
In case of fault the fault reader -V.A.G 1551- displays fault code
00527 for intake manifold temperature sender -G72- .

Arosa 1997 ➤

♦ Test box -V.A.G 1598/22-
2.5.1 Test sequence

VAS 5051 .)
Select function XX


15.4 °C 15.9 °C 16.7 °C
– If no realistic display appears in display zone 3 or a substitute

temperature of 136.8 °C is displayed, check intake manifold
temperature sender and the wiring to the sender as follows:
– Pull 2-pin connector off intake air temperature sender -G42-
-arrow- .

Arosa 1997 ➤
– Measure resistance between sender contacts 1+2.

Examples:
– Renew intake air temperature sender -G42- .
– Remove wiper
Protected arms Copying
by copyright. and cowl panel:
for private ⇒ Electrical
or commercial system;
purposes, in part or inRep.
whole, is not
Gr.permitted
92 ; windscreen
unless authorisedwiper
by SEATsystem
S.A. SEAT removing and installing

ness.
nector according to current flow diagram. Contact 1+ socket
13 Contact 2+ socket 25 Wire resistance: max. 1.5 Ω
2.6 Checking fuel temperature sender


Arosa 1997 ➤

♦ Test box -V.A.G 1598/22-
2.6.1 Test sequence

VAS 5051 .)
Select function XX


15.4 °C 15.9 °C 16.7 °C
– If no realistic display appears in display zone 1 or a substitute

temperature of -5.4 °C is displayed, check fuel temperature
sender and wiring to the sender as follows:
– Separate 10-pin connector -arrow- for fuel temperature sender
(connection to injection pump metering control).

Arosa 1997 ➤
– Measure resistance of sender at connector contacts 4+7.

Examples:
– Renew injection pump ⇒ page 84 .
– Connect test box -V.A.G

Protected 1598/22-
by copyright. Copying for to control
private unit wiring
or commercial purposes,har‐
ness.
– Check wiring for open circuit between test box and 10-pin
connector according to current flow diagram. Contact 4+ sock‐
et 76 Contact 7+ socket 53 Wire resistance: max. 1.5 Ω
2.7 Checking modulating piston movement

sender and meteringadjuster
The metering adjuster is an electro-magnetic swivelling positioner
which is controlled by the control unit via a directed duty cycle (on-
off ratio). The eccentric shaft on the metering adjuster moves the

Arosa 1997 ➤
modulating piston on the high pressure piston and thereby regu‐

lates the quantity of fuel injected.
The modulating piston movement sender informs the control unit
of the position of the metering adjuster -N146- and therefore stip‐
ulates the amount injected.
♦ Test box -V.A.G 1598/22-

• Coolant temperature at least 85 °C.
2.7.2 Test sequence

VAS 5051 .)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Select function XX

880 rpm 6.5 mg/H 1.580 V 87.3 °C
– Check coolant temperature in display zone 4. Specification: at

least 85 °C
Continue with check only when coolant temperature is attained.
880 rpm 6.5 mg/H 1.580 V 87.3 °C
– Check voltage supply from modulating piston movement send‐

er in display zone 3. Specification: 1.500... 2.100 V
– If specification is not attained. Check modulating piston move‐
ment sender and metering adjuster as described in following:

Arosa 1997 ➤
2.7.3 Checking modulating piston movement

sender -G149- .
– Separate 10-pin connector -arrow- for modulating piston
movement sender (connection to injection pump metering
control).
– Measure resistance between connector contacts 1 + 2 and 2

+ 3. Specification: 5.0 ... 7.0 Ω
Gr. 92 ; Windscreen wiper system Removing and installing

ness.
1.5 Ω

Arosa 1997 ➤
2.7.4 Checking metering adjuster -N146-

– Separate 10-pin connector -arrow- for metering adjuster (con‐
nection to injection pump metering control).
– Measure resistance between connector contacts 5+6. Speci‐

fication: 0.5...2.5 Ω

ness.
tact 5+ socket 28 Contact 6+ socket 59 Contact 6+ socket 66
Contact 6+ socket 80 Wire resistance: max. 1.5 Ω
2.8 Checking needle lift sender

The needle lift sender signal is used to determine the commence‐
ment of injection. If it fails the commencement of injection
switches to openloop control (according to engine speed and en‐
gine load). During normal operation the commencement of injec‐

Arosa 1997 ➤
tion is controlled by a closed-loop function (according to engine

speed, engine load and temperature).
♦ Test box -V.A.G 1598/22-
2.8.1 Test sequence

– Separate brown 2-pin connector for needle lift sender
-arrow- .
– Measure resistance between connector contacts. Specifica‐

tion: 80...120 Ω
– Renew No. 3 cylinder injector with needle lift sender -G80-
⇒ Item 14 (page 82) .

ness.

Arosa 1997 ➤
tact 2+ socket 55 Wire resistance: max. 1.5 Ω
2.9 Checking injection timing control range

♦ Test box -V.A.G 1598/22-
2.9.1 Test sequence

Checking the range of the injection timing control is undertaken
in function 04 (Basic settings). Using this procedure the com‐
mencement of injection valve is pulsed so that the extremity
values for advanced (early) and retarded (late) positions for the
timing device can be read in measured value block 004, display
zone 3.
VAS 5051 .)
Select function XX

Indicated on display: Basic setting HELP

Indicated on display: System in basic setting 4 →
880 rpm early 7.9 ° BTDC 66 %
Specification in display zone 3: 6.5...9.5° BTDC

After approx. 10 seconds the timing device is moved to the retar‐
ded (late) position. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Indicated on display: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
System
respect to the correctness of information in this in basic
document. setting
Copyright by SEAT 4
S.A. →
880 rpm late 3.9 ° BTDC 74 %
Specification in display zone 3: 2.5...5.5° BTDC

– If specification is not attained, check commencement of injec‐
tion valve as described in the following:

Arosa 1997 ➤

2.10 Checking commencement of injection

valve -N108-
– Separate 10-pin connector -arrow- for commencement of in‐
jection valve (connection to injection pump metering control).
– Measure resistance between connector contacts 9+10. Spec‐

ification: 12 ... 20 Ω
– Renew commencement of injection valve -N108-
⇒ Item 17 (page 82) .

ness. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.5 Ω

Arosa 1997 ➤
2.11 Checking throttle valve positioner

At low engine speeds the vacuum in the intake manifold is not
sufficient to ensure correct functioning of the exhaust gas recir‐
culation system. Therefore to increase vacuum the throttle valve
remains closed up to 2200 rpm after starting the engine.
♦ Test box -V.A.G 1598/22-

• unless
permitted Theauthorised
battery by voltage must
SEAT S.A. SEAT S.Abedoesatnotleast 11.5
guarantee V. any liability with
or accept
2.11.2 Test sequence

– Pull 2-pin connector off throttle valve positioner -arrow- .
– Measure resistance between throttle valve positioner con‐

tacts. Specification: 25...45 Ω
– Renew throttle valve positioner -V60- together with throttle
valve housing ⇒ page 82 , Removing and installing throttle
valve housing.
– If specification attained:
– Measure supply voltage at throttle valve positioner connector

contact 1 and at engine earth.
– Switch on ignition. Specification: approx. battery voltage

Arosa 1997 ➤

ness.
1.5 Ω
– Additionally check wires for shortunless
permitted to one another,
authorised by SEATto vehicle
earth and to battery positive. Specification: ∞Ω of information in this document. Copyright by SEAT S.A.
respect to the correctness


Arosa 1997 ➤
3 Checking additional signals
3.1 Checking speed signal

♦ Diode test lamp -V.A.G 1527-
♦ Test box -V.A.G 1598/22-

• There must be no faults stored in fault memory ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051 , Interrog‐
ating fault memory.
• Speedometer must be OK., checking speedometer: ⇒ Elec‐
trical system; Rep. Gr. 90
3.1.2 Test sequence
Note!
To check the speed signal the vehicle must be driven. To do this
a second person is necessary.
Caution
Secure fault reader to rear seat and operate from this position.
Observe the valid safety precautions when carrying out a road

test ⇒ page 77 .
VAS 5051 .)
Select function XX


– Carry out test drive with a 2nd person to observe display.
Specification display zone 1: Approx. road speed. Read measured value block 6 →
xxx km/h 0 0 0 000000 255
3. Checking additional signals 119

Arosa 1997 ➤
– Drive slower. The displayed value must decrease.

If no speed is indicated or the display values reduce when driving
slowly:
ness.
– Connect diode test lamp between socket 1 (earth) and socket
51 (speed signal).
– Lift vehicle at front left.
– Switch on ignition.
– Turn front wheel and observe the light emitting diode (LED) on
the diode test lamp. Light emitting diode must flash (approx.
four times per wheel rotation).
When the LED does not flash:
– Check wiring from engine control unit connector contact 51 to
dash panel insert for open/short circuit: ⇒ Current flow dia‐

Arosa 1997 ➤
4.1 Checking control unit voltage supply

♦ Test box -V.A.G 1598/22-

• The fuses 2, 3, 9 and 10 must be OK.
• Earth connection between engine and gearbox (on gearbox
bell housing) OK.
• All electrical consumers, e.g. lights and rear window heating
must be switched off.
4.1.2 Test sequence

– Remove the wiper arms and the cowl panel:
⇒ Electrical system; Rep. Gr. 92 ; Windscreen wiper system
Removing and installing windscreen wiper system
ness.
– Bridge sockets 33+1 with auxiliary cables from -V.A.G 1594- .
– Measure voltage between following sockets: 1+2, 1+28, 2+27
and 27+28 Specification: approx. battery voltage
– Check relay for terminal 30 -J317- voltage supply: ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations
– Check wiring connections for open circuit, short circuit and
transfer resistance at contacts according to current flow dia‐
gram.
If no fault is found in wiring and relay:
4.2 Replacing engine control unit


♦ Fault reader -V.A.G 1551- with cable -V.A.G 1551/3A-
4.2.1 Removing
– First print out the control unit identification and thereby the
previous control unit coding as follows:

Arosa 1997 ➤

When doing this the ignition must be switched on. (Connecting
fault reader and selecting engine electronics control unit ⇒ Ve‐
The control unit identification and the coding will appear on the 038906013L 1.7l R4 EDC 30SG 1821→
display, e.g.: Coding 00002 WSC xxxxx
– Print out the control unit identification by pressing the fault

reader print button.
Select function XX

– Release connector from control unit and pull off.
– Unclip control unit from retaining frame -arrows- .
4.2.2 Installing
– Place the new control unit into the retaining frame.
– Install control respect

unit connector and lock. in this document. Copyright by SEAT S.A.
to the correctness of information
– Check the previous coding and the code of the new control
unit ⇒ page 122 .
– Adapt (match) engine control unit to the electronic immobilizer
⇒ page 123 .
– Then subsequently interrogate the fault memory of the new
engine control unit (⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051 ) and erase the fault memory if neces‐
sary (⇒ Vehicle diagnosis, testing and information system VAS
5051 ).
4.3 Coding engine control unit

If the appropriate code for the vehicle is not displayed or if the
control unit has been renewed, the control unit must be coded as
follows.

Arosa 1997 ➤

4.3.1 Work sequence

When doing this the ignition must be switched on. (Connecting
fault reader and selecting engine electronics control unit ⇒ Ve‐
– Press → key.
Select function XX
– Press keys 0 and 7 for the function “Code control unit” and
Indicated on display: Code control unit Q
Input code
Protected by copyright. Copying for private or commercial purposes, in partnumber xxxxx
or in whole, is not (0-32000)
– Enter the appropriate code number for this vehicle and confirm
with Q key.
Coding For vehicles with

00001 Automatic gearbox (not relevant)
00002 Manual gearbox
The fault reader -V.A.G 1551- display will show the control unit 038906013L 1.7l R4 EDC 30SG 1821→
identification, e.g.: Coding 00002 WSC xxxxx
– Switch ignition off and then on again.
Note!
The coding entered will be activated by switching the ignition off

and then on again. If after entering the valid code the ignition is
not switched off and on again, the fault “Control unit incorrectly
coded” in the fault memory cannot be erased.
– Adapt (match) engine control unit to the electronic immobilizer

⇒ page 123 .
– Erasing fault memory ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .
4.4 Adapting (matching) engine control unit

to electronic immobilizer

Arosa 1997 ➤

• The fuses 2, 3, 9 and 10 must be OK.
• An authorized vehicle key must be available.

Arosa 1997 ➤
4.4.2 Work sequence

– Remove flap before fuse holder.
– Connect fault reader -V.A.G 1551- or vehicle system tester -
V.A.G 1552- with cable -V.A.G 1551/3A- .
– Operate fault reader or vehicle system tester taking into ac‐
count the information on the display:
– Press key 1 for “Rapid data transfer” .
– Press keys 2 and 5 for address word “Immobilizer” and con‐

firm entry with Q key.
6N0953257 IMMO VWZ3Z0V5171657 V00
Coding 09600 WSC xxxxx

Select function XX
– Press keys 1 and 0 for function “Adaption” and confirm entry

with Q key.
Indicated on display: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Adaption respect to the correctness of information in this document. Copyright by SEAT S.A.
Feed in channel number XX
– Press key 0 twice for “Channel number 0” and confirm entry

with Q key.
Adaption Q
Erase learnt values?
– Confirm input with Q key.

Adaption →
Learnt values have been erased
– Conclude adaption by pressing → key.

Select function XX

Arosa 1997 ➤
Note!
The identity of the engine control unit is read into the immobilizer
control unit when next switching the ignition on.

Arosa 1997 ➤
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 double clamp(s) and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Always renew self-locking nuts.
Exhaust manifold, front exhaust pipe with catalyst
1 - Seal
❑ Renew
3 - 25 Nm
4 - 40 Nm
5 - Frontpermitted
exhaust pipe
unless withbycat‐
authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
alyst respect to the correctness of information in this document. Copyright by SEAT S.A.
6 - To central silencer
7 - Mounting
Silencer with mountings
1. Removing and installing parts of exhaust system 127

Arosa 1997 ➤

alyst
2 - Marking
3 - Double clamp
4 - Dimension -a- = ca. 5 mm
5 - 40 Nm
6 - Centre silencer
7 - Mounting
8 - Tunnel bridge
9 - 15 Nm
10 - Mounting
❑ With retaining ring
❑ Renew if damaged respect to the correctness of information in this document. Copyright by SEAT S.A.
11 - 20 Nm + 1/4 turn (90 °)

further
❑ Renew
gle can be measured
12 - Rear silencer
13 - Marking
❑ For repair double clamp,
14 - Separating point
❑ For repair cases
❑ Marked by three impressions on circumference of connecting pipe
❑ Exhaust pipe and rear silencers are, as standard, installed as a single component. In repair cases the
exhaust pipe and rear silencer are supplied individually with a repair double clamp for connecting to‐
gether.
❑ Cut through connecting pipe with body saw e.g. -U-40075- at right angles at the separating point
15 - Repair double clamp
❑ Must be slid onto the markings, ⇒ Item 13 (page 128)

Arosa 1997 ➤
2 Exhaust gas recirculation system
Note!
♦ The function/ control of the exhaust gas recirculation system

is undertaken by diesel direct injection system control unit -
J248- via valve for exhaust gas recirculation -N18- to exhaust
gas recirculation valve.
♦ The cone shaped plunger in the mechanical exhaust gas re‐
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.
♦ Every conceivable valve position possible through pulsed con‐
trol.
♦ Always renew self-locking nuts.
2.1 Servicing parts of exhaust gas recirculation system
1 - Intake manifold
2 - Gasket
❑ Renew
3 - Vacuum pipe
❑ To exhaust gas recircu‐
lation valve -N18-
valve
❑ Checking activation:
⇒ Vehicle diagnosis,
testing and information Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
system VAS 5051 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 - Clamp
6 - 10 Nm
7 - Connecting pipe
9 - 25 Nm
2. Exhaust gas recirculation system 129

Arosa 1997 ➤
2.2 Vacuum hose connection diagram
1 - Vacuum pipe
❑ With filter
valve -N18-
❑ Checking activation:
⇒ Vehicle diagnosis,
testing and information
system VAS 5051
3 - Brake servo
valve
5 - Non-return valve
6 - To exhauster permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
2.3 Checking exhaust gas recirculation

valve

Arosa 1997 ➤
2.3.1 Test sequence

– Pull vacuum hose off exhaust gas recirculation valve -N18-
-arrow- .
– Connect hand vacuum pump -SAT 1390- to vacuum pipe to

exhaustgas recirculation valve -1- and produce a vacuum.
Specification: The membrane rod must moove towards the vac‐
uum connection.
Note!
The movement of the membrane rod on the mechanical exhaust

gas recirculation valve is seen very clearly when using a mirror.
– Pull hand vacuum pump hose off vacuum pipe to exhaust gas
recirculation valve.
Specification: The closing of the valve must be clearly heard,
(membrane rod moves towards the exhaust manifold).
– Renew exhaust gas recirculation valve ⇒ Item 4 (page 129) .
2.4 Checking exhaust gas recirculation valve

Arosa 1997 ➤

equipment required
1526-
♦ Test box -V.A.G 1598/22-

• The fuses 3 and 9 must be OK.

Arosa 1997 ➤
2.4.2 Test sequence

– Pull 2-pin connector off exhaust gas recirculation valve -N18-
-arrow- .
– Measure resistance between valve contacts. Specification:

14.0...18.0 Ω
Note!
At room temperature the resistance is in the area of the lower

tolerance and when engine is at operating temperature in region
of upper tolerance.

– Renew exhaust gas recirculation valve
permitted unless -N18-
authorised . S.A. SEAT S.A does not guarantee or accept any liability with
by SEAT
– Measure supply voltage of valve at contact 1 and at engine

earth.
– Switch on ignition. Specification: approx. battery voltage

ness.

Arosa 1997 ➤
tact 2+ socket 29 Wire resistance: max. 1.5 Ω

Arosa 1997 ➤
28 – Glow plug system

1 Checking glow plug system
Test conditions
• Diesel direct injection system control unit -J248- OK.
• Glow plug strip fuse -S 164- OK.
Test sequence
– Pull 4-pin connector off coolant temperature sender -G62- with
coolant temperature gauge sender -G2- -arrow- .
Note!
Pulling the connector off sender, simulates engine condition

“cold” and when switching the ignition on the relevant glow period
is carried out.

– Connect multimeter to measure voltage between a glow plug
connector and vehicle earth.
– Switch on ignition for approx. 20 seconds approx. battery volt‐
age must be displayed.
If no voltage is present:
– Check wiring for open/short circuit: ⇒ Current flow diagrams,
1.1 Checking glow plugs



1. Checking glow plug system 135

Arosa 1997 ➤
1.1.2 Test sequence

– Connect diode test lamp wire using auxiliary clips from auxili‐
ary cable set to battery positive (+).
– Place diode test lamp probe on each glow plug one after the
other. Diode lights up: Glow plug OK. Diode does not light up:
Renew glow plug.
– Install glow plugs with spanner -U-40082- Tightening torque:
15 Nm.
136 Rep. Gr. 28 - Glow plug system

Service
Workshop Manual
Arosa 1997 ➤
4-Cyl. Injection Engine (2 valves, roller rocket finger),
Mechanics
Engine ID ALD AUC ANV AKK AUD ANW
Edition 07.01

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling system
26 - Exhaust system

Copyright © 2015 Seat S.A S01AAKK8620

Arosa 1997 ➤
4-Cyl. Injection Engine (2 valves, roller rocket finger), Mechanics - Edition 07.01
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . 9
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Removing and installing cylinder block, sealing flange and flywheel . . . . . . . . . . . . . . . . . . 19
2.1 Aluminium cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Renewing crankshaft oil seal -belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Renewing crankshaft sealing flange -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.2 Replacing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3 Removing and installing cylinder head cover and camshaft . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4
permitted unless authorised Checking
by valve
SEAT S.A. SEAT guides
S.A does . . . .or.accept
not guarantee . . . any
. . .liability
. . . with
...................................... 54
2.5 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.2 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.4 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.6 Checking radiator fan V7 and V35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Contents i
Arosa 1997 ➤
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Removing and installing fuel tank with its attachments and fuel filter . . . . . . . . . . . . . . . . 78
1.2 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.5 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.6 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.7 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.8 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.2 Servicing parts of electronic
Protected power
by copyright. Copying control
for private (EPC) purposes,
or commercial . . . . .in. part
. . or
. .in.whole,
. . . .is.not ................ 91
2.3 Checking electronic
permitted unlessaccelerator warning
authorised by SEAT S.A. SEAT lamp
S.A does.not
. . . . . .
guarantee . or. accept
. . . . .
any
. . . .
liability . ...............
with 92
2.4 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.2 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3 Checking tank breather (vent) valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1 Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.1 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.2 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.3 Removing and installing parts of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4 Intake manifold: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.5 Dismantling and assembling fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.6 Dismantling and assembling air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Checking Lambda probe heating before catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Checking Lambda probe heating after catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.3 Checking throttle valve control part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.4 Checking intake manifold pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.5 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.6 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.7 Checking engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.8 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.9 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.10 Checking intake air system for leaks (unmetered air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.11 Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.12 Vacuum valve: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3 Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Idling check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Checking Lambda probe and Lambda regulation before catalyst . . . . . . . . . . . . . . . . . . . . 146
3.3 Checking Lambda probe and Lambda regulation after catalyst . . . . . . . . . . . . . . . . . . . . . . 150
3.4 Checking ageing of Lambda probe before catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.5 Checking engine operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.1 Checking control unit voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
ii Contents
Arosa 1997 ➤
4.2 Procedure after voltage supply open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

4.3 Replacing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.4 Coding engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.5 Coding variations of engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.6 Adapting engine control unit to throttle valve control part . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.7 Adapting engine control unit to electronic immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.1 Checking speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.2 Checking signal from/to air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.3 Checking signal from brake light switch and brake pedal switch . . . . . . . . . . . . . . . . . . . . 171
5.4 Checking rpm signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.5 Checking signal from power steering pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.6 Checking matching resistor of data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments . . . . . . . . 177
1.2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.3 Checking catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.1 Servicing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.2 Checking potentiometer for exhaust gas recirculation G212 . . . . . . . . . . . . . . . . . . . . . . 185
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.2 Removing and installing parts of the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.5 Checking Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.6 Checking ignition transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.7 Checking knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.8 Check misfiring recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Contents iii
Arosa 1997 ➤
iv Contents
Arosa 1997 ➤
1 Technical data
1.1 Engine number

The engine number (“Code letters” and “Serial number” ) can be
found on the front of the cylinder block at the gearbox end below
the thermostat housing.
Additionally there is a sticker on the toothed belt guard with “En‐
gine code” and “Serial number” .
The engine code is also included on the vehicle data plate.
1.2 Engine data

Engine code ALD ANV
Manufactured 05.99 ▸ 05.99 ▸
Exhaust emissions fulfil MVEG II standard D4 standard
Capacity cm³ 999 999
Output kW at rpm 37/5000 37/5000
Torque Nm at rpm 86/3000...3600 86/3000...3600 8
Bore mm ∅ 67.1 67.1
Stroke mm 70.6 70.6
Compression ratio 10.7 10.7
RON Protected by copyright. Copying for private ormind. 95inunleaded
commercial purposes,
1)
part or in whole, is not 95 unleaded1)
Injection, ignition Motronic Motronic
ME 7.5.10 ME 7.5.10
Knock control yes yes
Self-diagnosis yes yes
Lambda regulation 1 Lambda probe 2 Lambda probes 2
Catalyst yes yes2)
Exhaust gas recirculation no no
Charged no no
1) In exceptional circumstances min. 91 RON, however with reduced performance
2) Additionally with integrated pre-catalyst in exhaust manifold
Engine code AKK ANW

Manufactured 11.99 ▸ 11.99 ▸
Exhaust emissions fulfil MVEG II standard D4 standard
Capacity cm³ 1390 1390
Output kW at rpm 44/4700 44/4700
Torque Nm at rpm 116/3000 116/3000
Bore mm ∅ 76.5 76.5
Stroke mm 75.6 75.6
1. Technical data 1
Arosa 1997 ➤
Compression ratio 10.4 10.4 10

RON mind. 95 unleaded3) 95 unleaded3) 95 unle
Injection, ignition Motronic Motronic Motr
ME 7.5.10 ME 7.5.10 ME 7
Knock control yes yes ye
Self-diagnosis yes yes ye
Lambda regulation 1 Lambda probe 2 Lambda probes 2 Lambd
Catalyst yes yes4) ye
Exhaust gas recirculation no no n
Charged no no n
3) In exceptional circumstances min. 91 RON, however with reduced performance
4) Additionally with integrated pre-catalyst in exhaust manifold

Arosa 1997 ➤

1 Removing and installing engine

equipment required
♦ AR-2204A Mounting brack‐
et
♦ Lifting beam -U-30034-
♦ Counter-hold for belt pulley
-U-40011-
♦ Pliers for spring-type
clamps -T20029-
♦ Engine bracket -T20082-
♦ Workshop crane -V.A.G 1202 A-
1. Removing and installing engine 3

Arosa 1997 ➤
♦ grease -G 000 100- (vehicles with manual gearbox)

♦ Cable tie
1.1 Notes on removing
Note!


– With ignition switched off disconnect battery earth strap.
– All cable ties which are opened or cut open when removing
engine, must be replaced in the same position when installing
engine.
– Remove air cleaner: ⇒ page 102
– Remove battery and battery retainer.
– Open and close the expansion tank sealing cap to release
pressure in cooling system.
– Disconnect all electric wires from gearbox, alternator and
starter and move clear.
– Loosen or separate the following components:
♦ The hose from intake manifold to activated charcoal filter sys‐
tem
♦ The vacuum hose from inletProtected
manifold to brake servo
♦ The connector from coolant temperature sender ofand oil pres‐

respect to the correctness information in this document. Copyright by SEAT S.A.
sure switch
♦ The collective connectors below the thermostat housing
♦ The ignition transformer and Hall sender connectors
♦ The engine speed sender connector
♦ Lambda probe connector in exhaust manifold
♦ The 2-pin connector from knock sensor (rear of cylinder block)
– Now separate fuel supply as well as fuel return pipes at con‐
necting point on suspension strut turret.

Arosa 1997 ➤
Caution
Fuel supply pipes are under pressure! Before removing from

hose connection wrap a cloth around the connection. Then re‐
lease pressure by carefully pulling hose off connection.
– Pull off/disconnect all other electrical connections as neces‐

sary from engine and lay to one side.
– Separate front exhaust pipe from exhaust manifold
⇒ page 177 , exhaust manifold, front exhaust pipe and cata‐
lyst with attachments.
– Unbolt pendulum support at gearbox housing.
– Disconnect clutch cable: ⇒ Rep. Gr. 30 ; Servicing hydraulic
clutch control
– Disconnect selector mechanism from gearbox. ⇒ Rep. Gr.
34 ; Servicing gear change mechanism
– Loosen hose clips and pull coolant hoses off coolant thermo‐
stat housing.
– Loosen belt pulley securing bolts from power steering vane
pump.
– Remove power steering vane pump belt pulley securing bolts.
Use counterhold -U-40011- when doing this.
– Unbolt power steering vane pump and secure to sub-frame
with wire; hoses remain connected: ⇒ Running gear; Rep. Gr.
48 ; Assembly overview: vane pump, reservoir, hydraulic lines
Removing and installing power steering vane pump.
– Remove securing clamps for power steering pressure pipe.
– Removing air conditioner compressor:
– Observe additional information and removal instructions
⇒ page 9
– Remove left and right-hand drive shaft on gearbox and tie up:
⇒ Running gear; Rep. Gr. 40 ; Removing and installing drive
shaft
– Removing lock carrier with attachments: ⇒ General body re‐
pairs; Rep. Gr. 50 ; Body, front Removing and installing lock
carrier with attachments.

Arosa 1997 ➤
– Fit lifting beam -U-30034- as follows and lift slightly using a

workshop crane:
Pulley end: 2nd hole in hook at position -1-
Flywheel end: 1st hole in hook at position -3-
Caution
The hooks and locating pins must be secured with locking pins.
Note!
♦ The positions marked -1- and -2- on the bar face towards the
belt pulley end.
♦ The holes in the hook rails are counted up from the hook.
– Unbolt assembly at gearbox and engine mountings.

– Lower assembly until it is released from the gearbox mounting.
– Pull assembly out forwards. When doing this, if necessary turn
assembly and lower slightly.
Note!
When the assembly is lifted off, it must be carefully guided to pre‐

vent damage to the bodywork.
1.2 Securing engine to assembly stand

Engine must be mounted on mounting bracket AR-2204A with
engine bracket -T20082- when performing assembly work.
Work sequence permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove gearbox.
– Remove pressure plate.
– Remove flywheel. Hold flywheel with counter-hold -T20075- .
– Remove intermediate plate.
– Remove compact bracket: ⇒ Heating, Air conditioning; Rep.
Gr. 87 ; Removing and installing air conditioner compressor
bracket
– Secure engine (on exhaust system and oil filter side) to mount‐
ing bracket AR-2204A with adjustable adapters of engine
bracket -T20082- .

Arosa 1997 ➤
– Secure engine (on flywheel side) to mounting bracket

AR-2204A with mounting arm of engine bracket -T20082- .
1.3 Notes on installing

Installation is carried out in the reverse sequence, when doing this
note the following:
– Check clutch release bearing for wear, renew if necessary.
– Check centring of clutch drive plate, if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with -G 000 100- .
– Check whether the dowel sleeves for centralising engine/gear‐
box are in the cylinder block, install if necessary.

Arosa 1997 ➤
– When installing the engine mounting ensure that the pins on

the bonded rubber mounting engage in the engine support
bracket -arrows- .
– When swinging the assembly in, ensure that clearance exists
between the drive shafts.
– Align engine mountings stress-free by rocking.
Note!
Assembly mounting tightening torques ⇒ page 9 .
– Install drive shafts: ⇒ Running gear; Rep. Gr. 40 ; Removing

and installing drive shafts
– Installing P.A.S. vane pump: ⇒ Running gear; Rep. Gr. 48 ;
Assembly overview: vane pump, reservoir, hydraulic pipes
– Install air conditioner compressor.
– Electrical connections and routing: ⇒ Electrical system; Rep.
Gr. 97
– Installing clutch cable: ⇒ Rep. Gr. 30 ; Servicing hydraulic
clutch control
– Connecting selector mechanism to gearbox. ⇒ Rep. Gr. 34 ;
Servicing gear change mechanism
– Filling with coolant ⇒ page 71
– Install air cleaner: ⇒ page 102
– Perform the work sequence “Procedure after voltage supply
open circuit” . ⇒ page 102
Note!
The readiness code is reset or erased each time fault memory is

erased.
– Match engine electronics control unit to throttle valve control

part: ⇒ page 102

Bolted connection Tightening tor‐
que
M8 20 Nm
M10 45 Nm
M 12 60 Nm
in variation of this
Exhaust pipe to manifold
permitted unless authorised by SEAT S.A. SEAT 40S.ANm

Arosa 1997 ➤
1.5 Assembly mounting

Tightening torques
Note!
The assembly mounting securing bolts are stretch bolts and must
be replaced.
Engine mounting
A = 50 Nm
B = 25 Nm
C = 25 Nm + 1/8 turn (45°) further
D = 20 Nm + 1/8 turn (45°) further
Gearbox mounting
A = 30 Nm + 1/4 turn (90°) further
B = 20 Nm + 1/8 turn (45°) further
C = 50 Nm
Pendulum support
B = 20 Nm + 1/4 turn (90°) further
– Carry out a test drive and interrogate fault memory: ⇒ Vehicle
1.6 Additional information and removal in‐

structions for vehicles with air condition‐
er
Caution
The air conditioner refrigerant circuit must not be opened.

Arosa 1997 ➤
Note!
To prevent damage to condenser also to the refrigerant pipes/

hoses, ensure that the pipes and hoses are not stretched, kinked
or bent.
To facilitate removing and installing the engine without opening

the refrigerant circuit:
– Unbolt air conditioner fluid container.
– Remove retaining clamp(s) from refrigerant pipes.
– Removing lock carrier with attachments:
⇒ General body repairs; Rep. Gr. 50 ; Body, front Removing and
installing lock carrier with attachments.
– Set the lock carrier with radiator and condenser to the side so
that the refrigerant hoses and pipes -arrows- are not strained.
– Removing air conditioner compressor: ⇒ Heating, Air condi‐
tioning; Rep. Gr. 87 ; Air conditioning with manual controls
Removing and installing air conditioner compressor bracket,
Engine codes: ANV Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Arosa 1997 ➤
1 Dismantling and assembling engine
I ⇒ page 11
II ⇒ page 13
Part I

Arosa 1997 ➤

part
2 - Toothed belt
moving
❑ Check for wear
❑ Do not kink
and tensioning
⇒ page 36
3 - 20 Nm
4 - Toothed belt guard - coolant
pump
5 - 20 Nm + 1/4 turn (90 °) fur‐
ther
❑ Renew
❑ The turning further can
be done in several
stages
❑ The angle which must
be turned further can be
measured with protrac‐
tor -T20030-
❑ Note position when in‐
stalling the toothed belt

Arosa 1997 ➤
⇒ page 36
7 - 10 Nm
❑ Install with -D6-
8 - 10 Nm
10 - Coolant pump
❑ With integrated seal
❑ Seal must not be separated from coolant pump
❑ Replace damaged or leaking coolant pump together with seal
❑ Check for ease of movement
11 - Tensioner
❑ Removing, installing and tensioning ⇒ page 36
12 - 20 Nm
13 - Console
❑ Note position when installing the toothed belt ⇒ page 36
15 - 40 Nm + 1/4 turn (90 °) further
16 - 12 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Renew
17 - Belt pulley
❑ When installing note fixing arrangement
18 - 20 Nm
19 - Ribbed belt
❑ Mark direction of rotation before removing
❑ Removing and installing ribbed belt ⇒ page 14
20 - 90 Nm + 1/4 turn (90 °) further
❑ Renew
❑ Oil threads
❑ The turning further can be done in several stages
❑ The angle which must be turned further can be measured with protractor -T20030-
Part II
Note!
♦ Servicing the clutch:

♦ ⇒ Rep. Gr. 30 ; Servicing clutch Removing and installing clutch

Arosa 1997 ➤
1 - Cylinder block
bling aluminium cylinder
block ⇒ page 19
bling pistons and con‐
rods ⇒ page 31
2 - 45 Nm
❑ Renew
3 - Oil filter
❑ Loosen at hexagon bolt
head
❑ Tighten by hand
ter when installing
4 - Compact bracket
❑ For vane pump and al‐
ternator
compact bracket on ve‐
hicles with air condition‐
er: ⇒ Heating, Air con‐
ditioning; Rep. Gr. 87 ;
Air conditioning with
manual controls Re‐
moving and installing air
conditioner compressor
bracket
5 - 15 Nm
❑ Loosen and tighten the
bolts on the flywheel
side only using socket
insert -U-40051-
6 - Sump
❑ With attached seal
❑ Renew
8 - M8: 20 Nm + 1/4 turn (90 °) further
9 - 45 Nm
10 - Washer
12 - Tensioning element
1.1 Removing and installing ribbed belt

Vehicles without power assisted steering

Arosa 1997 ➤
♦ Tensioning lever -U-40050-
Work sequence
– Mark direction of rotation of ribbed belt.
– Loosen alternator securing bolts.
– Fit tensioning lever -U-40050- and swing alternator down‐
wards (use, for example, a torque wrench
permitted unlessas a drive
authorised for -S.A. SEAT S.A does not guarantee or accept any liability with
by SEAT
U-40050- ). respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove/fit ribbed belt
Note!
When installing the ribbed belt ensure that it sits correctly in the
pulleys.
– After fitting ribbed belt with alternator loose, rotate engine sev‐
eral times (approx. 10 revolutions of engine by operating
starter briefly.
– First tighten lower and then upper alternator bolts to 25 Nm.
Vehicles with power assisted steering
Removing
– Remove ribbed belt cover.
– Mark ribbed belt direction of rotation.
– Using a spanner on the securing bolt swivel tensioning roller

in direction of arrow.
– Remove ribbed V-belt.
Installing
– Place ribbed V-belt onto crankshaft pulley first. Slide belt onto
tensioning roller last.
Note!
pulleys.
Ribbed belt routing

Arosa 1997 ➤
Basic belt drive

1 - Crankshaft/pulley
2 - Ribbed belt
Belt drive without air conditioner compressor

2 - Ribbed belt
5 - Tensioner
Belt drive with air conditioner compressor
2 - Tensioner
4 - Air conditioner compressor
Note!
When installing the ribbed V-belt, ensure the belt runs in the right
direction and seats correctly on the belt pulleys.
The rest of the assembly is basically a reverse of the dismantling

sequence.
1.2 Checking semi-automatic toothed belt

tensioning roller

Arosa 1997 ➤
♦ -U-30025- or Support beam -10222A- with -10-222A/1-
Test sequence respect to the correctness of information in this document. Copyright by SEAT S.A.
The engine must be lowered slightly as follows to enable the

crankshaft sprocket to be removed:
– Fit support -U-30025- as shown.
– Take-up weight of engine, and remove right engine mounting.
– Lower engine slightly.
– Remove belt pulley as well as upper and lower toothed belt
guard.
– Now turn the crankshaft two turns in engine direction of rota‐
tion until it is again at top dead centre No. 1 cylinder.

Arosa 1997 ➤
– Note the position of the tensioning roller indicator -arrow- .

Press the toothed belt with firm thumb pressure. The indicator
must move.
– Release tension on toothed belt.
– Turn crankshaft two turns in engine direction of rotation.
– Then check the position of the indicator. It must have returned
to its original position.
If tensioning roller does not return to initial position:
– Replace tensioning roller.
If the tensioning roller is OK:
– Reinstall belt pulley and toothed belt guard upper and lower
parts.
– Refit right engine mounting with new bolts ⇒ page 9 , Engine
assembly mounting.
– Refit the ribbed belt and the cover.
Note!
pulleys.

sequence.

Arosa 1997 ➤

block, sealing flange and flywheel
2.1 Aluminium cylinder block
Caution
The crankshaft must not be removed. Just loosening the main

bearing caps will cause deformation of the cylinder block bear‐
ing pedestals. This deformation will cause a reduction of the
bearing clearance. Even if the bearing shells are not renewed
bearing damage could occur due to a different bearing clear‐
ance.
If the bearing cap bolts are loosened, the cylinder block must
be replaced complete with the crankshaft.
Measuring the main bearing clearance is not possible with nor‐
mal workshop equipment.
Note!
♦ For repairs to the clutch:

♦ ⇒ Rep. Gr. 30 ; Servicing clutch Removing and installing clutch
2. Removing and installing cylinder block, sealing flange and flywheel 19

Arosa 1997 ➤
1 - 10 Nm
2 - Suction pipe
3 - Aluminium cylinder block
4 - Knock sensor
5 - 20 Nm
❑ Tightening torque influ‐
ences the function of the
knock sensor
6 - 60 Nm + 1/4 turn (90 °) fur‐
ther
❑ Renew
7 - Flywheel
T20075- when remov‐
ing and installing
8 - 12 Nm
❑ Renew
9 - Sealing flange with sender
wheel and oil seal
with oil seal and sender
wheel
sealing flange
⇒ page 22 , Renewing
crankshaft sealing
flange -flywheel end-
10 - Gasket
❑ Renew
11 - Oil pump
❑ When installing note follower ⇒ Item 13 (page 20) on crankshaft
❑ Must be located on dowel sleeves
❑ Removing and installing ⇒ page 58 , Removing and installing parts of lubrication system
12 - Oil seal
13 - Follower
❑ Coat with oil before installing oil pump

Arosa 1997 ➤
2.2 Renewing crankshaft oil seal -belt pulley end

equipment required
♦ (∅ 32 mm) Seal puller -
T20031-
♦ Puller -T20081-
Removing
– First remove toothed belt ⇒ page 36 .
– Remove crankshaft toothed belt sprocket. Use counter-hold -
T20018- when doing this.
– Screw inner part of seal puller -T20031- (∅ 32 mm) out of outer
part.

Arosa 1997 ➤
– Lubricate threaded head of seal puller -T20031- (∅ 32 mm),

position and screw into seal as far as possible using force.
– Turn inner part against crankshaft until the seal is pulled out.
Installing
– Fit seal onto sleeve -T20081/2- .
– Position puller -T20081- with sleeve -T20081/2- on crankshaft

journal and screw in onto limit stop using a toothed belt sprock‐
et securing bolt.
– Install crankshaft toothed belt sprocket. Hold toothed belt
sprocket with counter-hold -T20018- when doing this and tight‐
en new securing bolt
Protected by to 90Copying
copyright. Nm +for1/4 turn.
private (90 °) purposes,
or commercial further.in part or in whole, is not
Note!
The angle which must be turned further can be measured with

protractor -T20030- .
When installing toothed belt and adjusting timing ⇒ page 36 .

2.3 Renewing crankshaft sealing flange -fly‐

wheel end-

Arosa 1997 ➤
♦ Assembly device -T10017-
♦ Torque wrench -SAT 8010- permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Ring insert (not open type) -SAT 8010/24C-

♦ Qty. 3 hexagon M6 x 35 mm bolts
♦ Feeler gauge
♦ Vernier caliper
Pressing sealing flange with sender wheel off crankshaft
Note!
♦ To show the work sequence more clearly, the sequence is de‐

scribed for a removed engine.
♦ The work sequence is the same when the engine is in the ve‐
hicle and the gearbox removed.
Work sequence
– Remove the flywheel.

Arosa 1997 ➤
– Set camshaft sprocket to mark -arrow A- .

– Set crankshaft to TDC No. 1 cylinder. The ground or offset
tooth on the crankshaft toothed belt pulley must align with the
marking -2V- on the sealing flange -arrow B- .
– Remove oil sump ⇒ page 61 .
– Remove engine speed sender -arrow- .

– Undo sealing flange securing bolts.
Note!
Sealing flange and sender wheel are pressed off the crankshaft
together with Qty. 3 M6 x 35 mm bolts.
– Screw Qty. 3 M6 x 35 mm bolts into the threaded holes

-arrows- of the sealing flange.
– Screw the bolts alternately (a 1/2 turn (180°) for each bolt) into
the sealing flange and press the sealing flange along with the
sender wheel off the crankshaft.
Pressing sealing flange with sender wheel onto crankshaft
Note!
♦ Gradual introduction of a new generation of sealing flanges

with PTFE seal (Teflon). The sealing flange with spring ring
will continue to be offered as spare part. When fitting a new
sealing flange, be careful to use the same type of sealing
flange that was previously fitted.
♦ The sealing flange with a PTFE sealing ring is equipped with
a sealing lip support ring. This support ring serves the function
of a fitting sleeve and may not be removed prior to installation.
♦ Sealing flange and sender wheel must not be separated or
twisted after removal from packaging.
♦ The sender wheel of a sealing flange with spring ring has an
Elastomer coating on the sealing surface to crankshaft. This
coating must never come into contact with dirt or grease.
♦ The sender wheel is held in its
Protected installation
by copyright. Copyingposition bycommercial
for private or a fixturepurposes, in part or in whole, is not
on the assembly device -T10017-
permitted locating
unless authorised pin.
♦ Sealing flange and seal are one unit and must be replaced
together with the sender wheel only.
♦ The assembly appliance -T10017- maintains its installation
position to the crankshaft via a guide pin which is inserted into
a threaded hole in the pressure plate/drive plate.

Arosa 1997 ➤
A - Hexagon nut
B - Clamping surface (ground section of spindle)
C - Tool bell housing
D - Socket head bolt
E - Guide pin
F - Locating pin
A-Assembling sealing flange with sender wheel on assembly ap‐
pliance -T10017-
– Screw hexagon nut -A- to shortly before the clamping surface

(ground section) -B- on the threaded spindle.
– Clamp assembly appliance -T10017- in a vice on clamping

surface (ground section) on threaded spindle.
– Press assembly bell housing -C- downwards so that it lies on
the hexagon nut -A- -arrow- .
Note!
Inner part of assembly appliance and assembly bell housing must

be at same height (level).
– Remove securing clip -A- on new sealing flange.
Note!
The sender wheel must not be taken out of the sealing flange or
twisted.

Arosa 1997 ➤
The locating hole -B- on the sender wheel -C- must align with the
marking -A- on the sealing flange.
– Place the sealing flange (with the forward side downwards) on

a clean flat surface.
– Push the sender wheel (sealing lip support ring for PTFE seal‐
ing ring) -A- downwards in direction of arrow until it lies on the
flat surface.
The upper edge of the sender wheel and the forward edge of the
sealing flange must align -arrows- .
– Place the sealing flange, with the forward side on the assembly
appliance -T10017- , so that the locating pin -A- can be inser‐
ted in the sender wheel hole -B- .
Note!
Ensure the sealing flange lies flat on the assembly appliance.

Arosa 1997 ➤
– Push the sender wheel -B- (Sealing lip support ring for PTFE
sealing ring) onto the surface of the assembly appliance whilst
tightening the three knurled screws -A- , so that the locating
pin cannot slide out of sender wheel hole.
Note!
Ensure the sender wheel remains fixed on the assembly appli‐

ance when installing the sealing flange.
B-Assembling appliance -T10017- with sealing flange on crank-

shaft flange
Prerequisites
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.
Work sequence
– Unscrew hexagon nut -A- to end of threaded spindle.

– Press assembly appliance threaded spindle in direction of ar‐
row, until the hexagon nut -A- lies against the assembly bell
housing -C- .
– Align flat side of assembly bell housing towards oil sump side
of crankcase sealing surface.
– Secure assembly appliance to crankshaft flange with hexagon

socket head bolts -A-
Note!
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 threads).
– Screw two M6 x 35 mm bolts -A- into cylinder block to guide
sealing flange.
C-Fitting assembly appliance -T10017- onto crankshaft flange

Arosa 1997 ➤
– Slide assembly bell housing -A- in direction of arrow by hand

until the sender wheel - B- (Sealing lip support ring for PTFE
sealing ring) lies against the crankshaft flange -C- .
Note!
The assembly appliance guide pin -D- is guided into threaded

hole in crankshaft during the fitting sequence. This ensures the
sender wheel reaches its final installation position.
– Hold assembly bell housing in this position and screw both

assembly appliance hexagon socket head bolts hand tight.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against the assembly bell housing -A- .
D-Pressing sender wheel onto crankshaft flange with assembly
appliance -T10017-
– Tighten assembly device hexagon nut using torque wrench -

SAT 8010- and ring insert -SAT 8010/24C- . Tightening torque:
35 Nm
Note!
A small air gap must be present between cylinder block and seal‐
ing flange after tightening hexagon nut to 35 Nm.
E-Checking sender wheel installation position on crankshaft
– Screw hexagon nut -A- to end of threaded spindle.

– Remove the two M6 x 35 mm hexagon bolts -B- from cylinder
block.
– Screw the three thumb ofwheels -C- out of sealing flange.
respect to the correctness information in this document. Copyright by SEAT S.A.
– Pull assembly appliance assembly bell housing -D- back to

hexagon nut -A- (Only for sealing flange with spring ring).
The sender wheel has the correct installation position on crank‐

shaft when a gap of -a- = 0.5 mm exists between crankshaft flange
-A- and sender wheel -B- .
Note!
If the sealing flange has a PTFE sealing ring, completely unbolt

the assembly appliance -T10017- and remove the sealing lip sup‐
port ring.
To enable the measurements to be shown more clearly the crank‐

shaft flange is illustrated without the fitted assembly appliance -
T10017- .

Arosa 1997 ➤
– Place a vernier caliper against the crankshaft flange -A-

(hatched area).
– Measure the distance -a- between vernier caliper and sender

wheel with a feeler gauge -A- .
Is measurement -a- too small:
– Re-press sender wheel ⇒ page 29 .
When dimension -a- is achieved:
– Remove assembly appliance.
– Tighten the new securing bolts for the sealing flange using al‐
ternate and diagonal sequence. Tightening torque: 12 Nm
– Install engine speed sender -arrow- . Tightening torque: 5 Nm

– Install sump ⇒ page 61 .
– Install flywheel with new bolts.
F-Re-pressing sender wheel
– Slide assembly
authorised bybell
SEAThousing -A-does
to not
sealing flange
or accept-B- by hand.
permitted unless S.A. SEAT S.A guarantee any liability with
– Screw two M6 x 35 mm bolts -C- into cylinder block to guide
sealing flange -B- .
– Screw hexagon nut -D- along threaded spindle, by hand, until
it contacts the assembly bell housing -A- .

Arosa 1997 ➤
– Tighten assembly device hexagon nut using torque wrench -

SAT 8010- and ring insert -SAT 8010/24C- . Tightening torque:
40 Nm
– Check installation position of sender wheel on crankshaft
again ⇒ page 28 .
If dimension -a- is too small again:
– Tighten hexagon nut to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 28 .

Honing dimension Conrod
in mm journal ∅
Basic dimension -0.022
42.00
-0.037
1st undersize -0.022
41.75
-0.037
2nd undersize -0.022
41.50
-0.037
3rd undersize -0.022
41.25
-0.037

Arosa 1997 ➤
3 Dismantling and assembling pistons and conrods
1 - Circlip
2 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C
drift -T20019-
3 - Piston
tion and cylinder num‐
ber
❑ Arrow on piston crown
points to pulley end
❑ Install using piston ring
clamp
4 - Compression rings
❑ Offset gaps by 120 °
compression rings with
piston ring pliers
piston crown
⇒ page 32
❑ Checking ring to groove
clearance ⇒ page 32
5 - Oil scraper ring
❑ Remove and install spi‐
ral-type expander care‐
fully permitted
by hand

Arosa 1997 ➤
piston crown
⇒ page 32
❑ Checking ring to groove clearance ⇒ page 32
6 - Conrod
❑ Only renew as a set
❑ Mark cylinder number -A-
❑ Installation position: Marking -B- faces towards pulley end
❑ Guided axially via piston
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate con-rod, this is due to the breaking procedure
(cracking) separating the cap from the con-rod
8 - Conrod bolt, 20 Nm + 1/4 turn (90 °) further
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance tighten to 20 Nm but not further
❑ The angle which must be turned further can be measured with protractor -T20030-
9 - Bearing shell
❑ Do not interchange used bearing
respect to the correctness shells
❑ Insert bearing shells centrally

❑ Check radial clearance with Plastigage: New: 0.020...0.061 mm Wear limit: 0.091 mm Do not rotate
crankshaft when checking radial clearance
10 - Cylinder block
❑ Checking cylinder bores ⇒ page 33
❑ Piston and cylinder dimensions ⇒ page 33
Checking piston ring gap

– Push ring squarely from above down to approx. 15 mm from
bottom end of cylinder.
Piston ring Wear limit
Compression rings 1.0 mm
Oil scraper ring 1.0 mm
Checking ring to groove clearance

Clean groove before check.
Piston ring Wear limit
Compression rings 0.15 mm
Oil scraper ring 0.15 mm

Arosa 1997 ➤
Checking piston

♦ External micrometer 60...90 mm
– Approx. 10 mm from lower edge and offset 90 ° to piston pin
axis. Deviations from nominal dimensions max. 0.04 mm
Nominal dimension ⇒ page 33 ; Piston and cylinder dimensions

Checking cylinder bores

♦ Internal dial gauge 50...100 mm
– Take measurements at 3 positions in both lateral -A- and lon‐
gitudinal -B- directions, as illustrated. Deviation from nominal
dimension max. 0.08 mm
Nominal dimension ⇒ page 33 ; Piston and cylinder dimensions
Note!
The cylinder block bore must not be measured with the engine
secured in engine mounting bracket AR-2204A using engine
brackets -T20082- , as there is a possibility that the measure‐
ments will be falsified.
3.1 Piston and cylinder dimensions

Honing Piston-∅ Cylinder bore-∅
dimension
Basic dimen. mm 67.085 67.11
1st undersize mm 67.335 67.36

Arosa 1997 ➤
2nd undersize mm 67.585 67.61

3rd undersize mm 67.835 67.86

Arosa 1997 ➤

head
Checking compressions ⇒ page 42
Note!
♦ When installing an exchange cylinder head, all the contact

surfaces between the support elements, roller rocker fingers
and the cams must be oiled before installing the cylinder head
cover.
♦ 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 renewed.
♦ Removing and installing intake manifold: ⇒ page 102
1 - 6 Nm + 1/4 turn (90 °) further

❑ Observe assembly in‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
structions and sequen‐
ces when loosening and
tightening ⇒ page 51
2 - Screening cap
3 - Sealing collar
4 - Cap
❑ Remove remnants of
old sealant
❑ Coat with -D 154 103-
before fitting
⇒ page 51
6 - 10 Nm
7 - Bracket
8 - Fitted pin
9 - Camshaft
ance ⇒ page 47
❑ Markings and timing
⇒ page 47

Arosa 1997 ➤
⇒ page 51
10 - 20 Nm
11 - Cylinder head bolt
❑ Renew
❑ Note installation instructions and sequence when loosening and tightening ⇒ page 38
12 - Lifting eye
13 - Cylinder head
❑ Check for distortion ⇒ page 36
❑ After replacing renew the complete coolant
14 - Support element
❑ With hydraulic
Protected valve
by copyright. clearance
Copying for private compensation
❑ Check respect
camshaft axial clearance
to the correctness of informationbefore installing
in this document. ⇒ page
Copyright by SEAT47S.A.

15 - Retaining clip
16 - Roller rocker finger
❑ Check bearing for ease of movement
❑ Use securing clip to clip onto support element when installing
❑ Metal gasket
❑ Renew
18 - Oil seal
Checking cylinder head for distortion

Max. permissible distortion: 0.05 mm
1.1 Removing, installing and tensioning

toothed belt
(Adjusting valve timing)

Arosa 1997 ➤
♦ -U-30025- or Support beam -10222A- with -10-222A/1-

Removing
– Fit support -U-30025- as shown.

– Take-up weight of engine, and remove right engine mounting.
– Lower engine slightly.

– Remove belt pulley as well as upper and lower toothed belt
guard.
– Release tensioner and take off toothed belt.
Installing
Prerequisites
• The engine must be no more than warm to touch.
• The pistons must not be positioned at TDC.
Note!
If a piston is at TDC the valves could strike the piston when turning
the camshaft.
Work sequence

Arosa 1997 ➤
– Set camshaft sprocket to mark -arrow A- .

– Set crankshaft to TDC No. 1 cylinder. The ground or offset
tooth on the crankshaft toothed belt pulley must align with the
marking on the seal flange -arrow B- .
– Fit toothed belt. For used belts note direction of rotation.
– Tighten tensioning roller securing bolt hand-tight. The slot in

the base plate -1- must locate around securing bolt -2- .
– Tension toothed belt by turning the tensioning roller in direc‐
tion of arrow until the indicator -3- aligns with the groove in the
base plate -arrow- .
– Tighten clamping nut on tensioning roller. Tightening torque:
20 Nm
– Now turn the crankshaft two turns in engine direction of rota‐
tion until it is again at top dead centre No. 1 cylinder.
– Now the position of the toothed belts and tensioning roller must
be checked again.
– Install toothed belt guard upper and lower parts.
– Install belt pulley (note fixing arrangement).
– Refit right engine mounting with new bolts ⇒ page 9 , Engine
assembly mounting.
– Refit the ribbed belt and the cover.
pulleys.

sequence.
1.2 Removing and installing cylinder head

Arosa 1997 ➤

equipment required
clamps -T20029-
♦ Pin driver with guide studs/
pins -T20049-
Prerequisites
• The engine must be no more than warm to touch.
Note!
♦ When repairing an engine where it is not necessary to dis‐

mantle the cylinder head, the cylinder head can be removed
without removing cylinder head cover or camshaft.
♦ Then start with work sequence 1.
If the cylinder head is to be dismantled Work sequence 2

⇒ page 40 .
Work sequence
– First check whether a coded radio is fitted. If this is the case
obtain the antitheft coding.
strap.

Arosa 1997 ➤

– Loosen toothed belt tensioning roller and remove toothed belt
from camshaft sprocket. Description of work ⇒ page 36 , Re‐
moving, installing and tensioning toothed belt.
– Remove camshaft sprocket. Use counter-hold -T20018- when
loosening and tightening the camshaft sprocket securing bolt.
– Open cylinder head cover sealing cap, unclip the screening
cover and take it out.
– Pull 3-pin connector off Hall sender -arrow- .
– Pull 4-pin connector off ignition transformer and remove igni‐
tion transformer.
– Further work necessary: Work sequence 1 and 2 continued on
this page.
Work sequence 2
– Remove cylinder head cover, ⇒ page 51 .
Work sequence 1 and 2
– Lift engine slightly and refit the right engine mounting.
– Now separate fuel
Protected by supply
copyright. as for
Copying well asorfuel
private return
commercial pipesin at
purposes, partcon‐
or in whole, is not
necting pointunless
permitted on suspension
authorised by SEATstrut.
Caution

– Seal the pipes so that the fuel system is not contaminated by

dirt etc.
– Loosen or separate the following components:
♦ The connector from coolant temperature sender and oil pres‐
sure switch
♦ The collective connectors below thermostat housing
♦ The engine speed sender connector
♦ Lambda probe connector in exhaust manifold
♦ Connector on knock sensor
– Remove fuel rail with all injectors from cylinder head.
⇒ page 109
– Pull the clamps which secure the coolant pipe to coolant pump
off the thermostat housing.
– Remove thermostat housing from cylinder head.
– Disconnect all other inter-connecting, coolant, vacuum and in‐
take hoses from cylinder head.
– Remove front exhaust pipe from exhaust manifold.
– Loosen dip stick guide tube from cylinder head.
– Remove lifting eye in area of oil filler hole.

Arosa 1997 ➤
– Loosen socket head bolts in the sequence given and then re‐
move completely.
– Carefully lift cylinder head off.
Installing
Note!
♦ Only remove the new cylinder head gasket from its packing
immediately before installing.
♦ Handle the new gasket with extreme care. Damaging will lead
to leaks.
– Place a clean cloth in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into the
coolant.
– Carefully clean cylinder head and cylinder block sealing sur‐
faces. Thereby ensuring that no scoring or scratches are
formed (when using abrasive paper the grade must not be less
than 100).
– Carefully remove metal particles, emery remains and cloths.
– Set No. by
Protected 1 copyright.
cylinder piston
Copying to top
for private dead centre
or commercial and
purposes, then
in part or in turn
whole, is not
crankshaft
permitted back slightly.
– To centralize cylinder head, screw guide pins from -T20049-

into holes for rear outer cylinder head bolts -arrows- .
– Place new cylinder head gasket on centralizing pins -A- . Let‐
tering (Part No.) must be readable.
– Fit cylinder head, screw in 8 remaining cylinder head bolts and
tighten by hand.
– Unscrew guide pins through bolt holes using pin driver from -
T20049- . To do this turn pin driver anti-clockwise until the pins
are free.
– Fit remaining cylinder head bolts and tighten hand-tight.

Arosa 1997 ➤
– Tighten cylinder head in tightening sequence as follows:

– Tighten all bolts to 30 Nm.
– Then tighten all bolts a 1/4 turn (90 °) further using a rigid
wrench.
– Then tighten all bolts again a 1/4 turn (90 °) further.
sequence.
Note!
When the camshaft is turned, the crankshaft must not be at TDC.

Danger of damage to valves or piston crowns.
– Install camshaft and cylinder head cover (if necessary)

⇒ page 53 .
– Install toothed belt and set valve timing ⇒ page 36 .
part: ⇒ page 165
Note!
The readiness code is reset or erased each time fault memory is

erased.
– Install air cleaner: ⇒ page 102
1.3 Checking compression pressures

Arosa 1997 ➤

equipment required
T20028-
♦ Compression tester -V.A.G
1763-
Test conditions
• Engine oil temperature must be at least 30 °C.
Work sequence
– Remove spark plugs using spark plug wrench -T20028- .

Arosa 1997 ➤
– Pull connector off Hall sender.

– Remove fuse 40 for fuel pump.
– Check compressions with compression tester -V.A.G 1381- /
-V.A.G 1763- .
Note!
See relevant test unit operating instructions for instructions on

how to use test unit.
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressure:
Permissible difference between all cylinders: 3 bar
– Insert spark plugs with spark plug wrench -T20028- and tight‐
en to 30 Nm.

Arosa 1997 ➤
2 Servicing valve gear
Note!
Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug
thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.5
mm in width, or when no more than the first turns of the spark plug thread are cracked.
1 - Camshaft
ance ⇒ page 47
❑ Markings and timing
⇒ page 47
⇒ page 51
2 - 6 Nm + 1/4 turn (90 °) further
❑ Renew
❑ Observe assembly in‐
structions and sequen‐
ces when loosening and
tightening ⇒ page 51
❑ Remove remnants of
old sealant
❑ Coat with -D 154 103-
before fitting
⇒ page 51
4 - Oil seal
❑ Lightly oil sealing lip of
oil seal
5 - Roller rocker finger
❑ Check bearing for ease
of movement
❑permitted
Use unless
securing clip
authorised by to clip
SEAT S.A. SEAT S.A does not guarantee or accept any liability with
onto support
respect element

Arosa 1997 ➤
when installing
6 - Retaining clip
7 - Support element
❑ With hydraulic valve clearance compensation
❑ Check camshaft axial clearance before installing ⇒ page 47
8 - 20 Nm
9 - Lifting eye
10 - Cylinder head
❑ Reworking valve seats ⇒ page 48
❑ Reworking sealing surface ⇒ page 46
11 - Valves
❑ Do not rework only grinding-in is permitted
12 - Valve guide
❑ Renewing ⇒ page
permitted unless 54 by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
13 - Service part - valve guide
❑ With collar
14 - Valve stem seal
15 - Valve spring
❑ Removing and installing: Cylinder head removed: with -T20034/1- Cylinder head installed:
⇒ page 56 , Renewing valve stem seals
16 - Upper valve spring plate
17 - Cotters
Reworking cylinder head sealing surface, cylinder block side

Cylinder head reworking dimension: a = At least 135.6 mm

Arosa 1997 ➤
Checking camshaft axial clearance

♦ Universal dial gauge holder -T20020-
♦ Dial gauge
Check with support elements and cylinder head cover
Protected removed.
– Load camshaft by pressing down with thumb respect
on camshaft
centre bearing and check axial clearance by moving camshaft
back and forth.
Camshaft identification, valve timing
Marking between number 1 cylinder inlet and exhaust cam tabs
“030 BP”
“CH PS5”
Valve timing at 1 mm valve lift
Engine code ALD, ANV, AKK, ANW,
AUC AUD
Inlet valve opens ATDC 9.9 ° 15.0 °
Inlet valve closes ABDC 28.9 ° 22.4 °
Exhaust valve opens BBDC 30.1 ° 16.7 °
Exhaust valve closes BTDC 11.1 ° 9.3 °

Arosa 1997 ➤
Valve dimensions
Note!
Valves must not be reworked. Only lapping-in is permitted.
Engine codes ALD, ANV, AUC

∅a mm 31.0 26.0
∅b mm 5.98 5.96
c mm 99.9 99.9
α ∠° 45 45
Engine codes AKK, ANW, AUD
∅a mm 34.0 28.0
∅b mm 5.973 5.953
c mm 99.2 99.2
α ∠° 45 45
2.1 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note!
♦ When repairing engines with leaking valves, it is not sufficient

to replace or renew valve seats and valves. It is also necessary
to check the valve guides for wear. This particularly important
on high mileage engines ⇒ page 54 .
♦ The valve seats should only be reworked just enough to pro‐
duce a perfect seating pattern. The maximum permissible
reworking dimension must be calculated before reworking
commences. If the reworking dimension is exceeded, the func‐
tion of the hydraulic tappets can no longer be guaranteed and
the cylinder head should be renewed.
The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.
Note!
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.

Arosa 1997 ➤
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate max. permissible reworking dimension from meas‐
ured distance and minimum dimension.
Minimum dimension: Inlet valve and outlet valve 32.1 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
- Measured gap 32.5 mm
= Max. permissible reworking dimension5) 0.4 mm
5) The max. permissible reworking dimension is shown on illustrations for rework‐
ing valve seats as dimension “b” .
Reworking inlet valve seat

a = ∅ 29.4 mm
b = Max. permissible reworking dimension6)
c = Max. 2 mm
Z = Cylinder head lower edge
α = 45 ° valve seat angle
β = 30 ° upper correction angle
γ = 60 ° lower correction angle
6) Calculating max. permissible reworking dimension ⇒ page 48 .
Reworking exhaust valve seat

a = ∅ 24.6 mm
b = Max. permissible reworking dimension7)
c = Max. 2 mm
Z = Cylinder head lower edge
α = 45 ° valve seat angle
β = 30 ° upper correction angle
γ = 60 ° lower correction angle
7) Calculating max. permissible reworking dimension ⇒ page 48 .
2.2 Replacing camshaft oil seal

Arosa 1997 ➤

equipment required
♦ (∅ 32 mm) Seal puller -
T20031-
♦ Puller -T20081-
Removing
– Remove toothed belt guard - upper part.
– Release toothed belt tensioning device and remove toothed
belt from camshaft sprocket, ⇒ page 36 , Removing, installing
and tensioning toothed belt.
– Turn crankshaft back slightly.
loosening and tightening the camshaft sprocket securing bolt.
– Remove rear toothed belt guard.
– Screw inner part of seal puller -T20031- (∅ 32 mm) out of outer
part. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Arosa 1997 ➤
– Lubricate threaded head of seal puller -T20031- (∅ 32 mm),

position and screw into seal as far as possible using force.
– Turn inner part against camshaft until the seal is pulled out.
Installing
– Fit seal onto sleeve -T20081/2- .
– Position puller -T20081- with sleeve -T20081/2- on camshaft

journal and screw in onto limit stop using a camshaft sprocket
securing bolt.
sequence.
– Install camshaft toothed belt sprocket. Hold camshaft sprocket
with counter-hold -T20018- when doing this and tighten new
securing bolt to 20 Nm + 1/4 turn. (90 °) further.
Note!

Installing toothed belt and adjusting timing ⇒ page 36 .

2.3 Removing and installing cylinder head

cover and camshaft

Arosa 1997 ➤
♦ Sealant -AMV 154 103-

Removing
Note!
♦ The sealing surfaces on cylinder head cover and cylinder head

must not be reworked.
♦ In this cylinder head the camshaft bearings are integrated into
the cylinder head and cylinder head cover. Before removing
cylinder head cover, the toothed belt tension must be relieved.
♦ If the cylinder head cover has been loosened, replace cam‐
shaft oil seal.
Work sequence
strap.
– Loosen toothed
Protected belt Copying
by copyright. tensioning roller
for private and remove
or commercial purposes, toothed belt is not
in part or in whole,
from camshaft sprocket.
correctnessDescription work ⇒Copyright
of document. page 36 , Re‐
respect to the of information in this by SEAT S.A.
moving, installing and tensioning toothed belt.
– Remove camshaft sprocket. When loosening camshaft
sprocket bolt counter-hold with -3036- .
– Remove rear toothed belt guard.
– Unscrew ignition transformer screws out of cylinder head cov‐
er.
– Open cylinder head cover sealing cap and unclip screening
cover and remove.

Arosa 1997 ➤
– Remove cylinder head cover bolts in the sequence prescribed

and loosen items 8 and 9 using diagonally and alternating se‐
quence.
– Carefully remove cylinder head cover.
– Lift camshaft carefully, remove and place on a clean surface.
– Remove roller rocker finger together with support elements
and place on a clean surface.
– Ensure the roller rocker fingers and the support elements are
not interchanged.
Installing
Prerequisites
• Prevent dirt and sealant remnants from entering cylinder head.
• Sealing surfaces must be free of oil and grease.
• When installing cylinder head cover or camshaft, the cams for
Cyl. 1 must face upwards.
– Remove sealant remnants on cylinder head and camshaft
housing with a commercially available sealant remover.
– Oil the camshaft contact surfaces.
– Insert support element in cylinder head and fit roller rocker
finger onto respective valve stem end and support element.
– Ensure all roller rocker fingers contact the valve ends -1- cor‐
rectly and they are clipped into their respective support ele‐
ments -2- .
– Carefully place camshaft in camshaft bearing of cylinder head.
– Apply a thin even coat of sealant onto the clean cylinder head
cover sealing surface.
Note!
The sealant must not be applied too thick, otherwise excess seal‐
ant can by
Protected enter theCopying
copyright. oil channels
for private oror camshaft
commercial bearing
purposes, and
in part or cause
in whole, is not
damage
permitted toauthorised
unless the engine.

Arosa 1997 ➤
– Install the cylinder head cover carefully from above ensuring

that the dowel pins fit in holes -arrows- in the cylinder head.
Note!
♦ Positioning and securing the cylinder head cover must be

completed without interruption, as the sealing surfaces start to
cure immediately they have contact.
♦ The cylinder head cover bolts must be replaced.
– First tighten bolts items 1 and 2 alternately using diagonal se‐

quence and tighten to 6 Nm.
– Then tighten the other bolts to 6 Nm in sequence prescribed.
– Then tighten all bolts a 1/4 turn (90 °) further.
Note!
Sealant must be left dry for approx. 30 minutes after installing

cylinder head cover.
– Install new oil seal in camshaft, ⇒ page 49 .

sequence.
Installing toothed belt and adjusting timing ⇒ page 36 .
part: ⇒ page 102
2.4 Checking valve guides

♦ Universal dial gauge holder -T20020-
♦ Dial gauge

Arosa 1997 ➤
Test sequence
– Insert new valve into guide until end of valve stem is flush with
end of 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.
– Determine rock. Wear limit: 0.8 mm
2.5 Renewing valve guides

♦ (∅ 6 mm) Driver -T20035-
♦ Hand reamer with cutting fluid -T20066-

Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– First check whether the valve seat insert rings
respect and
to the if necessary
the cylinder head sealing surface can be reworked. If this is
not the case then the valve guide should not be replaced.

Arosa 1997 ➤
– Drive out worn valve stem guide using driver -T20035- (∅ 6

mm) from camshaft side (valve stems guides with a repair
shoulder from the combustion chamber side).
Installing
– Coat new stem guide with oil, and press new stem guide in
from the camshaft side with driver -T20035- (∅ 6 mm) until the
shoulder is positioned correctly in the cold cylinder head.
Note!
When the shoulder on stem guide makes contact, the pressure

must not exceed 10 kN (approx. 1.0 t) otherwise shoulder may
break off.
– Ream valve stem guide with hand reamer -T20066- . Always

use cutting fluid when doing this.
– Reworking valve seats ⇒ page 48 .
2.6 Renewing valve stem seals

equipment required
T20028-
♦ Pressure hose -T20033-
♦ Assembly device with press
piece T20034/27 -T20034-
♦ Fitting tool -T20039-
♦ Puller -T20058-

Arosa 1997 ➤
Removing
– First remove toothed belt ⇒ page 36 .
– Then remove camshaft ⇒ page 51 .
– Remove roller rocker finger together with support elements
and place on a clean surface.
– Ensure the roller rocker fingers and the support elements are
not interchanged.
– Remove spark plugs with spark plug wrench -T20028- .
– Set piston of appropriate cylinder to “bottom dead centre” .
– Fit assembly device -T20034- with press piece -T20034/27- .
– Screw pressure hose -T20033- into threads of hole for spark
plug.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull valve stem seal off using -T20058- .
Note!
Tight cotters can be loosenedpermitted
by tapping lightly byonSEAT
unless authorised theS.A.
lever.
– Pull off valve stem seals with -3364- .

Installing
– Place the plastic sleeve supplied on the appropriate valve

stem. This will prevent the new valve stem seal being dam‐
aged.
– Fit new valve stem seal into fitting tool -T20039- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
sequence.
– Install camshaft and cylinder head cover ⇒ page 51 .
– Installing new seals for camshaft ⇒ page 49 .

Arosa 1997 ➤
17 – Lubrication
1 Removing and installing parts of the
lubrication system
Note!
The oil level must not be above the max. mark - danger of dam‐
aging catalyst! Marks ⇒ page 61 .
Checking oil pressure ⇒ page 65

Oil system capacity8) :
with oil filter 3.2 ltr.
8) Up-to-date figures:
⇒ Data sheets for exhaust emission test

Engine oil specifications:
Use engine oil to VW standard 500 00, 501 01 or 502 00. Only in
exceptional cases: Multi-grade oils corresponding to API-SF or
SG.

Arosa 1997 ➤
1 - Cap
2 - 0.3...0.6 bar oil pressure
switch -F1- , 25 Nm
3 - Guide tube
4 - 10 Nm
5 - Guide
❑ Pull off to extract oil
6 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 61
❑ Note position when in‐
stalling thebytoothed
Protected belt for private or commercial purposes, in part or in whole, is not
copyright. Copying
⇒ permitted
page 36 unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
8 - Oil filter
wrench
❑ Tighten by hand
❑ Observe installation in‐
structions on oil filter
9 - Gasket
❑ Renew
el sleeves
10 - Tensioner
1. Removing and installing parts of the lubrication system 59

Arosa 1997 ➤
and tensioning
⇒ page 36
11 - 20 Nm
12 - Toothed belt
❑ Check for wear
❑ Do not kink
❑ Removing, installing and tensioning ⇒ page 36
13 - Toothed belt guard - upper part
15 - Belt pulley
❑ When installing note fixing arrangement
16 - 90 Nm + 1/4 turn (90 °) further
❑ Renew
❑ Oil threads
❑ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
❑ Note position when installing the toothed belt ⇒ page 36
18 - 12 Nm
❑ Renew
19 - Oil seal
20 - Oil pump
❑ When installing note drive cam on crankshaft ⇒ Item 23 (page 60)
❑ Must be located on dowel sleeves
21 - Gasket
❑ Renew
22 - Suction pipe
23 - Drive cam
❑ Coat with oil before installing oil pump
24 - Cable guide
❑ With attached seal
❑ Renew
26 - Sump
❑ Removing and installing engines with liquid gasket ⇒ page 61
❑ Install with siliconeauthorised
permitted unless sealant by -D
SEAT 176 404 S.A
S.A. SEAT A2- ⇒ not
does page 61 or accept any liability with
guarantee
27 - 15 Nm
❑ Loosen and tighten the bolts on the flywheel end only using socket insert -U-40051-
28 - O-ring
❑ Renew

Arosa 1997 ➤
29 - Oil separator
30 - To air cleaner
Markings on oil dipstick

1 - max. mark
2 - min. mark
a - Area above hatched field up to max. mark: Do not top-up with
engine oil!
b - Oil level within hatched field: can be topped-up with engine oil
c - Area from min. mark up to hatched field: fill with max. 0.5 ltr.
of engine oil!
1.1 Removing and installing oil sump
♦ Socket insert -U-40051-
♦ Hand drill with plastic brush

♦ Flat scraper
♦ Silicone sealant -D 176 404 A2-
Work sequence
– Remove right-hand insulation tray: ⇒ General body repairs
exterior; Rep. Gr. 50 ; Body front Assembly overview
– Drain engine oil.
– Remove cable guide from the sump.

Arosa 1997 ➤
– Separate front exhaust pipe from exhaust manifold

⇒ page 177 , exhaust manifold, front exhaust pipe and cata‐
lyst with attachments.
– Unbolt right-hand drive shaft at gearbox. ⇒ Running gear;
Rep. Gr. 40 ; Servicing front suspension Removing and in‐
stalling wheel bearing, suspension strut and drive shaft
– Remove bolt from front wishbone mounting. ⇒ Running gear;
Rep. Gr. 40 ; Servicing front suspension Removing and in‐
stalling wheel bearing, suspension strut and drive shaft
– Remove cover plate for flywheel.
– Unbolt sump sealed with liquid gasket.
– Remove sump, it may be necessary to release sump by tap‐
ping lightly with a rubber head hammer.
– Remove sealant residue on cylinder block with a flat scraper.
– Remove sealant residue on the sump with a rotating brush,
e.g. a hand drill with a plastic brush (wear protective glasses).
– Clean sealing surface, must be free of oil and grease.
Installing
♦ Note the use by date of the sealant. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Sump must be installed within 5 minutes of applying silicone

sealing compound.
♦ Sump can be offered up easier and with greater security if, for
guide purposes, M6 studs are inserted into the cylinder block
flange at two positions.
– Cut off tube nozzle at forward marking (nozzle approx. 3 mm

∅).
– Apply silicone sealing compound, as shown, to clean sump
sealing surface. Sealing compound bead must be:
♦ 2...3 mm thick.
♦ and run on inside of bolt holes -arrows- .
Note!
The sealing compound bead must not be thicker, otherwise ex‐

cessive sealing compound will enter the sump and may block the
oil suction pipe strainer.
– Install sump immediately and tighten all sump bolts lightly.

– Tighten sump bolts to 15 Nm.
Note!
After installing sump the sealant must be allowed to dry for ap‐
prox. 30 minutes before engine oil is filled.
1.2 Removing and installing oil pump

Arosa 1997 ➤

equipment required
♦ Puller -T20081-
♦ Flat scraper
Removing
– Remove toothed belt ⇒ page 36 , removing, installing and ten‐
sioning toothed belt.
– Position crankshaft at TDC No. 1 cylinder -arrow- :
The chamfered tooth of toothed belt sprocket must align with the
marking (2V) on the oil pump.

Arosa 1997 ➤
– Turn crankshaft/toothed belt sprocket three teeth anti-clock‐

wise away from TDC:
The third tooth -arrow- to the right of the tooth ground down -A-
on the toothed belt sprocket must align with TDC mark on the oil
pump housing.
Note!
This procedure moves the crankshaft to the correct installation

position for the oil pump. One of the polygon cams on the crank‐
shaft is uppermost.
– Remove crankshaft toothed belt sprocket and toothed belt

tensioning roller. Hold toothed belt sprocket with counter-hold
-T20018- .
– Remove sump ⇒ page 61 .
– Remove suction pipe ⇒ Item 22 (page 60) .
– Remove oil pump.
– Remove gasket.
– Remove sealant remnants on cylinder block with a flat scraper.
– Clean sealing surfaces, they must be oil and grease free.
Installing
Conditions
• One of the polygon cams -arrow- on the crankshaft is upper‐

most.
Work sequence
– Fit gasket onto fitted pins in cylinder block.
– Coat the four crankshaft polygon cams with oil.
– Position one of the oil pump innerpermitted
rotorrespect
markings arrow
unless authorised -A-S.A.
by SEAT onSEAT S.A does not guarantee or accept any liability with
installation position mark arrow -B- on oil pump housing cover.
– Lightly oil sealing lip of oil pump oil seal.

Arosa 1997 ➤
– Fit sleeve -T20081/2- of puller -T20081- into pre-assembled

seal in oil pump.
– Guide oil pump carefully onto crankshaft polygon cams.
– Align inner rotor to crankshaft polygon cams by turning slightly
if necessary.
– Then slide oil pump carefully onto guide pins.
– Secure oil pump with new bolts. Tightening torque: 12 Nm
– Pull out sleeve -T20081/2- .
– Install suction pipe ⇒ Item 22 (page 60) .
– Install oil sump ⇒ page 61 .
sequence.
1.3 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester -V.A.G
1342-
1527 B-

Arosa 1997 ➤
Note!
Functional check and servicing the optical and acoustic oil pres‐
sure warning:
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐

tions
Test sequence
– Remove oil pressure switch -F1- and screw into tester.
– Screw tester into the cylinder head in place of the oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect diode test lamp -V.A.G 1527 B- using aux. cables
from -V.A.G 1594 A- to battery positive (+) and oil pressure
switch.
– If the LED lights up, renew oil pressure switch -F1- .
If the LED does not light up:
– Start engine and increase speed slowly. At 0.3...0.6 bar the
LED must light up; otherwise renew oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed 7.0 bar.

Arosa 1997 ➤
1 Removing and installing parts of cool‐
ing system
Note!
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary release pressure before commencing repair
work.
♦ Hoses are secured with spring-type clips. In cases of repair
only use spring-type clips.
♦ It is recommended that pliers -T20029- are used to remove
and install spring-type clamps.
Perform cooling system leakage test with cooling system tester -

V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
Parts of cooling system body side ⇒ page 67 .
Parts of cooling system engine side ⇒ page 69 .
Coolant hose connection diagram ⇒ page 71 .
Draining and filling with coolant ⇒ page 71 .
Coolant mixture ratios ⇒ page 71 , draining and filling with cool‐
ant
1.1 Parts of cooling system body side

Arosa 1997 ➤
1 - Radiator
⇒ page 73
❑ After replacing renew
entire coolant
2 - Lock carrier
3 - Radiator fan
4 - 10 Nm
5 - Bracket
6 - Connector
tion diagram
⇒ page 71
tion diagram
⇒ page 71
9 - Expansion tank
10 - Cap
❑ Check with -V.A.G
1274- and 1274/4
❑ Test pressure 1.4...1.6
bar
11 - Cover
12 - To thermostat housing
tion diagram
⇒ page 71
13 - To coolant pipe
14 - Thermo-switch -F18- , 35 Nm
❑ Switching temperatures: Stage 1 on: 92...97 °C off: 84...91 °C Stage 2 on: 99...105 °C off: 91...98 °C

Arosa 1997 ➤
1.2 Parts of cooling system engine side
1 - Retainer
❑ For connectors
2 - Self-tapping bolt
3 - From bottom of radiator
tion diagram
⇒ page 71
4 - Connection
5 - O-ring
❑ Renew
❑ Checking operation:
heat-up thermostat in
water the thermo ele‐
ment pin must move out
❑ Temperature check:
Opening starts (approx.
84 °C) and ends (ap‐
prox. 98 °C) cannot be
checked.
7 - To expansion tank
tion diagram
⇒ page 71
8 - To heat exchanger
9 - From expansion tank
tion diagram
⇒ page 71
10 - Retaining clip
12 - Coolant pump housing on cylinder block
13 - Seal
❑ Protected
Renewby copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - Coolant pipe
16 - 10 Nm
18 - Sealing plug
19 - To top of radiator
Coolant pump side

Arosa 1997 ➤
1 - Coolant pump
❑ With integrated seal
❑ Seal must not be sepa‐
rated from coolant pump
❑ Replace damaged or
leaking coolant pump
together with seal
❑ Check for ease of move‐
ment
2 - Toothed belt guard - coolant
pump
3 - 20 Nm
part
❑ Renew permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
6 - Toothed belt guard - lower
part
7 - Toothed belt
❑ Check for wear
❑ Do not kink
and tensioning
⇒ page 36

Arosa 1997 ➤
1.3 Coolant hose connection diagram
1 - Coolant pump
2 - Intake manifold
3 - Heating system heat ex‐
changer
4 - Expansion tank
6 - Radiator
9 - Cylinder block
1.4 Draining and filling cooling system


Arosa 1997 ➤
♦ Pliers for spring-type clamps -T20029-
Draining
– Remove cap from coolant expansion tank.
– Drain coolant from bottom radiator hose.
Note!
Filling
Note!
♦ Only use coolant additive G 12 in accordance with TL VW 774

D. Identification: coloured red Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ On no account must G 12 be mixed with other coolant addi‐ in this document. Copyright by SEAT S.A.
respect to the correctness of information
tives!
with other coolant. In this case the coolant must be changed.
♦ G 12 and coolant additives marked “In accordance with TL VW
774 D” prevent frost and corrosion damage, scaling and also
raise boiling point of coolant. For this reason the system must
be filled all year round with frost and corrosion protection ad‐
ditives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Protection against frost must be assured to about -25 °C (in
arctic climatic countries to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The anti-
freeze ratio must be at least 40 %.
♦ If for climatic reasons a greater frost protection is required, the
amount of G 12 can be increased, but only up to 60 % (frost
protection to about -40 °C), as otherwise frost protection is re‐
duced again and cooling effectiveness is also reduced.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:

Frost protection Anti-freeze G 129) Water9)
to amount

Arosa 1997 ➤
-25 °C 40 % 2.25 l 3.35 l

-35 °C 50 % 2.8 l 2.8 l
9) The quantity of coolant can vary depending upon the vehicle equipment.
– Fill with coolant up to max. mark on expansion tank.

– Fit expansion tank cap.
– Start engine and maintain an engine speed of about 2000 rpm
for approx. 3 minutes.
– Run engine until radiator fan cuts-in.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
on the max. mark, when the engine is cold, between the min.
and max. marks.
1.5 Removing and installing radiator

equipment required
clamps -T20029-

Arosa 1997 ➤
Removing
– First remove radiator grille and trim. ⇒ General body repairs;
Rep. Gr. 66 ; Trims Removing and installing radiator grille and
trim frame
– Remove front bumper cover and bumper carrier: ⇒ General
body repairs; Rep. Gr. 63 ; Front bumper Assembly overview
– Pull coolant hoses off radiator.
– Pull connectors off thermo-switch.
– Remove radiator securing bolts and take out radiator down‐
wards.
Vehicles with air conditioner:
– Observe additional information and removal work
⇒ page 74 .
Installing
Installation is carried out in the reverse order, when doing this
note the following:
– Electrical connections and routing: ⇒ Current flow diagrams,
Additional information and removal work on vehicles with air con‐
ditioner
Caution
The air conditioner refrigerant circuit must not be opened.
Note!
To prevent damage to condenser also to the refrigerant pipes/

hoses, ensure that the pipes and hoses are not stretched, kinked
or bent.
– Remove retaining clamp(s) from refrigerant pipes.

– Unbolt condenser from radiator and secure to lock carrier.
– Unbolt air conditioner fluid reservoir and allow to hang free.
– Remove condenser from radiator and pull forward as far as is
possible.
– Pull radiator out carefully, downwards.
1.6 Checking radiator fan -V7- and -V35-


Arosa 1997 ➤
♦ Diode test lamp -V.A.G 1527 B-
♦ Auxiliary test set -V.A.G 1594 A-

Check conditionspermitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• The main fuses must be OK.
• Radiator fan thermo switch -F18- OK.
Test sequence
– Pull 3-pin connector off radiator fan thermo switch -F18- .
– Bridge contact -1- and contact -2- of connector using auxiliary

cables from -V.A.G 1594 A- . 1st speed for radiator fans -V7-
and -V35- must begin to run.
– Bridge contact -2- and contact -3- of connector with auxiliary
cables from -V.A.G 1594 A- . 2nd speed for radiator fans -V7-
and -V35- must run.
If fan 1st or 2nd speeds do not run:
– Locate and rectify open circuit using current flow diagram:
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
If no wiring open circuit is found:
– Renew radiator fan -V7- or -V35- .
1.7 Removing and installing coolant pump

Arosa 1997 ➤

equipment required
♦ Piers for spring-type
clamps -T20029-
Note!
♦ The integrated coolant pump seal must not be separated from

the coolant pump.
♦ Damaged or leaking coolant pumps must be replaced com‐
plete with seal.
Removing
– Drain coolant ⇒ page 71
– Remove toothed belt ⇒ page 36 , removing, installing and ten‐
sioning toothed belt.
loosening and tightening camshaft sprocket bolt.
– Remove toothed belt tensioning roller.
– Remove bolts for tooth belt rear guard.
– Remove coolant pump securing bolts and remove coolant
pump together with toothed belt rear guard.

Arosa 1997 ➤
Installing
– Insert coolant pump together with toothed belt rear guard and
tighten securing bolts. Tightening torque: 20 Nm
sequence.
– Install camshaft sprocket. Hold camshaft sprocket with coun‐
ter-hold -T20018- when doing this and tighten new securing
bolt to 20 Nm + 1/4 turn (90 °) further.
Note!



Arosa 1997 ➤

1 Removing and installing parts of fuel
supply system
Note!
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. The use of clamp or screw-type clips is not
permissible.

Observe crash fuel shut-off ⇒ page 81 .
Removing and installing fuel tank with attachments and fuel filter
⇒ page 78 .
Servicing parts of electronic accelerator control (EPC)
⇒ page 91 .
Servicing parts of the activated charcoal filter system
⇒ page 97 .
1.1 Removing and installing fuel tank with its attachments and fuel filter

Arosa 1997 ➤
1 - Cap
2 - Tank flap unit
3 - Gravity/overflow valve
❑ To remove, release
locking lug and unclip
valve upwards out of fill‐
er neck
❑ Check valve for
through-flow valve verti‐
cal: open, valve tilted 45
°: closed
4 - O ring
6 - Union nut, 80 Nm
❑ Remove and install us‐
ing key -U-40055 A- or
-3217-
7 - Return pipe
❑ Blue
❑ From fuel manifold
⇒ page 109
8 - Fuel delivery unit
⇒ page 82
❑ Checking fuel pump
⇒ page 84
❑ Note fitting position on
fuel tank ⇒ page 80
9 - Fuel gauge sender
❑ Adjusting: ⇒ Current

Arosa 1997 ➤
flow diagrams, Electri‐

cal fault finding and Fitting locations
10 - Sealing ring
❑ Coat with fuel when installing
11 - Fuel filter
❑ Fitting position: Arrow points in through-flow direction
12 - 3 Nm
13 - Fuel tank
14 - 25 Nm
15 - Securing strap
❑ Note differing length
16 - Vent pipe
❑ To activated charcoal filter ⇒ Item 5 (page 98)
17 - Supply pipe
❑ Black
❑ To fuel manifold ⇒ page 109
18 - Spacer bush
19 - 12 Nm
20 - Vent valve
❑ To remove pull locking latch lightly to inside -arrow- and pull valve out ⇒ page 80 -arrow-
Fitting position of fuel delivery unit flange

Marking on the flange must align with marking on the fuel tank.
Checking vent valve

Lever in rest position: Closed
Lever pushed in direction of arrow: Open

Arosa 1997 ➤
1.2 Safety precautions when working on the

fuel supply system
When removing and installing the fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank the following
must be observed:
Caution

♦ Before commencing work, switch on exhaust extraction sys‐

tem and place an extraction hose close to the sender opening
in the fuel tank to extract escaping fuel fumes. 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 can
be used.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
♦ For safety reasons fuse No. 40 must be removed from fuse
holder before opening the fuel system, otherwise the fuel
pump can be activated by the door contact switch in driver's
door.

disconnecting.
parts immediately prior to
Protected by copyright. installation.
Copying for private or Do not use
commercial parts
purposes, that
have been stored
permitted loose (e.g.
unless authorised inS.A.
by SEAT tool boxes
SEAT etc.).
necessary.
1.4 Crash fuel shut-off

Function
Vehicles with an airbag are fitted with a crash fuel shut-off system.
It reduces the danger of a fire in a crash as the fuel pump is
switched off via the fuel pump relay. Simultaneously this system
provides an improved start for the engine. When the door is
opened the fuel pump is activated for 2 seconds to build-up the
pressure in fuel system.
When opening the fuel system:
– Check fuel pump relay: ⇒ Current flow diagrams, Electrical

Arosa 1997 ➤
1.5 Removing and installing fuel delivery

unit
♦ Key for union nut -U-40055 A-

Removing
– Note safety precautions before starting work ⇒ page 81
– Fold rear seat forwards.
– Remove cover from fuel delivery unit.
– Pull connector -1- and supply and return pipes -2- , -3- off
flange.
Caution


Arosa 1997 ➤
– Unscrew union nut from flange using key -U-40055 A- .

– Pull delivery unit and seal out of the opening in fuel tank.
Note!
If the delivery unit is to be renewed then drain old delivery unit

before disposal.
Installing
– Installing the fuel delivery unit is carried out in the reverse or‐
der.
Note!
♦ When inserting the fuel delivery unit ensure that the fuel gauge
sender is not bent.
♦ Coat flange seal with fuel when fitting.
♦ Fitting position of fuel delivery unit flange ⇒ page 80 .
1.6 Removing and installing fuel gauge

sender
Removing
– Removing fuel delivery unit ⇒ page 82 .
– Release and pull off the terminals for wires -3- and -4- .
– Lift retaining tabs -1- and -2- with a screwdriver and pull fuel
gauge sender out downwards -arrows- .
Installing
Installing is basically in the reverse order but note following:
– Insert fuel gauge sender in the guides on the fuel delivery unit
and push up until it engages.
– Installing fuel delivery unit ⇒ page 83 .
1.7 Removing and installing fuel tank

Special tools andrespect
workshop equipment required
♦ Engine/gearbox jack -SAT 1001-

Arosa 1997 ➤

Removing
– Note safety precautions before starting work ⇒ page 81
– Drain fuel tank, clean fuel filler neck and surrounding area.
– Unscrew securing bolts and remove tank flap unit.
– Fold rear seat bench forwards.
– Pull connector -1- and return pipe -2- off flange.

– Remove rear axle: ⇒ Running gear; Rep. Gr. 42 ; Servicing
rear axle Removing and installing rear axle.
– Detach filler pipe from body.
– Remove tensioning strap. When doing this support fuel tank
with engine/gearbox jack -V.A.G 1383 A- .
– Pull out fuel tank to the rear.
Installing
Installing is basically in the reverse order but note following:
♦ Breather and fuel hoses are to be installed kink-free.
♦ Do not interchange supply and return hose (return hose blue
or blue markings, supply hose black).
♦ Installing rear axle: ⇒ Running gear; Rep. Gr. 42 ; Servicing
rear axle Removing and installing rear axle.
Note!
After installing fuel gauge sender, check that the supply, return
and breather pipes are still clipped onto the fuel tank.
1.8 Checking fuel pump

Arosa 1997 ➤

equipment required
♦ Pressure tester -V.A.G
1318-
♦ Adapter -V.A.G1318/17-

Arosa 1997 ➤

1527 B-
♦ Remote control with V.A.G
1348/3-2 adapter cable -
V.A.G 1348/3A-
♦ Multimeter -V.A.G 1715-
♦ Key for union nut -
U-40055A-
♦ Measuring container
Note!
Observe functional description of crash fuel shut-off ⇒ page 81 .

Arosa 1997 ➤
Test sequence
Test conditions
• Battery voltage at least 11.5 V
• Fuse SB40 OK.
Checking function and voltage supply
Note!

– Fold rear seat forwards.

– Briefly operate starter. Fuel pump must be heard to run briefly
-approx. 1 second-.
If the fuel pump does not run:
– Remove cover in front of fuse holder.
– Pull fuse SB40 out of fuse holder.
– Connect remote control -V.A.G 1348/3A- with adapter cable -

V.A.G 1348/3-2- to contact 40b -arrow- to fuel pump and
battery positive (+).
– Operate remote control.
Fuel pump runs:
– Check activation of fuel pump relay: ⇒ Current flow diagrams,
Fuel pump does not run: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Arosa 1997 ➤
– Pull 4-pin connector -1- off fuel tank flange -2- .

– Connect diode test lamp -V.A.G 1527- using auxiliary cables
from -V.A.G 1594- to the outer contacts of the connector.
– Operate remote control. LED must light up
LED does not light up:
– Locate and eliminate open circuit using current flow diagram
LED lights up (voltage supply OK.):
– Fit key -U-40055A- on the three rounded ribs of union nut and
unscrew union nut from flange.
– Check that the electrical wires between flange and fuel pump
are connected.
If not open circuit can be found:
– Renew fuel delivery unit.
Checking delivery rate
Test conditions
• The voltage supply for the fuel pump OK.
• Remote control -V.A.G 1348/3A- is still connected.
Test sequence
– Remove filler cap from fuel tank filler neck.
Caution

– Pull fuel supply hose

Protected (whiteCopying
by copyright. marking) offorfuel
for private supply
commercial pipein-1-
purposes, part .or in whole, is not
– Connect pressure gauge -V.A.G 1318- with adapter /1 to fuel
supply pipe.
– Screw adapter hose /13 with adapter /7 to pressure gauge and
hold hose in measuring container.
– Open the pressure gauge shut-off tap. The lever then points
in the flow direction -A- .
– Operate remote control -V.A.G 1348/3A- and slowly close cut-
off tap, until pressure gauge shows 3 bar. From this point on
do not move position of cut-off tap.
– Empty the measuring container.
– The fuel pump delivery range is dependent upon battery volt‐
age. Therefore connect the multimeter with adapter cables
from -V.A.G 1594- to the vehicle battery.
– Operate remote control for 30 seconds and measure battery
voltage

Arosa 1997 ➤
– Compare the quantity of fuel delivered with specification.

-*- Minimum delivery cm³/30 seconds
-**- Voltage at fuel pump with engine stationary and pump running
(approx. 2 volts less than battery voltage).
Example:
During the test, a voltage of 12.5 volts is measured at the battery.
As the voltage at the pump is approx. 2 volts less than the battery
voltage, this will equate to a minimum delivery of 540 cm³/30 s.
If the minimum delivery rate is not attained:
– Check the fuel pipes for possible restrictions (kinks) or block‐
ages.
– Pull supply hose -1- off inlet to fuel filter.

– Connect pressure gauge -V.A.G 1318- with adapter -1318/17-
to fuel supply pipe.
– Repeat delivery rate check.
If thepermitted
minimum unlessdelivery rate
authorised by SEATis now
S.A. SEATattained:
– Replace the fuel filter.
If the minimum delivery rate is again not attained:
– Remove the fuel delivery unit and check the strainer filter for
soiling.
Only when up to now no fault has been detected:
– Replace the fuel delivery unit.
If the delivery rate has been attained but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Check the current draw of the fuel pump as follows:
– Reconnect all disconnected fuel pipes.

Arosa 1997 ➤
– Connect the multimeter -V.A.G 1715- using the current clamp

to the red/yellow wire from wiring harness.
– Measure the current draw of the fuel pump. Specification: max.
8 amps.
Note!
If the fuel system malfunction is intermittent, you can perform the

check during a test drive with the help of a 2nd person.
If the current draw is exceeded:

Checking fuel pump non-return valve
Test conditions
• Remote control -V.A.G 1348/3A- is still connected.
• Pressure gauge -V.A.G 1318- is still connected.
Test sequence
Note!
With this check the fuel supply pipe connections from the fuel de‐
livery unit to the point at which the pressure gauge -V.A.G 1318-
is connected will be checked for leaks at the same time.
– Close pressure gauge cut-off tap (lever at right angle

Protected to direc‐
tion of flow). permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Operate remote control at short intervals until a pressure of 3
bar has built up.
Caution
Danger of spray when opening the shut-off tap, hold container

over the pressure gauge free connection.
– If pressure builds up too high, lower excess pressure by care‐

fully opening the shut-off tap.
– Watch pressure drop. After 10 minutes the pressure must not
drop below 2 bar.
If the pressure drops further:
– Check pipe connections for leaks.
If no fault is detected in the pipes:

Arosa 1997 ➤
2 Electronic power control (EPC)
2.1 Function of EPC system

With the EPC system the throttle valve is not operated by a cable.
There is no mechanical connection between accelerator and
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 (drivers requirement) is the main
input value for the engine control unit.
The throttle valve is operated over the complete revolution and
load range bybyan
Protected electric
copyright. motor
Copying (throttle
for private valvepurposes,
or commercial positioner)
in part orin the is not
in whole,
throttle valve control part.
The throttle valve is operated by the throttle valve positioner which

is controlled by the engine control unit.
When the engine is not running and the ignition is switched on the
engine control unit moves the throttle valve exactly as prescribed
by the accelerator pedal position sender. This means that when
the accelerator is depressed halfway the throttle valve positioner
opens the throttle valve by the same amount, the throttle is then
approximately 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 depressed half way.
This also gives vastly improved consumption and exhaust emis‐
sion levels at certain load conditions.
The torque required by the engine can be produced by the engine
control unit by optimising the combination of throttle valve cross-
section and charge pressure.
It is incorrect to believe that the “EPC” is comprised of one or two
components only. The EPC is a system, which is comprised of all
components which have an influence, control or monitor the po‐
sition of the throttle valve, e.g. the accelerator pedal position
sender, the throttle valve control unit, the EPC warning lamp, the
engine control unit.
Checking electronic accelerator warning lamp ⇒ page 92 .
2.2 Servicing parts of electronic power control (EPC)
2. Electronic power control (EPC) 91

Arosa 1997 ➤
1 - Bracket
⇒ Running gear; Rep.
Gr. 46 ; Brake, Assem‐
bly overview brake
mechanism, brake ped‐
al/mounting bracket
2 - Connector
❑ Black, 6-pin
sender -G79-
❑ Not adjustable
❑ The accelerator pedal
position passes the po‐
sition of the pedal on to
the engine control unit
❑ Remove footwell cover
to remove sender
4 - 10 Nm
2.3 Checking electronic accelerator warning

lamp
Note!
The electronic accelerator warning lamp -K132- is known also as

the EPC warning lamp.

♦ Test box -V.A.G 1598/22-
Check conditions
• The fuses must be OK.

Arosa 1997 ➤
Note!
Checking function of warning lamp
The EPC warning lamp must light up.
– Start engine and run at idling speed.
The EPC warning lamp must go out when no EPC fault has been
stored.
Note!
Electronic accelerator warning lamp does not light up
– Remove cover in front of fuse holder. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not



ness.
– Bridge test box sockets 2 + 30 with aux. cables from -V.A.G
1594- .
– Switch ignition on. The fault lamp must light up
If the fault lamp does not light up:
– Remove dash panel insert and check the bulb and its voltage
supply.: ⇒ Electrical system; Rep. Gr. 90 ; Dash panel insert
Removing and installing dash panel insert
If no fault is found:
– Check wiring for open circuit between test box socket 30 and
dash panel insert using current flow diagram: ⇒ Current flow
Electronic accelerator fault lamp lights up continuously

ness.
– Check wiring for short to earth between test box socket 30 and
dash panel insert using current flow diagram: ⇒ Current flow
2.4 Checking accelerator pedal position sender

Arosa 1997 ➤

equipment required
1526-
♦ Test box -V.A.G 1598/22-
V.A.G 1552- with cable -
V.A.G 1551/3A-
Function
Both accelerator pedal position senders -G79- and -G185- on the
accelerator pedal pass the driver's requirements on to the engine
control unit independently of one another. Both senders are in‐
stalled permitted
together
Protected byin a housing.
Check conditions
• The fuses must be OK.

Test sequence
Select function XX

Indicated on display: Read measured value block

Arosa 1997 ➤
– Press keys 0 , 6 and 2 for the “Display group number 62”

and confirm entry with Q key.
Indicated on display: (1...4 = Display zones) Read measured value block 62 →
– Check specifications of sender 1 -G79- at idling stop in display

zone 3. Specification: 12...97 %
– Check specifications of sender 2 -G185)- t idling stop in display
zone 4. Specification: 4...49 %
Note!
The engine control unit calculates the voltage values of the angle
sender in percent relative to 5 Volt and displays these as a per‐
centage figure (5 Volt supply voltage equates to 100 %).
– Operate the accelerator pedal slowly until fully depressed and

observe the angle sender figures in display zones 3 and 4:
The percent figures in display zone 3 must rise evenly. The tol‐
erance range of 12...97 % is not covered completely.
The percent figures in display zone 4 must rise evenly. The tol‐
erance range of 4...49 % is not covered completely.
Note!
The figure displayed in display zone 3 must always be approxi‐

mately double that displayed in display zone 4.
End specification value not achieved:

– Press the → key. respect to the correctness of information in this document. Copyright by SEAT S.A.
Display does not change or is erratic:
– Check accelerator pedal position sender as follows:
– Remove cover in footwell (driver's side).
– Disconnect 6-pin connector for accelerator pedal position
sender.

Arosa 1997 ➤

ness.
nector (connector to control unit) using current flow diagram.
Contact 1 + socket 6 Contact 2 + socket 8 Contact 3 + socket
7 Contact 4 + socket 33 Contact 5 + socket 19 Contact 6 +
socket 45 Wire resistance: Max. 1.5 Ω

Arosa 1997 ➤
3 Activated charcoal filter system
3.1 Function
Depending upon the air pressure and ambient temperature, fuel
vapour will form above the level of fuel in the tank.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
Fuel vapours pass from the highest point in the tank through the
gravity valve (which closes at an angle of 45 °) and the breather
valve in limited quantities.
The activated charcoal stores these vapours like a sponge.
When the Lambda control is active when driving (engine warm),
the tank venting valve -N80- , also known as the regeneration
valve), is activated (pulsed) from engine control unit depending
upon load and engine speed. The opening period is dependent
on the input signals.
Intake manifold vacuum draws fresh
permitted airauthorised
unless through the vent
by SEAT opening
on the underside of the activated respect
charcoal filter during the purging
procedure (regenerating the activated charcoal). The fuel va‐

pours stored in the activated charcoal and fresh air are pulse-fed
for combustion.
The breather valve prevents fuel vapours from being drawn from
the tank when the tank venting valve is open and intake manifold
vacuum is present. It therefore ensures that the evacuation of the
activated charcoal filter has priority.
No voltage (e.g. wiring open circuit) the tank venting valve is
closed. The activated charcoal filter will not be purged.
Note!
♦ Hose connections are secured with either spring-type or

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

3.2 Servicing parts of the activated charcoal filter system
3. Activated charcoal filter system 97

Arosa 1997 ➤
1 - Retaining ring
2 - Bracket
❑ On body front right
3 - Tank breather (vent) valve
for activated charcoal filter -
N80-
❑ Valve closed with igni‐
tion switched off
❑ When the engine is
warm the valve will be
activated from the en‐
gine control unit
(pulsed)
❑ Check tank venting
valve ⇒ page 98
❑ Check activation of tank
venting valve: ⇒ Vehicle
diagnosis, testing and
information system VAS
5051 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Connector respect to the correctness of information in this document. Copyright by SEAT S.A.
5 - Breather pipe
❑ From gravity/overflow
valve on fuel tank
6 - Throttle valve control part
7 - Activated charcoal filter
❑ Location: in front right
wheel housing
❑ To remove, release se‐
curing tab -arrow- and
push container out up‐
wards
3.3 Checking tank breather (vent) valve

Engine codes: ANV, AUC, AUD, ANW
Note!
Tank venting valve is closed when no current is supplied.
Checking activation:
Test conditions
• Fuse No. 1 must be OK.
• Coolant temperature must be at least 80 °C, ⇒ display group
04, display zone 3.

Arosa 1997 ➤
Functional check
– Connect fault reader -V.A.G 1551- ( -V.A.G 1552- ). Start en‐
gine and select the engine control unit with the “Address word”
01. Connecting fault reader and selecting engine control unit:
Select function XX

Indicated on display: Basic setting

Indicated on display: (1...4 = Display zones)
Protected by copyright. Copying for private orSystem in purposes,
commercial basic setting
in part or in whole, is70
not →
Note!
The engine must not be loaded during this diagnosis because the
diagnosis will be interrupted and will not be started again until the
engine is revved-up.
When the diagnosis is initiated by the engine control unit the dis‐
play in display zone 4 jumps from “Test OFF” to “Test ON”
– Run engine at idling speed until the Specification “TBV OK” is
displayed in display zone 4.
If the display indicates as described:
– Press → key.
If the display does not indicate as described:
– Press → key.
– Introduce final control diagnosis and activate tank venting
valve -N80- : ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051
3.4 Checking fuel tank breather


Arosa 1997 ➤
♦ Vacuum tester -V.A.G 1368-
♦ Adapter -SAT1368/1-
Test conditions
• Ignition must be switched off
Test sequence
– First pull vent hose -1- from activated charcoal filter off tank
venting valve -2- .
– Connect hand vacuum pump -SAT 1390- and vacuum tester
-V.A.G 1368- to hose -1- as shown.
– Set vacuum tester to -A- /-B- position.
– Operate hand vacuum pump -SAT 1390- several times. Vac‐
uum must not build up.
If vacuum builds up:
– Check breather connection
permitted unless authorised by -3-
SEATlocated
S.A. SEATonS.A bottom of activated
charcoal filter -4- for soiling, clean if necessary.

If vacuum does not build up:

– Temporarily seal breather connection -3- and operate vacuum
pump again several times. A vacuum must build up. (Vacuum
non-return valve in activated charcoal filter must close).
– Renew activated charcoal filter.
Checking lines to fuel tank and fuel cap

Arosa 1997 ➤
– Pull vent hose -1- from fuel tank off activated charcoal filter
-2- .
– Connect hand vacuum pump -SAT 1390- and vacuum tester
-V.A.G 1368- to hose -1- as shown.
– Set vacuum tester to -A- /-B- position.
– Remove fuel filler cap from filler neck.
– Operate -V.A.G 1390- several times. Vacuum must not build-
up.
If vacuum builds-up:
– Check gravity/overflow valve ⇒ Item 3 (page 79)
– Check line -1- from fuel tank for blockage.
– Refit fuel filler cap.
Note!
If the fuel level in the tank is low the hand vacuum must be oper‐
ated at least 20...30 times.

– Replace fuel tank cap.

Arosa 1997 ➤

1 Servicing injection system
1.1 Fitting locations overview

Components A and B are not shown on the illustration.
A - Brake pedal switch -F47- or brake light switch -F-
B - Accelerator pedal position sender -G79-

sender -G71- * with intake air
temperature sender -G42- *
2 - Knock sensor 1 -G61- *
3 - Lambda probe 2 after cata‐
lyst -G130- *, 50 Nm
4 - Motronic control unit -J220-
*
5 - Throttle valve control part -
J338- *
7 - Intake manifold
8 - Engine speed sender -G28-
*
9 - 3 pin connector
❑ Black
❑ For engine speed send‐
er -G28- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 - Power steering pressure
switch -F88-
11 - Ignition transformer -
N152- *
❑ With ignition cable iden‐
tification, do not inter‐
change
❑ ⇒ Item 2 (page 188)
12 - Connector
❑ Only engine codes

Arosa 1997 ➤
ANV, AUC, AUD, ANW

❑ For Lambda probe 2 af‐
ter catalyst -G130- and Lambda probe heating -Z29-
❑ Black, 4 pin
❑ Contacts 3 and 4 gold plated
14 - Connector
❑ For Lambda probe 1 before catalyst -G39- and Lambda probe heating -Z19-
Engine code ALD, AKK
❑ Black, 4 pin
❑ Connector contacts 3 and 4 are goldplated
❑ Only engine codes ANV, AUC, AUD, ANW
❑ Black, 6-pin
❑ Contacts gold plated
15 - Hall sender -G40- *
❑ ⇒ Item 8 (page 188)
16 - Lambda probe 1 before catalyst -G39- *, 50 Nm
17 - Fuel rail
18 - Injectors -N30- ... -N33- )*
19 - Tank venting valve -N80- */** ⇒ page 97
20 - Activated charcoal filter ⇒ page 97
1.2 General notes on injection

Servicing ignition part:
⇒ page 187
♦ The engine control unit is equipped with self-diagnosis. Before
carrying out repairs and fault finding the fault memory must be
interrogated. Also the vacuum hoses and connections must
be checked (unmetered 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.
♦ Components marked with * are checked via the self diagnosis
5051 , interrogating and erasing fault memory.
♦ Components marked with **can be checked with the final con‐
trol diagnosis ⇒ Vehicle diagnosis, testing and information
system VAS 5051 .
♦ For trouble-free operation of the electrical components, a volt‐
♦ 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.
1. Servicing injection system 103

Arosa 1997 ➤
essary erased. ⇒ Vehicle diagnosis, testing and information
system VAS 5051 , interrogating and erasing fault memory
♦ Vehicles with an airbag are fitted with a crash/fuel shut-off. It
reduces the risk of a vehicle burning in the event of a crash in
that the fuel pump is switched off by the fuel pump relay. At
the same time this device improves the starting of the engine
because as soon as the door is opened the fuel pump is acti‐
vated to build-up pressure in the fuel system.
Safety precautions ⇒ page 111
Rules for cleanliness ⇒ page 112
Checking intake system for leaks (unmetered air) ⇒ page 140 .
Checking engine operating mode ⇒ page 157
1.3 Removing and installing parts of the injection system
1 - Motronic control unit -J220-

*
❑ Fitting location
⇒ page 102 , engine
compartment overview
❑ For injection system,
Lambda regulation, ac‐
tivated charcoal filter
tank venting valve,
knock control, speed
governing, ignition and
self-diagnosis
❑ Checking voltage sup‐
ply ⇒ page 159
❑ Procedure after voltage
supply open circuit
⇒ page 161
❑ If replaced carry out ba‐
sic setting ⇒ page 165
❑ On replacement, the
control unit must be
matched to the electron‐
ic immobilizer
⇒ page 167
2 - Retaining frame
3 - Supply hose
❑ Black respect
with white marks of information in this document. Copyright by SEAT S.A.
to the correctness
❑ Secure with spring-type

clips
❑ From fuel filter:

Arosa 1997 ➤
⇒ page 78
4 - Return hose
❑ Blue or with blue mark‐
ing
❑ Secure with spring-type clips
❑ To the fuel delivery unit in fuel tank ⇒ page 78
5 - 10 Nm
6 - Cable guide
❑ Clipped onto fuel rail
7 - Securing clip
❑ Note version
8 - Connector
❑ Black, 2-pin
❑ For injector -N30- ... -N33- )
9 - Connector
❑ Black, 6-pin
❑ For throttle valve control part -J338-
❑ Connector contacts are gold-plated
10 - Connector
❑ Black, 4 pin
❑ For intake manifold pressure sender and sender for intake air temperature in intake manifold
❑ Connector contacts are gold-plated
11 - Fuel manifold with injectors
12 - Vacuum hose
13 - 20 Nm
15 - From brake servo
16 - 5 Nm
17 - Engine speed sender -G28- *
❑ Fitting location ⇒ page 102 , fitting location overview
❑ To remove, remove intake manifold ⇒ Item 14 (page 105)
18 - Connector
❑ For Lambda probe 2 after catalyst -G130- and Lambda probe heating -Z29-
❑ Black, 4 pin
❑ Contacts 3 and 4 gold plated

Arosa 1997 ➤
19 - Lambda probe 2 after catalyst -G130- *, 50 Nm

❑ Fitting location ⇒ page 102 , engine compartment overview
❑ Grease only the threads with -G 052 112 A3- ; -G 052 112 A3- must not get into the slots on the probe
body
❑ Probe heating voltage supply via fuel pump relay -J17-
❑ Check Lambda probe heating for Lambda probe after catalyst ⇒ page 118
❑ Check Lambda probe and Lambda regulation after catalyst ⇒ page 150
20 - Lambda probe 1 before catalyst -G39- *, 50 Nm
❑ Grease only the threads with -G 052 112 A3- ;must not get into the slots on the probe body
❑ Probe heating voltage supply via fuel pump relay -J17-
❑ Checking Lambda probe heating before catalyst ⇒ page 114
❑ Checking Lambda probe and Lambda regulation before catalyst ⇒ page 146
Engine codes ANV, AUC, AUD, ANW
❑ Checking Lambda probe ageing Lambda probe 1 ⇒ page 155
21 - Connector
❑ For Lambda probe 1 before catalyst -G39- and Lambda probe heating -Z19-
Engine code ALD, AKK
❑ Black, 4 pin
❑ Connector contacts 3 and 4 are goldplated
Engine codes
Protected ANV, AUC,
by copyright. AUD,
Copying for privateANW
❑ Black, 6-pin
❑ Contacts gold plated

22 - Seal
❑ Renew
24 - Retaining clip
25 - O ring
❑ Blue
❑ For engine control unit
❑ Resistance values between contacts 1 and 3 ⇒ page 110
27 - Connector
❑ Black, 4 pin
❑ For coolant temperature sender -G62- and coolant temperature gauge sender -G2-
28 - Plug
29 - Guide tube
❑ For dipstick

Arosa 1997 ➤
30 - 3 Nm
❑ Notes on installing ⇒ page 111
31 - Vent pipe
❑ From tank venting valve in activated charcoal filter: ⇒ page 97
32 - Connector
❑ Only disconnect or connect with ignition switched off
1.4 Intake manifold: dismantling and assembling
1 - Breather line
❑ It comes from the acti‐
vated charcoal filter sys‐
tem solenoid valve:
⇒ page 97
2 - Support
❑ Engines AUC, AUD
3 - Vacuum valve
4 - Vacuum hose
❑ It goes to throttle valve
control part -J338-
5 - Screw
❑ 10 Nm
6 - Ventilation hose
❑ It comes from the open‐
ing of the oil deflector
connection
7 - Throttle valve control part -
J338- *
❑ If replaced match en‐
gine control unit
⇒ page 165
❑ Connector contacts are

Arosa 1997 ➤
gold-plated
8 - Oil seal
❑ Substitute
9 - Vacuum hose
❑ It comes from the fuel pressure regulator ⇒ Item 6 (page 109)
10 - Screw
❑ 20 Nm
❑ Removing and installing ⇒ page 104 , Injection system-components: removal and installation
12 - From brake servo
13 - Oil seal
❑ Substitute
14 - O-ring
15 - Intake manifold pressure sender -G71- * with intake air temperature sender -G42- *
❑ Checking intake manifold pressure sender ⇒ page 123
❑ Checking intake air temperature sender ⇒ page 124
❑ Intake air temperature sender resistance values between contacts 1 and 2 ⇒ page 111
16 - Screw
❑ 3 Nm
17 - Connection opening

Arosa 1997 ➤
1.5 Dismantling and assembling fuel rail with injectors
1 - Fuel manifold
⇒ page 135 , checking
spray pattern and injec‐
tors for leaks
2 - 10 Nm
3 - Retaining clip
4 - O ring
❑ Before installing mois‐
ten with clean engine oil
❑ Checking ⇒ page 137 ,
checking fuel pressure
regulator
Protected and
by copyright. holding
permittedpressure
6 - Vacuum hose
❑ To intake manifold
7 - Retaining clip
❑ Ensure seated correctly
at injector and fuel rail
8 - O ring
❑ Renew
❑ Before installing mois‐
ten with clean engine oil
9 - Injectors -N30- ... -N33- )*
❑ Resistance 12...17 Ω
10 - Return hose
❑ Blue or with blue marking
❑ To the fuel delivery unit in fuel tank ⇒ page 78
11 - Supply hose
❑ Black with white marks
❑ From fuel filter: ⇒ page 78

Arosa 1997 ➤
1.6 Dismantling and assembling air cleaner

Removing and installing air cleaner ⇒ page 111
1 - Plug
2 - Hexagon bolt, 10 Nm
❑ With guide for spacer
3 - Spacer sleeve
4 - Air cleaner upper part
5 - Filter element
6 - Gasket
tion
7 - Seal
8 - Stop
9 - 3 Nm
❑ Notes on installing
⇒ page 111
10 - Air cleaner lower part
11 - Air intake housing with
regulating flap
❑ Check intake air pre‐
heating ⇒ page 141
12 - Connecting piece for cold
air intake
tion Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Crankcase breather hose
❑ From oil separator: ⇒ page 58
Resistance values for coolant temperature sender -G62-

The diagram is divided into two temperature ranges:
A - From 0...50 °C
B - From 50...105 °C
Examples:
♦ 30 °C is in range A and corresponds to a resistance of 1.5...2.0
kΩ
♦ 80 °C is in range B and corresponds to a resistance of
275...375 Ω

Arosa 1997 ➤
Resistance values for intake air temperature sender -G42-

The diagram is divided into two temperature ranges:
A - From 0...50 °C
B - From 50...105 °C
Examples:
♦ 20 °C is in range A and corresponds to a resistance of 2.3...2.6
kΩ
♦ 80 °C is in range B and corresponds to a resistance of
290...330 Ω
Removing and installing air cleaner

Removing
– Pull cold air intake
Protected hose off
by copyright. air cleaner
Copying for private orupper part.
– Remove plugs -1- .to the correctness of information in this document. Copyright by SEAT S.A.
respect
– Remove securing screws -2- .

– Pull crankcase breather hose -4- off air cleaner housing.
– Unclip ignition cables -5- out of air cleaner upper part.
– Remove air cleaner.
Installing
– Installing the air cleaner is carried out in the reverse order.
– Tighten securing screws -2- to 10 Nm. (Ensure that the spacer

sleeves -3- are first fitted into the air cleaner upper part.)
Note!
♦ To secure the air cleaner lower part to the air cleaner upper
part self tapping screws are used. If these screws are loos‐
ened or tightened with a power tool the thread in the air cleaner
upper or lower parts can be damaged.
♦ For this reason the use of a power tool can only be used when:
♦ The power tool maximum speed is 200 rpm.
♦ The tightening torque is set to a maximum of 3 Nm.
1.7 Safety precautions
Caution
The fuel system is pressurized! Before loosening hose con‐

nections or opening the test connection, wrap a cloth around
the connection. Then release pressure by carefully pulling off
the hose or carefully unscrewing sealing plug.
To prevent injuries to persons and/or damage to the fuel injection

and ignition system, the following must be noted:
♦ For safety reasons the fuse No. 40 must be removed from the
fuse holder before opening the fuel system, otherwise the fuel
pump can be activated by the door contact switch.

Arosa 1997 ➤
♦ Do not touch or disconnect ignition wiring when the engine is

running or being turned at starter speed.
connecting injection or ignition system wiring or tester cables.
♦ If the engine is to be turned at starter speed, without starting:
– Pull 4 pin connector off ignition transformer -arrow- .
– Pull plug -arrows- off all injectors.

disconnecting.
necessary.

Arosa 1997 ➤
1.9 Technical data

Engine codes ALD, AKK, AUD, ANV, AUC, ANW
Testing idling speed
Idling speed11) 1/min 600...80010)
System Motronic ME7.5.10
Spare part no. ⇒ spare part film
Rpm limitation 1/min from approx. 5700
10) Up-to-date specifications:

11) Not adjustable
12) Replacing engine control unit ⇒ page 162

Arosa 1997 ➤
2 Checking components
2.1 Checking Lambda probe heating before

catalyst
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤
Check conditions
• All fuses must be OK.
• Fuel pump relay must be OK
Test sequence
gine and select “Address word” 01 of engine control unit. When
doing this the engine must be running at idling speed. (Con‐
necting fault reader and selecting engine control unit ⇒ Vehicle
diagnosis, testing and information system VAS 5051 .)
Select function XX


– Check status of Lambda probe heating before catalyst in dis‐

play zone 2: Display: Htg.bC.ON
Note!
The Lambda probe heating may be switched on or off depending

on the operating mode of the engine, therefore the display in dis‐
play zone 2 may show "Htg.bC.ON or alternating from Htg.bC.ON
to Htg.bC.OFF.
If the specification is obtained:

– Press → key.
– Press keys 0 and 6 for the function
Protected “End
by copyright. output”
Copying andorconfirm


Only engine codes ANV, AUC, AUD, ANW
Engine code ALD ⇒ page 117
2. Checking components 115

Arosa 1997 ➤
– Separate 6-pin connector (black) to Lambda probe before cat‐

alyst -G39- -arrow- .
– Set multimeter to “Resistance measurement” range.
– Check probe heating resistance at connector to Lambda probe

contacts 3 and 4 Specification: 2,5...10 Ω (at room tempera‐
ture).
If it is determined that probe heating has an open circuit:
– Replace the Lambda probe before catalyst -G39- .
– Erase learnt values and adapt engine control unit
⇒ page 165
If probe heating has continuity:
Checking voltage supply
– Connect the Multimeter with aux. cables from -V.A.G 1594- to

measure voltage on contacts 3 + 4 (connector to engine con‐
trol unit).
– Measure the voltage supply: When display group 41, display
zone 2 displays Display, Htg.bC.ON: Specification: 11.0...14.5
V Display, Htg. bC.ON/Htg.bC.OFF (alternating) Specifica‐
tion: Between 0,0...12.0 V fluctuating
– Press → key.

ness.

Arosa 1997 ➤
– Check wire between test box and 6-pin connector (connector

to control unit) for open circuit using current flow diagram.
Contact 4+socket 1 Wire resistance: max. 1.5 Ω
– Check wire between 6-pin connector contact 3 and fuel pump
relay -J17- for open circuit using current flow diagram. Wire
resistance: max. 1.5 Ω
Only engine code ALD, AKK

– Check probe heating for continuity at Lambda probe connector

contacts 1 + 2.
Note!
The heater element resistance is approx. 1...5 Ω at room tem‐

perature. Even slight increases in room temperature increase the
resistance greatly.
If it is determined that probe heating has an open circuit:

– Renew Lambda probe before catalyst -G39-
⇒ Item 16 (page 103) .
If probe heating has continuity:
– Set multimeter to “Voltage measurement” range.
– Connect multimeter using aux. cables from -V.A.G 1594- to

measure voltage at contacts 1+2 (connector to engine control
unit).
– Start engine and run at idling speed. Specification: 11.0...15.0
V

Arosa 1997 ➤
– Check wiring between 4 pin connector contact 2 and engine

earth for open circuit Wire resistance: Max. 1.5 Ω
– Check wire between 4 pin connector contact 1 and fuel pump
2.2 Checking Lambda probe heating after

catalyst
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤
Check conditions
Test sequence
Select function XX

Indicated
Protected byon display:

– Check status of Lambda probe heating after catalyst in display

zone 4: Display: Htg.aC.ON
Note!
The Lambda probe heating may be switched on or off depending

on the operating mode of the engine, therefore the display in dis‐
play zone 4 may show "Htg.aC.ON or alternating from Htg.aC.ON
to Htg.aC.OFF.

– Press → key.
– Separate 4-pin connector (black) to Lambda probe after cat‐


Arosa 1997 ➤
– Connect multimeter using aux. cables from -V.A.G 1594- to

unit).
– Measure the voltage supply: When display group 41, display
zone 4 displays Display, Htg.aC.ON: Specification: 11.0...14.5
V Display, Htg. aC.ON/Htg.aC.OFF (alternating) Specifica‐
tion: Between 0.0...12.0 V fluctuating
– Press → key.

ness.
– Check wires between test box and 4-pin connector (connector

Contact 2+socket 13 Wire resistance: max. 1.5 Ω
2.3 Checking throttle valve control part

Components of throttleProtected
valve bycontrol part -J338- : Throttle valve
drive -G186- , angle sender 1 forauthorised
throttleby valve drive
SEAT -G187-
S.A does notand
permitted unless SEAT S.A. guarantee or accept any liability with
angle sender 2 for throttlerespect
valveto drive -G188-
the correctness .
Note!
If the throttle valve control part is replaced, the new control part
must without fail be adapted to the engine control unit
⇒ page 165 .

Arosa 1997 ➤

♦ Test box -V.A.G 1598/22-
Check conditions
• Throttle valve not damaged or dirty.
04, display zone 3.
Test sequence
– Connect the fault reader -V.A.G 1551- ( -V.A.G 1552- ). Then
switch ignition on and select engine control unit with the “Ad‐
dress word” 01. (Connecting fault reader and selecting engine
control unit ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051 .)
Select function XX

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Read measured value block
– Check throttle valve angle at idling stop from sender 1 -G187-

in display zone 1 Specification: 10...90 %
– Check throttle valve at idling stop from sender 2 -G188- in dis‐
play zone 2. Specification: 90...10 %
– Depress accelerator slowly to full throttle position and observe
angles displayed in display zones 1 and 2:
The percentage figure in display zone 1 must increase evenly.
Although the tolerance range 10...90 % will not be fully exploited.
The percentage figure in display zone 2 must decrease evenly.
Although the tolerance range 90...10 % will not be fully exploited.
Note!
♦ The reason why the display in display zone 1 increases and

the display in display zone 2 decreases is because the poten‐
tiometers (angle senders) in the throttle valve control part run
in opposite directions.
♦ This means that the voltage of one angle sender moves to‐
wards 5 volts. (The more the throttle valve is opened the higher
the voltage; percentage figure increases).
♦ Whilst the voltage of angle sender 2 decreases from 5 volts
towards 0 volts. (The more the throttle valve is opened the
lower the voltage; percentage figure decreases).
– Press → key.

Arosa 1997 ➤
If the displays do not indicate as described:
– Remove air cleaner ⇒ page 111 .
– Pull 6-pin connector off throttle valve control part -arrow- .
– Measure resistance at throttle valve drive between contacts 3

+ 5 Specification: 1.0...5.0 Ω
– Replace throttle valve control part ⇒ Item 3 (page 107) .
– Interrogate fault memory, if necessary, repair any faults and
then erase fault memory ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051 , permitted
interrogating and erasing fault
memory. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Adapt engine control unit to throttle valve control part

⇒ page 165 .
– Check voltage supply of throttle valve control part and wiring
to control unit ⇒ page 122 .
– Check the accelerator pedal position sender. ⇒ page 78
If the voltage supply and wiring is OK:
– Replace engine control unit ⇒ page 162 .
Checking voltage supply and wiring to control unit
Test conditions
Test sequence
– Connect Multimeter to measure voltage at connector contacts

2 + 6.
– Switch on ignition. Specification: min. 4.5 V

Arosa 1997 ➤
– Connect Multimeter to measure voltage at connector contact

2 and earth.
If the specifications are not attained:

ness.

Contact 1+socket 68 Contact 2+socket 55 Contact 3+socket
80 Contact 4+socket 75 Contact 5+socket 66 Contact 6+sock‐
et 61 Wire resistance: max. 1.5 Ω
– Check engine control unit voltage supply ⇒ page 159 .
2.4 Checking intake manifold pressure

sender
Only gold-plated contacts may be used when servicing the sender

connector contacts

♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤
Test sequence
– Pull 4-pin connector off intake manifold pressure sender -G71-
and intake air temperature sender -G42- -arrow- .

ness.

to control unit) for to
respect open circuit ofusing
the correctness current
information flow diagram.
Contact 3+socket 62 Contact 4+socket 70 Wire resistance:
max. 1.5 Ω
– Renew the intake manifold pressure sender -G71- with intake
air temperature sender -G42- ⇒ Item 11 (page 108) .
2.5 Checking intake air temperature sender
Note!
Only gold-plated contacts may be used when servicing the sender

connector contacts

♦ Test box -V.A.G 1598/22-
♦ Chilling spray (commercially available)

Arosa 1997 ➤
Test sequence
tem VAS 5051 .)
Select function XX


– Read off intake air temperature value

Protected in display
by copyright. Copyingzone 4. or commercial purposes, in part or in whole, is not
for private
– Perform check according to following
respect totable:
the correctness of information in this document. Copyright by SEAT S.A.
Display Cause Continuation of

check
Approx. ambi‐ --- ⇒ page 125
ent tempera-
ture13)
-40 °C Open circuit or short to ⇒ page 125
positive
129 °C Short to earth ⇒ page 127
13) If a temperature is displayed which is below the ambient air temperature of
the sender, check sender wiring for transfer resistances. Note when doing this
that sender is heated from external sources, e.g. radiated heat when engine is not
running.
Continuation of check when display = ambient temperature:

Functional check of sender
– Remove intake air temperature sender together with intake
manifold pressure sender (connector remains connected).
– Note intake air temperature value in display zone 4.
– Spray sender with commercial chilling agent whilst observing
the temperature value. The temperature value must decrease.
– Press → key.
Continuation of check when display -40 °C:

Arosa 1997 ➤
– Pull 4 pin connector off intake air temperature sender -G42-

with intake manifold pressure sender -G71- -arrow- .
– Bridge connector contacts 1+2 using aux. cables from -V.A.G

1594- and observe display.
Display jumps to 129 °C:
– Press → key.
If the display remains at -40 °C:
– Press → key.

ness.

Arosa 1997 ➤

max. 1.5 Ω
– Check wiring additionally for short circuit to battery positive.
Specification: ∞ Ω
Continuation of check when display shows 129 °C:
– Pull 4 pin connector off intake air temperature sender -G42-

with intake manifold pressure sender -G71- -arrow- .
If the display jumps to -40 °C:
– Press → key.
If display remains at 129 °C:
– Press → key.
Gr. 92 ; windscreen wiper system removing and
respect to the installing

ness.

Arosa 1997 ➤

max. 1.5 Ω
2.6 Checking coolant temperature sender

♦ Test box -V.A.G 1598/22-
♦ Hand multimeter -V.A.G 1526-
unless or multimeter -V.A.G 1715-
Test conditions
• Engine must be cold.
Test sequence
tem VAS 5051 .)
Select function XX


– Read off coolant temperature value in display zone 3.

– Perform check according to following table:

Arosa 1997 ➤
Display Cause Continuation of

check
Approx. cool‐ --- Only if sporadic
ant tempera- faults
ture14) have been
detected:15)
⇒ page 129
-40 °C Open circuit or short to ⇒ page 129
positive
129 °C Short to earth ⇒ page 130
14) If a temperature is displayed which deviates greatly from the ambient tem‐
perature of the sender, check sender wiring for transfer resistances.
15) Check is only possible when the engine is cold.
Continuation of check when display = coolant temperature:

Functional check of sender
Select function XX


– Observe coolant temperature value in display zone 3 with en‐

gine running. The temperature value must increase evenly
without interruption.
Note!
♦ Temperature increases in steps of 1.0 °C.

♦ If irregular engine running occurs in certain
permitted temperature
unless authorised rang‐
es and the temperature figure does respect
not increase without in‐
terruption, the temperature signal is temporarily interrupted

and the sender must be renewed.
– Press → key.
– Replace coolant temperature sender -G62- with coolant tem‐
Continuation of check when display shows -40 °C:

Arosa 1997 ➤
– Pull the 4 pin connector off coolant temperature sender -G62-

with coolant temperature gauge sender -G2- -arrow-
– Bridge connector contacts 1+3 using aux. cables from -V.A.G

1594- and observe display. Display jumps to 129 °C:
– Press → key.
If the display remains at -40 °C:
– Press → key.

ness.
– Check wires for open circuit between test box and 4-pin con‐
nector (connector to control unit) using current flow diagram.
max. 1.5 Ω
Continuation of check when display shows 129 °C:

Arosa 1997 ➤

If the display jumps to -40 °C:
– Press → key.
If display remains at 129 °C:
– Press → key.

ness.
–Protected
Check wires for
by copyright. open
Copying circuit
for private between
or commercial test box
purposes, in partand 4-pinis con‐
or in whole, not
nector
permitted unless(connector to S.A.
authorised by SEAT control
SEAT S.Aunit)
doesusing current
not guarantee flow
or accept anydiagram.
liability with
Contact 3+socket
respect to the correctness 74 Contact
of information 4+socket
in this 54 Wire
document. Copyright by resistance:
SEAT S.A.
max. 1.5 Ω
2.7 Checking engine speed sender

The engine speed sender -G28- is a speed and reference mark
sender. The engine will not start if there is no speed signal. If the
speed signal fails when the engine is running, it will cause the
engine to stall immediately.
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤

Test conditions
Test sequence
– Detach black 3-pin connector to engine speed sender
-arrow- (on thermostat housing).
– Connect multimeter to measure voltage using aux. cables

from -V.A.G 1594- to contacts 1 (positive) and 3 (earth) on
engine speed sender connector.

ness.
– Check wires between test box and 3-pin permitted
connector
unless(connector
to control unit) for open circuit using current flow
respectdiagram.
– Additionally check wires for short to one another. Specifica‐
tion: ∞Ω
If no wiring fault is detected and voltage was present between
contacts 1+3:
– Replace engine speed sender -G28- ⇒ Item 17 (page 105) .
If no wiring fault is detected and no voltage was present between
contacts 1+3:

Arosa 1997 ➤
2.8 Checking injectors

Checking activation
♦ Test box -V.A.G 1598/22-
Check conditions
• Earth connection between engine (on gearbox bell housing)
and body (below battery) OK.
• Earth connection in plenum chamber OK.
• Engine speed sender must be OK, checking< qv-kap
ziel="MGAKK2407110160">.
• Hall sender must be OK, checking ⇒ page 190 .
Test sequence

Arosa 1997 ➤
– Connect diode test lamp -V.A.G 1527- using aux. cables from
-V.A.G 1594- to connector contacts of Cyl. 1.
– Operate the starter and check the voltage supply for No. 1
cylinder injector. The LED must light up
– Repeat check at the injector connectors for Cyls. 2...4.
If the LED does not light up on any cylinder:
– Connect diode test lamp to Cyl. 1 connector, contact 1 and

earth. The LED must light up
– Repeat check at the injector connectors for Cyls. 2...4.
If the LED does not light up:
relay -J17- for open circuit according to current flow diagram.
Wire resistance: max. 1.5 Ω
If the LED does not light up on one or several cylinders:

ness.
– Check wires between test box and 2-pin connectors
permitted unlessfor injec‐by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
tors (connector to control unit) for open circuit using current
flow diagram. Injector 1: contact 2+socket 79 Injector 2: con‐

tact 2+socket 59 Injector 3: contact 2+socket 73 Injector 4:
contact 2+socket 65 Injector: max. 1.5 Ω
tion: ∞Ω
– Check wiring between connector contacts 1 of injectors for
open circuit to one another. Wire resistance: Max. 1.5 Ω
Checking resistance of injectors
Test sequence

Arosa 1997 ➤
– Check resistance of injectors between contacts. Specification:

12...17 Ω
Note!
The resistance figures are valid for approx. 20 °C. At higher tem‐
peratures the resistance figures will increase.

– Renew defective injector ⇒ Item 9 (page 109) .
Perform installation of injectors in reverse order. When doing this
note the following:
♦ Renew O-rings on all injectors and lightly moisten with clean
engine oil.
♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
♦ With injectors secured to fuel rail, fit fuel rail on cylinder head
and press in evenly.
Checking spray pattern and for leaks

equipment required
♦ Dynamometric wrenches -
SAT 8010-
♦ Digital potentiometer -
V.A.G 1630-
♦ Measuring container

Arosa 1997 ➤
Test conditions
• The fuel pressure must be in order, checking ⇒ page 137 ,
checking fuel pressure regulator and holding pressure.
Test sequence

– Connect digital potentiometer -V.A.G 1630- using aux. cables

from -V.A.G 1594- to connector contacts 1+3 and set connec‐
ted side to 15 kΩ.
– Pull the vacuum hose off fuel pressure regulator -arrow- .

– Unclip injector wiring harness on fuel rail.
–permitted
Remove fuel rail complete with injectors from cylinder head
(fuel hoses remain connected) ⇒ Item 11 (page 105) .


Arosa 1997 ➤
– Hold a small container under the injector to be checked and

pull connectors off all other injectors.
– Have 2nd person operate starter. Injector must spray in pul‐
ses.
– Repeat check with other injectors ensuring that injector to be
checked is only connected.
– Switch off ignition and afterwards check injectors for leaks. No
more than 2 drops/min may leak from each injector.
If the fuel loss is greater:
– Renew defective injector ⇒ Item 9 (page 109) .
Perform installation of injectors in reverse order. When doing this
note the following:
♦ Renew O-rings on all injectors and lightly moisten with clean
engine oil.
♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
♦ With injectors secured to fuel rail, fit fuel rail on cylinder head
and press in evenly.
2.9 Checking fuel pressure regulator and holding pressure

The fuel pressure regulator regulates the fuel pressure depending
on intake manifold pressure.
The specification for the check is dependent upon the working
pressure of the fuel pump. This is approx. 3.0 bar

Arosa 1997 ➤

equipment required
♦ Pressure gauge -V.A.G
1318-
♦ Hose adapter -V.A.G
1318/16-
♦ Pliers for flexible clamps -
T20029-
Test sequence
– Pull fuel pump fuse No. 40 out of fuse holder.
– Pull off supply pipe/hose -1- (with white marking) and collect
fuel that leaks out with a cloth.
Caution


Arosa 1997 ➤
– Connect pressure gauge -V.A.G 1318- with adapter -V.A.G

1318/10- to supply hose -1- and with adapter -V.A.G 1318/11-
and hose adapter -V.A.G 1318/16- to supply pipe.
– Open shut-off tap on pressure gauge. The handle points in
direction of flow.
– Insert fuel pump fuse No. 40 into fuse holder.
– Measure fuel pressure. Specification: Approx. 2.5 bar
– Pull vacuum hose off fuel pressure regulator -arrow- . The fuel
pressure must increase to approx. 3.0 bar.
– Check quantity supplied by fuel pump. ⇒ page 78
– Check for leaks and holding pressure by observing pressure
drop on gauge. After 10 minutes there must be a residual
pressure of at least 2.0 bar.
If the holding pressure drops below 2 bar:
– Switch ignition off after the pressure has built-up. At the same
time close pressure measured device cut-off tap (handle cross
through-flow direction -arrow- ).
– Observe pressure drop on gauge.
If the pressure does not drop:
– Check fuel pump non-return valve. ⇒ page 78
If the pressure drops again: of information in this document. Copyright by SEAT S.A.

Arosa 1997 ➤
– Open pressure gauge -V.A.G 1318- shut-off tap (handle in di‐

rection of flow).
– Switch ignition off after the pressure has build-up. At the same
time clampoff the return hose (with blue marking) -2- .
– Renew fuel pressure regulator ⇒ Item 5 (page 109) .
If the pressure drops again:
– Check pipe connections, O-rings on fuel manifold and injec‐
tors for leaks.
– Check pressure gauge for leaks.
Note!
Before removing pressure gauge place a cloth around the con‐

nections to be loosened.
2.10 Checking intake air system for leaks

(unmetered air)
Checking with engine leak detector spray -G 001 800 A1-
Note!
♦ The vacuum in the intake system will cause the leak detector
spray respect
to be todrawn in with the unmetered air. The leak detector
spray reduces the ignitability of the mixture. This leads to a
drop in engine speed and to a change of Lambda probe read‐
ing.
♦ The safety precautions listed on the container must be ad‐
hered to.

♦ Engine leak detector spray -G 001 800 A1-

Arosa 1997 ➤
Test conditions
04, display zone 3.
Test sequence
Select function XX

Indicated on display: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee
Read or accept
measured any liability
value block with
InputCopyright
display by group
SEAT S.A. number XXX

Only continue with the test when

• The coolant temperature exceeds 80 °C -display zone 2-
– Observe the engine speed in display zone 1 and the Lambda
regulation in display zone 3.
– Systematically spray parts of the intake system with engine
leak detector spray.
If the engine speed drops or the Lambda regulator changes:
– Press → key.
– Check sprayed areas of intake system for leaks and rectify if
necessary.
If the engine speed or Lambda regulator does not change:
– Press → key.
2.11 Checking intake air preheating

♦ Chilling spray (commercially available)
Checking regulating flap

Arosa 1997 ➤
– Check control flap position -1- .

♦ Above +23 °C flap must close warm air connection
♦ Below +10 °C flap opens warm air connection
Note!
The function of the thermo-element can be checked easily by

spraying it with a commercial chilling agent, to do this the air in‐
take housing must be removed ⇒ page 110 , Dismantling and
assembling air cleaner.
2.12 Vacuum valve: checking

♦ Vacuum tester -V.A.G 1368-

• Engine must be stopped.
2.12.2 Test sequence

– Remove air cleaner ⇒ page 111
– Remove the vacuum valve -1- ⇒ Item 3 (page 107)
– Connect the vacuum valve -V.A.G 1368- -connection A- (the
arrow in the vacuum valve 1 points towards -V.A.G 1368- ).

Arosa 1997 ➤
– Connect hand vacuum pump -SAT 1390- to vacuum tester -

V.A.G 1368- -connection B- .
– Set vacuum tester to position -A- /-B- .
Note!
In the rest position, the vacuum valve is open

– Replace the vacuum pump.

– Cover the nozzle -2- of the vacuum valve.
– Hold the vacuum valve.
– Operate hand vacuum pump -SAT 1390- several times until
the valve closes, clicking audibly.
Note!
The vacuum valve will close with a pressure of between 250 and
350 mbar
If the valvve does not close:

– Replace the vacuum pump.

Arosa 1997 ➤
3 Checking functions
3.1 Idling check
Note!
♦ Idling speed, ignition timing and CO content not adjustable.

♦ The idling speed is regulated to specification by the throttle
valve positioner in conjunction with the DIS function.
♦ CO content regulated by Lambda regulation. Faults in Lambda
control are detected in self-diagnosis and stored in fault mem‐
ory.

Check conditions
• Exhaust system between cylinder head and catalyst free of
leaks
must be switched off
• If the vehicle is equipped with an air conditioner, this must be
switched off.
04, display zone 3.
Test sequence
– Interrogate fault memory, if necessary, repair fault and then
erase fault memory. ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051 , interrogating and erasing fault memory
– Then:
♦ Leave fault reader -V.A.G 1551- connected.
♦ Continue running engine at idling speed.
Select function XX



Arosa 1997 ➤
Note!
In the “System in basic setting” function the tank venting valve -

N80- is closed and the air conditioner compressor switched off.
– Check the adjustment conditions for basic setting in display

zone 4: Specification: 1x111111 Significance of the numbers
– Briefly increase engine speed (rev- up) and then allow engine
to run at idling speed for 2 minutes.
Checking idling speed
– Change to display group 56 as follows:
– Press C key.
– Pressrespect keys 0 , 5 and
to the correctness 6 for in“Display
of information group
this document. number
Copyright by SEAT56”S.A. and
– Check operating modes in display zone 4 Specification: x x 0

x 0 (Significance ⇒ Vehicle diagnosis, testing and information
system VAS 5051 )
– Check specified idling speed in display zone 2. Specification:
700 rpm
– Check idling speed in display zone 1. Specification: 600...800
rpm 16)
16) Up-to-date specifications:
Note!
During the idling check the tank venting valve -N80- and the air
conditioner are switched off and the Lambda regulation learning
process is initiated.
– Press → key.
If the idling speed is not obtained:
– Adapt the engine control unit to the throttle valve control part
⇒ page 165
– Carry out test drive.
test ⇒ page 111 .
– Again interrogate the control unit fault memory.
– Repeat the idling check.
If the specifications are not obtained again:
– Check throttle valve control part ⇒ page 120 .
– Check the operating condition of engine ⇒ page 157 .
– Check intake air system for unmetered air ⇒ page 140
– Check the signals from/to air conditioner ⇒ page 170 .
3. Checking functions 145

Arosa 1997 ➤
3.2 Checking Lambda probe and Lambda

regulation before catalyst
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤
Check conditions
• Exhaust system between catalyst and cylinder head must be
free of leaks
04, display zone 3.
Functional check
Select function XX


– Check Lambda control status before catalyst (display zone 1):

Specification: 1 1 1 (Significance ⇒ Vehicle diagnosis, testing
and information system VAS 5051 )
Note!
♦ The first position of the 3 digit number block fluctuates be‐

tween 0 and 1 (Lambda probe heating on and off).
♦ Depending upon the status of the Lambda control the 3 digit
number block can show 0 or 1.
♦ The bits in display zone 1 will not be set to 1 until the catalyst
temperature has exceeded 400.0 °C (⇒ display group 34, dis‐
play zone 2).

– Check the Lambda probepermitted
heating before
unless catalyst
⇒ page 114 . respect to the correctness of information in this document. Copyright by SEAT S.A.

– Press C key.

Arosa 1997 ➤
– Check Lambda learnt values at idling speed (additive) in dis‐

play zone 1. Specification: -10.0...10.0 %
– Check Lambda learnt values at part load (multiplicative) in
display zone 2. Specification: -10.0...10.0 %
– ⇒ Vehicle diagnosis, testing and information system VAS
5051 , Evaluating display group 32
If the specifications are obtained:
– Change to display group 33 as follows: -V.A.G 1551- : Press
key 3 -V.A.G 1552- : Press key ↑
– Observe Lambda regulation in display zone 1. The display

must fluctuate at least 2 % in the range -10.0...10.0 %
– Press → key. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
If the Lambda regulation does not fluctuate in display zone 1:
– Check Lambda probe wiring for Lambda probe 1
⇒ page 148 .
Engine codes ANV, AUC, AUD, ANW ⇒ page 148 .
Engine code ALD, AKK ⇒ page 149 .
If the Lambda regulation in display zone 1 does not fluctuate as
stated:
– Carry out road test and burn Lambda probes clean and repeat
check.
test ⇒ page 111 .
If the the specifications in display zone 1 are not obtained even
after a test drive, or the value does not fluctuate by at least 2 %:
– Check ageing of the Lambda probe before catalyst
⇒ page 155 .
Check Lambda probe wiring Lambda probe 1
Engine code ALD ⇒ page 149

Arosa 1997 ➤

ness.


20 Contact 6+socket 35 Wire resistance: max. 1.5 Ω
– Additionally check wires all for short to one another. Specifi‐
cation: ∞Ω
⇒ Item 20 (page 106) .
Check Lambda probe wiring Lambda probe 1
Only engine code ALD, AKK
– Separate the 4-pin connector (black) to Lambda probe before

catalyst -G39- -arrow- .

Arosa 1997 ➤
– Connect multimeter with aux. cables from -V.A.G 1594- to

unit).
– Switch on ignition and measure basic voltage. Specification:
0.40...0.50 V
⇒ Item 20 (page 106) .

ness.
– Check wiring between test box and 4 pin connector (to control
unit) for open circuit according to current flow diagram. Con‐
tact 3+socket 21 Contact 4+socket 47 Wire resistance: max.
1.5 Ω
– Check wiring at connector contacts 3+4 for short circuit to
contacts 1+2 according to current flow diagram. Specification:
∞Ω
⇒ Item 20 (page 106) .
3.3 Checking Lambda probe and Lambda

regulation after catalyst
Note!
Only gold-plated contacts may be used when servicing Lambda

probe connector contacts 3 and 4.
Special tools and workshop equipment

Protected required
♦ Fault reader -V.A.G 1551-respect
or vehicle systemof tester
to the correctness -V.A.G
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤

Arosa 1997 ➤
Check conditions
free of leaks
04, display zone 3.
Functional check
Select function XX

Basic setting

System in basic setting 37 →
– Depress brake pedal.

The engine speed is increased by the control unit to approx.
1100...1300 rpm.
– Run engine at increased speed until the catalyst temperature
increases to min. 400 °C.
Note!
This process can take a few minutes.
– Press C key.
Thepermitted
engineunless
speed decreases toSEAT
idling speed.
authorised by SEAT S.A. S.A does not guarantee or accept any liability with
Basic setting

– Check Lambda control status after catalyst (display zone 2):

Specification: 1 1 1 (Significance ⇒ Vehicle diagnosis, testing
and information system VAS 5051 )

Arosa 1997 ➤
Note!
♦ The first position of the 3 digit number block fluctuates be‐

tween 0 and 1 (Lambda probe heating on and off).
♦ Depending upon the status of the Lambda control the 3 digit
number block can show 0 or 1.
♦ The bits in display zone 1 will not be set to 1 until the catalyst
temperature has exceeded 400.0 °C (⇒ display group 34, dis‐
play zone 2).

– Check Lambda probe heating after catalyst ⇒ page 118 .
– Press C key.
Basic setting


1100...1300 rpm.
– Check the Lambda probe voltage after catalyst in display zone
1: Specification: 0.000...1.000 V (can fluctuate slightly)
If the display in display zone 1 remains constant:
– Press
permitted → key. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
– Continue check according to following table.
Appears on display
Constant 1.085 V ♦ Short to positive via: Lambda probe, probe wiring, earth wiring, engine control unit
Constant between ♦ Open circuit via: Lambda probe, probe wiring, earth wiring, engine control unit
0.400...0.500 V
Constant 0.000 V ♦ Short to earth via: Lambda probe, probe wiring, earth wiring, engine control unit
– Run the engine at increased speed until the display in display

zone 4 jumps from “Test OFF” to"Test ON. The catalyst tem‐
perature in display zone 2 must be min. 400 °C.
– Maintain the increased engine speed until the display in dis‐
play zone 4 shows the specification "B1-P2 OK.

Arosa 1997 ➤
Note!
If display zone 4 shows “B1-P2 n.OK” :

– Press → key.
– Check exhaust system for leaks: ⇒ page 177
– Carry out a test drive to remove possible residue on Lambda
probe and repeat check.
test ⇒ page 111 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the specifications are again not attained: respect to the correctness of information in this document. Copyright by SEAT S.A.
– Replace the Lambda probe after catalyst -G130-

⇒ Item 19 (page 106) .
Checking Lambda probe 2 basic voltage
– Separate 4-pin connector (black) to Lambda probe after cat‐
– Connect multimeter with aux. cables from -V.A.G 1594- to

unit).
– Start engine and measure the basic voltage. Specification:
0.400...0.500 V
– Check Lambda probe wiring for Lambda probe 2
⇒ page 154 .
⇒ Item 19 (page 106) .
Checking Lambda probe wiring Lambda probe 2

Arosa 1997 ➤

ness.

max. 1.5 Ω
– Check wiring at connector contacts 3+4 for short circuit to
contacts 1+2 using current flow diagram. Specification: ∞ Ω
⇒ Item 19 (page 106) .
3.4 Checking ageing of Lambda probe be‐

fore catalyst

Arosa 1997 ➤
Test conditions
free of leaks
04, display zone 3.
Functional check
Select function XX

Basic setting


1100...1300 rpm.
– Maintain the engine speed until the display in display zone 4
jumps from “Test OFF” to “Test ON” . The catalyst temperature
in display zone
Protected 2 mustCopying
by copyright. be min. 400or°C.
Note!
– Check amplitude duration in display zone 3: Specification:

0.7... 2.00
– Continue to maintain engine speed until the specification “B1-
P1” appears in display zone 4.
– Press → key.
– Carry out a road test to free Lambda probe of possible resi‐
dues and repeat the test.
test ⇒ page 111 .
If the specifications are again not attained:

Arosa 1997 ➤

⇒ Item 20 (page 106) .
3.5 Checking engine operating mode
Note!
Checks whether engine control unit recognises the engine oper‐

ating modes idling, overrun, part throttle, enrichment, full throttle.

Test conditions
04, display zone 3.
Test sequence
Select function XX


– Check whether the control unit recognises the operating mode

(display zone 4):
♦ Idling:
As long as the engine is running at idling speed idling must be
displayed Display: Idling
♦ Overrun mode:
– Increase engine speed to above 3000 rpm.

– Close throttle abruptly.

As long as the engine speed is above 1400 rpm overrun must be
displayed Display: Overrun
Note!
Below 1400 rpm idling speed will be recognised.
♦ Part throttle:
– Rev up evenly.
As long as the engine is being revved up evenly, part throttle must
be displayed Display: Part throt.

Arosa 1997 ➤
♦ Enrichment:
– Floor accelerator pedal (onto throttle valve stop).
Acceleration enrichment must be displayed briefly Display: En‐
richment
♦ Full throttle:
– Floor accelerator pedal (onto throttle valve stop).
Full throttle must be displayed briefly Display: Full throttle
Note!
A test drive may have to be performed to show “Full throttle” in

display.

test ⇒ page 111 .
– Press → key.
formation system VAS 5051 , interrogating and erasing fault
memory.
– Check throttle valve control part ⇒ page 120 .
– Check parts of the electronic throttle control (EPC) for ease of
movement: ⇒ page 78

Arosa 1997 ➤
4.1 Checking control unit voltage supply

♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤
Check conditions
• Earth connection between engine (on gearbox bell housing)
and body (below battery) OK.
• Earth connection in plenum chamber OK.
switched off.
• Alternator OK, checking: ⇒ Current flow diagrams, Electrical
Test sequence
Select function XX
– Press keys 0 and 8 for the function “Read
permitted measured
unless authorised by value


– Read off figure displayed in display zone 2. Specification: At

least 11.5 V
– Press keys 0 and 6 for the “End output” function and confirm
input with the Q key.

Arosa 1997 ➤

ness.
Checking voltage supply terminal 30
– Measure voltage supply with multimeter and aux. cables from
-V.A.G 1594- between test box sockets 2+15 and 15+28:
Specification: min. 11.5 V
– Check wiring connections to relay plate according to current
flow diagram. ⇒ Current flow diagrams, Electrical fault finding
Checking voltage supply terminal 15
– Measure voltage supply with multimeter and aux. cables from
-V.A.G 1594- between test box sockets 2+27 and 27+28:
If the specification is authorised
not attained:
permitted unless by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Check wiring connections to relay plate according to current
flow diagram. ⇒ Current flow diagrams, Electrical fault finding
4.2 Procedure after voltage supply open cir‐

cuit
All values learnt by the engine control unit and the basic setting
values as well as the readiness code will be erased if the voltage
supply is interrupted. Therefore, depending upon the vehicle mile‐
age it can lead to serious engine running problems.
Work sequence
Perform the following operations after voltage supply open circuit:
– Switch ignition on for at least 10 seconds.
– Adapt the engine control unit to the throttle valve control part
⇒ page 165
– Perform idling check ⇒ page 144
Note!
During the idling check the tank venting valve -N80- and the air
conditioner are switched off and the Lambda regulation learning
process is initiated.
– Perform a longer test drive until the poor driving characteristics

are eliminated.
During the road test the following operating conditions must be
fulfilled:
♦ The coolant temperature must exceed 80 °C .
♦ When the temperature is reached, the operating conditions
Idling Part throttle Full throttle Overrun must be attained sev‐
eral times.
♦ At full throttle the speed must exceed 3500 rpm.

Arosa 1997 ➤
4.3 Replacing engine control unit

♦ Fault reader -V.A.G 1551- with cable -V.A.G 1551/3A-
Removing
– First print out the control unit identification and thereby the
previous control unit coding as follows:
tem VAS 5051 .)
The control unit identification and the coding will appear on the 030906032E ME 7.5.10 2853 →
display, e.g.: Coding XXXXX WSC XXXXX
– Print out the control unit identification by pressing the fault

reader print button.
– Release connector from control unit and pull off.

Arosa 1997 ➤
– Unclip the control unit from the retaining frame -arrows- .

Installing
– Place the new control unit into the retaining frame.
– Install control unit connector and lock.
– Adapt new control unit to throttle valve control part
⇒ page 165
– Perform adaption of exhaust gas recirculation potentiometer.
Conditions
Select function XX

Basic setting

Indicated on display: (1...4 = display zones)
Basic setting 74 →
xxx % xxx % x ADP. runs
– Observe displayed value in display zone 4. (4th digit from left)

Specification: ADP. OKby copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– Adapt new control unit to the electronic immobilizer

⇒ page 167 ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051
– Then subsequently interrogate the fault memory of the new
engine control unit and erase the fault memory if necessary
– Perform idling check ⇒ page 144
4.4 Coding engine control unit
Note!
♦ A 5-character code must always be displayed during the con‐

trol unit identification.
♦ The control unit must be recoded if the vehicle relevant coding
is not displayed or the control unit has been renewed.

♦ Fault reader -V.A.G 1551- with cable -V.A.G 1551/3-
Work sequence

Arosa 1997 ➤

tem VAS 5051 .)
Select function XX
– Press keys 0 and 7 for the function “Code control unit” and
Indicated on display: Coding control unit Q
Enter code number XXXXX (0-32000)
– Enter the relevant code number for this vehicle and confirm
with Q key.
Coding variations for engine control unit ⇒ page 164 .
The control unit identification and coding are indicated on the dis‐ 030906032G ME 7.5.10 2921 →
play, e.g.: Coding 00031 WSC 00000
Indicated on display when a non-authorised code number has Function is not recognised or cannot →
been entered. be performed at the moment.

Note!
The code unit entered and shown on the display will not be used
by the engine control unit until the ignition has been switched off
once. An incorrect coding leads to:
♦ Engine running faults (gear change jerks, load change jerks,

etc.)
♦ Increased fuel consumption
♦ Increased exhaust gas emissions
♦ Faults stored in fault memory which are not actually present
♦ Functions will not be performed (Lambda regulation, activation
of the activated charcoal filter system, etc.).
♦ On front wheel drive vehicles the traction control will not func‐
tion (TC warning lamp comes on)
♦ Reduced gearbox life
4.5 Coding variations of engine control unit

1st position: 2nd position: 3rd position: 4th position:
Vehicle code Emissions code Special code CAN data bus code
0= No code 0= No code 0= No code 0= No code
1= --- 1= --- 1= --- 1= ABS
2= --- 2= --- 2= --- 2= Airbag
3= --- 3= --- 3= --- 3= ABS and airbag
4= --- 4 Copying
Protected by copyright. = ---
for private or commercial purposes, in4 = or in whole, is not ---
part 4= ---
5= --- respect to the correctness
5= --- 5 =
--- 5= ---
The code number is compiled as shown in the following example:
1st position: Vehicle code (no code at present) 0

Arosa 1997 ➤
2nd position: Emissions code (no code at present) 0

3rd position: Special code (no code a present) 0
4th position: CAN data bus code (ABS and airbag) 3
5th position: Gearbox code (5-speed manual gearbox) 1
Code number: 0 0 0 3 1
4.6 Adapting engine control unit to throttle

valve control part
The adaption teaches the engine control unit the various positions
of the throttle unit when the ignition is switched on and the engine
is not running. These positions are stored in the control unit. The
feedback of the throttle valve position is via both angle senders
for throttle valve drive.
Adapting sequence must be performed
Protected byif:
♦ The voltage supply is interruptedrespect to the correctness of information in this document. Copyright by SEAT S.A.
♦ The throttle valve control unit is removed and installed or
cleaned
♦ The throttle valve control unit is renewed
♦ The engine control unit is replaced
♦ If when installing another engine another throttle valve control
unit is installed
♦ The engine control unit is renewed.
Check conditions
• Ignition on, engine not running
• No faults must be stored in fault memory ⇒ Vehicle diagnosis,
testing and information system VAS 5051 , interrogating and
erasing fault memory.
switched off.
• The throttle valve must be at idling speed position (The accel‐
erator must not be operated during the test).
• The throttle valve part must not be dirty (carbonization).
• Coolant temperature must be 5...105 °C ⇒ display group 04,
display zone 3.
Work sequence
tem VAS 5051 .)
Select function XX

Arosa 1997 ➤


Indicated on display: (1...4 = display zones) Basic setting 60 →
xxx % xxx % x ADP. runs
After pressing the Q key the throttle valve positioner is switched

so that it is not supplied with voltage at start of test.
♦ Learning step 1: The engine control unit checks if all test con‐
ditions are fulfilled.
♦ Learning step 2: The throttle valve part is switched to no volt‐
age (emergency operation position). The angle sender values
of the emergency operation position are stored in engine con‐
trol unit.
♦ Learning step 3: The throttle valve is set to a value above the
emergency operation point.
♦ Learning step 4: The final stage of the throttle valve positioner
is switched off. Now the mechanical spring must set the throttle
valve to the previously learnt emergency operation position
within a certain time (spring closing test).
♦ Learning step 5: The throttle valve is closed by the throttle
valve positioner (lower mechanical stop).
♦ Learning step 6: The throttle valve angle value on lower me‐
chanical stop will be stored in control unit. Then the lower
electrical stop will be defined (calculated) and stored in the
control unit.
♦ Learning step 7: The final stage is switched off at the lower
mechanical stop. Now the mechanical spring must set the
throttle valve in the emergency operation position (spring
opening test).
♦ Learning step 8: The sender angle values are checked.
♦ Learning step 9: Adaption ends.
Indicated on display: (1...4 = display zones) Basic setting 60 →
xxx % xxx % 9 ADP. OK.
Adapting has been performed successfully.

– Terminate engine basic setting at earliest after 30 seconds by
pressing the → key.
To store the values: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Switch off ignition. respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!
If the basic setting of the control unit is interrupted, the cause

could be one of the following:
♦ The test conditions were not fulfilled.

♦ Throttle valve control unit or wiring is defective. Check
⇒ page 120 .

Arosa 1997 ➤
After an interruption a fault is stored in fault memory. When next

switching on ignition the basic setting is automatically performed
again.
4.7 Adapting engine control unit to electron‐

ic immobilizer
Engine code: AUC
♦ Vehicle Diagnosis, Testing and Information System -VAS
5051-
♦ Diagnosis cable -VAS 5051/1 or VAS 5051/3-
Conditions
• Authorized vehicle key required.

Arosa 1997 ➤
Work sequence
– Pull out ashtray -1- .
– Fit connector from diagnosis cable -VAS 5051/1 or VAS
5051/3- to diagnosis connection.
– Operate fault reader or vehicle system tester taking into ac‐
count the information on the display:
– Press button on display for “Vehicle self-diagnosis” .
– Press keys 2 and 5 for address word “Immobilizer” and con‐
firm entry with Q key.
6H0953257 IMMO VWZ3Z0V6474044 V64
Coding 00000 WSC XXXXX

Select function XX
– Press keys 1 and 0 for function “Adaption” and confirm entry

with Q key.
Adaption
Feed in channel number XX
– Press key 0 twice for “Channel number 0” and confirm entry

with Q key.
Adaption Q
Erase learnt values?
– Confirm input with Q key.

Adaption →
Learnt values have been erased

entry with the Q key. Indicated on display:
– Switch off ignition.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note!
The identity of the engine control unit is read into the immobilizer
control unit when next switching the ignition on.

Arosa 1997 ➤
5 Checking additional signals
5.1 Checking speed signal

♦ Test box -V.A.G 1598/22-
Check conditions
• Speedometer must be OK., checking speedometer: ⇒ Elec‐
trical system; Rep. Gr. 90
Test sequence
Note!
To check the speed signal the vehicle must be driven. To do this

a second person is necessary.
Caution
Secure fault reader to rear seat and operate from this position.

test ⇒ page 111 .
Rapid
respect to the correctness of information in this document. data
Copyright by transfer
SEAT S.A. HELP
Select function XX


– Carry out test drive with a 2nd person to observe display.

– Observe figure displayed in display zone 3: Specification: ap‐
prox. driven speed

Arosa 1997 ➤
– Drive slower. The displayed value must decrease.

If no speed is indicated or the display values reduce when driving
slowly:
ness.
– Connect multimeter to measure voltage between test box
sockets 27 (terminal 15) + 5 (speed signal).
– Lift vehicle at front left.
– Rotate front wheel and observe voltage display. Specification:
between 0 and at least 4 Volt fluctuating
Note!
If necessary, hold the front right wheel to prevent it from turning.
If the display does not fluctuate:

– Check wiring to speedometer/speedometer sender: ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations
5.2 Checking signal from/to air conditioning

system
♦ Test box -V.A.G 1598/22-
Test conditions
• Air conditioner functioning OK.
• Air conditioner must be switched off

• Vehicle at room temperature (warmer than + 15 °C).

Test sequence

Arosa 1997 ➤

Select function XX


– Observe display in display zone 3. It must show A/C-Low.

– Observe display in display zone 4. It must show Compr. OFF.
– Switch on air conditioning system.
– Select lowest temperature and highest blower speed.
The display in display zone 3 must change to A/C-High.
The display in display zone 4 must change to Compr. ON.
– Floor accelerator pedal quickly and then release (brief burst of
throttle).
The display in display zone 4 must change from Compr.ON to
Compr. OFF for a few seconds (compressor switch-off when ve‐
hicle is accelerating).
If the display does not change:
Gr. 92 ; windscreen wiper system removing
respect andofinstalling
to the correctness information in this document. Copyright by SEAT S.A.
ness.
– Check wiring for open circuit between test box sockets 17 +
42 and air conditioner using current flow diagram. Wire resist‐
ance: max. 1.5 Ω
If no fault can be found in the wiring:
formation system VAS 5051 , interrogating and erasing fault
memory.
– Check function of air conditioner control unit.
5.3 Checking signal from brake light switch

and brake pedal switch
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤

Check conditions
Test sequence
Note!
– Pull the connector off brake light/brake pedal switch.
– Connect the multimeter to measure resistance between con‐

tacts 1 and 4. Specification: ∞ Ω (no continuity)
– Depress brake pedal. Specification: approx. 0 Ω
– Connect the multimeter to measure resistance between con‐
tacts 2 and 3. Specification: approx. 0 Ω
– Depress the brake pedal. Specification: ∞ Ω (no continuity)
– Replace the brake light/brake pedal switch.
– Connect multimeter to measure voltage between contact 1

and earth. Specification: at least 11.5 V
– Switch ignition on.
– Connect the multimeter to measure voltage between contact
2 and earth. Specification: at least 11.5 V
If the specifications are not obtained: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check the wire between 4-pin connector contact 1 respect
and main
fuse/contact 2 and central electrics using current flow diagram.
cations

ness.

Arosa 1997 ➤
nector using current flow diagram. Contact 3+socket 51 Con‐
tact 4+socket 23 Wire resistance: Max. 1.5 Ω
– Additionally check wires for short to one another.
– Additionally check the wiring for short to battery positive or
earth.
5.4 Checking rpm signal
Note!
The engine rpm signal output is on contact 41 of engine control

unit. Amongst other things the signal is necessary for the rev.
counter incopyright.
Protected by dash panelCopying insert.
♦ Test box -V.A.G 1598/22-
Test conditions
Test sequence
ness.
– Check wiring from test box contact 41 to dash panel insert for
open circuit using current flow diagram: ⇒ Current flow dia‐
5.5 Checking signal from power steering

pressure switch
1552- with cable -V.A.G 1551/3-
♦ Test box -V.A.G 1598/22-

Arosa 1997 ➤

Test sequence
Select function XX


– Observe values for the power assisted steering pressure

switch displayed in display zone 4. Specification: 0 x x x x
– Turn steering wheel to full lock and observe value displayed
in display zone 4 (1st digit from left) Specification: 1 x x x x
– Connect multimeter -V.A.G 1526- to pressure switch contacts.
– Start the engine and run at idling speed. Check pressure
switch for continuity. Specification: ∞ Ω
– Turn steering wheel to full lock. The pressure switch must
switch to continuity.
– Renew pressure switch for power assisted steering:
– Check the wiring ⇒ page 174 .
Checking wiring connections

Arosa 1997 ➤

ness.
– Check wiring between test box and 2-pin connector for open
circuit using current flow diagram. Contact 1+socket 49 Con‐
tact 2+socket 21 Wire resistance: Max. 1.5 Ω
– Additionally check wires for short to one another.
– Additionally check the wiring for short to battery positive or
earth.
5.6 Checking matching resistor of data bus

Function
The engine control unit communicates with other data bus-com‐
patible control units.
The control units are connected via a twisted pair of data bus
wires (“high” and “low” ) and exchange information (messages).
Information missing from the data bus will be recognised as a fault
by both the engine control unit and other data bus control units.
The data bus requires a matching resistor to function fault free.
This central matching resistor is located in the engine control unit.
Test conditions
• A data bus fault has been recognised by the self-diagnosis.
♦ Test box -V.A.G 1598/22-
Test sequence
– Unlock the engine control unit connector and pull it off.
– Connect test box -V.A.G 1598/22- to engine control unit.
– Check centralized matching resistor
permittedin engine
unless control
authorised by SEATunit.
– To do this perform a resistance measurement between the test
box Sockets 31 + 32 Specification: 60...72 Ω
If the resistance measurement is outside the specified range:

Arosa 1997 ➤
If the resistance value is within the specified range:

– Repair the fault: ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations

Arosa 1997 ➤
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 it has sufficient clearance to the
bodywork. If necessary, loosen double clamp(s) and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking
permittednuts.
♦ Components marked with * will be checked by self-diagnosis:
– Check catalytic converter ⇒ page 180 .
1.1 Exhaust manifold, front exhaust pipe and catalytic converter with attach‐
ments

Arosa 1997 ➤
1 - Warm air collector plate

2 - 10 Nm
❑ Note tightening se‐
quence ⇒ page 179
❑ With integrated pre-cat‐
alytic converter, with en‐
gine codes ANV, AUC,
ANW, AUD only
4 - Gasket
❑ Renew
5 - Lock nut, 25 Nm
6 - Lambda probe 2 after cata‐
lytic converter -G130- *, 50 Nm
❑ Engine codes ANV,
AUC, ANW, AUD only
❑ Grease only the threads
with -G 052 112 A3- ; -G
052 112 A3- must not
get into the slots on the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
probe body
ring spanner -U-40080-
or -3337-
7 - To silencer
8 - Marking
9 - Connector
❑ Engine codes ANV,
AUC, ANW, AUD only
❑ For Lambda probe 2 af‐

Arosa 1997 ➤
ter catalytic converter -

G130- and Lambda probe heating -Z29-
❑ Black, 4-pin
10 - Front exhaust pipe with catalytic converter
❑ Check catalytic converter (engine codes ANV, AUC, ANW, AUD) ⇒ page 180
11 - Mounting
12 - Locating nut, 40 Nm
13 - Connector
❑ For Lambda probe 1 before catalytic converter -G39- and Lambda probe heating -Z19-
Engine codes ALD, AKK:
❑ Black,4-pin
Engine codes ANV, AUC, ANW, AUD:
❑ Black, 6-pin
14 - Lambda probe 1 before catalytic converter -G39- *, 50 Nm
❑ Grease only the threads with -G 052 112 A3- ; -G 052 112 A3- must not get into the slots on the probe
body
❑ Remove and install with ring spanner -U-40080- or -3337-
❑ Check Lambda probe ageing (Engine codes ANV, AUC, ANW, AUD only) ⇒ page 180 , Checking cat‐
alytic converter
15 - Bracket
❑ For electric wiring of Lambda probe 1 before catalytic converter
Note!
Tighten warm air collector plate in sequence as illustrated to en‐

sure it is installed free of stress.
Tightening sequence, warm air collector plate on exhaust mani‐

fold.

Arosa 1997 ➤
1.2 Silencer with mountings

alytic converter
2 - Marking
❑ Three times on circum‐
ference
❑ S = Manual gearbox
3 - Double clamp
4 - Dimension-a- = ca. 5 mm
5 - Mushroom head screw
6 - 23 Nm
7 - Front silencer17)
❑ Insert in double clamp to
marking
8 - Mounting
9 - Connecting piece
10 - 15 Nm
11 - Mounting
❑ Renew if damaged Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - 22 Nm + 1/4 turn (90 °) respect to the correctness of information in this document. Copyright by SEAT S.A.
further
13 - Rear silencer17)
14 - Marking
❑ Visible from below
❑ For repair double clamp
15 - Separating point
❑ For repair cases
17)
❑ Marked by impressions on connecting pipe

16 - Repair double clamp
❑ Must be slid onto the markings ⇒ Item 14 (page 180)
17) Front and rear silencers are installed as a single component as standard. In
repair cases the front and rear silencers are supplied individually and a repair
double clamp ⇒ Item 16 (page 180) is supplied as a joint. Cut through con‐
necting pipe at right-angles at separating point ⇒ Item 15 (page 180) with a
body saw e.g. -U-40075- .
1.3 Checking catalytic converter

Engine codes ANV, AUC, ANW, AUD only

Arosa 1997 ➤
Test conditions
• Fuse No. 1 must be OK.
• Vehicle stationary
switched off.
• Exhaust system between catalytic converter and cylinder head
must be free of leaks
04, display zone 3.
• Intake air temperature less than 60° C ⇒ display group 04,
display zone 4
Functional check
gine and select the engine control unit with the “Address word”
01. Connecting fault reader and selecting engine control unit:
Lambda probe ageing diagnosis (cycle duration monitor)
Select function XX
– Press keys 0 and 4 for the “Introduce basic setting” function

Basic setting


Engine speed is raised to approx. 1100...1300 rpm by engine
control unit.
– Allow engine to run at increased engine speed until display
zone 4 jumps from “Test OFF” to “Test ON” . The catalytic
converter temperature in display zone 2 must be a minimum
of 400 °C.
Note!

– Check the amplitude quality
permitted unless in display
authorised by SEAT S.A.zone
SEAT3:S.ASpecification:
0.7... 2.00 respect to the correctness of information in this document. Copyright by SEAT S.A.
– Allow engine to continue to run at increased engine speed until

display zone 4 displays the specification “B1-P1 OK.” .

Arosa 1997 ➤

– Press C key.
The engine speed drops to idling speed.
Catalytic converter diagnosis
Note!
The diagnosis will only be terminated if the Lambda probe ageing

diagnosis is first successfully completed.
Basic setting

System in basic setting 46 permitted
→ unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

Engine speed is raised to approx. 1100...1300 rpm.
– Allow engine to run at increased engine speed until display
zone 4 jumps from “Test OFF” to “Test ON” . The catalytic
converter temperature in display zone 2 must be a minimum
of 400 °C.
– Check the amplitude relationship in display zone 3: Specifica‐
tion: Max. 0.40
– Allow the engine to continue to run at increased engine speed
until display zone 4 displays “Cat B1 OK.”
– Press → key.
The engine speed drops to idling speed.

Arosa 1997 ➤
2 Exhaust gas recirculation system
Note!
♦ The function/control of the exhaust gas recirculation system is

checked by the self-diagnosis of the Motronic control unit -
J220- .
♦ Pulsed control makes every conceivable valve position possi‐
ble.
♦ Checking exhaust gas recirculation valve -N18- . ⇒ Vehicle
♦ The cone shaped plunger in the (electric) EGR valve ensures
that various cross sectional openings are possible at different
plunger lifts.
♦ Components marked with an * are checked via the self-diag‐
nosis. ⇒ Vehicle diagnosis, testing and information system
VAS 5051
♦ Components marked with ** are checked via the final control
diagnosis. ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051
2.1 Servicing parts of exhaust gas recirculation system

Only engine code AUC

Arosa 1997 ➤
1 - Intake manifold
2 - Oil seal
3 - Connecting pipe
4 - Self-tapping bolt, 8 Nm
❑ max. rotational speed if
using power tools: 350
rpm
5 - EGR valve -N18- */** with
potentiometer for exhaust gas
recirculation -G212- *
❑ Check EGR valve -
N18- : ⇒ Vehicle diagno‐
tion system VAS
Protected 5051Copying for private or commercial purposes, in part or in whole, is not
by copyright.
❑ If the valverespect
has tobeen re‐
newed, an adaption
must be performed via
measured value block
74.
❑ Check potentiometer for
exhaust gas recircula‐
tion -G212-
⇒ page 185
6 - 10 Nm
7 - 8 Nm
8 - Gasket
❑ Renew
9 - Breather pipe
10 - Connection to intake mani‐
fold
11 - Cylinder head
12 - 6-pin connector

Arosa 1997 ➤
2.2 Checking potentiometer for exhaust gas recirculation -G212-

Only engine code AUC

equipment required
1526-
♦ Test box -V.A.G 1598/22-
Test conditions
• Fuses 30, 31 and 36 must be OK.
Test sequence

Arosa 1997 ➤
– Pull off 6-pin connector -1- (grey) from EGR valve.
– Connect multimeter to contacts 2 and 4 of 6-pin connector for

volt-age measurement.

ness.
nector using current flow diagram. Contact 2 and test box
socket 62 Contact 4 and test box socket 54 Contact 6 and test
box socket 69 Wire resistance: max. 1.5 Ω
– Additionally check wiring for short to one another, and for short
to positive or earth.
– Depending on conditions, renew following components:
Voltage supply and wiring OK:
– Renew EGR valve -N18- with potentiometer -G212- .
– Erase learnt values and re-adapt engine control unit
⇒ page 165
If no wiring fault is detected and voltage supply is not OK:
– Renew engine control unit. ⇒ page 102

Arosa 1997 ➤
1 Servicing ignition system
1.1 General notes on ignition system

♦ Only the components which specifically relate to the ignition
system are dealt with here. For the other components of the
injection and ignition system ⇒ page 102
♦ The engine control unit is equipped with self diagnosis.
♦ Components marked with * are checked via the self diagnosis
♦ For trouble-free operation of the electrical components a volt‐
♦ Before carrying out repairs and for fault finding, interrogate
fault memory ⇒ Vehicle diagnosis, testing and information
essary erased. ⇒ Vehicle diagnosis, testing and information
Safety precautions ⇒ page 189
Test data,Protected
spark byplugs ⇒ page
copyright. Copying 189
1.2 Removing and installing parts of the ignition system
Note!
Motronic control unit -J220- * with connectors ⇒ Item 4 (page 102) .
1. Servicing ignition system 187

Arosa 1997 ➤
1 - Connector
❑ Black, 4 pin
❑ For ignition transformer
-N152-
2 - Ignition transformer -N152-
*
❑ With marking for ignition
cables: A = Cylinder 1 B
= Cylinder 3 C = Cylin‐
der 2 D = Cylinder 4
3 - 10 Nm
4 - Connector
❑ Black, 2-pin
❑ For knock sensor 1 -
G61-
❑ Sensor and connector
contacts are goldplated
❑ Checking ⇒ page 194 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Sensor and connector permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
contacts are goldplated
6 - 20 Nm
❑ Tightening torque influ‐
ences the function of the
knock sensor
7 - Connector
❑ Black, 3-pin
❑ Hall sender -G40-
9 - O ring
10 - Spark plug, 30 Nm
❑ Remove and install with spark plug spanner -3122B-
❑ Type and electrode gap ⇒ page 189 , test data, spark plugs
11 - Bracket
❑ For ignition transformer -N152-
12 - H.T. cable
❑ With suppression connector and spark plug connector
❑ Resistance 4.8...7.2 kΩ

Arosa 1997 ➤
1.3 Safety precautions

To prevent injuries to persons and/or damage to the fuel injection
and ignition system, the following must be noted:
♦ Do not touch or disconnect ignition wiring when the engine is
running or being turned at starter speed.
connecting injection or ignition system wiring or tester cables.
♦ If the engine is to be turned at starter speed, without starting:
– Pull 4 pin connector offcopyright.
Protected by ignition transformer
Copying -arrow- purposes,
for private or commercial . in part or in whole, is not
1.4 Test data, spark plugs

Engine code ALD, ANV, AUC, ANW, AUD, AKK
Ignition sequence 1-3-4-2
Spark plugs18) ,19)
VW/Audi -101 000 062 AB-
Manufacturers sign NGK PZFR 5 D-11
Distance of electrodes max. 1,0... 1,1 mm
Tightening torque 30 Nm
18) The up-to-date figures and the spark plug change intervals:

Arosa 1997 ➤
19) Remove and install spark plugs with -3122B-
1.5 Checking Hall sender

♦ Test box -V.A.G 1598/22-
Check conditions
switched off.
• Hall sender screwed on tight
Test sequence
– Connect multimeter to measure voltage with adapter cables

from -V.A.G 1594- to contacts 1 (positive) and 3 (earth) on the
Hall sender connector.
windscreen wiper system permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

Arosa 1997 ➤

ness.
– Check wiring between test box and 3-pin connector (connector

tion: ∞Ω
contacts 1+3:
– Renew Hall sender -G40- ⇒ Item 8 (page 188) .
If no wiring fault is detected and no voltage was present between
contactsProtected
1+3: by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Replacerespect
engineto thecontrol unit ⇒ pagein this
162 .
correctness of information document. Copyright by SEAT S.A.
1.6 Checking ignition transformer

♦ Test box -V.A.G 1598/22-
Check conditions
switched off.
• Hall sender must be OK, checking ⇒ page 190 .
• Engine speed sender must be OK, checking ⇒ page 131 .
Test sequence

Arosa 1997 ➤

– Using multimeter and adapter cables from -V.A.G 1594-

measure the supply voltage between contacts 2+4 of discon‐
nected connector.
– Check wire between 4 pin connector contact 2 and relay plate

for open circuit according to current flow diagram. Wire resist‐
ance: max. 1.5 Ω
– Check wire between 4 pin connector contact 4 and earth for
open circuit according to current flow diagram. Wire resist‐
ance: max. 1.5 Ω
Checking activation
Caution
During the following test do not touch the terminals of the ig‐
nition transformer or test cables.
– Pull plug -arrows-

Protectedoff all injectors.

Arosa 1997 ➤
– Connect diode test lamp -V.A.G 1527- with adapter cables

from -V.A.G 1594- to contacts 1 + 4 (ignition output 1), con‐
tacts 3 + 4 (ignition output 2) of disconnected connector.
– Operate starter and check the ignition signal from engine con‐
trol unit. The LED must flicker
If the LED flickers and there is voltage between contacts 2 + 4:
– Renew ignition transformer -N152- ⇒ Item 2 (page 188) .
The LED does not flicker:
– Check wiring ⇒ page 193
Checking wiring

ness.

to control unit) for open circuit using current flow diagram..
Contact
Protected 1+socket
by copyright. Copying for57 Contact
private 3+socket
or commercial purposes,71 Wire
in part resistance:
or in whole, is not
permitted max. 1.5 Ω by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
tion: ∞Ω
contacts 2+4:
Checking secondary resistance
– Check the secondary winding on terminal 4 between Cyl. 1

+Cyl. 4, Cyl. 2+Cyl. 3. Specification: 4.0... 6.0 kΩ (at 20 °C)
– Renew ignition transformer -N152- ⇒ Item 2 (page 188) .

Arosa 1997 ➤
1.7 Checking knock sensor
Note!
♦ It is extremely important to keep to the tightening torque of 20

Nm to ensure the knock sensors perform perfectly.
♦ Only gold-plated contacts may be used when servicing the
knock sensor connector contacts.

♦ Test box -V.A.G 1598/22-
Test conditions
• Knock sensor fault recognised by self-diagnosis ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051 , interrog‐
ating and erasing faultProtected
memory. by copyright. Copying for private or commercial purposes, in part or in whole, is not
Test sequence permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Pull 2 pin connector off knock sensor -arrow- .


ness.

Arosa 1997 ➤

max. 1.5 Ω
tion: ∞Ω
– Loosen knock sensor and tighten again to 20 Nm.
– Carry out test drive.
Observe the valid safety precautions when carrying out a test
drive ⇒ page 189 .
fulfilled:
♦ The coolant temperature must exceed 80 °C .
♦ When the temperature is reached, the operating conditions
Idling Part throttle Full throttle Overrun must be attained sev‐
eral times.
♦ At full throttle the permitted
speedunless
must exceed
authorised 3500
by SEAT S.A.rpm.
– Again interrogate the control unit fault memory.
If the fault is still present:
– Replace knock sensor -G61- ⇒ Item 5 (page 188) .
1.8 Check misfiring recognition

Test sequence
Select function XX


– Check the misfire recognition status in display zone 4. Speci‐

fication: “activated”
– Check total misfires in display zone 3. Specification: 0
– Press → key.

Arosa 1997 ➤
– Check the misfire recognition status in display zone 4. Speci‐

fication: “activated”
– Check misfiring of Cyl. 1...Cyl. 3 in display zones 1...3. Spec‐
ification: 0
– Press → key.
5051 , Evaluating display group 15 and display group 16.
Indicated on display: (1 and 4 = Display zones) Read measured value block 16 →
1 4
– Check misfire recognition status in display zone 4. Specifica‐

tion: “activated”
– Check misfiring of Cyl. 4 in display zone 1 Specification: 0
– Press → key.
5051 , Evaluating display group 15 and display group 16.

Service
Workshop Manual
Arosa 1997 ➤
4LV injection and ignition system
Engine ID AQQ AUB
Edition 11.00

Service
Repair Group
01 - Self-diagnosis

Copyright © 2015 Seat S.A S01QAQQ8620

Arosa 1997 ➤
4LV injection and ignition system - Edition 11.00
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Self-diagnosis - general considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Characteristics of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Self-diagnosis technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Meaning of the EPC warning light (electronic accelerator activation warning light) located on
the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Meaning of exhaust emissions warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Fault reader V.A.G. 1551 : connecting and selecting the engine electronics control unit . . 4
1.6 Data system, vehicle testing and diagnosis VAS 5051 : connecting and selecting the engine
electronics control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Fault memory: consulting and clearing . . . . . Copying
Protected by copyright. . . . . .for. private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. .in.whole,
. . . is. .not. 10
2.2 Fault table: codes SAE P0 . . . . .respect . . . . to. the
. . correctness
. . . . . . .of.information
. . . . . .in. this
. . document.
. . . . . . Copyright
. . . . . by
. .SEAT. . . S.A.
..... 11
2.3 Fault table: codes SAE P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Conformity code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6 Conformity code: consulting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 Conformity codes: generating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Final control diagnosis: carrying out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2 Read measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Analysis measured value block, display groups 0...6 -basic functions- . . . . . . . . . . . . . . . . 36
6 Analysis measured value block, display groups 10...29 -ignition- . . . . . . . . . . . . . . . . . . . . 40
7 Analysis measured value block, display groups 30...49 -lambda control- . . . . . . . . . . . . . . 43
8 Analysis measured value block, display group 50...69 -rev control- . . . . . . . . . . . . . . . . . . 48
9 Analysis measured value block, display group 70...75 -exhaust recirculation- . . . . . . . . . . 51
10 Analysis measurement value blocks, display group 100 -conformity code- . . . . . . . . . . . . 53
11 Analysis measurement value blocks, display groups 120...129 -communication- . . . . . . . . 54

1 Injection system: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.2 General instructions for injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Injection system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Injection system: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1 Intake manifold: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Fuel distributor with injectors: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Air filter: disassembly and as-sembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.5 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3 Component test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.1 Pre-catalyst lambda probe heating: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2 Post-catalyst lambda probe heating: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Throttle valve control unit: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.4 Intake manifold pressure sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.5 Intake air temperature sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.6 Coolant temperature sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.7 Engine revs sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Contents i
Arosa 1997 ➤
3.8 Injectors: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4 Jet profile and leakage: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.1 Fuel pressure regulator and re-taining pressure: testing . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Intake system: testing for leakage (infiltrated air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3 Intake air preheating: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.1 Lambda probe and pre-catalyst lambda probe: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.2 Post-catalyst lambda probe and control lambda posterior: testing . . . . . . . . . . . . . . . . . . . . 96
5.3 Engine load states: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.4 Idling test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.1 Control unit voltage supply: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.2 Procedure after an interruption in the voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.3 Engine control unit: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.4 Engine control unit: encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.5 Engine control unit: adapt to theProtected throttlebyvalve control
copyright. unit
Copying for private. or
. .commercial
. . . . . .purposes,
. . . . . in. .part
. .or. in. .whole,
. . . is. not
. 106
6.6 Engine control unit: adapt to the electronic immobiliser
respect to the . . . . .in. this
correctness of information . . document.
. . . . . .Copyright
. . . . . by. .SEAT
. . . S.A.
. . . . 108
7 Supplementary signals: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.1 Speed signal: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.2 Signals from/to the air conditioning: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.3 Signals from the brake light and brake pedal switches: testing . . . . . . . . . . . . . . . . . . . . . . 112
7.4 Revs signal: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.5 Data bus: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1 Ignition system: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 General information: ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.2 Ignition system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.4 Settings data, sparkplugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.5 Hall sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.6 Ignition transformer: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.7 Knock sensor: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.8 Ignition/combustion fault finding: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ii Contents
Arosa 1997 ➤
01 – Self-diagnosis
1 Self-diagnosis - general considera‐
tions
Note!
Self-diagnosis monitors only a part on the injection and ignition

system.
1.1 Characteristics of self-diagnosis

The injection and ignition system control unit 4LV -J448- is equip‐
ped with a fault memory.
When a fault occurs in the controlled sensors or components, the
fault and its type are stored in the fault memory.
After analysing the data, the engine control unit distinguishes 127
different fault indexes Fault table, pages ⇒ page 11 and
⇒ page 1 , and stores them until the fault memory is cleared.
Transient (sporadic) faults are printed out with the indication
“sporadic fault” . On the display these faults appear with the ad‐
ditional abbreviation “/SP” . Sporadic faults can originate in a
loose contact or transient open circuit in wiring. If the sporadic
fault does not reoccur over 40 heating phases (engine start-up at
a temperature below 50 °C and engine cutout at temperatures
above 72 °C).
Stored faults can be read with the -V.A.G. 1551- or -V.A.G. 1552-
or with the new diagnosis unit -VAS 5051- ⇒ page 8 . Fault
memory: consulting and clearing.
Once the fault(s) has/have been eliminated, the fault memory
must be cleared ⇒ page 8 . Fault memory: consulting and
clearing.
Note!
For general information on self-diagnosis see the instruction man‐

uals of the -V.A.G. 1551- and -V.A.G. 1552- or the new diagnosis
unit -VAS 5051- .
1.2 Self-diagnosis technical data
1.2.1 Control unit identification

The control unit version is displayed when the -V.A.G. 1551- or -
V.A.G. 1552- is connected and after
Protected by copyright. selecting
Copying the
for private or enginepurposes,
commercial elec‐ in part or in whole, is not
tronics control unit ⇒ page 3 .
1.2.2 Selectable functions when using the -

V.A.G. 1551- or -V.A.G. 1552-
The following table shows the conditions in which the desired
functions can be selected ⇒ page 2 .
1.2.3 Implementation
Engine code letters AQQ
1. Self-diagnosis - general considerations 1

Arosa 1997 ➤
System designation MARELLI 4LV

Exhaust emissions according to Standard D4
Electronic accelerator Yes
Self-diagnosis Yes
Final control diagnosis Yes
Data transmission mode to the Rapid data transmission
-V.A.G. 1551/1552-
Control unit encoding -V.A.G. 1551/1552- -VAS 5051-
Fault memory Permanent memory1),
Self-adapting value memory Volatile memory2)
Lambda control Yes
Knock control 1 knock sensor
Variable intake manifold No
Variable distribution No
Supercharger pressure control No
Secondary air system
Exhaust gas recirculation
1) Independent of the voltage supply.
2) The values are cleared in the event of an interruption in the voltage supply.
1.2.4 Selectable functions when using fault reader -V.A.G. 1551/1552- or unit -
VAS 5051-
The following table contains a summary of the conditions in which
the desired functions can be selected:
Function Premise
Functions of fault reader -V.A.G. 1551- , -V.A.G. 1552- or -VAS Engine off, Engine idling
5051- ignition on
01 Consult control unit version yes yes
02 Consult fault memory yes3), yes
03 Final control diagnosis yes no
04 Basic settings4) yes no
05 Clear fault memory yes yes
06 End transmission yes yes
08 Read measured value block yes yes
3) Do so if the engine does not start. The ignition must be on.
4) Do soProtected
after replacing the control unit, the throttle valve control unit or the engine and after disconnecting the battery.
1.3 Meaning of the EPC warning light (elec‐

tronic accelerator activation warning
light) located on the instrument panel
EPC stands for Electronic Power Control: electronic engine out‐
put control (electronic accelerator).
2 Rep. Gr. 01 - Self-diagnosis

Arosa 1997 ➤
Location of EPC warning lamp

If a fault is found in the electronic accelerator system while the
engine is running, the engine control unit lights up the EPC warn‐
ing lamp (these faults are identified in the fault table). At the same
time, the fault is stored in the engine control unit fault memory.
1.3.1 Function test

– Switch on the ignition:
The EPC warning lamp should be on.
If the EPC warning lamp does not light up with the ignition on:
– Test the instrument panel and the EPC warning lamp as fol‐
lows: ⇒ Electrical system, self-diagnosis; Rep. Gr. 01
If the EPC warning lamp lights up with the ignition on:
– Start the engine and let it idle:
The EPC warning lamp should switch off after a few seconds.
If the EPC warning lamp does not switch off:

– Consult the fault memory; eliminate any faults and clear the
memory ⇒ page 10 ; Fault memory: consulting and clearing.
1.4 Meaning of exhaust emissions warning

lamp
1.4.1 Engine: AUB

When the engine control unit detects a fault, the exhaust warning
lamp lights up.
Location of the exhaust warning lamp.
Note!
♦ The exhaust warning lamp can flash or stay lit. In either case
consult the fault memory ⇒ page 10 :
♦ The warning lamp flashes: there is fault that in the current
driving state could damage the catalyst. In this case, drive only
at very low revs.
♦ The warning lamp stays lit: there is a fault that may degrade
the composition of exhaust emissions. Consult the engine or
automatic gearbox control unit fault memory.
♦ If there is a fault in vehicle driving performance or a complaint
from the customer and the exhaust warning lamp does not light
up, consult the fault memory: there could be stored in the
memory a type of fault that does not light up the warning lamp
instantaneously.

Arosa 1997 ➤
1.4.2 Function test

– Switch on the ignition:
The exhaust warning lamp should light up.
If the exhaust warning lamp does not light up with the ignition on:
– Test the instrument panel and the exhaust warning lamp as
follows: ⇒ Electrical system, self-diagnosis; Rep. Gr. 01
If the exhaust warning lamp lights up with the ignition on:
– Start the engine and let it idle:
The exhaust warning lamp should switch off after a few seconds.
If the exhaust warning lamp does not switch off:
– Consult the fault memory,
Protected eliminate
by copyright. Copying forany faults
private and clear
or commercial the
memory ⇒ page 10unless
permitted ; Fault memory:
authorised by SEAT consulting andnotclearing.
S.A. SEAT S.A does guarantee or accept any liability with
1.5 Fault reader -V.A.G. 1551- : connecting

and selecting the engine electronics
control unit
Note!
♦ Instead of fault reader -V.A.G. 1551- , vehicle systems tester

-V.A.G. 1552- can also be used, although in this case the data
cannot be printed out.
♦ Lead -V.A.G. 1551/3B-

Arosa 1997 ➤

• Fuses 1, 2, 3, 4, 8, 9, 10, 26, 27 and 32, OK.
• Earth connections between the engine (at the gearbox hous‐
ing) and bodywork (next to the battery), OK.
• Earth connections at the water tank, OK.
• All electrical consumers, e.g., the lights and heated window,
must be off.

Arosa 1997 ➤
1.5.2 Work sequence

– Remove the front cover from the fusebox.
– Connect the fault reader -V.A.G. 1551- ( -V.A.G. 1552- ) with
the lead -V.A.G. 1551/3B- .
With the fault reader connected:
– According to the desired function: switch on the ignition or start
the engine ⇒ page 2 , table “Selectable functions” .
Note!
♦ If no message appears on the display, test the voltage supply

of the diagnosis connector ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations .
♦ If the display does not show the messages indicated in the
work sequence: ⇒ Instructions for use of the fault reader
♦ If, due to keyboard error, the message “Data transmission er‐
ror” appears, disconnect the fault reader lead, reconnect it and
repeat the work sequence.
Reading on display:
V.A.G. - SELF-DIAGNOSIS HELP
1 - Rapid data transmission*
V.A.G. - SELF-DIAGNOSIS HELP

2 - Flash code output*
* appear alternately.
– Operate the fault reader watching the reading on the display:
– Press 1 for “Rapid data transmission” .
Reading on display:
Enter address code XX
– Press 0 and 1 for the address code “Engine electronics” and
confirm the entry with the Q key.
The display of the fault reader -V.A.G. 1551- shows the control
unit identification, e.g.:
036 906 034 L MARELLI 4LV 3038 →
Encoding 00001 WSC XXXXX
♦ -036 906 034 L- = control unit reference no (see Spare parts

catalogue for current version)
♦ MARELLI 4LV = system and version designation
♦ 3038 = control unit software version
♦ Encoding 00001 = control unit encoding
♦ WSCxxxxx = repair shop identification the -V.A.G. 1551- with
which last encoding was done. (As long as the factory encod‐
ing is not changed, display = WSC 00000.)
Note!
If the control unit version corresponding to the vehicle is not dis‐

played, replace the control unit ⇒ page 104

Arosa 1997 ➤
– Press → .
Reading on display:
Select function XX
– Continue according to the repair descriptions.
1.6 Data system, vehicle testing and diag‐

nosis -VAS 5051- : connecting and se‐
lecting the engine electronics control
unit
All the functions permitted by the -V.A.G. 1551/1552- can also be
done with the new unit -VAS 5051- in the mode “vehicle self-di‐
agnosis” : ⇒ Vehicle diagnosis, testing and information system
VAS 5051; Data system instruction manual, vehicle testing and
diagnosis -VAS 5051- .
♦ Data system, vehicle testing and diagnosis -VAS 5051-

• The
Protected batteryCopying
by copyright. voltage must
for private be at least
or commercial 11.5in V.
• Fuses 1, 2, 3, 4, 8, 9, 10, 26, 27 and 32, OK.by SEAT S.A.
respect to the correctness of information in this document. Copyright
• Earth connections between the engine (at the gearbox hous‐

ing) and bodywork (next to the battery), OK.
• Water tank earth connections, OK.
1.6.2 Work sequence


Arosa 1997 ➤
– Connect the -VAS 5051- with diagnosis lead -VAS 5051/1 or

VAS 5051/3- , as follows:
– Connect the diagnosis lead at the diagnosis terminal.
– According the function desired, switch on the ignition or Start
the engine and run it at idling revs ⇒ page 2 “Selectable func‐
tions”
Note!
♦ In functions “04 - Basic settings” and “08 - Read measured

value block” the different display fields are shown from top to
bottom.
♦ If the display does not show the messages in work sequence:
5051; Instruction manual for the data system, vehicle testing
and diagnosis -VAS 5051- .
Reading on display:
1.6.3 Select operating mode:

– Press 1 for the operating mode “Rapid data transmission” .
Reading on display:
1.6.4 Select the vehicle system:

– Touch the display “01 - Engine electronics” -arrow- .

Arosa 1997 ➤
The display shows the control unit identification and the encoding
-arrow- , e.g.:
Note!
If the control unit version corresponding to the vehicle is not dis‐

played, replace the control unit ⇒ page 104 .
Reading on display:
1.6.5 Select diagnosis function:

In this situation all diagnosis functions are available.
– Touch the desired function on the display.
– Continue according to the repair descriptions.

Arosa 1997 ➤
2 Fault memory
Consult the fault memories of all the control units ⇒ page 10 ,
Automatic test cycle
2.1 Fault memory: consulting and clearing

♦ Fault reader -V.A.G. 1551- (or vehicle systems tester -V.A.G.
1552- ) with lead -V.A.G. 1551/3B-
2.1.1 Work sequence
Note!
All the functions carried out up to now with the -V.A.G. 1551/1552-
can also be done with the new unit -VAS 5051- .
– Connect the -V.A.G. 1551- ( -V.A.G. 1552- ). Start the
permitted engine
and enter the “address code” 01 to select the enginerespect
electron‐
ics control unit. (Fault reader: connecting and selecting the
engine control unit ⇒ page 3 .)
Only if the engine does not start:
– Operate the starter motor for about 6 seconds. Then, leave the
ignition on.
– Press Print to activate the fault reader printer. The light on
the key should come on.
Reading on display: Rapid data transmission HELP
Select function XX
– Operate the fault reader watching the reading on the display:

– Press 0 and 2 for the function “Consult the fault memory” and
The display shows the number of faults stored or “No fault found” . X faults found
If no fault is stored:
– Press → .
– If one or more faults are stored:
The stored faults are displayed and printed out one after the other.
Once the stored faults are printed, the display reads: Rapid data transmission HELP
Select function XX
– Press 0 and 5 for the function “Clear the fault memory” and
Reading on display: Rapid data transmission →
The fault memory is clear
Note!
The fault memory does not clear if the ignition is switched off be‐
tween “Consult the fault memory” and “Clear the fault memory” .
– Press → .
Select function XX

Arosa 1997 ➤

the entry with the Q key.
Select function XX

– Eliminate the faults emitted using the corresponding fault ta‐
ble: Codes SAE P0 ⇒ page 11 odes SAE P1 ⇒ page 41
2.1.2 Automatic test cycle

When doing test and installation work, the other control units can
also detect problems, e.g. detached connectors. Therefore, once
work is finished, consult and clear the fault memories of all the
control units, as follows:
– Press 0 twice to enter the address code “Automatic verifica‐
tion” and confirm the entry with the Q key. The -V.A.G. 1551-
emits successively all known address codes.
If a control unit responds with its identification, the display shows
the number of faults found or emits the message “no fault found” .
Possible system faults stored are displayed and printed out suc‐
cessively. Then the -V.A.G. 1551- sends the following address
code.
The automatic verification has ended when the display shows the Rapid data transmission HELP
following: Enter address code XX
– Clear all the fault memories and then road test the vehicle.
met:
♦ The coolant temperature must exceed 80 °C
♦ Once the temperature has been reached, the following load
states must be reached several times idling half load full load
deceleration
♦ At full load revs must exceed 3.500 rpm
– Re-consult the fault memories of all the control units via the
“Automatic test cycle” .
If no fault is stored: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press → . respect to the correctness of information in this document. Copyright by SEAT S.A.

Select function XX

2.2 Fault table: codes SAE P0

Indications:
♦ The fault code table is ordered by codes SAE and V.A.G.
♦ There is also the EPC warning light in the instrument panel
which warns of the faults related to the electronic accelerator
♦ Explanations about fault types (e.g.: “Open circuit/short circuit
to earth” ): ⇒ Instructions for use of the fault reader
2. Fault memory 11
Arosa 1997 ➤
♦ If faulty components are indicated: “First test the wiring and

connectors of the components and the earth wiring of the sys‐
tem, following the wiring diagram. This is especially valid when
the faults are identified as” sporadic" (SP)
♦ Clear the fault memory after eliminating the existing faults
⇒ page 8 .
-V.A.G. 1551- printer output, e.g.:
16497 P0113 035 Intake air temp. sender -G42- Signal very high
Sporadic fault
Explanation:
♦ 16497 = fault index
♦ P0113 = supplementary index (for now, only for USA)
♦ 030 = number representing fault type
♦ Intake air temperature sender -G42- = faulty current circuit or
faulty component
♦ Signal very high = text indicating the fault type
♦ Sporadic fault = the fault does not occur always, e.g. a loose
contact
Fault code Fault description text
SAE V.A.G.
P0106 16490 Intake manifold pressure/air pressure ⇒ -G71- / -F96- , signal very high – Test th
⇒ pag
P0107 16491 Intake manifold pressure/air pressure ⇒ -G71- / -F96- , signal very low
P0108 16492 Intake manifold pressure/air pressure ⇒ -G71- / -F96- , signal very high
P0112 16496 Intakepermitted
air temperature sender
unless authorised by SEAT -G42-
S.A. SEAT, S.A
signal very
does not low or accept any liability with
guarantee – Test th
⇒ pag
P0113 16497 Intake air temperature sender -G42- , signal very high
P0116 16500 Coolant temperature sender -G62- , signal not plausible – Test th
⇒ pag
P0117 16501 Coolant temperature sender -G62- , signal very low – Test th
system
Coola
P0118 16502 Coolant temperature sender -G62- , signal very high

SAE V.A.G.
P0130 16514 Bank 1 probe 1, Fault in the electrical circuit – Test th
lambd
P0131 16515 Bank 1 probe 1, voltage insufficient – Test th
⇒ pag
P0132 16516 Bank 1 probe 1, voltage excessive
P0133 16517 Bank 1 probe 1, signal very slow
P0134 16518 Bank 1 probe 1, inactive
P0135 16519 Bank 1 probe 1, heating circuit electrical fault
P0136 16520 Bank 1 probe 2, fault in the electrical circuit – Test th
probe
P0137 16521 Bank 1 probe 2, voltage insufficient – Test th
lambd
P0138 16522 Bank 1 probe 2, voltage excessive – Test th
probe

Arosa 1997 ➤
P0140 16524 Bank 1 probe 2, inactive
Fault code Description of the fault

SAE V.A.G.
P0170 16554 Cyl. bank 1, fuel quantity adjuster, faulty operation –
–
–

SAE V.A.G.
P0171 16555 Bank 1, Fuel dosing system, system very lean –
–
–

SAE V.A.G.
P0172 16556 Bank 1, Fuel dosing system, system very rich –
–
–

SAE V.A.G.
P0300 16684 Combustion fault found –
P0301 16685 Cyl. 1, combustion fault found –
P0302 16686 Cyl. 2, combustion fault found –
P0303 16687 Cyl. 3, combustion fault found
P0304 16688 Cyl. 4, combustion fault found

SAE V.A.G.
P0321 16705 Engine revs sender -G28- , signal not plausible –
P0322 16706 Engine revs sender -G28- , without signal
2. Fault memory 13
Arosa 1997 ➤
P0325 16709 Knock sensor 1 -G61- , fault in the electrical circuit – Test th
P0326 16710 Knock sensor 1 -G61- , signal not plausible
P0327 16711 Knock sensor 1 -G61- , signal very low
P0328 16712 Knock sensor 1 -G61- , signal very high
P0341 16725 Camshaft position sensor -G40- , signal not plausible – Test th
P0342 16726 Camshaft position sensor -G40- , signal very low
P0343 16727 Camshaft position sensor -G40- , signal very high

SAE V.A.G.
P0401 16785 Protected
Exhaust recirculation system, insufficient flow – Test th
⇒ pag
P0402 16786 Exhaust recirculation system, excessive flow
P0420 16804 Bank 1, Catalyst system, faulty performance – Test th

lambd
– Test th
26 ; Ex
installi

SAE V.A.G.
P0441 16825 Fuel tank breather system, faulty flow – Test h
tank to
20 ; A
charco
P0461 16845 Fuel level signal, signal not plausible – Test th
⇒ Cur
and Fi
P0501 16885 Vehicle speed signal, signal not plausible – Test th

SAE V.A.G.
P0532 16916 AC pressure sensor, signal very low – Test -G
ditioni
P0533 16917 AC pressure sensor, signal very high
P0562 16946 Voltage supply, insufficient voltage – How to
age su
P0563 16947 Voltage supply, excessive voltage
P0571 16955 Brake light switch, signal not plausible – Test th
⇒ pag
P0604 16988 Control unit faulty – Repla
⇒ pag
P0605 16989 Control unit faulty
2.3 Fault table: codes SAE P1

Indications:
♦ The fault code table is ordered by codes SAE and V.A.G.

Arosa 1997 ➤
♦ Once the fault has been eliminated, clear the memory

⇒ page 8
SAE V.A.G.
P1102 17510 Bank 1, probe 1 heating circuit, short circuit to positive –
P1105 17513 Bank 1, probe 2 heating circuit, short circuit to positive –
P1112 17520 Lambda control bank 1 system very rich –
P1115 17523 Bank 1, probe 1 heating circuit, short circuit to earth –
P1116 17524 Bank 1, probe 1 heating circuit open circuit

P1117 17525 Bank 1, probe 2 heating circuit, short circuit to earth –
P1118 17526 Bank 1, probe 2 heating circuit open circuit

SAE V.A.G.
P1136 17544 Bank 1, mixture self-adaptation (addit.) system very lean –
–
–
Note!
addit. = additional means that the fault is only noticed at idle.

SAE V.A.G.
P1151 17559 Bank 1, mixture self-adaptation range 1, below lean limit –
–
–
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with –

SAE V.A.G.
2. Fault memory 15
Arosa 1997 ➤
P0151 17559 From ⇒ page 14 – Test th

Cyl. bank 1, mix self-adaptation range 1, below lean limit Rep. G
– Test th
age: ⇒
system
– Test th
regula
– Test th
da reg

SAE V.A.G.
P1152 17560 Bank 1, mixture self-adaptation range 2, below lean limit – Test th
ing pre
– Test th
– Test th
testing
– Test th
⇒ pag
– Test th
26 ; Ex
installi

SAEProtected byV.A.G.
P1152 17560
permitted unless authorised by From
SEAT S.A. ⇒SEAT
page S.A1does not guarantee or accept any liability with – Test th
Bank 1, mix self-adaptation range 2, below lean limit
Rep. G
– Test th
age: ⇒
system
– Test th
regula
– Test th
da reg

SAE V.A.G.
P1155 17563 Intake manifold pressure sender -G71- , short circuit to positive14) – Test th
⇒ pag
P1156 17564 Intake manifold pressure sender -G71- , open circuit/short circuit to earth14)
P1157 17565 Intake manifold pressure sender -G71- , voltage supply14)
P1158 17566 Intake manifold pressure sender -G71- , signal not plausible14)

SAE V.A.G.
P1165 17573 Bank 1, mixture self-adaptation range 1, above rich limit – Test th
ing pre
– Test th
– Test th
testing

Arosa 1997 ➤

SAE V.A.G.
P1165 17573 From ⇒ page 1 –
Cyl. bank 1, mix self-adaptation range 1, above enrichment limit
–

SAE V.A.G.
P1166 17574 Bank 1, mixture self-adaptation range 2, above rich limit –
–
–

SAE V.A.G.
P1166 17574 From ⇒permitted
page 1 unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Cyl. bank 1, respect
mix self-adaptation range 2,
to the correctness of information above
in this enrichment
document. limitS.A.
Copyright by SEAT

SAE V.A.G.
P1171 17579 Throttle valve control angle 2 sender -G188- , signal not plausible5) –
P1172 17580 Throttle valve control angle 2 sender -G188- , signal very low5)
P1173 17581 Throttle valve control angle 2 sender -G188- , signal very high5)
5) When this fault appears, the engine control unit lights the EPC warning light in the instrument panel. Meaning of the EPC warning light
⇒ page 2 .
2. Fault memory 17
Arosa 1997 ➤

SAE V.A.G.
P1174 17582 Bank 1, fuel dosing system, discrepancies in injection timing – Test th
ing pre
– Test th
– Test th
testing
– Test th
⇒ pag
– Test th
26 ; Ex
installi

SAE V.A.G.
P1174 17582 From ⇒ page 1 Test
Cyl. bank 1, fuel quantity adjuster, injection timing out of phase
Rep. G
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with – Test th
Gr. 20
– Test th
regula
– Test th
da reg

SAE V.A.G.
P1176 17584 Cyl. bank 1, post-catalyst lambda regulation, regulation limit reached – Test th
air) ⇒
– Test th
da reg
– Test th
⇒ pag

SAE V.A.G.
P1178 17586 Lineal lambda probe/pump current, open circuit – Test th
lambd
P1179 17587 Lineal lambda probe/pump current, short circuit to earth
P1180 17588 Lineal lambda probe/pump current, short circuit to positive – Test th
⇒ pag
P1181 17589 Lineal lambda probe/reference voltage interruption – Test th
regula
P1182 17590 Lineal lambda probe/reference voltage short circuit to earth – Test th
⇒ pag
P1183 17591 Lineal lambda probe/reference voltage short circuit to positive – Test th
⇒ pag
P1190 17598 Lineal lambda probe/reference voltage implausible – Test th
P1196 17604 Cyl. bank 1, probe 2, heating circuit electrical fault – Test th
⇒ pag

Arosa 1997 ➤
P1198 17606 Bank 1 - probe 2, heating circuit electrical fault

P1213 17621 Injector cyl. 1 -N30- , short circuit to positive –
P1214 17622 Injector cyl. 2 -N30- , short circuit to positive

SAE V.A.G.
P1237 17645 Injector cyl. 1 -N30- , open circuit –
P1238 17646 Injector cyl. 2 -N31- , open circuit
P1253 17661 Fuel consumption signal, short circuit to earth –

SAE V.A.G.
P1341 17749 Ignition output 1, short circuit to earth –
P1342 17750 Ignition output 1, short circuit to positive –
P1343 17751 Ignition output 2, short circuit to earth
P1344 17752 Ignition output 2, short circuit to positive
P1348 17756 Ignition output 1, open circuit
P1349 17757 Ignition output 2, open circuit
P1386 17794 Control unit faulty6) –
P1388 17796 Control unit faulty6) –

6) When this fault appears, the engine control unit lights the EPC warning light in the instrument panel. Meaning of the EPC warning lamp
⇒ page 2 .

SAE V.A.G.
P1398 17806 TD Engine revs signal, short circuit to earth –
P1399 17807 TD Engine revs signal, short circuit to positive
P1401 17809 Exhaust recirculation valve -N18- , short circuit to earth –
P1402 17810 Exhaust recirculation valve -N18- , short circuit to positive

P1403 17811 Exhaust
Protected by copyright. Copyingrecirculation system,
for private or commercial control
purposes, in part difference
or in whole, is not

SAE V.A.G.
P1410 17818 Fuel tank breather valve -N80- , short circuit to positive –
P1425 17833 Fuel tank breather valve -N80- , short circuit to earth
2. Fault memory 19
Arosa 1997 ➤
P1426 17834 Fuel tank breather valve -N80- , open circuit

SAE V.A.G.
P1439 17847 Exhaust recirculation potentiometer -G212- , error in basic settings – Test th
⇒ pag
26 ; E
P1440 17848 Exhaust recirculation valve -N18- , open circuit
P1442 17850 Exhaust recirculation potentiometer -G212- , signal very high
P1443 17851 Exhaust recirculation potentiometer -G212- , signal very low
P1500 17908 Fuel pump relay -J17- , fault in the electrical circuit – Test th
grams
tions
P1501 17909 Fuel pump relay -J17- , short circuit to earth
P1502 17910 Fuel pump relay -J17- , short circuit to positive

SAE V.A.G.
P1504 17912 Intake circuit, leak found – Test th
air) ⇒
– Test th
Rep. G
– Test a
valve 1
system
1: test
– Test th

SAE V.A.G.
P1541 17949 Fuel pump relay -J17- , open circuit – Test th
grams
tions
P1542 17950 Throttle valve activation angle -G187- , signal not plausible7) – Test th
P1543 17951 Throttle valve activation angle -G187- , signal very low7)
P1544 17952 Throttle valve activation angle -G187- , signal very high7)
P1545 17953 Throttle valve control, functioning faulty 7)
⇒ page 2 .

SAE V.A.G.
P1553 17961 Altitude sender signal/intake manifold pressure, implausible ratio8) ,9) – Test th
⇒ pag
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with – Test th
respect to the correctness of information in this document. Copyright by SEAT S.A. air) ⇒
– Test th
Rep. G

Arosa 1997 ➤
–
8) When this fault appears, the engine control unit lights up the EPC warning lamp in the instrument panel. Meaning of EPC warning lamp
⇒ page 2 .
9) After eliminating this fault, let the engine idle for at least 5 minutes to ensure correct self-adaptation.

SAE V.A.G.
P1554 17962 Throttle valve control unit -J338- , conditions for basic settings, not met10) –
P1559 17967 Throttle valve control unit -J338- , error in basic settings10)
P1560 17968 Maximum engine revs exceeded –
P1564 17972 Throttle valve control unit -J338- , low voltage during the basic settings10) –
P1565 17973 Throttle valve control unit -J338- , lower limit not reached10) –
⇒ page 2 .

SAE V.A.G.
P1570 17978unlessControl unit blocked –
P1581 17989 Throttle valve control unit -J338- , basic settings not carried out –
P1602 18010 Voltage supply at terminal 30, insufficient voltage –

P1603 18011 Control unit faulty –
P1611 18019 Requirement fault lamp ON, short circuit to earth –
P1612 18020 Engine control unit, encoding faulty

P1613 18021 Requirement fault lamp ON, open circuit/short circuit to positive
P1623 18031 Engine unit data bus, no signal –
⇒ page 2 .

SAE V.A.G.
P1630 18038 Accelerator position sender -G79- , signal very low12) –
P1631 18039 Accelerator position sender -G79- , signal very high12)

P1633 18041 Accelerator position sender 2 -G185- , signal very low12)
P1634 18042 Accelerator position sender 2 -G185- , signal very high12)
P1639 18047 Accelerator position sender 1/2 -G79- + -G185- , signal not plausible 12)
P1636 18044 Engine unit data bus no message from airbag CU –
2. Fault memory 21
Arosa 1997 ➤
P1640 18048 Control unit faulty – Repla

⇒ pag
P1648 18056 Engine unit data bus faulty – Test d
grams
tions
P1649 18057 Engine unit data bus no message from ABS CU
⇒ page 2 .

SAE V.A.G.
P1656 18064 Air conditioning input/output, short circuit to earth – Test a
diagra
cation
P1657 18065unlessAir conditioning
by SEAT S.A.input/output,
SEAT S.A does notshort circuit toanypositive
permitted authorised guarantee or accept liability with
P1677 18085 Electronic accelerator control warning light -K132- , short circuit to positive13) – Test th
engine
Accele
P1678 18086 Electronic accelerator control warning light -K132- , short circuit to earth13)
P1679 18087 Electronic accelerator control warning light -K132- , open circuit13)
P1690 18098 Self-diagnosis warning lamp -K83- , fault in electrical circuit – Test th
⇒ pag
P1691 18099 Self-diagnosis warning lamp -K83- , open circuit
P1692 18100 Self-diagnosis warning lamp -K83- , short circuit to earth
P1693 18101 Self-diagnosis warning lamp -K83- , short circuit to positive
⇒ page 2 .
14) Hier hat der Redakteur keine Fussnote eingegeben.
2.4 Conformity code

2.5 Functioning
The conformity code is an 8-digit numerical code that indicates
the state of diagnostics relevant to exhaust emissions.
When the diagnosis of a system (for example, the catalyst) has
been carried out successfully, the digit corresponding to the nu‐
merical code changes from 1 to 0.
Diagnoses are carried out periodically under normal driving con‐
ditions. After repairing a system relevant to exhaust emissions,
the conformity code should be generated to ensure the correct
operation of the systems in question. If a fault is detected during
diagnosis, it is stored in the memory.
The conformity code is cleared each time the fault memory is
cleared or the voltage supply is interrupted.
2.6 Conformity code: consulting
2.6.1 Engine: AUB


Arosa 1997 ➤

1552- with lead -V.A.G. 1551/3B-
2.6.2 Work sequence

– Connect the -V.A.G. 1551- ( -V.A.G. 1552- ). Switch on the
ignition and enter “address code” 01 to select the engine con‐
trol unit. (Fault reader: Connecting and selecting the engine
control unit ⇒ page 4 .)
The display reads: Rapid data transmission HELP
Select function XX
– Press 1 and 5 for the function “Conformity code” and press

If all affected systems have passed the diagnosis with the result
“OK” , this message appears:
The display reads: Conformity code
00000000 - Test complete
– Press → .
If the display reads: Conformity code
00101101 - Test incomplete
One of the diagnoses has had a negative result:

– Press → .
– Generate the conformity code ⇒ page 23 .
Meaning ofunless
permitted the 8-digit
authorisednumerical block
by SEAT S.A. SEAT S.A for
doesthe conformity
not guarantee code
All digits must be “0” before generating the conformity code
1 2 3 4 5 6 7 8 Diagnostic function
0 Catalyst
0 Catalyst heating (at this time there is no diagnosis/always “0” )
0 Activated charcoal filter system (filter deaeration system)
0 Secondary air system (does not exist/always “0” )
0 Air conditioning(at this time there is no diagnosis/always “0” )
0 Lambda probes
0 Lambda probe heating
0 Exhaust gas recirculation
2.7 Conformity codes: generating

1552- with lead -V.A.G. 1551/3B-
2. Fault memory 23
Arosa 1997 ➤
♦ Pedal depressor -V.A.G. 1788/10-

• All fuses OK.
• Vehicle stopped.
• On vehicles with air conditioner, the AC must be off.
• Exhaust system, airtight between the catalyst and cylinder‐
head.
• Coolant temperature, 80 °C minimum ⇒ display group 04, dis‐
play field 3.
• Intake air temperature below 60 °C ⇒ display group 04, display
field 4.
2.7.2 Work sequence Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect the -V.A.G. 1551- ( -V.A.G. 1552- ). Switchrespect
on theto the correctness of information in this document. Copyright by SEAT S.A.

2.7.3 Operation 1: consult the fault memory

Select function XX
– Press 0 and 2 for the function “consult fault memory” and

The display shows the number of faults stored or “No fault found” . X faults found
If a fault is stored:
– Eliminate faults on the print out, using the fault table:
Codes SAE P0 ⇒ page 11
Codes SAE P1 ⇒ page 14
If no fault is stored:
– Press → .
2.7.4 Operation 2: clear the fault memory

Select function XX
– Press 0 and 5 for the function “Clear fault memory” and press

Arosa 1997 ➤
Note!
The conformity code returns to zero and is cleared each time the
fault memory is cleared.
The display reads: Rapid data transmission →

The fault memory is clear
Note!
The fault memory will not clear if the ignition is switched off be‐
tween consulting and clearing the fault memory.
– Press → .
Note!
Do not shut off the engine during the following operations.
2.7.5 Operation 3: diagnosis of the activated

charcoal filter system (filter deaeration
system)
The display reads: respect to the correctness of information in this document. Copyright by SEAT Rapid
S.A. data transmission HELP
Select function XX
The display reads: Basic settings HELP

– Press 0 , 7 and 0 for the function “Display group number 70”

The display reads: (1...4 = display fields) System in basic settings 70 →
1 2 3 4
– When the engine control unit starts the diagnosis, the mes‐
sage in field 4 changes from “Test OFF” to “Test ON” .
– Let the engine idle until display field 4 reads:
Target value: “VDD OK”
If the described message does not appear:
– Consult the fault memory ⇒ page 10 .
– Give about three throttle bursts and repeat the diagnosis.
If the described message appears:
– Press C .
2.7.6 Operation 4: lambda probe ageing diag‐

nosis (period monitoring)

2. Fault memory 25
Arosa 1997 ➤

1 2 3 4
– Give two throttle bursts, raising revs to over 5000/min.

– With the -V.A.G. 1788/10- adjust engine revs to 1500...3900/
min.
– Hold these revs until the message in display field 4 changes
from “Test OFF” to “Test ON” .
– Let the engine run at these revs until display field 4 shows the
Target value “F1-S1 OK”
– Press → .
Select function XX
– Press 0 and 8 for the function “Read measurement value

block” and press Q to confirm the entry.
The display reads: Read measurement value block HELP

The display reads: (1...2 = display fields) Read measurement value block 30 →
1 2
– Test the operative state of the pre-catalyst lambda regulation

(display field 1):
Target value: 1 1 1 (meaning ⇒ page 43 )
– Test the operative state of the post-catalyst lambda regulation
(display field 2):
Target value: 1 1 0 (meaning ⇒ page 43 )
Note!
The third bit in display field 2 only changes to 1 when the engine
is running at half load (2500-4000/min).
– Press → .
2.7.7 Operation 5: catalyst diagnosis
Note!
This diagnosis ends only if there are no faults related to the lamb‐
da probes and the activated charcoal filter system.

Select function XX


Arosa 1997 ➤
– Press 0 , 4 and 6 for “Display group number 46” and press


1 2 3 4
– Hold revs at 1500...3900/min until the message in display field

4 changes from “Test OFF” to “Test ON” . The catalyst tem‐
perature in display field 2 must be 300 °C minimum.
– Hold revs at 1500...3900/min until display field 4 shows the
target value “Cat F1 OK” .
Note!
It may take a few minutes for the message to change from “Test
ON” to “Cat F1 OK” .

– Press C .
2.7.8 Operation 6: exhaust gas recirculation

system diagnosis
– Press 0 , 7 and 5 for the function
respect to“Display group
the correctness number
of information 75”
1 2 3 4
– Give 5 throttle bursts to maximum revs.

When the engine control unit starts the diagnosis, the message
in field 4 changes from “Test OFF” to “Test ON” .
– Let the engine idle until display field 4 reads:
Target value: “Sys. OK” .
If the described message does not appear:
If the described message appears:
– Press → .
– Consult the conformity code ⇒ page 22 .
2. Fault memory 27
Arosa 1997 ➤
3 Final control diagnosis
3.1 Final control diagnosis: carrying out

During the final control diagnosis the following components are
activated in the order shown:
1 - Throttle valve activator -V60-
2 - Activated charcoal filter solenoid valve 1 -N80-
3 - Exhaust recirculation valve -N18-
4 - Engine revs signal
5 - Fuel pump relay -J17-
6 - Air conditioning motor/compressor electrical connection
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
♦ Diode light -V.A.G. 1527-
♦ Wiring diagram

• Fuses 1, 2, 3, 4, 8, 9, 10, 26, 27 and 32 OK.
must be off.
• Throttle valve potentiometer -G69- , OK.
3.1.2 Test conditions for vehicles with air con‐

ditioning
• The vehicle is atrespect
ambient temperature
to the correctness (over
of information +15
in this °C). Copyright by SEAT S.A.
document.
• Air conditioning on.

• Minimum temperature and maximum blower speed, preselec‐
ted.

Arosa 1997 ➤
Note!
♦ The final control diagnosis can only be carried out with the
engine off and the ignition on.
♦ The final control diagnosis is interrupted when the engine is
started or a turnover pulse is detected.
♦ During the final control diagnosis, the different activators re‐
main activated until you go on to the following activator press‐
ing →.
♦ The activators are tested by sound or by touch.
3.1.3 Work sequence

ignition and enter “address code” 01, to select the engine
electronics control unit. (Fault reader: connecting and select‐
ing the engine electronics control unit ⇒ page 3 .)
Select function XX
– Operate the fault reader taking into account the reading on the
display.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press 0 and 3 to
respect forthethe function
correctness “Final incontrol
of information diagnosis”
this document. . SEAT S.A.
Copyright by
Reading on display: Rapid data transmission Q

03 - Final control diagnosis
3.1.4 Activate the throttle valve activator -

V60- :
– Confirm the entry with the Q key.
Reading on display: Final control diagnosis →
Throttle valve activator -V60
The activator should open and close the throttle valve until the
key → is pressed to activate the following activator.
If the throttle valve activator does not move:
– Test the throttle valve activator ⇒ page 70 , Throttle valve
control unit: testing
3.1.5 Activate activated charcoal filter sole‐

noid valve 1 -N80- :
– Press → .
Act. char. filter solenoid v. 1 -N80
Activated charcoal filter solenoid valve 1 (right suspension turret)

should click until the key → is pressed to activate the following
activator.
– Detach the activated charcoal filter hose from the solenoid
valve.
– Connect the auxiliary hose to the free connection of the valve.
– During the final control diagnosis, blow through the auxiliary
hose (in the direction of the throttle valve control unit). The
valve should open and close
If the solenoid valve does not click:
3. Final control diagnosis 29

Arosa 1997 ➤
Continue the test ⇒ page 6 .
3.1.6 Activate the exhaust recirculation valve

-N18- :
– Press → .
Exhaust recirculation valve -N18
The exhaust recirculation valve (engine compartment, to the left,

on the cylinderhead) should click until you press the button → to
activate the next actuator.
If the exhaust recirculation valve does not click:
Continue the test ⇒ page 6 .
3.1.7 Indicate the engine revs signal:
Note!
This test is only possible on vehicles equipped with a rev counter.

On the vehicles without rev counter, the final control diagnosis
can be continued by pressing the key → , when the following
message appears.
– Press → .
Engine revs signal
The rev counter should read approx. 3000 rpm until the key → is
pressed to activate the following activator.
If no there is no reading: respect to the correctness of information in this document. Copyright by SEAT S.A.
– Test the wiring to the rev counter Rev signal: testing

⇒ page 111
3.1.8 Activate the fuel pump relay -J17-

– Press → .
Fuel pump relay -J17
The fuel pump relay (on the relay holder plate) should click until
you press the button → to activate the next actuator.
Note!
During fuel pump relay activation you should hear the fuel pump
start up intermittently. Do not activate the door contact switch
during the test.
If the relay does not click:

– Test the fuel pump relay: ⇒ Current flow diagrams, Electrical

Arosa 1997 ➤
3.1.9 Test the electrical connection to the air

conditioning system:
Note!
The test is only for vehicles equipped with air conditioning. In the
case of vehicles without air conditioning, you can end the final
control diagnosis by pressing the key → when the following mes‐
sage appears.

AC engine/compressor electr. connection
The magnetic connection of the air conditioning compressor

should click until the key → is pressed to end the final control
diagnosis.
If the magnetic connection does not click:
– Test the wiring from/to the air conditioning
Protected bysystem
⇒ page 70 . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
If the magnetic connection clicks:
– Press → .
Select function XX

3.1.10 Continuation of the test if the activated

charcoal filter solenoid valve 1 does not
click:
– Detach the connector -1- of the solenoid valve -2- -N80- and
connect the diode light -V.A.G. 1527- to the detached con‐
nector, using the auxiliary leads of the -V.A.G. 1594- . The
diode light should flash (brighten and dim)
The diode light flashes:
– Continue the final control diagnosis until the end.
– Replace solenoid valve 1 -N80- ⇒ Rep. Gr. 20 ; Activated
charcoal filter system Activated charcoal filter system compo‐
nents: repairing
The diode light does not flash:

Arosa 1997 ➤
– Connect test box -V.A.G. 1598/31- to the wiring harness of the

control unit, without connecting the engine control unit.
– Test the wiring for open circuits between test box female con‐
tact 64+ double-contact connector 2, following the wiring dia‐
gram. Wire resistance: 1.5 Ω max.
– Also test the wiring for short circuits to battery positive and
earth. Target value: ∞ Ω
– Test for open circuits in the wiring between double-contact
connector 1 and the fuel pump relay -J17- , following the wiring
diagram. Wire resistance: 1.5 Ω max.
If no wiring fault is found:
– Replace the engine control unit ⇒ page 104 .
3.1.11 Continuation of the test if the exhaust

recirculation valve does not click:
– Remove the double connector from the exhaust recirculation
valve -N18- -arrow- (at the camshaft housing, to the left).
The diode light flashes:
– Connect the diode light -V.A.G. 1527- to the removed con‐

nector, using the auxiliary leads of the -V.A.G. 1594- and
between contacts 1 + 5 test: The diode light should flash
(brighten and dim)
– Replace the exhaust recirculation valveof -N18-
respect to the correctness :⇒
information Rep.
in this Gr. Copyright by SEAT S.A.
document.
26 ; Exhaust recirculation system: Exhaust recirculation sys‐
tem components: repairing
The diode light does not flash:

Arosa 1997 ➤

contact 114 + 6-contacts connector, contact 5, follow the wir‐
ing diagram. Wire resistance: 1.5 Ω max.
– Also test the wiring for short circuits to battery
Protected positive
by copyright. Copyingand
earth. Target value: ∞ Ω permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Test for open circuits in the wiring between contact 1 of the 6-
contacts connector and the fuel pump relay -J17- , following
the wiring diagram. Wire resistance: 1.5 Ω max.
If no wiring fault is found:

Arosa 1997 ➤
4 Measured value block
4.1 Safety measures

If test and measurement units is to be used during the road test,
proceed as follows:
♦ Always install the test and measurement units in the rear seat
to be operated from there by a second mechanic.
Operating the test and measurement units from the front passen‐
ger seat could result in injury should the airbag be activated in the
4.2 Read measured value block

The measurement values in the functions “Read measured value
block” and “Basic settings” are described in the sections dealing
with the testing of the different components. The following table
is only intended as a summary.
1552- with lead -V.A.G. 1551/3B-

must be off.
• If the vehicle has air conditioning, it must be off.
• There should be no faults stored in the memory ⇒ page 8 ,
Fault memory: consulting and clearing.
play field 3.
4.2.2 Work sequence

– Connect the -V.A.G. 1551- ( -V.A.G. 1552- ). Start the engine
and enter “address
Protected code”
by copyright. Copying01, select
for private the engine
or commercial electronics
control unit.unless
permitted (Fault reader:
authorised connecting
by SEAT S.A. SEAT S.A and
doesselecting
not guaranteethe engine
electronics control
respect unit ⇒ page
to the correctness 3 .) in this document. Copyright by SEAT S.A.
of information

Select function XX

and confirm the entry with the Q key.
Reading on display: Read measured value block HELP
Enter display group no. XXX
– Select the desired display group number.
Note!
Display group 1 is only an example for showing how to proceed.
– Press 0 , 0 and 1 for “Display group number” and confirm the

Reading on display: (1...4 = display fields) Read measured value block 1 →

Arosa 1997 ➤
Note!
Proceed as follows to go on to another display group:
Display group -V.A.G. 1551- -V.A.G. 1552-

above Press 3 Press ↑
below Press 1 Press ↓
skip Press C Press C
– If the target values are reached in the display fields, Press

→ .

Select function XX

Note!
The measured value blocks not described in this section, are cur‐
rently only meant for Development and Production. The values
displayed have no significance for fault finding in Technical As‐
sistance.
4. Measured value block 35

Arosa 1997 ➤
5 Analysis measured value block, display groups 0...6 -basic functions-

Display group 1 -basic functions-
• Engine idling
Read measured value block 1 → ◂ Message on the display

xxxx rpm xxx °C x.xxx % xxxxxxxx
1 2 3 ◂ Display fields
4 Tar
Conditions for basic settings 11
Lambda control value -1
Coolant temperature 80
Engine revs (idling revs) 640
Meaning of the 8-digit numerical block, display field 4 -conditions
of settings-
Meaning if digit = 1
1 2 3 4 5 6 7 8 Meaning
1 Coolant temperature above 80 °C
1 Revs less than 2000 rpm
1 Throttle valve closed
1 Lambda control, OK
1 Idle switch OFF
1 Air conditioning compressor off
1 Catalyst preheating (above 300 °C)
1 No fault found via the self-diagnosis
Analysis display group 1, display field 1 - engine revs (idling revs)
Display -V.A.G. 1551-

less than 640 rpm ♦ Throttle valve control unit, jammed
♦ Air filter very dirty
more than 930 rpm ♦ Significant amount of infiltrated air (not compensable with idle stabilisation)
♦ Throttle valve control unit, jammed or faulty
Analysis display group 1, unless
permitted display fieldby2SEAT
authorised - coolant temperature

less than 80 °C ♦ Engine very cold
♦ Coolant temperature sender or wiring to engine control unit
over 110 °C ♦ Radiator dirty
♦ Radiator fan does not work
♦ Thermostat faulty

Arosa 1997 ➤

• Engine idling

xxxx rpm xxx.x % x.x ms xxx mbar
1 2 3 4 ◂ Display fields
Intake manifold pressure
Injection timing
Engine load
Engine revs (idling revs)
Analysis display group 2, display field 3 - injection timing

less than 2.0 ms ♦ Significant fuel flow from the activated charcoal filter system
♦ There are incorrect injectors installed with greater flow
over 5.0 ms ♦ High engine load due to electrical consumers, air conditioning or power steer
Analysis display group 2, display field 4 - intake manifold pressure

less than 240 mbar ♦ Significant quantity of infiltrated air between the intake manifold and the air fil
over 480 mbar ♦ Engine subject to load from supplementary mechanical groups

• Engine idling
Read measur. value
permitted unless block
authorised 3 S.A. SEAT S.A does not guarantee or accept
by SEAT → any liability◂with
The display reads
xxxx/minrespect to thexxx mbar xxx.x % xx.x° before
TDC
Ignition angle
Throttle valve angle (potentiometer 1 -G187- )
Intake manifold pressure

• Engine idling
Read measur. value block 4 → ◂ The display reads

xxxx/min xx.xxx V xxx.x °C xxx.x °C
5. Analysis measured value block, display groups 0...6 -basic functions- 37

Arosa 1997 ➤
Intake air temperature -40.

Engine control unit voltage supply 12.0
Analysis display group 4, display field 2 - voltage supply of the
engine control unit

less than 12.000 V ♦ Alternator faulty, battery very low
♦ Battery subject to high load shortly after start-up due to high current load and suppl
♦ Contact resistance in voltage supply, or at the earth connection of the engine contro
♦ Electrical consumption when the ignition is off
over 15.000 V ♦ Alternator voltage regulator, faulty
♦ Excess voltage due to start-up with auxiliary leads or quick charger
Analysis display group 4,Protected

display by field 3 -Copying
copyright. coolant temperature

less than 80.0 °C ♦ Engine very cold
over 110.0 °C ♦ Radiator dirty
♦ Radiator fan does not work
♦ Thermostat faulty
-40 °C constant ♦ Open circuit in wiring
120 °C constant ♦ Short circuit between wires 1 and 3
Analysis display group 4, display field 4 - intake air temperature

-40.0 °C constant ♦ Open circuit or short circuit to positive
120.0 °C constant ♦ Short circuit to earth

• Engine idling

xxxx rpm xxx % xxx km/h text
1 2 3 4 ◂ Display fields Tar

Arosa 1997 ➤
Engine load state (idling, half load, enrichment,

deceleration, full load)
Running speed
Engine load

• Engine idling

xxxx rpm xxx.x % xxx.x °C xx.x %
Correction factor depending on altitude
Intake air temperature
Engine load
Note!
♦ Note on thepermitted
display field
unless 3: by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
♦ The whole temperature range is displayed as the target value.
The value displayed should be higher than ambient tempera‐
ture.
5. Analysis measured value block, display groups 0...6 -basic functions- 39

Arosa 1997 ➤
6 Analysis measured value block, display groups 10...29 -ignition-

Display group 10 -ignition-
• Engine idling

xxxx/min xxx.x % xxx.x % xx.x° before TDC
Ignition angle 0...
Throttle valve angle (potentiometer 1 -G187- )
Engine load
Analysis display group 10, display field 2 - engine load

less than the 10 % ♦ Only lower values can be displayed when decelerating
more than the 20 % ♦ Idling faulty (does not work in all cylinders)
♦ Throttle valve control unit, faulty
♦ Electrical consumers on
♦ Steering wheel to limit
Analysis display group 10, display field 3 - throttle valve angle

over 11 % ♦ Adaptation of engine control unit to throttle valve drive not carried out
♦ Throttle valve potentiometer, in throttle valve drive, faulty
♦ Throttle valve jammed

Display group 14 -ignition- total ignition faults

• Running

xxxx/min xx.x % xxx text
Fault finding (activated, deactivated) ac
Total ignition faults
Engine load 12.0
Engine revs 790.
Analysis display group 14, display field 3 - total ignition faults


Arosa 1997 ➤
more than 0 ♦ Spark plug faulty

♦ Spark plug connector faulty
♦ Ignition coil faulty
♦ Injector faulty
♦ Exhaust gas recirculation valve, jammed
Display group 15 -ignition- fault finding from cyl. 1 to cyl. 3

• Running

xxx xxx xxx text
Fault finding (activated, deactivated)
Ignition faults at cyl. 3
Display group 16 -ignition- fault finding cyl. 4

• Running

xxx -- -- text
Fault finding (activated, deactivated)
Analysis display group 15, display fields 1 to 3 or display group

16, display field 1 - ignition faults from cylinder 1 to cylinder 4
more than 0 ♦ Spark plug faulty
♦ Spark plug connector faulty
♦ Ignition coil faulty
♦ Injector faulty
♦ Exhaust gas recirculation valve, jammed
Display group 22 -ignition- knock control cyl. 1 and cyl. 2

• Running

xxxx/min x.xx % xx.x °KW xx.x °KW
6. Analysis measured value block, display groups 10...29 -ignition- 41

Arosa 1997 ➤
Retarded ignition angle cyl. 2 for knock control 0...14

Retarded ignition angle cyl. 1 knock control 0...14
Engine load 12.0
Engine revs 790.
Display group 23 -ignition- knock control cyl. 3 and cyl. 4

• Running

xxxx/min x.xx % xx.x °KW xx.x °KW
Engine load 12.0
Engine revs 790.
Analysis display group 22/23, display fields 3 and 4 - ignition angle
retardation

All the cylinders above 14° crankshaft ♦ Knock sensor faulty
♦ Connector corroded
♦ Knock sensor, faulty tightening
♦ Accessory engine components, loose
♦ Poor fuel quality
One cylinder clearly diverges from the ♦ Connector corroded

others
♦ Engine faulty
♦ Accessory engine components, loose
Display group 28 -ignition- knock

permittedcontrol
• Running

xxxx/min xx.x % xxx.x °C --
Engine load 12.0
Engine revs 790.

Arosa 1997 ➤
7 Analysis measured value block, display groups 30...49 -lambda con‐

trol-
Display group 30 -lambda control-
• Engine idling

xxx xx.x % --- ---
Post-catalyst lambda control operative state

Pre-catalyst lambda control operative state
Note!
♦ Notes on display field 2:

♦ At half load the third digit changes to 1.
Meaning of the 3-digit numerical block, display fields 1:

Meaning in case of digits
1 2 3 Meaning
1 Lambda control active
1 Lambda probe heating ON
Display group 32 - lambda control - lambda learning values

• Engine idling

xx.x % xx.x %
Pre-catalyst lambda self-adaptive value at half load (multiplicative)

Pre-catalyst lambda self-adaptive value at idling revs (additive)
7. Analysis measured value block, display groups 30...49 -lambda control- 43

Arosa 1997 ➤
Note!
♦ Notes on the display fields 1 and 2:

♦ Low values: the engine runs on an overly rich mixture, thus the
lambda control makes the mixture leaner.
♦ High values: the engine runs on an overly lean mixture, thus
the lambda control enriches the mixture.
♦ When the control unit receives no voltage, all the self-adaptive
values are restarted.
♦ add = additive - the fault (e.g., infiltrated air) loses influence as
revs are raised. In the case of the self-adaptive additive value,
the injection timing changes according to a fixed magnitude
that does not depend on basic ignition timing.
♦ mul = multiplicative - the fault (e.g. faulty injector) loses influ‐
ence as revs are raised. In the case of the self-adaptive
multiplicative value there is a percentile change in the injection
timing that depends on basic ignition timing.
Analysis display group 32, display fields 1 and 2 - lambda self-

adaptive values

Low lambda learning values ♦ Low learning values at idling, with normal self-adaptive values at half load: possibili
♦ Injector leaky
♦ Fuel pressure very high
♦ Solenoid valve 1 for activated charcoal filter always open
♦ Fault in the lambda probe heating or lambda probe is dirty

High lambda ♦ High learning values at idling, with lower self-adaptive value at half load: possibility
self-adaptive values
♦ Injector blocked
♦ Fuel pressure very low
♦ Infiltrated air in the exhaust manifold gasket
♦ Fault in the lambda probe heating or lambda probe is dirty

Display group 33 -lambda regulation- lambda regulation values

• Engine idling

xx.x % x.xxx V -- --
Pre-catalyst lambda probe voltage 0.3

Arosa 1997 ➤
Pre-catalyst lambda regulator
Note!
♦ Note on display field 1:

♦ The value displayed should oscillate around 0.0 %. If a con‐
stant 0.0% is displayed, lambda regulation has switched from
the regulation to the control mode due to a fault in lambda
regulation. Consult the fault memory ⇒ page 10 .
Lambda probe voltage Uλ in mV

A: High lambda probe voltage
♦ Rich mixture (excess fuel or lack of air)
♦ High CO value
B: Low lambda probe voltage
♦ Lean mixture (lack of fuel or excess air)
♦ Low CO value
Analysis display group 33, display field 1 - pre-catalyst lambda

probe
Outside the target range ♦ Negative range: engine very rich, the lambda control reduces the richness of
♦ Positive range: engine very lean, the lambda control enriches the mixture
♦ Infiltrated air
♦ Injector faulty
♦ Self-adaptive lambda values, to limit
Display group 34 - lambda regulation - diagnosis pre-catalyst lambda probe (ageing test via amplitude quality monitorin
– Give two throttle bursts, raising revs to over 5000/min.
• Vehicle stopped, engine running at fast idle

• Control unit is mode 04 - basic settings

xxxx/min xxx.x °C xx.xx s text
4
Result of pre-catalyst lambda probe ageing test
(Test OFF/Test ON/F1-S1 OK/F1-S1 not OK)
Pre-catalyst lambda probe period
Catalyst temperature
Engine revs

Arosa 1997 ➤
Note!
♦ Note on display fields 3 and 4:

♦ The period is the time between two voltage jumps (for exam‐
ple, rich - lean - rich) of the lambda probe and thus indicates
the probe ageing state. If the period exceeds the predeter‐
mined time, display field 4 shows = F1-S1 not OK.
Display group 36 -lambda control- control after the catalyst

• Engine idling

xx.x V text --- ---
Post-catalyst lambda probe voltage 0.000

Analysis display group 36, display field 1 - post-catalyst lambda
probe

constant 1.100 V ♦ Short circuit to positive caused by lambda probe, probe wire, earth wire, engine con
constant between ♦ Open circuit caused by lambda probe, probe wire, earth wire, engine control unit
0.400 V...0.500 V
constant 0.000 V ♦ Short circuit to earth caused by lambda probe, probe wire, earth wire, engine contro
Display group 41 -lambda control- lambda probe heating

• Engine idling

-- text xx Ohm text
Post-catalyst lambda probe heating CfS
CfS
Without
respectvalue for technical
to the correctness assistance
Pre-catalyst lambda probe heating CfS

CfS
Note!
According to the engine load state, the lambda probe heaters are
activated and desactivated; that is in the display fields 2 and 4 the
messages CfS a(d)Ca ON or CfS a(d)Ca ON/CfS a(d)Ca OFF
may appear.
Display group 46 -lambda regulation- catalyst diagnosis (catalytic conversion test)

Arosa 1997 ➤

• Vehicle stopped, engine running at fast idle

xxxx/min xxxx °C xx % text
4
Result of catalytic conversion test (Test OFF/
Test ON/CatF1 OK/CatF1 not OK)
Catalytic conversion measurement value
Catalyst temperature
Engine revs
Note!
♦ Note on display group 46:

♦ Catalytic conversion test conditions: No faults stored in the
memory, engine idling, coolant temperature 60...120 °C, lamb‐
da regulation active and stable.
Display group 99 -lambda control- operative state lambda control

• Engine idling
• Control unit in mode 08 - Read measured value block, lambda control ON

xxxx rpm xxx.x °C x.x % text
Pre-catalyst lambda control operative state
Pre-catalyst lambda probe

Coolant temperature

Arosa 1997 ➤
8 Analysis measured value block, display group 50...69 -rev control-

Display group 50 -rev control- operative states
• Engine idling

xxxx rpm xxxx rpm text text
Operative state of the air conditioning compres‐ Com
sor NO/YES Com
Operative state of the air conditioning A/
A
Engine revs (target value for the idling revs) 7
Engine revs (real value for the idling revs) 640
Note!

♦ The display shows the target engine revs established by the
engine control unit (internal mathematical value of the control
unit).
Note!
♦ Notes on display fields 3 and 4:

♦ On vehicles without air conditioning “Compr. NO” always ap‐
pears.
♦ Test the signals from/to the air conditioning compressor
⇒ page 111 .
Display group 54 -speed control-

• Running
Read measur. value block 54 → ◂ The display reads:

xxxx/min text xxx.x % xxx.x %
Throttle valve angle (potentiometer 1 -G187- ) 0.0.
Accelerator pedal position sender 1 -G79- 0.0.
Engine load state:
Idling, half load, enriching, deceleration, full load
Engine revs 790.
Note!
♦ Note on display fields 1:

♦ From 6600/min The tester stops displaying engine revs.

Arosa 1997 ➤
Note!
♦ Note on display fields 2:

♦ The display shows load state in function of revs or load. Start‐
ing from higher revs with the throttle valve closed, the display
shows “deceleration” only as far as 1450/min; below that value
the message “idling” reappears.
Display group 55 -idling control- idling stabilisation

• Engine idling

xxxx/min xx.x Nm xx.x % xxx
Load states
Adaptive value for idling control: -6.
Protected by copyright. Copying for private or commercial purposes, inAir
partconditioning
or in whole, is not ON
permitted unless authorised by SEAT S.A. SEAT S.A does not guaranteeAir conditioning
or accept OFF
any liability with
Idling control
Display group 56 -speed control- idling stabilisation

• Engine idling

xxxx/min xxxx/min xx.xx Nm xxx
Load states
Idling control
Engine revs (idling revs target value)
Engine revs (idling revs real value)
Meaning of 3-digit numerical block, display field 4 - load states

Meaning if digit = 1
1 2 3 Meaning
1 Air conditioning compressor, on
1 Gear engaged (automatic gearbox)
1 Air conditioning, on
Display group 60 -speed control- electronic accelerator system adaptation

• Ignition on, engine off

xx % xx % x text
8. Analysis measured value block, display group 50...69 -rev control- 49

Arosa 1997 ➤
Adaptation state (ADP. ON/ADP. OK/ADP. ER‐ A

ROR)
Self-adaptation step counter
Throttle valve angle (potentiometer 2 -G188- ) 0
Display group 61 -idling control- idling stabilisation

• Running

xxxx/min -- xxx.x % xxx
Load states
Throttle valve angle (potentiometer 1 -G187- ) 0.
Engine revs 790.
Display group 62 -idling control- electronic accelerator system

Read measur. value block 62 Protected by copyright.→ ◂ The

Copying for private display purposes,
or commercial reads in part or in whole, is not
xx % xx % xx % respect to the xx %
4 Tar
Accelerator pedal position sender 2 -G185- 0.
Accelerator pedal position sender 1 -G79- 0.
Display group 66 - Brake switches position

• Engine idling

km/h xxx
1 2 3 4 ◂ Display fields Targ
Position of brake switches

Speed 0
Meaning of the 3 digits in display field 2, brake switches
1 1 1 Meaning
Brake depressed (brake light switch)
Brake depressed (brake pedal switch)
Always 0

Arosa 1997 ➤
9 Analysis measured value block, display group 70...75 -exhaust recir‐

culation-
Display group 70 -exhaust emissions reduction- diagnosis activated charcoal filter system (filter deaeration system)
• Engine idling
• Coolant temperature, 80.0 °C minimum

xx.x % xx.x % xxx mbar text
Result of activated charcoal filter system diag‐
nosis (Test OFF/Test ON/VDD OK/VDD not OK)
Intake
Protected by copyright. Copying for private or commercial purposes, manifold
in part or in whole,pressure
is not
Resultin of
respect to the correctness of information this current diagnosis
Degree of opening
Note!
VDD stands for filter deaeration valve (activated charcoal filter

solenoid valve 1).
Note!

♦ During the diagnosis the value displayed oscillates approx.
6%, within a range of 13...25%.
Display group 74 -exhaust emission reduction- actuator adaptation

• Control unit in function 04 - basic settings

xxx V xxx V xxx V text
Result ADP ON/ADP OK ERROR
Present potentiometer voltage
Position 100 %
Position 0 (basic settings)
9. Analysis measured value block, display group 70...75 -exhaust recirculation- 51

Arosa 1997 ➤
Note!
♦ Notes on display group 74:

♦ When adapting the exhaust recirculation valve it must be con‐
nected.
♦ When display group 75 is selected in function 04 “Basic set‐
tings” , the engine control unit is adapted to the exhaust
recirculation valve. This adaptation must be carried out if the
exhaust recirculation valve (or entire engine) or engine control
unit is replaced.
Display group 75 -exhaust gas recirculation-

• Engine idling
– Give 5 throttle bursts to maximum revs
xxxx/min xxx mbar xxx mbar text
Result Test ON/Test OFF/ S
Sys. OK/Sys. Not OK
Pressure difference in intake manifold 50 m
Intake manifold pressure 240.
Engine revs 1800
Note!

♦ The pressure difference in the intake manifold depends on
load. A fault can occur even with a difference of less than 140
mbar.

Arosa 1997 ➤
10 Analysis measurement value blocks, display group 100 -conformity

code-
Display group 100 -conformity code-
• Engine idling

xxxxxxxx xxx.x °C xxx.x s xxxxxxxx
4
Diagnostic state
Time since engine start-up
Coolant temperature
Conformity code
Meaning of the 8-digit numerical block, display field 1 - conformity

code
All digits must be “0” before generating the conformity code
1 2 3 4 5 6 7 8 Diagnostic function
0 Catalyst
0 Catalyst heating (at this time there is no diagnosis/always “0” )
0 Activated charcoal filter system (filter deaeration system)
0 Secondary air system (does not exist/always “0” )
0 Air conditioning(at this time there is no diagnosis/always “0” )
0 Lambda probes
0 Lambda probe heating
0 Exhaust gas recirculation
10. Analysis measurement value blocks, display group 100 -conformity code- 53
Arosa 1997 ➤
11 Analysis measurement value blocks, display groups 120...129 -com‐

munication-
Display group 125 -communication- data bus messages
• Engine idling

-- text -- --
ABS state A
Note!
♦ Note on display group 125:

♦ Target value = 1; control units with active data bus are dis‐
played.

Arosa 1997 ➤

1 Injection system: repairing
1.1 Location of components

sender -G71- with intake air
temperature sender
3 - Intake manifold
4 - Injector -N30- ... -N33- )
5 - Control unit 4LV -J537-
6 - Knock sensor 1 -G61-
❑ Location: engine block,
intake side
❑ ⇒ Item 6 (page 120) .
J338-
9 - Engine revsto sender -G28-
❑ Location: engine block,
intake side
10 - 3-contacts connector
❑ Black
❑ For engine revs sender
-G28-
11 - Ignition transformer -
N152-
❑ With identification for ig‐
nition wiring, do not
1. Injection system: repairing 55

Arosa 1997 ➤
swap
❑ ⇒ Item 2 (page 120)
12 - 4 and 6-contacts connector
❑ Black
❑ To lambda probe and pre- and post- catalyst lambda heating
❑ With sender for coolant temperature gauge -G2-
14 - Exhaust recirculation system -N18- with exhaust recirculation potentiometer -G212- ⇒ Rep. Gr. 26 ;
Exhaust recirculation system Exhaust recirculation system components: repairing
❑ ⇒ Item 9 (page 120)
16 - Pre-catalyst lambda probe -G39- , 50 Nm, post-catalyst lambda probe -G130- , 50 Nm
❑ Location: probe before the cat. At exhaust manifold, post-catalyst lamb-da probe. At the main catalyst
17 - Activated charcoal filter solenoid valve 1 -N80-
❑ Activated charcoal filter system: ⇒ Rep. Gr. 20 ; Fuel supply system components: removing and installing
Activated charcoal filter system components: repairing
1.2 General instructions for injection

Ignition unit: repairing ⇒ page 119
♦ The control unit for the injection system and ignition is equip‐
ped with selfdiagnosis. Before repairing and for fault finding,
first consult the fault memory. Also check the vacuum hoses
and the connections (infiltrated air).
♦ The fuel hoses in the engine compartment should be immobi‐
lised with strip clamps; do notbyuse
Protected tightening
copyright. Copying foror screw
private clamps.
♦ Before disconnecting andrespect
connecting the battery, switch off
the ignition; otherwise, the engine control unit can be dam‐

aged.
♦ The components marked with * are tested via self-diagnosis
⇒ page 10 , Fault memory: consulting and clearing.
♦ The components marked with ** are tested via final control
diagnosis ⇒ page 6 .
♦ For optimum functioning of the electrical components, a min‐
imum voltage of 11.5 V is required.
♦ Do not use silicone-based sealant. The silicon particles drawn
into the engine do not burn and damage the lambda probe.
♦ After fault finding, reparation or testing of components, if the
engine starts up briefly and then cuts out, this may be due to
the immobiliser blocking the engine control unit. In this case,
consult the fault memory and, if necessary, proceed to the
adaptation of the control unit ⇒ page 106 .
♦ During some tests the control unit may detect and store a fault.
Thus, once all tests and reparations are finished, consult the
fault memory, clearing it if necessary ⇒ page 10 , Fault mem‐
ory: consulting and clearing.
Safety measures ⇒ page 64
Cleaning rules ⇒ page 64
Test the intake system for leakage (infiltrated air) ⇒ page 90
Test the engine load states ⇒ page 97

Arosa 1997 ➤
1.3 Injection system components: removing and installing
1 - Plug
❑ Check installing position
2 - 3 Nm
❑ Check the note on in‐
stallation ⇒ page 63
3 - Air filter
❑ Air filter: removing and
installing ⇒ page 63
sembly ⇒ page 62
4 - Wiring guide
❑ Clipped to the fuel dis‐
tributor
5 - 10 Nm
6 - Fuel distributor with injec‐
tors
sembly ⇒ page 61
7 - Intake manifold
sembly ⇒ page 60
8 - From the activated charcoal
filter solenoid valve -N80- */**
⇒ Rep. Gr. 20 ; Fuel supply
system components: removing
and installing Activated char‐
coal filter system: repairing
9 - Connector
❑ by Black,
Protected copyright. 6-contacts
❑ To throttle valve
respect to the correctness control

Arosa 1997 ➤
unit -J338-
❑ Connector with gold
contacts
11 - Gasket
❑ Replace
12 - Connection line
❑ To the exhaust recirculation system: ⇒ Rep. Gr. 26 ; Exhaust recirculation system Exhaust recirculation
system components: repairing
13 - 5 Nm
14 - Engine revs sender -G28- *
❑ Before removing, remove the intake manifold, ⇒ Item 7 (page 57)
❑ Location ⇒ page 55 , component location synoptic chart
15 - Pre-catalyst lambda probe -G39- *, 50 Nm
❑ Lubricate the thread only with -G5- . The -G5- should not get into the grooves of the probe
❑ Remove and install with -U-40080-
❑ Test the lambda control ⇒ page 92
❑ Voltage supply of the probe heating via the fuel pump relay -J17-
❑ Test the pre-catalyst lambda probe heating ⇒ page 66
❑ Test the continuity of flow of the probe heating

16 - 6-contacts connector
❑ Black
❑ To lambda probe and pre-catalyst lambda probe heating (post-catalyst lambda probe with 4-contacts
connector)
❑ Contacts 3 and 4 of the connector, gold
18 - Clip
19 - O-ring
❑ Replace if worn
20 - Plug
❑ Before removing, reduce the cooling system pressure
❑ To engine control unit
❑ With sender for coolant temperature gauge -G2-
❑ Before removing, reduce the cooling system pressure
❑ Resistance values between contacts 1 and 3 ⇒ page 62
22 - Connector
❑ Black, 4-contacts
❑ To coolant temperature sender -G62- and sender for coolant temperature gauge -G2-
23 - Mounting frame
24 - Connectors
❑ Connect and disconnect the connectors with the ignition off

Arosa 1997 ➤
25 - Engine control unit

❑ (Control unit for injection system 4LV -J357- )
❑ Test the voltage supply ⇒ page 70
❑ In the event of replacement carry out the basic settings ⇒ page 104
❑ In the event of replacement, the control unit must be adapted to the electronic immobiliser ⇒ page 106
❑ Encode engine control unit ⇒ page 103
26 - Hot air intake hose
❑ From the hot air intake flap: ⇒ Rep. Gr. 26 ; Exhaust recirculation system components: removing and
installing
27 - Connecting sleeve for cold air intake
❑ Also clipped to the body
28 - Ring gasket
❑ Replace
29 - 20 Nm
30 - Vacuum hose
31 - Supply hose
❑ Black, with white mark
❑ Immobilise with strip clamps
❑ From the fuel filter: ⇒ Rep. Gr. 20 ; Fuel supply system components: removing and installing Fuel tank
with accessory parts and fuel filter: removing and installing
32 - Return hose
❑ Black, with blue mark
❑ To the fuel transport unit in the tank ⇒ Rep. Gr. 20 ; Fuel supply system components: removing and
installing Fuel tank with accessory parts and fuel filter: removing and installing
33 - Connector
❑ Black, bipolar Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To injector -N30- ... -N33- ) respect to the correctness of information in this document. Copyright by SEAT S.A.
34 - Connector
❑ Black, bipolar
❑ To knock sensor 1 -G61-
❑ Connector with gold contacts
35 - Connector
❑ To intake manifold pressure sender and intake air temperature sender
36 - 5 Nm
37 - Breather hose of the engine oil sump
❑ From the oil separator ⇒ Rep. Gr. 17 ; Lubrication system components: removing and installing

Arosa 1997 ➤
2 Injection system: repairing
2.1 Intake manifold: disassembly and assembly

Engines AQQ, AUB
1 - Throttle valve drive -J338- *

ment, adapt the engine
control unit
⇒ page 106
❑ Connector with gold
contacts
❑ Without pulley for accel‐
erator drive cable, since
it is an electronic accel‐
erator
❑ 6-pin connector
2 - 10 Nm
3 - Seal
❑ Replace
4 - Intake hole
5 - Gasket
❑ Replace
6 - Connecting line
7 - 10 Nm
8 - Ring gasket
❑ Replace
9 - Guide plate
❑ Check the fitting posi‐
tion
❑ Replace if worn
10 - O-ring
❑ Replace if worn
11 - 3 Nm
12 - Intake manifold pressure sender -G71- * with intake air temperature sender -G42- *
❑ Test the intake manifold pressure sender ⇒ page 72
❑Protected
Testbythe intake
copyright. air temperature
Copying sender
for private or commercial ⇒ page
purposes, 74in whole, is not
in part or
❑ Resistance valuesoffor
respect to the correctness intakein air
information temperature
this document. Copyrightsender between contacts 1 and 2 ⇒ page 63
by SEAT S.A.

❑ Removing and fitting ⇒ page 57 , Injection system components: removing and fitting
14 - Vacuum hose
❑ Comes from fuel pressure regulator ⇒ Item 12 (page 61)
15 - 20 Nm

Arosa 1997 ➤
2.2 Fuel distributor with injectors: disassembly and assembly
1 - Lock washer
tion
❑ Replace if worn
2 - 5 Nm
3 - 10 Nm
4 - Fuel distributor
⇒ page 86 , Injectors:
testing the jet profile and
leakage
5 - Clip
❑ Check correct seating in
the injector and in the
fuel distributor
6 - O-ring
❑ Replace
❑ Apply a bit of clean en‐
gine oil before fitting
7 - Injector -N30- ... -N33- )*
❑ Resistance 14.0...17.0
Ω
8 - Supply hose
❑ Black, with white mark
❑ Immobilise with strip
clamps
❑ From the fuel filter ⇒
Rep. Gr. 20 ; Fuel sup‐
ply system components:
Fuel tank with accessory parts and fuel filter: removing and installing
9 - Return hose
❑ To the fuel transport unit in the tank ⇒ Rep. Gr. 20 ; Fuel supply system components: removing and
installing
Protected by copyright.Fuel tank
Copying withoraccessory
for private partsinand
commercial purposes, part orfuel filter:
in whole, is notremoving and installing
10 - respect
O-ringto the correctness of information in this document. Copyright by SEAT S.A.
❑ Replace if worn
❑ Test ⇒ page 66 , Fuel pressure regulator and retaining pressure: testing
12 - Vacuum hose
❑ Goes to the intake manifold ⇒ Item 13 (page 60)

Arosa 1997 ➤
2.3 Air filter: disassembly and as-sembly

Removing and installing the air filter ⇒ page 63
1 - 3 Nm
❑ Check the note on in‐
stallation ⇒ page 63
2 - Plug
tion
3 - Breather hose of the engine
oil sump
❑ From the oil separator:
⇒ Rep. Gr. 17 ; Lubri‐
cation system compo‐
nents: removing and in‐
stalling
4 - Upper part of the air filter
5 - Filter element
6 - Lower air filter element
7 - Ring gasket
❑ Replace if worn
8 - Connection hose
9 - Hot air intake hose
❑ From the hot air intake
flap: ⇒ Rep. Gr. 26 ;
Exhaust recirculation
system components: re‐
moving and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 - Air intake conduct with respect to the correctness of information in this document. Copyright by SEAT S.A.
regulating flap
❑ Test the intake air pre‐
heating ⇒ page 91
11 - 5 Nm
12 - Set of cold air intake connecting lines
Resistance values for the coolant temperature sender -G62-

The diagram is subdivided into temperatures ranges:
A - 0...50 °C
B - 50...105 °C
Examples:
1.5...2.0 kΩ
♦ 80 °C is within range B and corresponds to a resistance of
275...375 Ω

Arosa 1997 ➤
Resistance values for the intake air temperature sender -G42-

The diagram is subdivided into temperatures ranges:
A - 0...50 °C
B - 50...105 °C
Examples:
2.3...2.6 kΩ
♦ 80 °C is within range B and corresponds to a resistance of
290...330 Ω
Removing and installing the air filter
2.3.1 Removing
– Remove the camshaft housing cover.
– Remove the plug -1- .
– Remove the engine oil sump breather hose from the upper part
of the air filter -2- .
– Loosen the bolts marked with arrows to remove the air filter.
– Remove the air filter.
2.3.2 Install
– Install the air filter in the reverse order of removal.
Note!
♦ In production self-threading bolts are used for fixing the air fil‐
ter to the plastic intake manifold and the upper part of the air
filter to the lower part. Loosening or tightening these bolts with
a screwdriver can damage the thread on the intake manifold
or the lower air filter element.
♦ When using an electric/pneumatic screwdriver for loosening
or tightening the bolts respect the following conditions:
♦ Maximum speed of the electric/pneumatic screwdriver: 200
rpm, maximum
♦ Tightening torque: 3 Nm, maximum

Arosa 1997 ➤
2.4 Safety measures
Caution
The fuel system is under pressure. Before loosening the hose

connections or opening the test plug, place a cloth around the
connection point. Then reduce the pressure carefully removing
the hose or removing the closing bolt.
To avoid personal injury and/or the damage to the injection sys‐

tem and ignition proceed as follows:
♦ Do not touch or remove the injection wiring with the engine
running or the ignition on.
♦ Disconnect and connect the injection system and ignition wir‐
ing, including the test unit wiring, only with the ignition off.
If test and measurement units is to be used during the road test,
proceed as follows:
Operating test and measurement units from the front passenger
seat could result in injury should the airbag be activated in the
♦ To turn the engine over with the ignition on without it starting
up:
– Remove the 4-contacts connector from the ignition transform‐
er -arrow- .
– Remove the connectors -arrows- from the injectors.
2.5 Cleaning rules

In working on the fuel supply/injection system, carefully follow the
“5 rules” for cleaning:
before releasing them.

Arosa 1997 ➤
♦ Deposit the parts removed over a clean surface and cover

them. Do not use cloths that shed fibres!
♦ Only install clean components: Removing the replacement
parts from their wrapping right before carrying out assembly.
Do not install components that have been stored without wrap‐
ping (e.g. in the toolbox, etc.).
♦ As the system is open: Avoid the use of compressed air when
2.6 Technical data

Engine code letters AQQ AUB
Idling test
Idling revs15) rpm 640...930 640...930
System permitted unless authorised by SEAT S.A. SEAT S.A does 4LV
not guarantee or accept any liability with4LV
Code17) -6K0 906 034 L- -6K0 906 034 BA-
Rev control rpm approx. 5,700 approx. 6600
15) Not adjustable
16) Replace the engine control unit ⇒ page 104

17) Current engine control unit code ⇒ Spare parts microfiche

Arosa 1997 ➤
3 Component test
3.1 Pre-catalyst lambda probe heating: test‐

ing
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526 A- or multimeter -V.A.G.
1715-
♦ Wiring diagram

• Fuse no. 8, OK
• Fuel pump relay, OK
3.1.2 Test process

and enter the “address code” 01 to select the engine control
unit. (Fault reader: connecting and selecting the engine control
unit ⇒ page 3 .)
Select function XX

and confirm the entry with the Q key. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Reading on display: respect to the correctnessRead
of information in thisvalue
measured document. Copyright by SEAT HELP
block S.A.

– Test the state of the lambda probe heating in display field 2:

Message: CfS. aCa ON
If the target value does not reached:

Arosa 1997 ➤
– Detach the 6-contacts connector (black) from the pre-catalyst

lambda probe -G39- -arrow- .
– Test the continuity of flow of the probe heating in the connector

to the lambda probe, contacts 1+2.
If an open circuit is found in the probe heating:
– Replace the pre-catalyst lambda probe -G39- .
If there is probe heating flow:
– Switch the multimeter to voltage test and connect to contacts

1+2 of the engine control unit connector using the auxiliary
leads of the -V.A.G. 1594- .
– Start the engine and run it at idle.
– Test the voltage supply and watch display group 41, display
field 2: Message: CfS. aCa ON Target value: 11.0...15.0 V
Message: CfS. aCa ON/CfS. aCa OFF (alternately): Target
value: oscillates between 0.0...12.0 V
– Connect test box
permitted unless-V.A.G.
authorised 1598/31- to the
by SEAT S.A. SEAT S.Awiring
does not harness
guarantee or of theany liability with
accept
control unit,respect
withoutto theconnecting the engine
correctness of information control Copyright
in this document. unit. by SEAT S.A.
3. Component test 67
Arosa 1997 ➤
the 6-contacts connector (connector of the control unit) fol‐
lowing the wiring diagram. Contact 1+female contact 5 Wire
– Test for open circuits in the wiring between the 6-contacts
connector, contact 2, and the fuel pump relay -J17- , following
the wiring diagram. ⇒ Current flow diagrams, Electrical fault
3.2 Post-catalyst lambda probe heating:

testing
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram

• Fuse no. 8, OK
• Fuel pump relay, OK
3.2.2 Test process

– Disconnect the 4-contacts connector
respect to theto the lambda
correctness probe
of information - document. Copyright by SEAT S.A.
in this
G130- -arrow- .

Arosa 1997 ➤
– Test the continuity of flow of the probe heating in the connector

to the lambda probe, contacts 1+2.
Note!
At ambient temperature, the resistance of the heating element is

approx. 1...5 Ω. If the temperature rises a bit the resistance in‐
creases considerably.
If an open circuit is found in the probe heating:

– Replace the post-catalyst lambda probe -G130- . ⇒ Rep. Gr.
26 ; Exhaust manifold, front exhaust pipe with catalyst and
accessory parts.
If there is flow of the probe heating:
3.2.3 Test the voltage supply

– Switch the multimeter to voltage test and connect to contacts
1+2 of the engine control unit connector using the auxiliary
leads of the -V.A.G. 1594 A- .
Target value: oscillates between 11.0...15.0 V

– Test for open circuits in the wiring between 4-contacts con‐

nector, contact 2, and female contact 63. Wire resistance: 1.5
Ω max.
– Test for open circuits between 4-contacts connector, contact
1, and the fuel pump relay -J17- , following the wiring diagram.
Wire resistance: 1.5 Ω max.
Arosa 1997 ➤
3.3 Throttle valve control unit: testing

Throttle valve control unit components -J338- : Throttle valve
control -G186- , throttle valve control angle 1 sender -G187- and
throttle valve control angle 2 sender -G188- .
Note!
When replacing, or removing and installing, the throttle valve con‐

trol unit, it is necessary to adapt the new throttle valve control unit
to the engine control unit ⇒ page 104 .

♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram

• Throttle valve not damaged or dirty.
3.3.2 Test process

– Detach the 6-contacts connector from the throttle valve control
unit -arrow- .
– Measure the resistance of the throttle valve activator between

contacts 3+5. Target value: 3...200 Ω
– Replace the throttle valve control unit -J338- .
– Test the voltage supply of the throttle valve control unit and
the wiring to the control unit ⇒ page 70 .
If the voltage supply and the wiring are OK:
3.3.3 Test the voltage supply and the wiring to

the control unit
Test condition

Arosa 1997 ➤
Test process
– Detach the 6-contacts connector from the throttle valve control
unit.
– To test the voltage, connect the multimeter to contacts 2+6 of
the connector, using the auxiliary leads of the -V.A.G. 1594
A- .
– Switch on the ignition. Target value: 4.5 V min
– To test the voltage, connect the multimeter to contact 2 of the

connector and earth.
– Connect the test box -V.A.G. 1598/31- to the wiring harness

of the control unit, without connecting the engine control unit.
the connector, following the wiring diagram. Contact 1+female
permittedcontact 92 Contact 2+female contact 83 Contact 3+female
contact
respect to the117 Contact
correctness 4+female
of information contactCopyright
in this document. 84 Contact
by SEAT 5+female
S.A.
contact 118 Contact 6+female contact 91 Wire resistance: 1.5
Ω max.
– Also test the wiring shorts circuit between wires.
– Test the wiring for short circuits to battery positive or earth.
– Test the voltage supply of the engine control unit ⇒ page 70 .
Arosa 1997 ➤
3.4 Intake manifold pressure sender: testing
Note!
To repair the contacts of the sender connector use only gold con‐
tacts.

1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram
3.4.1 Test process

Select function XX


– Read the intake manifold pressure value in field 2 and store

the value.
– Open the throttle valve briefly. In doing so, the intake manifold
pressure should increase briefly.
If the value displayed holds constant at 91 mbar or 1254 mbar:
Displayed value Cause Continue test
91 mbar Open circuit
Protected or short
by copyright. cir‐for private⇒orpage
Copying 73 purposes, in part or in whole, is not
commercial
cuit torespect
earth
1254 mbar Short circuit to positive ⇒ page 74

Arosa 1997 ➤
3.4.2 If the display reads 91 mbar, continue

the test as follows:
– Unplug the 4-pin connector from the intake manifold pressure
sender -G71- with intake air temperature sender -G42-
-arrow- (the engine may cut out).
– Bridge connector contacts 3+4 with auxiliary leads -V.A.G.

1594 C- and check the display.
If the displayed value jumps to 1254 mbar:
– Press → .
– Replace the intake manifold pressure sender -G71- with intake
If the displayed value holds Protected
at 91 mbar:
– Press → . respect to the correctness of information in this document. Copyright by SEAT S.A.

– Connect test box -V.A.G. 1598/31- to the control unit wiring

harness, without connecting the engine control unit.
Arosa 1997 ➤
the connector following the wiring diagram.
Contact 3+female contact 98
– Also test contact wire 4 for short circuit to earth and contact 1.
3.4.3 If the display reads 1254 mbar, continue

the test as follows:
– Unplug the 4-pin connector from the intake manifold pressure
sender -G71- with intake air temperature sender -G42-
-arrow- (the engine may cutS.A.
out).
If the displayed value jumps to 91 mbar:
– Press → .
– Replace the intake manifold pressure sender -G71- with intake
If the displayed value holds at 1254 mbar:
– Press → .
– Free the control unit connectors and unplug them.
– Test the wiring to the control unit connector at 4-pin connector

contact 4 for short circuit with contact wire 3 and battery pos‐
itive.
3.5 Intake air temperature sender: testing
Note!
Use only gold contacts to repair the sender connector contacts.

Arosa 1997 ➤

1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
♦ Auxiliary measurement set -V.A.G. 1594 C-
♦ Wiring diagram
♦ Cooling spray (standard)
3.5.1 Test process

Select function XX


1 2 3 4
– Read thepermitted
intakeunless
air temperature
authorised by SEATvalue in S.A
S.A. SEAT field 4.not guarantee or accept any liability with
does
If the target value is not reached.
– Continue the test according to the following table:
Displayed value Cause Continue test
-40 °C Open circuit or short ⇒ page 75
circuit to positive
120 °C Short circuit to earth ⇒ page 77
Approx. ambient tem‐ -- ⇒ page 77
perature18)
18) If the display shows a temperature lower than sender ambient temperature,
first test the sender wiring for contact resistances. Note that the sender can heat
up due to irradiated heat when the vehicle is stopped.
3.5.2 If the display reads -40 °C continue the

test as follows:
– Unplug the 4-pin connector from the intake air temperature
sender -G42- with intake manifold pressure sender -G71-
-arrow- .
Arosa 1997 ➤
– Bridge connector contacts 1+2 with auxiliary leads -V.A.G.

1594 C- and check the values on the display.
If the displayed value jumps to 120 °C:
– Press → .
– Press 0 and 6 for the function “End transmission” and press

– Replace the intake air temperature sender -G42- with intake
manifold pressure sender -G71- ⇒ Item 11 (page 60) .
If the displayed value holds at -40 °C:
– Press → .

the 4-pin connector following the wiring diagram.
– Also test the wire for short circuit to battery positive.

Arosa 1997 ➤
3.5.3 If the display reads -120 °C, continue the

test as follows:
– Unplug the 4-pin connector from the intake air temperature
sender -G42- with intake manifold pressure sender -G71-
-arrow- .
If the reading changes to -40 °C:
– Press → .

If the displayed value holds at 120 °C:
– Press → .

Target value:permitted
∞ Ω unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
3.5.4 Continuation of the test if display shows

the ambient temperature:
Function test of the sender:
Arosa 1997 ➤
– Remove the intake air temperature sender with intake mani‐

fold pressure sender (the connector remains plugged in).
– Store the intake air temperature value displayed in field 4.
– Spray the sender with standard cooling spray, watching the
temperature value. The temperature value should fall.
– Press → .
3.6 Coolant temperature sender: testing

1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Auxiliary measurement set -V.A.G. 1594 C-respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Wiring diagram
3.6.1 Test process

Select function XX


1 2 3 4
– Read the coolant temperature value displayed in field 2.

Display Cause Continue test
-40 °C Open circuit or short ⇒ page 79
circuit to positive
120 °C Short circuit to earth ⇒ page 80
Approx. coolant tem‐ -- Only in event of
perature19) display of spora‐
dic fault:20)
⇒ page 81
19) If the display shows a temperature that differs significantly from sender am‐
bient temperature, test the sender wiring for contact resistances.
20) The test is only possible when the engine is cold.

Arosa 1997 ➤
If the display reads -40 °C, continue the test as follows:

– Unplug the 4-pin connector from the coolant temperature
sender -G62- with coolant temperature indicator sender -G2-
-arrow- .
– Bridge connector contacts with auxiliary leads -V.A.G. 1594

C- and check the values on the display. ▸ 11.99: contacts 1 +
3 12.99 ▸: contacts 3 + 4
If the displayed value jumps to 120: °C:
– Press → .
– Replace thepermitted
coolant temperature
unless sender
authorised by SEAT -G62-
S.A. SEAT with
S.A does not coolant
guarantee or accept any liability with
temperature indicator
respect sender -G2- of⇒information
to the correctness Item 21in this
(page 58) Copyright
document. . by SEAT S.A.
If the displayed value holds at -40 °C:

– Press → .

Arosa 1997 ➤
▸ 11.99 12.99 ▸
Contact 1+female contact 108 Contact 3 + female contact 93
– Replace the coolant temperature sender -G62- with coolant
temperature indicator sender -G2- ⇒ Item 21 (page 58) .
If the display reads 120 °C, continue the test as follows:
– Unplug the 4-pin connector from the coolant temperature

sender -G62- with coolant temperature indicator sender -G2-
-arrow- .
If the displayed value jumps to -40:
permitted unless°C:
– Press → .
If the displayed value holds at 120 °C:
– Press → .


Arosa 1997 ➤
▸ 11.99 12.99 ▸
If the display shows the coolant temperature, continue the test as
follows:

• The engine must be cold.
Function test of the sender:
Select function XX


Q to confirm
Protectedthe entry. Copying for private or commercial purposes, in part or in whole, is not
by copyright.
The display reads:
respect (1...4 = display
to the correctness fields) in this document. Copyright by SEAT S.A.
of information Read measurement value block 1 →
1 2 3 4
– With the engine running, watch the coolant temperature value

in display field 2. The value should rise steadily.
Note!
♦ If the value displayed on the fault reader jumps from 2...5 °C,
it is due to the control unit; it is not due to a faulty sender.
♦ Within a certain temperature range, if engine performance is
faulty and the temperature value does not rise steadily, that
means that there are transient interruptions in the temperature
signal and the sender must be replaced.
– Press → .
Arosa 1997 ➤
3.7 Engine revs sender: testing

The engine revs sender -G28- is a revolutions and reference mark
sender. If the rev signal fails when the engine is running, the en‐
gine may cut out.
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagrams

• Battery voltage 11.5 V minimum
3.7.2 Test process Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach the black triple connector to the engine
respect revs sender
-arrow- (on the intake manifold, to the right).
– To test the voltage, connect the multimeter to contacts 1 (pos‐

itive) and 3 (earth) of the engine revs sender connector using
the auxiliary leads of the -V.A.G. 1594 A- .
– Switch on the ignition. Target value: 4.5 V min.


Arosa 1997 ➤
the triple connector, following the wiring diagram. Contact 1
+female contact 87 Contact 2+female contact 82 Contact 3
+female contact 108 Wire resistance: 1.5 Ω max.
– Also test the wiring for short circuit between wires. Target val‐
ue: ∞ Ω
If no faults are found in the wiring and there is voltage between
contacts 1+3:
– Replace the engine revs sender -G28- ⇒ Item 14 (page 58) .
If no faults are found in the wiring and there isn't voltage between
contacts 1+3:
3.8 Injectors: testing
3.8.1 Test the activation

♦ Test box -V.A.G. 1598/31-
1715-
♦ Diode test light -V.A.G. 1527-
♦ Wiring diagram

• Fuse no. 7, OK.
• Earth connections between engine (gearbox housing) and
bodywork (below the battery), OK.
• Earth connections at the water tank,permitted
OK. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• Engine revs sender, OK; test ⇒ page 82 .
• Hall sender, OK; test ⇒ page 122 .
3.8.3 Test process

– Remove the camshaft housing cover -arrows- .
Arosa 1997 ➤
– Detach the 4-contacts connector from the ignition transformer

-arrows- .
– Remove the terminal connectors -arrows- from the injectors.
– Connect the diode light -V.A.G. 1527- with auxiliary leads of

the -V.A.G. 1594- to the contacts of the cylinder 1 connector.
– Switch on the starter motor and test the voltage supply of the
cylinder 1 injector. The diode light should light up.
– Repeat the test at the injector connectors corresponding to
cylinders 2...4.
If the diode light does not flash for any cylinder:
– Connect the diode light to the connector of cylinder 1, contact

1 and earth. The diode light should light up.
– Repeat the test at the injector connectors corresponding to
cylinders 2...4.
If the diode does not light up:
– Switch offbythe
Protected ignition.
– Test for open
respect circuits
to the in ofthe
correctness wiringin between
information this document.double-contact
connector 1 and the fuel pump relay -J17- , following the wiring
If the diode light does not come on at one or more cylinders:

Arosa 1997 ➤

the double connector, following the wiring diagram. Injector 1,
contact 2+female contact 96 Injector 2, contact 2+female con‐
tact 97 Injector 3, contact 2+female contact 88 Injector 4,
contact 2+female contact 89 Wire resistance: 1.5 Ω max.
– Also test the wiring for short circuit between wires.
Protected Target
by copyright. val‐ for private or commercial purposes, in part or in whole, is not
Copying
ue: ∞ Ω permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Test for open circuits in the wiring between the contacts 1 of
the injector connectors. Wire resistance: 1.5 Ω max.
3.8.4 Test the resistances of the injectors

Test process
– Test the resistance of the injectors between the contacts. Tar‐
get value: 14.0...17.0 Ω (at 20 °C)
With the engine at operating temperature, the resistance rises
approx. 4...6 Ω.
– Replace the faulty injector ⇒ Item 7 (page 61)
Arosa 1997 ➤
4 Jet profile and leakage: testing

equipment required
♦ Torque spanner -V.A.G.
1331- (5...50 Nm)
-V.A.G. 1594 A-
♦ Digital potentiometer -
V.A.G. 1630-
♦ Measuring glass
Test condition
• The fuel pressure should be OK, test ⇒ page 70 , Fuel pressure
regulator and retaining pressure: testing.
Test process

Arosa 1997 ➤
– Detach the 4-contacts connector from the coolant temperature

sender -G62- with the sender for coolant temperature gauge
-G2- -arrow- .
– Connect digital potentiometer -V.A.G. 1630- to contacts 1 + 3

of the connector, using auxiliary leads of the -V.A.G. 1594 A- ,
and set the connected side to 15 kΩ.
– Remove the vacuum hose from the fuel pressure regulator

-arrow- .
– From the intake manifold, remove the fuel distributor complete
with all the injectors (the fuel hoses remain attached)
– Place a small recipient under the injector to be tested and re‐

move the connectors from the other injectors.
– Have another person operate the starter motor. The injector
jet should pulsate.
– Repeat the test at the other injectors checking that only the
injector to be tested is connected. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Next, test the injectors for leakage. Not more
respectthan 2 drops/min
should escape
If the loss of fuel is greater:
– Replace the faulty injector ⇒ Item 7 (page 61)
The injectors are installed in the reverse order, taking into account
the following:
♦ The O-rings of all the injectors must be replaced and the new
ones lubricated with a bit of clean engine oil.
♦ Position the fuel distributor with the injectors immobilised on
the intake manifold and bolt it evenly.
4. Jet profile and leakage: testing 87

Arosa 1997 ➤
– Plug digital potentiometer -V.A.G. 1630- into the connector

contacts with auxiliary leads -V.A.G. 1594 C- and set the con‐
nected side to 15 kΩ.
▸ 11.99 12.99 ▸
Contact 1 Contact 3
Contact 3 Contact 4
4.1 Fuel pressure regulator and re-taining pressure: testing

The fuel pressure regulator regulates the fuel pressure in function
of the intake manifold pressure.
The target value for this test depends on the operating pressure
of the fuel pump that rises to approx. 3.0 bar

equipment required
1318-
♦ Adaptor -1318/10-
♦ Adaptor -1318/11-
♦ Hose adaptor -V.A.G.
1318/16-
♦ Pliers for opening flexible
clamps -T20029-

Arosa 1997 ➤
4.1.1 Test process

– Remove the supply hose -1- (with white mark) and wipe up
spilt fuel with a cloth.
Caution

place a cloth round the connection point. Next, eliminate the
pressure loosening the connection carefully.
– Connect vacuum meter -V.A.G. 1318- to the supply hose -1-

and with the adaptor V.A.G. 1328/10, and to the supply line
with adaptor -V.A.G. 1318/11- and adaptor -V.A.G. 1318/16- .
– Open the shut-off valve of the pressure gauge. The lever
points in the direction of flow.
– Test the fuel pressure Target value: approx. 2.5 bar
– Remove the vacuum hose from the fuel pressure regulator

-arrow- . The fuel pressure should rise to approx. 3.0 bar
If the targetProtected
valuebyiscopyright.
not reached:
– Test the flow of tothe

the fuel pump. ⇒ Rep. Gr.document.
20 ; Fuel supply
respect correctness of information in this Copyright by SEAT S.A.
system components: removing and installing Fuel pump: test‐
ing
– Test the leakage and the retaining pressure, watching the drop
in pressure in the pressure gauge. After 10 minutes, a mini‐
mum pressure of 2.0 bar should remain.
If the retaining pressure drops under 2 bar:

Arosa 1997 ➤
– Once the pressure is up, switch off the ignition, at the same
closing the shutoff valve of pressure gauge -V.A.G. 1318-
(lever perpendicular to direction of flow -arrow- ).
– Watch the drop in pressure in the pressure gauge.
– Test the fuel pump retaining valve: ⇒ Rep. Gr. 20 ; Fuel supply
system components: removing and installing Fuel pump: test‐
ing
– Open the shut-off valve of pressure gauge -V.A.G. 1318- (lev‐

er pointing in direction of flow).
– As soon as the pressure is up, switch off the ignition, at the

same time squeezing off flow in the return hose (with blue
mark) -2- .
– Replace the fuel pressure regulator ⇒ Item 11 (page 61)
– Test for leakage at the line connections, O-rings of the fuel
distributor and injectors.
– Test for leakage in the pressure gauge.
Note!
Before removing the pressure gauge, place cloths round the con‐
nection point.
4.2 Intake system: testing for leakage (infil‐

trated air)
4.2.1 Test with leak detection spray -G 0010

800 A1-

Arosa 1997 ➤

1552- with lead -V.A.G. 1551/3B-
♦ Leak detection spray -G 0010 800 A1-

play field 2.
4.2.3 Test process
Note!
♦ Due to the decompression in the intake system, the leak de‐

tection spray is drawn in with the infiltrated air. The spray
reduces the flammability of the mixture. This causes engine
revs to fall and a variation in lambda probe voltage.
♦ Carefully follow all safety instructions on the container.

and enter the “address code” 01 topermitted
select the engine control
unit. (Fault reader: connecting and selecting the
respect engine
to the control
unit ⇒ page 3 .)
Select function XX

– Press 0 , 3 and 3 for “display group 33” and confirm the entry
with the Q key.
– Watch the lambda probe voltage in display field 2.

– Apply leak detection spray systematically to the components
of the intake system.
If the engine revs fall or the lambda probe voltage varies:
– Press → .
– Test the sprayed area of the intake system for leaks and elim‐
inate the possible fault.
If the engine revs and the lambda probe voltage do not vary:
– Press → .
4.3 Intake air preheating: testing

♦ Cooling spray (standard)

Arosa 1997 ➤
4.3.1 Test the regulating flap

– Remove the intake hose from the air filter.
– Test the position of the regulating flap -1- .
♦ Above +23 °C, the flap should close hot air intake.
♦ Under +10 °C, the flap opens hot air intake.
Note!
The functioning of the heat element -2- can be easily tested with
standard cooling spray.

Arosa 1997 ➤
5 Function test
5.1 Lambda probe and pre-catalyst lambda

probe: testing
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram

• Fuse no. 8, OK.
• Exhaust system, airtight between the catalyst and the cylinder
head.
play field 3.
5.1.2 Function test

unit ⇒ page 3 .)
Select function XX

Readingrespect
on display:
to the correctness of information in this document. Copyright by SEAT S.A. Read measured value block HELP
– Press 0 , 3 and 0 for “Display group 30” and confirm the entry
with the Q key.
– Test the pre-catalyst lambda control state (display field 1):

Target value: 1 1 1 Meaning of the numbers ⇒ page 34 .
– Test the pre-catalyst lambda probe heating ⇒ page 66 .
– Press → .

5. Function test 93
Arosa 1997 ➤
– Watch the lambda control in display field 1. The value dis‐

played should oscillate by 2 %, minimum, within the range of:
-10.0...10.0 %
– Test the lambda probe voltage in display field 2. The voltage
should oscillate at least 20 times per minute within the range
of 0...1.0 V.
If in the field 2 the display shows a value constant:
Display Cause Continue
the test
Between Open circuit ⇒ page 118 Ba‐
0.400... 0.500 V sic voltage: test‐
ing
⇒ page 94
Lambda probe
wiring: testing
1.105 V Short circuit to posi‐
tive
0.000 V Short circuit to earth
If the lambda control displayed in field 1 does not oscillate within
the prescribed range:
– Press → .
– Road test the vehicle to clean lambda probe of soot, then re‐
peat the test.
Take the necessary precautions when doing road test
⇒ page 64 .
If the target value is not reached in display field 1, not even after
the road test, or if the value does not oscillate by 2 %, minimum:
5.1.3 Test the basic voltage

– Detach the 6-contacts connector (black) to the pre-catalyst

Arosa 1997 ➤
– To test the voltage, connect the multimeter to connectors 3 +

4 (connector to the engine control unit), using the auxiliary
– Switch on the ignition and test the basic voltage. Target value:
0.40...0.50 V
– Test the lambda probe wiring ⇒ page 94 .
5.1.4 Test the lambda probe wiring

the 4-contacts connector, following the wiring diagram. Con‐
tact 3+female contact 52 Contact 4+female contact 71 Contact
5+female contact 70 Contact 6+female contact 51 Wire re‐
– Following the wiring diagram, test the connector wiring con‐
tacts 3 + 4 for short circuits to contacts 1 + 2.
If no faultProtected
is found in the wiring:
– Replace the pre-catalyst
respect lambda
to the correctness probe
of information in this-G39- . Copyright by SEAT S.A.
document.

The display reads:
Read measurement value block HELP

The display reads: (1...4 = display fields)

Read measurement value block 33 →
1 2 3 4
– Watch the lambda regulation in display field 1. The value

should oscillate 2 % minimum within the range:
- 10.0...10.0 %, -15.0...15.0 %
– Watch lambda probe voltage in display field 2. The voltage
should oscillate at least 20 times per minute within the range:
0...1.0 V, 0.3...0.6 V, oscillating
5. Function test 95
Arosa 1997 ➤
5.2 Post-catalyst lambda probe and control

lambda posterior: testing
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram

• Fuse no. 8, OK.
• Exhaust system, airtight between the catalyst and the cylinder
head.
play field 3.
5.2.2 Function test

unit ⇒ page 3 .)
Select function XX

with the Q key.
Reading on display: (1...4 = display fields)

– Test the lambda control state after the catalyst (display field
2): Target value: 1 1 0 Meaning of the numbers ⇒ page 34 .
Note!
The 3rd bit in display field 2 only goes to 1 when the engine is
running at half load (2500-4000 rpm).

– Test the post-catalyst lambda probe heating ⇒ page 68
– Press → .

Arosa 1997 ➤

1 2 3 4
– Test the post-catalyst lambda probe voltage at the “additive”

idling in display field 1. Target value: 0.000...1.000 V
Display Cause Continue
the test
Between Open circuit ⇒ page 96 Basic
0.400... 0.500 V voltage: testing
⇒ page 75
Lambda probe
wiring: testing
1.105 V Short circuit to posi‐
tive
0.000 V Short circuit to earth
If the lambda control, shown in field 1, does not oscillate within
the prescribed range:
– Press → .
– Road test the vehicle to clean the lambda probe of soot. Re‐
peat the test.
⇒ page 64 .
If the target value is not reach in display field 1 even after the road
test, or the value does not oscillate a minimum of 2%.
accessory parts.
5.2.3 Test the basic voltage

– Remove the 4-contacts connector (black) to the pre-catalyst
5. Function test 97
Arosa 1997 ➤
– To test the voltage, connect the multimeter to connectors 3 +

4 (connector to the engine control unit), using the auxiliary
– Switch on the ignition and test the basic voltage. Target value:
0.40...0.50 V
accessory parts.
5.2.4 Test the lambda probe wiring

tact 3+female contact 68 Contact 4+female contact 69 Wire
– Following the wiring diagram, test the connector wiring, con‐
tacts 3 + 4, for short circuits to contacts 1 + 2.
If no fault is
Protected found in
by copyright. the for
Copying wiring:
– Replace the
respect to the post-catalyst lambda
correctness of information in thisprobe -G130-
document. Copyright.by
⇒SEAT
Rep.
S.A.Gr.

accessory parts.
5.3 Engine load states: testing
Note!
Test the engine control unit to see that it identifies the engine load
states (idling, deceleration, half load, enrichment, full load).

1552- with lead -V.A.G. 1551/3B-

play field 3.
5.3.2 Test process


Arosa 1997 ➤

unit ⇒ page 3 .)
Select function XX


with the Q key.
– Test the control unit to see that it identifies the engine load
states (display field 4):
♦ Idling:
While the engine runs at idling revs, the idling message should
appear. Message: Idling
♦ Protected
Deceleration:
– Raise revs to over 3000 rpm.
– Abruptly close the throttle valve.

While the revs are over 1400 rpm, the deceleration message
should appear. Message: Deceleration
Note!
♦ Under 1400 rpm is recognised as idling.

♦ Half load:
– Accelerate uniformly.
While accelerating uniformly, the half load message should ap‐
pear. Message: Half load
♦ Enrichment:
– Accelerate to full gas (to throttle valve limit).
The enrichment message should appear briefly during accelera‐
tion. Message: Enrichment
⇒ page 64 .
– Press → .
– Consult the fault memory; eliminate the possible faults and
clear the memory ⇒ page 8 , Fault memory: consulting and
clearing
– Test the throttle valve control unit ⇒ page 70
5. Function test 99
Arosa 1997 ➤
5.4 Idling test
Note!
♦ Idling revs, ignition timing and CO content cannot be adjusted.

♦ Idling revs are regulated to target values by the throttle valve
drive in conjunction with the DIS function (digital idling stabili‐
sation).
♦ CO content is adjusted to the target value by lambda regula‐
tion. Through self-diagnosis possible faults in lambda regula‐
tion are found and stored in the fault memory.

1552- with lead -V.A.G. 1551/3B- .

• Exhaust system, airtight between the cylinderhead and cata‐
lyst.
play field 3.
• All electrical consumers, for example lights and heated rear
window, must be off.
• On vehicles with air conditioner, the AC must be off.
5.4.2 Test process

– Consult the fault memory; if necessary eliminate the fault and
clear the memory ⇒ page 10 ; Fault memory: consulting and
clearing.
– Then:
♦ Leave fault reader -V.A.G. 1551- connected
♦ Let the engine idle
Select function XX


5.4.3 Test idling revs

1 2 3 4
– Check the load states in display field 4:

Target value: 000 Meaning of digits ⇒ page 49 .
– Check idling revs in display field 2.

Arosa 1997 ➤
Target value: 790/min
Note!
During the idling test the activated charcoal filter solenoid valve
and air conditioning are deactivated and lambda regulation self-
adaptation begins.
– Check idling revs in display field 1.

Target value: 640...930/min
– Press → .
If idling revs are not reached:
– Adapt the engine control unit to the throttle valve drive
⇒ page 106
– Run a road test.
– Consult the control unit fault memory again.
– Repeat the idling test.
If the target values are still not reached:
– Test the throttle valve
permitteddrive ⇒ pageby70
unless authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Test the engine load states ⇒ page 98
– Test the intake system for infiltrated air ⇒ page 90
5. Function test 101

Arosa 1997 ➤
6.1 Control unit voltage supply: testing

equipment required
or vehicle systems tester -
V.A.G. 1552- with lead -
V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
ter -V.A.G. 1715-
-V.A.G. 1594 A-
♦ Wiring diagram
Test conditions
• Fuses no. 1 and 2, OK.
• All electrical consumers, e.g., the lights and heated window
should be off.
• Alternator OK, test: ⇒ Current flow diagrams, Electrical fault
6.1.1 Test process

unit ⇒ page 3 .)

Arosa 1997 ➤

Select function XX


– Read the value displayed in field 2. Target value: 11.5 V min.

– Press → .
6.1.2 Test the voltage supply at terminal 30

– Test the voltage supply with a multimeter and auxiliary leads
of the -V.A.G. 1594 A- between female contacts 1 + 3 of the
test box: Target value: 11.5 V min.
– Test the wiring to the relay plate following the Wiring diagram.
cations
6.1.3 Test the voltage supply at terminal 15

– Test the voltage supply with a multimeter and auxiliary leads
of the -V.A.G. 1594 A- between female contacts 2 + 4 of the
test box. permitted
– Switch on the ignition. Target value: 11.5 V min.


– Test the wiring to the relay plate following the Wiring diagram.
cations
6.2 Procedure after an interruption in the

voltage supply
When the voltage supply is interrupted, the control unit loses all
the self-adaptive or the basic settings values, and the conformity
code is cleared. As a result, depending on the mileage on the

Arosa 1997 ➤
vehicle, significant faults in the dynamic performance of the en‐

gine may occur.
1552- with lead -V.A.G. 1551/3B-
6.2.1 Work sequence

After interruption in the voltage supply the followings operations
must be undertaken:
– Switch on the ignition during 10 seconds minimum.
– Adapt the engine control unit to the throttle valve control unit
⇒ page 104 .
Note!
During the idling test, the activated charcoal filter solenoid valve
and the air conditioning are switched off, and the lambda control
self-adaptation process begins.
– Do a road test long enough to eliminate dynamic performance

problems.
met:
states must be attained several times idling half load full load
deceleration
♦ At full load revs must exceed 3500 rpm
6.3 Engine control unit: replacing

♦ Fault reader -V.A.G. 1551- with lead -V.A.G. 1551/3B-
6.3.1 Work sequence

– First print out the control unit identification and, at the same
time, the previous control unit code, as follows:
ignition and enter the “address code” 01 to select the engine
control unit. (Fault reader: connecting and selecting the engine
The display shows the control unit identification and the code, 036 906 034 L MARELLI 4LV 3038 →
e.g.: Encoding 00001 WSC XXXXX
– Press Print on the fault reader to respect
print toout
the the control unit in this document. Copyright by SEAT S.A.
correctness of information
identification.
– Press → .
Select function XX

Arosa 1997 ➤
– Remove the wiper arms and air deflector: ⇒ Electrical system;

Rep. Gr. 92 ; Windscreen wipers: removing and installing
– Free the connectors from the control unit and remove them.
– Remove the attachments from the support frame -arrow- and
remove the control unit.
– Fit the new control unit in the support frame and fix it.
– Fit the control unit connectors and block them.
– Check the previous encoding and encode the new control unit
⇒ page 103 .
– Adapt the new control unit to the throttle valve control unit
⇒ page 104 .
– Adapt the new control unit to the electronic immobiliser
⇒ page 106 .
– Finally, consult the fault memory of the new engine control unit
and, if necessary, clear the fault memory ⇒ page 8 , Fault
memory: consulting and clearing
Note!
This operation must be carried out after encoding the new engine
control unit and adapting the new unit to the throttle valve drive.
6.3.2 Adapt the exhaust gas recirculation po‐

tentiometer
Select function XX



xxx % xxx % x ADP.ON
– Check the value in display field 4. (4th digit from the left)
Target value: ADP. OK
– To end the adaptation Press → .
6.4 Engine control unit: encoding

Note!
♦ During the control unit identification a 5-digit code should al‐

ways be displayed.
♦ If the encoding corresponding to the vehicle is not displayed
or the control unit has been replaced, encode the control unit
as follows.

♦ Fault reader -V.A.G. 1551- with lead -V.A.G. 1551/3B- .

Arosa 1997 ➤
6.4.1 Work sequence

Select function XX
– Press 0 and 7 for the function “Encode the control unit” and
Reading on display: Encode control unit Q
– Enter the code corresponding to this vehicle and confirm the

Engine control unit encoding ⇒ page 104
The display shows the control unit identification and the encoding, 036 906 034 L MARELLI 4LV S3038 →
e.g.: Encoding 00001 WSC XXXXX
If this reading appears on the display, it means that an unauthor‐ Function known or not →
ised code has been entered. Available at this moment
– Press → .
Note!
♦ The engine control unit does not use the encoding entered and
displayed until 60 seconds after switching on the ignition.
♦ Erroneous encoding causes the following:
♦ Faulty driving performance (rough shifting, abrupt downshift‐
ing, etc.)
♦ Fuel consumption higher than normal.
♦ Exhaust emissions higher than normal.
♦ Nonexistent faults stored in the fault memory.
♦ Certain functions are not carried out (lambda control, activa‐
tion of the activated charcoal filter system, etc.).
♦ On vehicles with front wheel drive, the slip control does not
work (the ASR warning light comes on).
♦ Reduced gearbox life.
6.4.2 Engine control unit encoding

Code For vehicles
with
00001 Manual gear‐
box
6.5 Engine control permitted
unit:respect
adapt to the throttle
valve control unit
Via the adaptation, with the ignition on and the engine off, the
engine control unit learns different throttle valve positions. These
positions are stored in the control unit. The two throttle valve con‐

Arosa 1997 ➤
trol angle senders confirm the temporary position of the throttle

valve.
The adaptation must be carried out in the followings cases:
♦ After an interruption in the voltage supply.
♦ After removing and installing the throttle valve control unit.
♦ After replacing the throttle valve control unit.
♦ After replacing the engine control unit.
♦ Change of throttle valve control unit due to change of engine.
1552- with lead -V.A.G. 1551/3B-

• No faults should be stored in the memory ⇒ page 8 , Fault
memory: consulting.
• The throttle valve should be at idling position.
• The coolant temperature should be 5...95 °C ⇒ display group
04, display field 3
6.5.2 Work sequence

ignition and enter the “address code”
Protected01 to select
by copyright. theforengine
Copying private or commercial purposes, in part or in whole, is not
control unit. (Fault reader: connecting and
permitted unless selecting
authorised the
by SEAT engine


Select function XX
– Press 0 and 4 for the function “Start basic settings” and con‐
firm the entry with the Q key.
Reading on display: Basic settings HELP

Reading on display: (1...4 = display fields) System in basic settings 60 →
XXX % XXX % X ADP. ON
After pressing Q, the current to the throttle valve activator is cut

out first.
In this state, the mechanical spring in the throttle valve control
unit, sets the throttle valve at an emergency position. The engine
control unit stores the values captured by the two angle senders
in this emergency position.
Immediately afterwards, the throttle valve opens until it reaches
a certain value. Once that value has been reached, the current to
the throttle valve activator once again cuts out. The mechanical
spring should now set the throttle valve in the emergency position
previously learnt. To do so, it has a certain time (test of the spring).
Next, the activator closes the throttle valve; the values from the
angle senders in the throttle valve control unit are stored in the
If the engine control unit leaves the throttle valve activator without
current while the vehicle is running, the result is accelerated and
irregular idling. The engine takes time to respond to acceleration.

Arosa 1997 ➤
Reading on display: (1...4 = display fields) System in basic settings 60 →

XXX % XXX% X ADP. OK
The adaptation has been carried out successfully.

To store the values:
Note!
♦ If the control unit interrupts the basic settings, it may be due

to various reasons:
♦ The test conditions are not met.
♦ The throttle valve does not reach the mechanical idling limit
due to the accumulation of dirt, e.g. burnt oil deposits, the
faulty adjustment of the accelerator control wiring.
♦ Insufficient battery voltage.
♦ The throttle valve control unit or the wiring is faulty, test
⇒ page 70 .
♦ After an interruption, a fault is stored in the memory, when the
basic settings are carried out again automatically.
– End engine basic settings pressing the key → .

6.6 Engine control unit: adapt to the elec‐

tronic immobiliser
1552- with lead -V.A.G. 1551/3B-

• An authorised key is required.
6.6.2 Work sequence


Arosa 1997 ➤
– Connect fault reader -V.A.G. 1551- or vehicle systems tester

-V.A.G. 1552- , using the lead -V.A.G. 1551/3B- .
– Operate the fault reader or the vehicle systems tester, taking
into account the message on the display.
– Press 1 for the operating mode “Rapid data transmission” .
– Press 2 and 5 for address code “Immobiliser” and press Q to
confirm the entry.
Reading on display:
6H0953257B INMO VWZ3Z0X4021641V71
Encoding 09600 WSC XXXXX
– Press → .
Reading on display:
Select function XX
– Press 1 and 0 for the function “Adaptation” and confirm the

Reading on display:
Adaptation
– Press 0 twice for the function “Channel number 0” and confirm

Reading on display:
Adaptation Q
Clear adaptive values?
– Confirm the entryunless
permitted withauthorised
the Q bykey.
Reading on display:
Adaptation →
The adaptive values are cleared
– End the adaptation pressing the key → .

Reading on display:
Note!
When the ignition is switched on again, the engine control unit

identification is entered in the immobiliser control unit.

Arosa 1997 ➤
7 Supplementary signals: testing
7.1 Speed signal: testing

1552- with lead -V.A.G. 1551/3B-
♦ Hand-held multimeter -V.A.G. 1598/31-
1715-
♦ Wiring diagram

• Battery voltage 11.5 V minimum.
memory: consulting.
• The speedometer should be OK. Test the speedometer: ⇒
Electrical system; Rep. Gr. 90
7.1.2 Test process
Note!
To test the speed signal the vehicle must be moving. To do so

another person is required.
Caution
Secure the fault reader in the rear seat and operate it from
there. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 64 .
unit ⇒ page 3 .)
Select function XX


– Do a road test with a second person to watch the values shown

on the display.

Arosa 1997 ➤
– Watch the value displayed in the field 3: Target value: approx.

running speed
– Press → .
If no speed is displayed:
– To test the voltage, connect the multimeter between female
contacts 4 (terminal 15) + 54 (speed signal) of the test box.
– Raise the vehicle at the front left.
– Turn the front left wheel by hand watching the voltage display.
Target value: oscillates between 1 and at least 4 volts
Note!
When doing so, the front right wheel should not turn; if necessary,
block it.
If the value shown does not oscillate:

– Test the wiring to the speedometer or to the speedometer
sender: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
7.2 Signals from/to the air conditioning: test‐

ing
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram

must be off.
• Functioning of the air conditioning, OK.
• The air conditioning should be off.
memory: consulting.
• The vehicle should be at ambient temperature (over Copying
Protected by copyright. +15 °C).
7.2.2 Test process respect to the correctness of information in this document. Copyright by SEAT S.A.


Arosa 1997 ➤

unit ⇒ page 3 .)
Select function XX


Watch the message in field 4. It should read Compr. NO

– Activate the air conditioning.
– Set to the lowest temperature and maximum blower speed.
The message on display field 4 should change to Compr. YES
– Press → .
If the message does not change:
contacts 40 + 41 and the air conditioning system, following the
wiring diagram. Wire resistance: 1.5 Ω max.
7.3 Signals from the brake light and brake

pedal switches: testing
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram

• Fuses 1, 2 and 20, OK.

Arosa 1997 ➤
7.3.2 Test process

Select function XX


– Watch the value in field 2: (3rd and 4th digits to the left) Target
value: 0 0 0 0
– Depress the brake pedal all the way and watch the value in
field 2: Target value: 0 0 1 1 Meaning of the numbers
⇒ page 40
– Press → .
– Remove the lining from under the steering column: ⇒ Body‐
work - Assembly work, interior; Rep. Gr. 68 ; Instrument panel
driver side parcel tray: removing
– Disconnect the connector from the brake light/brake pedal
switch.
– To measure the resistance, connect the multimeter between
switch contacts 1 and 4. Target value: ∞ Ω (no flow)
– Depress the brake pedal. Target value: 0.0 Ω approx.
switch contacts 2 and 3. Target value: 0.0 Ω approx.
– Depress the brake pedal. Target value: ∞ Ω (no flow)
If the target value are not reached:
– Replace the brake pedal switch.
If the target values are reached: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Arosa 1997 ➤
– Connect the multimeter to test the voltage between contact 1

and earth. Target value: 11.5 V minimum.
– To measure the voltage, connect the multimeter between con‐
tact 2 and earth. Target value: 11.5 V minimum.
– With the wiring diagram, test the wiring between 4-contacts
connector contact 1 and fuse 15 for open circuits. Wiring re‐
– With the wiring diagram, test the wiring between 4-contacts
connector contact 2 and fuse 24 for open circuits. Wiring re‐

the 2-contacts connector (connector to the control unit) fol‐
lowing the wiring diagram: Contact 3 + female contact 55
Contact 4 + female contact 56 Wire resistance: max. 1.5 Ω
– Also test all the wiring for short circuits between wires.
– Also test the wiring for short circuits to positive, battery and
earth.
7.3.3 Brake light switch signal: testing

– Remove the lining under the steering column: ⇒ Bodywork -
fitting work, interior; Rep. Gr. 68 ; Instrument panel driver side
parcel tray: removing
– Unplug the 2-pin connector from the brake light switch
-arrow- .
the switch contacts.

Arosa 1997 ➤
Target value: approx. ∞ Ω (without flow)

– Depress the brake pedal.
Target value: approx. 0.0 Ω (flow)
– Replace the brake light switch -F- and then adjust it.

– Connect the multimeter to measure the voltage between con‐
tact 1 and earth.
Target value: 11.5 V minimum
– Test for open circuits in the wiring between 2-pin connector
contact 1 and the fuse box.
Wiring resistance: max. 1.5 Ω

the 2-pin connector (connector towards the control unit) fol‐
lowing the wiring diagram.
– Also test all wiring for short circuits between wires:
– Also test the wiring permitted
for short circuits
unless authorisedtobybattery
SEAT S.A. positive
SEAT S.A doesand not guarantee or accept any liability with
earth. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Adjust the brake light switch:
7.3.4 Brake pedal switch signal: testing

– Remove the lining under the steering column: ⇒ Bodywork -
Fitting work, interior; Rep. Gr. 68 ; Instrument panel Driver
side parcel tray: removing

Arosa 1997 ➤
– Unplug the 2-pin connector from the brake pedal switch

-arrow- .

the switch contacts.
Target value: approx. ∞ Ω (flow)
– Depress the brake pedal.
Target value: approx. ∞ Ω (without flow)
– Replace the brake pedal switch -F47- and then adjust it.
– Connect the multimeter to measure the voltage between con‐

tact 1 and earth.
Target value: 11.5 V minimum
If the targetpermitted
valueunless
is not reached:
– Test for open circuits in the wiring between 2-pin connector
contact 1 and central electrics.


Arosa 1997 ➤
the 2-pin connector (connector towards the control unit) fol‐
lowing the wiring diagram.
– Also test all wiring for short circuits between wires.
– Also test the wiring for short circuits to battery positive and
earth.
If no fault is found in the voltage supply and wiring:
7.4 Revs signal: testing

♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram

memory: consulting.
7.4.2 Test process

– Test for open circuits inbythe wiring from contact 37 oforthe test
permitted unless authorised SEAT S.A. SEAT S.A does not guarantee accept any liability with
box to therespect
instrument panel,of following
to the correctness information in the wiring Copyright
this document. diagram.by SEAT S.A.
cations
7.5 Data bus: testing
7.5.1 Functioning
The communication between the engine control unit and the ABS/
ESP control unit, the instrument panel, the steering angle sender
and the unit occurs via a CAN data bus.
These control units, prepared for data bus, are interconnected via
two data bus wires twisted around each other (CAN_High and
CAN_Low), and exchange information (messages). The lack of
information in the data bus is interpreted as a fault by the engine
control unit and by the other control units interconnected through
the CAN data bus.

Arosa 1997 ➤
To function without static problems, the CAN data bus requires a

matching resistor of 66 Ω. This matching resistor is found at the

• The CAN data bus self-diagnosis has detected a fault.
♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram
7.5.3 Test process

– Free the connectors from the engine control unit and remove
them.
– Connect test box -V.A.G. 1598/31- to the engine control unit,
without connecting the wiring harness of the control unit.
– Test the central matching resistor incorporated in the engine
control unit.
– For this purpose, test the resistance between female contacts
58 + 60 Target value: 60...72 Ω
If the resistance value is not within the target range:
If the resistance value is within the target range:
– Detach the test box -V.A.G. 1598/31- from the engine control
unit.
of the engine control unit.
– Test the wiring of the CAN data bus for short circuits between
wires:
– For this purpose, test the resistance between female contacts
58 + 60 of the test box: Target value: ∞ Ω
If the target value is reached Protected
(the wiring has Copying
by copyright. no short circuits
for private be‐ purposes, in part or in whole, is not
or commercial
tween wires): permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Following the wiring diagram, test the wiring to the compo‐

nents of the CAN data bus for short circuits to positive or earth
or an open circuit: ⇒ Current flow diagrams, Electrical fault
If the target value is not reached (the wiring has a short circuit
between wires):
– Eliminate the wiring fault following the wiring diagram: ⇒ Cur‐

Arosa 1997 ➤
1 Ignition system: repairing
1.1 General information: ignition system

♦ This section only deals with the components related only with
the ignition. The other injection and ignition system compo‐
nents ⇒ page 55
♦ Before disconnecting and connecting the battery, switch off
the ignition; if not, the engine control unit may be affected con‐
siderably.
♦ The engine control unit is equipped with self-diagnosis.
♦ The components marked with * are tested by self-diagnosis.
♦ For the optimum functioning of the electrical components a
minimum voltage of 11.5 V is required.
♦ Before carrying out a reparation and for the fault finding, con‐
sult the fault memory ⇒ page 8 , Fault memory: consulting and
clearing.
♦ In some tests the control unit may detect and store a fault.
Thus, once all tests and reparations are done, consult the fault
memory, clearing
Protected it Copying
by copyright. if necessary ⇒commercial
for private or page 8 purposes,
, Fault inmemory:
part or in whole, is not
consulting andauthorised
permitted unless clearing by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If the engine starts up briefly and then cuts out after fault find‐
ing, reparation or component test, this might be due to the
immobiliser blocking the engine control unit. In this case, con‐
sult the fault memory proceeding, if necessary, to the adapta‐
tion of the control unit ⇒ page 106 .
Safety measures ⇒ page 121 .
Test data, sparkplugs ⇒ page 121 .
1.2 Ignition system components: removing and installing
Note!
Control unit 4LV -J448- * with connectors ⇒ Item 25 (page 59)
1. Ignition system: repairing 119

Arosa 1997 ➤
1 - Ignition wire
❑ With antistatic connec‐
tor and sparkplug cap
❑ Resistance 4,8...7,2 kΩ
❑ Test the continuity of
flow
2 - Ignition transformer -N152-
❑ With indication for igni‐
tion wiring A = cylinder 1
B = cylinder 2 C = cylin‐
der 3 D = cylinder 4
optic chart
3 - Connector
❑ To ignition transformer -
N152-
4 - 10 Nm
5 - Connector
❑ Black, bipolar
❑ To knock sensor 1 -
G61-
❑ Gold contacts at sensor
and connector
❑ Gold contacts at sensor
and connector
optic chart
7 - 20 Nm
❑ The tightening torque affects the functioning of the knock sensor
8 - Connector
❑ To Hall sender -G40-
❑ Replace if worn permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
11 - Sparkplug, 30 Nm
❑ Remove and install with the sparkplug spanner -T20028-
❑ Type and separation of electrodes ⇒ page 121 ; Test data, sparkplugs
12 - Ignition wiring guide

Arosa 1997 ➤
1.3 Safety measures

To avoid personal injury and/or damage to the injection system
and ignition, proceed as follows:
♦ Do not touch or remove the injection wiring with the engine
running or the ignition on.
♦ Always switch off the ignition before disconnecting or con‐
necting the wiring of the injection system and ignition, or the
wiring of the test units.
up, e.g. to test the compression, remove the connector from
the ignition transformer.
If the use of test and measurement units is required during a road
test, proceed as follows:
Operating the test and measurement units from the front passen‐
ger seat could result in injury should the airbag be activated in the
up:
-arrow- .
– Remove the connectors -arrows- from the injectors.
1.4 Settings data, sparkplugs

Engine code letters permitted unless authorised by SEAT S.A. SEAT S.A does AQQ not guarantee or accept any liability with AUB
Firing order 1-3-4-2 1-3-4-2
Sparkplugs
VW/Audi -101 000 033 AA- -101 000 033 AA-
Manufacturer's designation NGK BKUR 6 ET-10 NGK BKUR 6 ET-10
Separation of electrodes 0.9...1.1 mm 0.9...1.1 mm

Arosa 1997 ➤
Tightening torque 30 Nm 30 Nm
1.5 Hall sender: testing

♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagrams

1.5.2 Test process

– Detach the 3-contacts connector from the Hallpermitted

sender
-arrow- . respect to the correctness of information in this document. Copyright by SEAT S.A.
– To test the voltage, connect the multimeter to contacts 1 (pos‐

itive) and 3 (earth) of the connector at the Hall sender, using
the auxiliary leads of the -V.A.G. 1594 A- .

Arosa 1997 ➤

the triple connector, following the wiring diagram. Contact 1
+female contact 98 Contact 2+female contact 86 Contact 3
+female contact 108 Wire resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires. Target
value: ∞ Ω
If no wiring fault is detected and there is voltage between contacts
1 + 3:
– Replace the Hall sender -G40- ⇒ Item 9 (page 120)
– If no wiring fault is detected and there is no voltage between
contacts 1 + 3:
1.6 Ignition transformer: testing

♦ Test box -V.A.G. 1598/31-
1715-
♦ Diode test light -V.A.G. 1527- permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Wiring diagram

• Fuses 1, 2 and 4 OK.
• Hall sender, OK; test ⇒ page 122
• Engine revs sender, OK, test ⇒ page 82

Arosa 1997 ➤
1.6.2 Test process

-arrow- .
1.6.3 Test the voltage supply

– Test the voltage supply with the multimeter andProtected
auxiliary leads
of the -V.A.G. 1594 A- between contacts 2 + 4permitted
of the unless
detached
connector. respect to the correctness of information in this document. Copyright by SEAT S.A.


connector, contact 2 and the relay panel, following the wiring
connector, contact 4 and earth, following the wiring diagram.
Wire resistance: 1.5 Ω max.
1.6.4 Test the excitation
Caution
During the following test, do not touch the terminals of the ig‐
nition coils or the test wiring.

Arosa 1997 ➤
– Remove the camshaft housing cover -arrow- .
– Remove the terminal connectors -arrows- of the injectors.
Connect the diode light -V.A.G. 1527- with auxiliary leads of the
-V.A.G. 1594- to the Contacts 1+4 (ignition output 1) Contacts 3
+4 (ignition output 2) of the detached connector
– Switch on the starter motor and test the ignition signal of the
engine control unit. The diode light should flash.
If the diode light flashes and there is voltage between contacts 2
+ 4:
– Replace the ignition transformer -N152-
⇒ Item 2 (page 120) .
If the diode light does not flash:
– Test the wiring ⇒ page 125 .
1.6.5 Test the wiring


Arosa 1997 ➤
tact 1+female contact 102 Contact 3+female contact 103 Wire
ue: ∞ Ω max.
If no wiring fault is detected and there is voltage between contacts
2 + 4:
1.6.6 Test the secondary resistors

– Test the secondary resistors at terminal 4 between cyl. 1+cyl.
4, cyl. 2+cyl. 3 Target value: 4.0...6.0 kΩ (at 20 °C)
– Replace the ignition transformer -N152-
⇒ Item 2 (page 120) .
1.7 Knock sensor: testing
Note!
♦ Use a tightening torque of exactly 20 Nm to ensure optimum

functioning of the knock sensor.
♦ When repairing the contacts of the knock sensor connector
use only gold contacts.

♦ Test box -V.A.G. 1598/31-
1715-
♦ Wiring diagram
1.7.1
permitted unlessTest condition
• Fault at the knock sensor detected by self-diagnosis

⇒ page 8 , Fault memory: consulting and clearing

Arosa 1997 ➤
1.7.2 Test process

– Detach the 2-contacts connector from the knock sensor
-arrow- .

the double connector, following the wiring diagram. Contact 1
+female contact 106 Contact 2+female contact 99 Wire re‐
ue: ∞ Ω max.
If no fault is found in the wiring: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Loosen the knock sensor andpermitted
retighten
respect it
to to
the a torqueofofinformation
20 Nm.in this document. Copyright by SEAT S.A.
correctness
– Road test the vehicle.

Take the necessary precautions when doing a road test
⇒ page 121 .
met:
states must be reached several times idling half load full load
deceleration
♦ At full load, revs must exceed 3500 rpm
– Reconsult the fault memory of the control unit.
If the fault persists:
– Replace the knock sensor -G61- ⇒ Item 6 (page 120) .
1.8 Ignition/combustion fault finding: testing
1.8.1 Engines: AUB


Arosa 1997 ➤

1552- with lead -V.A.G. 1551/3B-
1.8.2 Test process

Select function XX


1 2 3 4
– Check the state of ignition fault finding in display field 4.

Target value: “activated”
– Check total ignition faults in display field 3:
Target value: 0
– Press → .
– Change display group 15, as follows:
-V.A.G. 1551- : press 3 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
-V.A.G. 1552- : press ↑ respect to the correctness of information in this document. Copyright by SEAT S.A.
1 2 3 4

– Check ignition faults cyl. 1...cyl. 3 in display fields 1 and 3.
Target value: 0
– Press → .
– Analysis of display group 15 and display field 16 ⇒ page 41
– Change display group 16, as follows:

Arosa 1997 ➤
-V.A.G.1551- : press 3
-V.A.G. 1552- : press ↑
Read measurement value block 16 →
1 2 3 4
– The display reads: (1...4 = display fields)

– Check ignition faults in display field 1, cyl. 4.
Target value: 0
– Press → .
– Analysis of display group 15 and display field 16 ⇒ page 41 .

Service
Workshop Manual
Arosa 1997 ➤
085 5-speed manual gearbox
Edition 10.02

Service
Repair Group
00 - Technical data
30 - Clutch
35 - Gears, Shafts

Copyright © 2015 Seat S.A S01B0858620

Arosa 1997 ➤
085 5-speed manual gearbox - Edition 10.02
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 ...................................................................... 1
1.1 Code letters, group numbers, ratios, filling quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Power transmission diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Calculation of the gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 General instructions for gearbox repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Clutch actioning: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Working of clutch cables with automatic adjustment: checking . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Clutch cable: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Clutch cable for vehicles with steering wheel on the right: removing and installing . . . . . . 19
1.4 Clutch pedal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Clutch release assembly: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Clutch: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Gear drive mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.1 by copyright.
Protected Gear drive
Copyingmechanism assembly
for private or commercial position
purposes, . . . . is. not
in part or in whole, ..................
............... 30
1.2respect toGear stick protective
the correctness of information incover: repairing
this document. Copyright .by. SEAT
. . . .S.A.
..................... ............... 32
1.3 Gear lever dust sleeves and knob: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.4 Gear lever: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.5 Cables and drive mechanism: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.6 Gear drive mechanism: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.7 Gear box actioning: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.1 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Oil level for gears: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Gearbox: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1 Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5 Clutch housing: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6 Selector finger and control bush: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1 Input shaft: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2 Input shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Layshaft: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4 Layshaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Flanged shaft oil seals: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.1 Flanged shaft oil seals: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2 Differential: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3 Differential crown: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.1 Differential crown: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4 Differential: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5 Adjustment chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Contents i
Arosa 1997 ➤
ii Contents
Arosa 1997 ➤
Location on the gearbox
The 085 5-speed manual gearbox is fitted to the Arosa 1997 ▸,
combined with the 4 cylinder engine.
Code letters and date of manufacture -arrow 1- , type of gearbox
arrow -arrow 2- .
Type of gearbox
085 5-speed manual gearbox -arrow 2- .
Code letters and date of manufacture of gearbox -arrow 1-

Example: DXD 15 01 8
I I I l
I I I l
Identifying Day Month Year -1998-
of manufacture
The additional data refers to the manufacturing process.
Note!
The gearbox code letters are also on the vehicle data plate.
1.1 Code letters, group numbers, ratios, filling quantities

Manual gearbox 085 5-speed
Code letters DED DKC 1) DKF
Correspondence Type Arosa 1997 ▸ Arosa 1997 ▸ Arosa 1997 ▸
Engine 1.7 ltr. - SDI 44 KW 1.0 ltr. - 37 KW 1.4 ltr. - 44 KW
1.4 ltr. 16v - 55 KW
Gear ratio Z1 :Z2 Final drive 60 : 18 = 3,333 64 : 15 = 4,267 62 : 16 = 3,875
1st gear 38 : 11 = 3,455 38 : 11 = 3,455 38 : 11 = 3,455
2nd gear 43 : 22 = 1,955 43 : 22 = 1,955 43 : 22 = 1,955
3rd gear 40 : 32 = 1,250 40 : 32 = 1,250 40 : 32 = 1,250
4th gear 42 : 45 = 0,933 41 : 46 = 0,891 42 : 45 = 0,933
5th gear 37 : 50 = 0,740 37 : 50 = 0,740 37 : 50 = 0,740
1. 1
Arosa 1997 ➤

6th gear - - -
Reverse 44 : 13 = 3,385 44 : 13 = 3,385 44 : 13 = 3,385
Speedometer 12 : 20 = 0,600 12 : 20 = 0,600 12 : 20 = 0,600
1) Vehicles for France.
Code letters DED DKC 2) DKF

Filling amount 2.7 litres
Specification Gear oil G50 SAE 75W90 (synthetic oil) 3)
Clutch actioning mechanical mechanical mechanical
Clutch plate ∅ 190 mm 190 mm 190/200 mm
Drive shaft flange 89 mm 89 mm 89 mm
itotal in top gear 2,466 3,158 2,868
2) Vehicles for France.
gear authorised
oil, observations ⇒ page
by SEAT S.A. 11does
3) Do not mix different permitted
types ofunless SEAT S.A . not guarantee or accept any liability with
Code letters DKG DPX DQW
Engine 1.0 ltr. - 37 KW 1.7 ltr. - SDI 44 KW 1.4 ltr. - 44 KW
1st gear 38 : 11 = 3,455 38 : 11 = 3,455 38 : 11 = 3,455
2nd gear 44 : 21 = 2,095 43 : 22 = 1,955 43 : 22 = 1,955
3rd gear 42 : 29 = 1,448 40 : 32 = 1,250 40 : 32 = 1,250
4th gear 45 : 41 = 1,098 42 : 45 = 0,933 42 : 45 = 0,933
5th gear 41 : 46 = 0,891 37 : 50 = 0,740 37 : 50 = 0,740
6th gear - - -
Reverse 44 : 13 = 3,385 44 : 13 = 3,385 44 : 13 = 3,385
Speedometer 12 : 20 = 0,600 12 : 20 = 0,600 12 : 20 = 0,600
Code letters DKG DPX DQW

4) Do not mix different types of gear oil, observations ⇒ page 11 .

Code letters DXD DXJ DXP
Engine 1.0 ltr. - 37 KW 1.4 ltr. - 74 KW 1.4 ltr. - 44 KW

Arosa 1997 ➤

1st gear 38 : 11 = 3,455 38 : 11 = 3,455 38 : 11 = 3,455
2nd gear 44 : 21 = 2,095 44 : 21 = 2,095 43 : 22 = 1,955
3rd gear 42 : 29 = 1,448 42 : 29 = 1,448 40 : 32 = 1,250
4th gear 45 : 41 = 1,098 45 : 41 = 1,098 42 : 45 = 0,933
5th gear 41 : 46 = 0,891 41 : 46 = 0,891 37 : 50 = 0,740
6th gear - - -
Reverse 44 : 13 = 3,385 44 : 13 = 3,385 44 : 13 = 3,385
Speedometer 12 : 20 = 0,600 12 : 20 = 0,600 12 : 20 = 0,600
Code letters DXD DXJ DXP


Code letters DXQ ESY ETB
Engine 1.7 ltr. - SDI 44 KW 1.0 ltr. - 37 KW 1.4 ltr. - 74 KW
1st gear 38 : 11 = 3,455 38 : 11 = 3,455 38 : 11 = 3,455
2nd gear 43 : 22 = 1,955 44 : 21 = 2,095 44 : 21 = 2,095
3rd gear 40 : 32 = 1,250 42 : 29 = 1,448 42 : 29 = 1,448
4th gear 42 : 45 = 0,933 45 : 41 = 1,098 45 : 41 = 1,098
5th gear 37 : 50 = 0,740 41 : 46 = 0,891 41 : 46 = 0,891
6th gear - - -
Reverse 44 : 13 = 3,385 44 : 13 = 3,385 44 : 13 = 3,385
Speedometer 12 : 20 = 0,600 12 : 20 = 0,600 12 : 20 = 0,600
Code letters DXQ ESY ETB

Specification Gear oil G50 SAE 75W90 (synthetic oil) 6) Gear oil API GL4
75W90 (high-per‐
formance synthetic) 6)
Clutch plate permitted
∅Protected 190 mm 190 mm
200 mm
Drive shaft flange respect to the correctness of information in 89 mm
this document. Copyright by SEAT 89 mm
S.A. 89 mm
1. 3
Arosa 1997 ➤

Code letters ETD ETF FFE
Engine 1.4 ltr. - 44 KW 1.7 ltr. SDI - 44 KW 1.0 ltr. - 37 KW
1st gear 38 : 11 = 3,455 38 : 11 = 3,455 38 : 11 = 3,455
2nd gear 43 : 22 = 1,955 43 : 22 = 1,955 44 : 21 = 2,095
3rd gear 40 : 32 = 1,250 40 : 32 = 1,250 42 : 29 = 1,448
4th gear 42 : 45 = 0,933 42 : 45 = 0,933 45 : 41 = 1,098
5th gear 37 : 50 = 0,740 37 : 50 = 0,740 41 : 46 = 0,891
6th gear - - -
Reverse 44 : 13 = 3,385 44 : 13 = 3,385 37 : 11 = 3,364
Speedometer 12 : 20 = 0,600 12 : 20 = 0,600 12 : 20 = 0,600
Code letters ETD ETF FFE
Specification Gear oil G50 SAE 75W90 (synthetic oil) 7) Gear oil API GL4
75W90 (special oil) 7)
Clutch plate ∅ 190 mm 190 mm 190 mm

Code letters FFG FHX FPQ
Engine 1.7 ltr. SDI - 44 KW 1.4 ltr. - 74 KW 1.4 ltr. - 44 KW
1st gear 38 : 11 = 3,455 38 : 11 = 3,455 38 : 11 = 3,455
2nd gear 43 : 22 = 1,955 44 : 21 = 2,095 44 : 21 = 2,095
3rd gear 40 : 32 = 1,250 42 : 29 = 1,448 42 : 29 = 1,448
4th gear 42 : 45 = 0,933 45 : 41 = 1,098 45 : 41 = 1,098
5th gear 37 : 50 = 0,740 41 : 46 = 0,891 40 : 47 = 0,851
6th gear - - -
Reverse 37 : 11 = 3,364 37 : 11 = 3,364 37 : 11 = 3,364
Speedometer 12 : 20 = 0,600 12 : 20 = 0,600 12 : 20 = 0,600

Filling amount 2,7 Liter

Arosa 1997 ➤

Specification Gear oil API GL4 Gear oil API GL4 Gear oil API GL4
75W90 (special oil) 8) 75W90 (high-per‐ 75W90 (special oil) 8)
formance synthetic) 8)
1. 5
Arosa 1997 ➤
2 Power transmission diagram

The -arrows- indicate direction of movement
Designation
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Layshaft
6 - Differential
The -arrows- indicate direction of movement

Ratio

Arosa 1997 ➤
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse
A - Final drive
T - Speedometer action
2. Power transmission diagram 7

Arosa 1997 ➤
3 Calculation of the gear ratio “i”

The gear ratio is obtained by dividing the number of teeth on the
driven gear by the number of teeth on the driving gear.
Example:
5th gear Conical gears
Driving gear 47 (Z1 = Primary) 15 (Z1 = Sprocket)
(primary)
Driven gear 40 (Z2 = Secondary) 64 (Z2 = Crown)
(secondary)
i = Z2 : Z1
This way we can find out:
iG = Gear ratio of a gear
iG = Z2 SecondaryZ1 Primary = 4047 = 0,851
iA = Gear ratio of the differential
iA = Z2 CrownZ1 Sprocket = 6415 = 4,267
itotal = Total gear ratio
Is obtained by multiplying the gear ratios of the longest gear and
the conical gears.
itotal = iG x iA = 0,851 x 4,267 = 3,631

Arosa 1997 ➤
4 General instructions for gearbox re‐

pairs
To achieve a perfect and successful repair of the gearbox it is
imperative to keep everything scrupulously clean and use the
correct tools in perfect working order. When carrying out repairs
bear in mind basic safety rules.
Here is a summary of general instructions for certain repair jobs,
which would otherwise appear several times in the different sec‐
tions of this Workshop Manual. Thus, these instructions must be
taken into account for this Workshop Manual.
Gearbox
♦ Before fitting the gearbox to the engine, make sure that the
dowel pegs between both elements are in good condition and
correctly seated.
♦ If the gearbox is replaced, fill with oil to the lower edge of the
filling hole.
♦ Filling levels and type of oil ⇒ page 1 , Code letters, group
numbers, ratios, filling quantities.
Gaskets
♦ Renew all O-rings
♦ Before applying sealing products (liquid gasket), clean all con‐
tact surfaces thoroughly and use -AMV 188 200 03- sealing
paste.
♦ Apply paste uniformly, not too thick.
Oil seals
♦ Before fitting, coat lightly with gearbox oil on the outside sur‐
face and fill the space between oil lips with grease -arrow- .
♦ Once the oilseals are fitted, check the oil level and top up if
necessary.
Safety locks

Arosa 1997 ➤
♦ Renew all safety rings, taking care not to stretch them exces‐
sively when fitting.
♦ The safety rings must be perfectly seated in their groove.
♦ Renew all split pins.
♦ On fitting split pins, their groove must be longitudinal with re‐
spect to the trajectory of the force, as in the illustration.
Nuts and bolts
♦ Loosen and tighten nuts and bolts on covers and casings in
diagonal sequence.
♦ For delicate parts, e.g. the clutch press, do not tilt them and
always loosen the bolts gradually and in diagonal sequence.
♦ The torque settings refer to non-oiled nuts and bolts.
♦ All locknuts must be renewed.
Bearings
♦ Needle bearings must be fitted with the thickest side plate fac‐
ing the assembly tool.
♦ All gearbox bearings will be fitted after having been lubricated
with gearbox oil. Lubricate with special care to measure friction
torque.
♦ Bearings corresponding to the same shaft will be all replaced
together. Use bearings from the same manufacturer as far as
possible.
♦ Bearings should be heated to 100 °C approx. before fitting.
Use electric blower -SAT 1416- and the digital thermometer -
SAT 4002- to check temperature.
♦ Do not mix external tracks of the same size bearings; they are
matched pairs.
Shims
♦ Before fitting shims, check thickness measuring several points
of the surface with a micrometer.
♦ The existence of different thickness shims will enable the se‐
lection of the right one for the application.
♦ Shims must not have lips or be damaged.
♦ Only fit shims in perfect state.
Syncromesh rings Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Do not mix up rings from different
respectgears. If theyofare
to the correctness to bein re-
information this document. Copyright by SEAT S.A.
used, always fit to the same gear they came from.
♦ Check for wear and replace if necessary.
♦ On fitting coat with gearbox oil.
Gears
♦ Before fitting clean thoroughly. First heat to 100 °C approx.
Use electric blower -SAT 1416- and the digital thermometer -
SAT 4002- to check temperature.
Removal of outer rings of roller bearings and bearing bushes with
tool set -T20140-
Remove the outer rings of the roller bearings or the bearing bush‐
es as follows:
– Measure (if possible) the internal diameter of the external ring
of the roller bearing or the bearing bush.

Arosa 1997 ➤
– Select the correct clamp from the tool set according to:
If the diameter measured is less than 30 mm:
– Fit the plunger for small clamps /10 and the correct clamp for
internal diameters.
If the diameter measured is more than 30 mm:
– Fit the plunger /28 with clamp /29 and the correct claws for the
internal diameter.
– Screw the nut /5 and washer on the plunger.
– Place the tool on the outer ring of the roller bearing or the
bearing bush and fit the threaded legs so that they are firmly
secured.
Note!
The legs of bridge /1 have different-sized cut-outs -arrows- to fa‐

cilitate the support on surfaces with different heights, edges or
ribs.
– Adjust the threaded legs of the bridge /1 so that the bridge is

parallel to the surface of the casing.
– Open the clamp until the bar is housed below the exterior roller
bearing or the bearing bush.
– Action the extractor until the outer ring of the roller bearing or
bearing bush is extracted.
Note!
Due to the fact that on some occasions the space for the claw is
minimal, a first extraction should be carried out to remove the
bush, and then open the claws as far as possible to ensure the
maximum contact surface. Then continue with the extraction.
Oils
♦ New gearbox code letters have been Protected
introduced, withCopying
by copyright. a new for private or commercial purposes, in part or in whole, is not
mineral gear oil -API GL4 SAE 75W-permitted
. This type of oil must
only be used in the specified gearboxes and never in those

that used the former oil -API GL4 SAE 75W90- (synthetic oil).
♦ Oils with different denominations and standards should never
be mixed as this modifies the properties of the lubricant

Arosa 1997 ➤
30 – Clutch
1 Clutch actioning: repairing
Note!
♦ With the ignition switched off, disconnect the earth strap.

♦ For vehicles fitted with a coded radio, first check the anti-theft code.
♦ Lubricate all points of support and sliding surfaces with -G 052 142 A2- grease.
1 - Support
❑ First remove the steer‐
ing column before re‐
moving the bracket ⇒
Running gear, axles,
steering; Rep. Gr. 48 ;
Airbag, steering wheel,
steering column
2 - 2 Nm
❑ For support to the body
3 - Support
4 - Clutch cable
❑ Checking functioning
⇒ page 13
⇒ page 14
5 - Bellows
❑ Fit to the bulkhead
6 - Housing plate
❑ For the clutch cable in
the clutch pedal
7 - Support
❑ Fit so that the rubber
guide -arrow- is in the
orifice in theProtected
housing by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Rubber stop permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Fit to the support stand
9 - 25 Nm
10 - 25 Nm
❑ 5 units
❑ For the support stand to
the servobrake threaded bolt
11 - Washer
12 - Bearing bush
❑ For the clutch pedal
❑ Coat with MoS2 grease
13 - Clutch pedal
Removing and installing

Arosa 1997 ➤
14 - Brake and clutch pedal shaft

15 - Bearing bush
❑ To fit in the steering column
16 - Bearing bush
❑ Insert in the bearing bush ⇒ Item 15 (page 13) - and then seat the brake pedal
17 - Brake pedal
18 - Washer
19 - 25 Nm
20 - Support
❑ It is bolted together with the battery console
21 - Gearbox
1.1 Working of clutch cables with automatic

adjustment: checking
• The clutch adjustment mechanism must not be damaged.
– Press clutch pedal to the floor at least 5 times.
– Move the clutch release lever in the opposite direction to ac‐
tivation -arrow- , approx. 10 mm. The clutch release lever
should move freely.
Note!
♦ To avoid premature clutch cable replacement, take note of the

following during the checking operations:
♦ Press the clutch at least 5 times before repeating the func‐
tioning checks.
♦ Wait for the moment when the clutch release lever cannot be
moved in the opposite direction to actioning before setting up
the clutch cable adjustment mechanism.
If the functioning of the readjustment mechanism cannot be tested

as described in page 30-5, it may be outside service tolerances
due to mistreatment (e.g. if it has been hooked very tensely to the
clutch release lever).
Symptom:
The clutch release lever on the gearbox connot move in the op‐
posite direction to actioning
Protected even
by copyright. after
Copying pushing
for private the pedal
or commercial several
times.
A non-functioning adjustment mechanism makes the clutch slip

and thus wear prematurely.
1. Clutch actioning: repairing 13

Arosa 1997 ➤
1.1.1 Putting clutch cable to work with auto‐

matic adjustment
– Remove the clutch cable from its location on the clutch release
lever, pulling in the -direction of the arrow- .
– Extract the rubber stop from its location in the gearbox casing.
– Slide cable -A- several times until the adjustment mechanism

-B- can be compressed.
– Tension the clutch cable with the tensioning cap or the strap
⇒ page 14 .
Hook the clutch cable to the clutch release lever as described

below:
– Fit the rubber stop -3- into its location in the gearbox casing.
– Fit the clutch cable into its location on the clutch release lever
-1- .
– Remove the automatic adjustment mechanism tensioning
cap.
– Checking the functioning of the clutch cable with automatic
adjustment ⇒ page 13 .
1.2 Clutch cable: removing and installing

– Before removing the clutch cable with automatic adjustment,
check functioning ⇒ page 13 .
1.2.1 Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– For removing and fitting the clutch cable with automatic ad‐
justment, the automatic adjustment mechanism must be com‐
pressed with the tensioning cap as shown in the illustration.
– It can also be compressed with the retaining strap shown in
the illustration.

Arosa 1997 ➤
– The ring -arrow- of the retaining strap must be cut.

Both the tensioning cap and the retaining strap to compress the
adjustment mechanism are supplied with the new clutch cables.
– Press clutch pedal to the floor at least 5 times.
– Move the clutch release lever in the opposite direction to ac‐

tivation, approximately 10 mm. The clutch release lever should
move freely.
Note!
In this way the clutch cable automatic adjustment mechanism is

tensioned.
– Fit the tensioning cap -A- or the retianing strap onto the two
projections -arrows- of the automatic adjustment mechanism.
lever.
– Extract the rubber stop from its location in the gearbox casing.
– Unhook the cable from the clutch pedal -arrow- ⇒ page 19 .

Arosa 1997 ➤
– Extract the clutch cable from its support -arrow- and remove.
1.2.2 Fitting (clutch cable tensioned)

– Pull the clutch cable through the bulkhead and fit the bellows.
– Lubricate the clutch cable securing/clutch pedal area with -G
052 142 A2- grease.
– Fit the clutch cable to the clutch pedal -arrow- .
Fit the clutch cable to the clutch release lever as described below:
– Pull the sleeve -2- in the direction of vehicle movement and fit
the clutch cable into its location on the clutch release lever
-1- .
– Secure the clutch cable to its location -arrow- .
Note!
On securing the clutch cable to its location do not bend, otherwise

the automatic adjustment mechanism could stop working prop‐
erly.

Arosa 1997 ➤
– Remove the retaining strap or the automatic adjustment mech‐

anism tensioning cap -arrows- .
Once the functioning has been checked, continue assembly
⇒ page 19 , Clutch pedal: removing and fitting.
1.2.3 Fitting (clutch cable not tensioned)

– Pull the clutch cable through the bulkhead.
– Lubricate the clutch cable securing/clutch pedal area with -G
052 142 A2- grease.
– Hook the clutch cable onto the clutch pedal -arrow- .
– Pull the end of the cable in the -direction of the arrow 1- and
maintain pulled. Slide the sleeve with adjustment mechanism
-B- several times in the direction of the arrow
-direction of the arrow 2- until it can be compressed aginst the
bulkhead wall.

Arosa 1997 ➤
– Fit the tensioning cap -A- or the retaining strap onto the two
projections -arrows- of the automatic adjustment mechanism.
– Fit the bellows to the wall of the bulkhead.
Fit the clutch cable to the clutch release lever as described below:
– Pull the sleeve -2- in the direction of vehicle movement and fit
the clutch cable into its location on the clutch release lever
-1- .
– Secure the clutch cable to its location -arrow- .
Note!
On securing the clutch cable to its location do not bend, otherwise

the automatic adjustment mechanism could stop working prop‐
erly.
– Remove the retaining strap or the automatic adjustment mech‐

anism tensioning cap -arrows- .
Once the functioning has been checked, continue assembly
⇒ page 19 , Clutch pedal: removing and fitting.

Arosa 1997 ➤
1.3 Clutch cable for vehicles with steering

wheel on the right: removing and instal‐
ling
1.3.1 Removing
– Loosen nut and adjustment counter nut -arrow- .
lever.
– Remove the rubber stop from its location in the gearbox cas‐
ing.
– Unhook the cable from the clutch pedal ⇒ page 19 .
– Separate the cable from the bracket on the bulkhead and re‐
move it.
1.3.2 Installing
– Lubricate the attacment point for the cable in the clutch pedal
withProtected
MoS2 bygrease.
– Pull therespect
cableto through theof bulkhead
the correctness and
information in this fit theCopyright
document. bellows. by SEAT S.A.
– Hook the cable to the clutch pedal.

– Fit by pressing the rubber stop -A- into its housing.
– Fit cable -B- on the clutch release lever.
– Fit the cable to the bracket on bulkhead.
1.3.3 Adjusting the clutch

– Loosen nut and adjustment counter nut -arrow- .
– Adjust the clutch by turning the adjusting nut until clutch pedal
has 15 - 20 mm play.
– Loosen nut and adjustment counter nut.
1.4 Clutch pedal: removing and installing


Arosa 1997 ➤
1.4.1 Removing
strap.
Note!
code.
– Remove shelf and footwell cover on the driver's side: ⇒ Body‐

work repairs, installation work, interior; Rep. Gr. 68 ; Shelves,
trim, covers and trays .
– Unbolt the relay plate and move aside.
Vehicles with automatic adjustment clutch cables
– Tension the clutch cable and remove it from the gearbox
⇒ page 14 .
Right hand drive vehicles
– Remove clutch cable from gearbox ⇒ page 19 .
– Remove the cables from their housings, on the protective cov‐
er of the clutch pedal.
– Remove the bracket block cover, pressing the tab -arrow 1-
and pulling the cover upwards -arrow 2- .

Arosa 1997 ➤
– Release the cable from the clutch pedal -arrow- .
– Loosen the hexagon bolt -arrow 1- from the brake and clutch
pedal shaft and remove with its washer.
– Carefully remove the pedal shaft -arrow 2- . While keeping the
brake pedal in its position from the right -arrow 1- using a
punch.
Caution
Do not move the brake pedal or the steering column. These

have no support once the pedal shaft has been removed.
Do not move the brake pedal or the steering column. These have
no support once the pedal shaft has been removed.
1.4.2 Installation
– Lubricate contact surfaces with MoS2 grease.
– Fit the clutch pedal to the pedal shaft with the bush and the
washer.
– Fit the clutch and brake pedal shaft as far as it will go; move
the brake pedal if necessary.
– Remove bolt M8 or the punch on the right.
– Fit the washer and tighten the nut to 25 Nm.
– Secure the clutch cable to the clutch pedal -arrow- .
– Fit the clutch cable on the gearbox ⇒ page 14 .

Arosa 1997 ➤
– Fit the cover to the support block -arrows- .

– Bolt on the relay plate and the fuseholder; check the cable and
relay connectors; securing them if necessary.
– Fit the cover and the shelf situated below the dash panel: ⇒
Bodywork repairs, installation work, interior; Rep. Gr. 68 ;
Shelves, trim, covers and trays .
Clutch cables with automatic adjustment
Clutch cable for vehicles with steering wheel on the right
– Carrying out clutch pedal adjustment ⇒ page 19 .

Arosa 1997 ➤
2 Clutch release assembly: repairing

equipment required
♦ Kit XZN -U-40020-
♦ Extractor -U-40087-
Note!
♦ To carry out any work on the clutch release lever, it will be necessary to remove the gearbox from the vehicle
⇒ page 44 .
♦ Lubricate all the bearings and contact surfaces with -G 000 603- .
2. Clutch release assembly: repairing 23

Arosa 1997 ➤
1 - Clutch release lever

❑ Check smoothness of
operation
❑ Fitting position
⇒ page 26
2 - Oil seal
❑ Renew
❑ Remove levering care‐
fully with a screwdriver
3 - Upper bearing bush
4 - Clutch housing
❑ Repairing ⇒ page 70
5 - Lower bearing bush
6 - Circlip permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Sepatate them by car‐
fully levering with a
screwdriver, before re‐
moving the clutch re‐
lease fork
7 - Clutch release fork
❑ Fit it with the clutch re‐
lease lever ⇒ page 26
8 - Clutch release collar
❑ Never clean. Except
with a cloth
❑ Replace noisy bearings
9 - Securing clip
❑ Fit on the clutch release collar
10 - Support spring
❑ Fit over the retaining pin and then in the clutch release collar
11 - 18 Nm
❑ Self-locking
❑ Always renew
❑ To separate and fit use a spanner of the right diameter from tool -U-40020-
12 - Guide sleeve
❑ Lubricate the clutch release bearing guide

Arosa 1997 ➤
Remove the upper bush bearing

– Remove the upper bush bearing from the clutch housing with
tool -U-40088- (side B).
Remove the lower bush bearing

– Place tap from tool -U-40087- on the bush and screw as far as
it will go.
– Action the hammer tool until the bush is removed.
Fitting the lower bush bearing

– Fit the lower bush bearing of the clutch housing with tool -
U-40088- (side B).
– As far as it will go.
Fitting the upper bush bearing

– Fit the upper bush bearing of the clutch housing with tool -
U-40088- (side B).
2. Clutch release assembly: repairing 25

Arosa 1997 ➤
Fitting the articulation flange oil seal

– Coat the oil seal with grase -G 000 603- .
Fit the clutch release lever and the clutch release fork
– Fit the clutch release lever with the clutch release fork so that
the reinforced tooth -arrows- of the lever shaft coincides with
its housing in the fork -arrow- .

Arosa 1997 ➤
3 Clutch: repairing
♦ Guide centraliser -U-10050-10-
♦ Holding tool -T20075 A-
Note!
♦ Replace any clutch plates and pressure plates with damaged or loose rivets.
♦ If replaced fit clutch and pressure plate according to the Parts Catalogue.
3. Clutch: repairing 27
Arosa 1997 ➤
1 - Engine flywheel
❑ Check that the centring
pins are correctly seat‐
ed
❑ The contact surfaces
with the clutch plate
must be free from
grease and without
grooves
❑ Removing and fitting the
flywheel ⇒ Rep. Gr. 13 ;
Cylinder block, sealing
flange and flywheel: re‐
2 - Clutch plate
❑ Diameter ⇒ page 00-3,
Code letters, group
numbers, ratios, filling
quantities
❑ If replaced fit plate and
pressure plate accord‐
ing to the Parts Cata‐
logue
❑ Lightly lubricate the
splines
❑ Assembly position: The
spring cage should be
facing the clutch press
❑ Centring the clutch plate Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 29 respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!
Clean the input shaft and clutch

plate splines. Elimimate rust from
used clutch plates. Apply a very thin
layer of -G 000 100- grease to the
input shaft splines. Move the clutch
plate backwards and forwards on
the input shaft until it slides freely.
Eliminate excess grease.
3 - Clutch press
❑ Check the ends of the diaphragm ⇒ page 29
Note!
The clutch presses are greased and

protected from corrosion. Only
clean the contact surface with the
clutch plate of any trace of grease or
oil, otherwise the life of the clutch
will be reduced.
4 - 20 Nm
❑ Loosen and tighten diagonally several times

Arosa 1997 ➤
Removing and fitting the clutch press and centring the clutch plate
– To remove and fit the clutch press, lock the flywheel with tool
-T20075 A- .
– Use tool -U-10050- with the right spline adaptor to centre the
clutch plate.
Note!
♦ The contact surfaces of the clutch press and the clutch plate
must rest entirely on the flywheel.
♦ Tighten the securing nuts uniformly and diagonally to avoid
damaging the press centring holes and the flywheel centring
pins.
Checking the ends of the diaphragm -arrows-

• The wear limit is up to half the thickness of the diaphragm.
3. Clutch: repairing 29
Arosa 1997 ➤
1 Gear drive mechanism: repairing
1.1 Gear drive mechanism assembly position

-Arrow A- : gear selection movement
-Arrow B- : Selection movement
A - Connection cable to con‐

nect gears
B - Selection cable for track se‐
lection
C - Thermal protection plate
1 - Selection rod
2 - Return lever with selector
rod
3 - Countersupport
❑ Bolted to the gearbox
and the subframe
Note!
Lubricate all the articulations and sliding surfaces with -G 052 142 A2- grease.

Arosa 1997 ➤
I - Gear lever protective cover:

repair ⇒ page 32
II - Gear lever: repair
⇒ page 33
III - Cables and drive mecha‐
nism: removing and installing
⇒ page 38
Gear drive mechanism: Re‐
moving and fitting
⇒ page 38

Arosa 1997 ➤
1.2 Gear stick protective cover: repairing
1 - Gear lever knob

❑ Fit to the gear lever
⇒ page 32
2 - Dust sleeve
❑ Remove and fit together
with the knob before fit‐
ting ⇒ page 32
3 - Attachment bush
4 - Clip
❑ To secure the knob to
the gear lever
5 - Frame
6 - Rubber cover
❑ Not fitted to all vehicles
7 - Plastic nut
❑ permitted
To secure
unless the console toS.A. SEAT S.A does not guarantee or accept any liability with
authorised by SEAT
the protective cover of information in this document. Copyright by SEAT S.A.
8 - Spacer
❑ Between the console
and the protective cover
9 - Gasket
❑ Between the protective
cover and the bodywork
❑ Self-adhesive
❑ Stick it onto the protec‐
tive cover
10 - 15 Nm
11 - Lever protection box
12 - Gasket
❑ Self-adhesive
❑ Stick it under the protective cover
13 - Gasket
❑ Between the actioning cables and the protective cover
14 - 15 Nm
15 - Central console
1.3 Gear lever dust sleeves and knob: re‐

moving and fitting

Arosa 1997 ➤
♦ Pliers -T20072-
1.3.1 Removing
– Turn the dust sleeve inside out.
– Release the clip by levering with a screwdriver and pull the
knob upwards.
1.3.2 Fit
– Turn the dust sleeve inside out and insert the gear lever knob
-arrow- .
– Fit the bush into its housing and secure it.
Note!
The fixing bush tabs must be fitted in the knob housings.
– Place the clip on the knob and fit it onto the gear lever, pushing
it on as far as it will go.
– Tighten the gear lever knob clamp.
Note!
To tighten the clamp one can also use the -T20072- tool.
– Fit the dust cover onto the centre console.

1.4 Gear lever: repairing

Arosa 1997 ➤
1 - 25 Nm
❑ To secure the protective
cover to the bodywork
2 - 25 Nm
❑ To secure the protective
cover to the bodywork
3 - Cover
4 - Selection cable
❑ Connected to the selec‐
tor bracket
5 - Connection cable
❑ Connected to the gear
lever
6 - Pin
7 - 15 Nm
❑ To attach the support
bolt to the support plate
8 - Support bolt
9 - Support plate
10 - Safety washer
11 - Bearing bush
❑ It fits in only one position
12 - Selector bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Selector casing respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Fit to the support plate

after fitting the complete
gear lever
14 - Cap
15 - Bearing bush
16 - Legged spring
17 - Guide bush
❑ Fit it into the bearing bush
18 - Bush
19 - Safety washer
20 - Spacer
22 - Gear lever guide
23 - Gear lever
24 - Damping washer
1.5 Cables and drive mechanism: removing

and installing

Arosa 1997 ➤

Arosa 1997 ➤
1 - Connection cable
⇒ page 30
2 - Track selection cable
⇒ page 30
❑ Fit before fitting the con‐
nection cable
3 - Safety washer
4 - Insulator
❑ Remove and fit with a
drift
5 - Pin
6 - Washer permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7 - Return lever
❑ Remove the bracket be‐
fore removing it
⇒ page 39
⇒ page 38
8 - Selector rod
⇒ page 38
9 - Spherical head
10 - 20 Nm
❑ Renew
11 - Control finger
12 - 20 Nm
13 - Safety washer
14 - Bearing bush
❑ For the selection rod
❑ Remove the bracket before removing the bush
15 - Holding washer
16 - 25 Nm
17 - Support
18 - Bearing bush
❑ For the coupling lever
❑ Remove the bracket before removing the bush ⇒ page 39
❑ It fits in only one position
❑ Insert by pressure
19 - Bolt
❑ To secure the gearbox to the engine
❑ Threaded for the counter-hold

Arosa 1997 ➤
20 - Washer
21 - Nut
❑ Fit to the square side -arrow- in the selection rod
22 - Selection rod
❑ Remove the bracket before removing it ⇒ page 39
❑ Fitting position ⇒ page 38
23 - Washer
24 - Insulator
❑ Remove and fit with a drift
25 - Combi bolt, 20 Nm
26 - 15 Nm
27 - Bracket
❑ To secure the counter-hold to the subframe
28 - Washer
29 - 20 Nm
30 - Countersupport
31 - 20 Nm
32 - 15 Nm
❑ Self-locking
33 - Rubber washer
Removing the selector rod bush-bearing
Removing the return lever bush-bearing

Arosa 1997 ➤
Assembly position of the connection rod, the return lever, selector

rod, control finger
1- Control cable
2- Selector rod: it is inserted into the control finger -arrow-
3- Selector cable
4- Coupling lever
5- Support block
6- Control finger
7- Selector rod
Note!
The counter-hold, for the control and selector cable is not show
in the illustration.
1.6 Gear drive mechanism: removing and

fitting
1.6.1 Remove the actioning cables together

with the protective box and the counter-
hold
Removal
strap.
Note!
code.
– Release the dust sleeve from the frame.

– Turn the dust sleeve inside out and remove the gear lever
knob, losening the clip -arrow 1- .
– Unscrew the centre console securing bolts -arrow 2- .
– Remove the insulation tray,byifcopyright.
Protected fitted:Copying
⇒ Bodywork
for private orRepairs, in‐
stallation work, exterior;
permittedRep. Gr. 50by; Body,
unless authorised SEAT S.A.front . does not guarantee or accept any liability with
SEAT S.A
– Remove the front section of the exhaust pipe: ⇒ Rep. Gr. 26 ;
Exhaust system components: removal and fitting .

Arosa 1997 ➤
– Remove the front beam -arrow- and the rear, located under
the exhaust system.
– Remove of the front and rear themal insulation plates.
– Remove the control cable -arrow A- and the selector cable

-arrow B- .
– Remove the counter-hold bracket -arrow- from the subframe.
– Unscrew the counter-support bolt -arrow- and remove the sup‐

port. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unbolt the gear lever protection box from
respect to thethe bodywork.
– Remove the actioning cables together with the protective box

and the counter-hold.
Installation
– Adjusting the gearbox drive mechanism ⇒ page 40 .
1.6.2 Removing and fitting the selector rod

bracket and the return lever
Removal
– Remove the insulation tray, if fitted: ⇒ Bodywork Repairs, in‐
stallation work, exterior; Rep. Gr. 50 ; Body, front .

Arosa 1997 ➤
– Remove the control cable -arrow 1- and the selector cable

-arrow 2- .
– Unbolt the selector rod with ball joint from the control finger
-arrow 3- .
– Remove the control finger by loosening the bolt -arrow 4- .
– Unbolt the selector rod bracket from the gearbox -arrow- .

A - long socket spanner, e/c 13 mm
Installation
– Adjusting the gearbox drive mechanism ⇒ page 40 .
1.7 Gear box actioning: adjusting

♦ Adjustment tool -U-40056-

Arosa 1997 ➤
Note!
♦ In order to adjust the gearbox drive correctly, it is necessary

to take the following points into account:
♦ The vehicle must have its four wheels securely on the ground
or on a parallel elevator.
♦ All gearbox actioning elements must be in perfect working or‐
der.
♦ The gearbox action must be smooth, with no harshness.
♦ The gearbox, the clutch actioning and the clutch, must be in
perfect condition.
Prerequisites
• Gearbox in neutral
– Loosen bolt -A-
Protected and nut
by copyright. -B-foruntil
Copying the
private control cable
or commercial purposes,and
in partthe
or inball
whole, is not
jointpermitted
of the selection rod/selector cable can move freely in the
slotted holes.
– Remove the gear lever knob with the dust sleeve ⇒ page 38 .
– Remove the centre console frame.

– Removing the center console: ⇒ Bodywork repairs, installa‐
tion work, interior; Rep. Gr. 68 ; Shelves, trim, covers and
trays .
– Loosen the screw -A- .

– Fit tool -U-40056- .
– Move the hook for securing the tool under the support plate
and tighten bolt -B- .
– Move the gear lever to the left until it it locked in the hole in the
sliding guide.
– Push the gear lever with the sliding guide to the left
-direction of arrow- as far as it will go, and lock the guide by
tightening bolt -C- .

Arosa 1997 ➤
– Move the gear lever to the right -arrow- , until it it locked in the
hole in the sliding guide.
– Tighten bolt -A- to 15 Nm.
– Tighten bolt -A- to 25 Nm and bolt -B- to 20 Nm.
Note!
When tightening, do not move the control finger or the ball joint.
– Remove the tool from the lever.

Functioning permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• The gear stick must be in neutral position in the 3rd/4th gear
track.
– Engage clutch.
– Select all the gears several times. Check that the reverse gear
selection lock is working correctly.
If on selecting all gears several times there is still stiffness, do the
following:
– Remove the gear lever knob with the dust sleeve ⇒ page 38 .
– Select 1st gear.
– Eliminate gear action play, pressing the gear lever carefully
left.
– Then push the lever to the left firmly, as far as it will go, in the
-direction of arrow- .
On carrying out this second movement, the lower end of the
spring will travel as in -a- .
– Measure movement -a- with the depth gauge of a caliper.

Arosa 1997 ➤
– To do this, place the caliper perpendicularly over the legged

spring -arrow 1- .
– Measure the distance between the spring -arrow 1- and the
support plate -arrow 2- , before and after making the second
movement.
– Distance -a- should be 1 - 3 mm.

– If not, adjust the gearbox actioning mechanism ⇒ page 40 .
– Fitting the centre console: ⇒ Bodywork repairs, installation
work, interior;
Protected Rep.
by copyright. Gr.for68
Copying ; Shelves,
private trim,
or commercial covers
purposes, in part and traysis not
or in whole, .
Continued fortoall
respect vehiclesof information in this document. Copyright by SEAT S.A.
the correctness
– Fit the frame, the dust sleeve and the gear lever knob.

Arosa 1997 ➤
2 Gearbox: removing and installing
2.1 Gearbox: removing and installing

equipment required
♦ Hydraulic column jack -SAT
1040-
8010-
♦ Base -T20145-
♦ Bracket -U-30025E-
♦ Kit XZN -U-40020-
2.1.1 Removing
strap.
Note!
code.
– Remove air filter: ⇒ Rep. Gr. 24 ; Injection system: repairing .

– Press the clutch to the floor several times.
lever: Clutch cables with automatic adjustment ⇒ page 14 .

Arosa 1997 ➤
Clutch cables without automatic adjustment (steering wheel

on the right) ⇒ page 19 .
– Disconnect the speedometer sender connector -arrow- .
– Separate the connector with its bracket, from the cluch hous‐
ing, at the front.
– Unbolt the cable and connector bracket from the gearbox

-arrow 2- .
– Separate the reversing light connector -arrow 1- .
– Unbolt the earth cable from the engine to gearbox bolt.
– Remove the cable guide from its gearbox fittings.
– Remove the upper bolts that secure the engine to the gearbox.
– Remove sump insulation tray, if fitted: ⇒ Bodywork Repairs,
installation work, exterior; Rep. Gr. 50 ; Body, front .
– Remove the drive shafts from the gearbox flangesbyusing theSEAT S.A does not guarantee or accept any liability with
permitted unless authorised SEAT S.A.
correct spanner from tool Kit XZN -U-40020-
respect to the.correctness of information in this document. Copyright by SEAT S.A.
– Turn steering towards the left completely.

– Hold the left-hand driveshaft as high as possible and secure it
conveniently, taking care not to damage it.
– Remove the counter-hold bracket -arrow- from the subframe.

Vehicles with a diesel engine
– Remove front exhaust pipe: ⇒ Rep. Gr. 26 ; Exhaust system
components: removal and fitting .
– Remove the counter-support bolt -arrow- and remove the sup‐

port.

Arosa 1997 ➤

-arrow 2- .
– Unbolt the selector rod with ball joint from the control finger
-arrow 3- .
– Remove the control finger by loosening the bolt -arrow 4- .
– Unbolt the selector rod bracket from the gearbox -arrows- .

– Remove the flywheel cover plate.
– Remove the pendulum support, unbolting -1- and -3- and re‐
moving nut -2- .
– Removing the cable guide bracket -arrow- .

– Removing the starter motor -1- : ⇒ Electrical system; Rep. Gr.
Note!
In diesel-powered vehicles, the starter motor is located at the front

of the gearbox casing.

Arosa 1997 ➤
– Fit the bracket -U-30025E- .

– Pretension the engine assembly slightly by means of the sup‐
port device spindles.
Note!
Remove all cable brackets, cables and hoses that could interfere
with the fitting of the support tool.
– Remove the two hexagon bolts -arrows- from the left gearbox
console.
– Carefully tilt the engine to the left. To do this, lower the left-
hand spindle of support device -U-30025E- slightly.
– Fit tool -T20145- together with tool -T20138- onto jack -SAT
1040- .
– Place the jack below the gearbox, and secure tool -T20138-
to the gearbox, in such a way that it is secure -arrows- .
– Remove the lower gearbox
Protected bolts.
– Release the gearbox from
respect the
to the dowelofpegs
correctness andin lower
information it care‐
fully.
2.1.2 Installation
– Clean the input shaft and clutch plate splines.
– Apply a very thin layer of -G 000 100- grease to the input shaft
splines.
– Move the clutch plate backwards and forwards on the input
shaft until it slides freely. Remove excess grease.
– Check that the gearbox/engine dowel pegs are fitted to the
engine, if not, fit them ⇒ page 51 .
– Make sure the intermediate plate is correctly seated on the
engine.
– Secure the gearbox to tool -T20138- .
– Fit the gearbox to the engine taking care to cause no damage.

Arosa 1997 ➤
Note!
On fitting the gearbox make sure that the input shaft and the ad‐
justment bushes are correctly located.
– Fit the gearbox to engine bolts, at the lower part of the clutch
housing.
– Lower the vehicle.
– Raise the engine, using the spindles of -U-30025E- support
tool, until it is level.
– Fit the two hexagon bolts -arrows- to the left gearbox console
and tighten them to.
– Remove support tool -U-30025E- .
Caution
Do not remove support tool -U-30025E- until the left-hand

gearbox console bolts have been tightened.
– Fit the upper bolts that secure the engine to the gearbox.
– Fitting the starter motor -1- : ⇒ Electrical system; Rep. Gr.

Note!
In diesel-powered vehicles, the starter motor is located at the front

of the gearbox casing.
– Removing the cable guide bracket -arrow- .

Arosa 1997 ➤
– Fit the pendulum support, fitting bolts -3- , nut -2- and bolt
-1- .
– Fit the flywheel cover plate.
– Bolt the selector rod bracket to the gearbox -arrows- .

– Clean the threaded hole in the connecting fingerbywith
Protected an Copying
copyright. M8 for private or commercial purposes, in part or in whole, is not
tap. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Always renew the bolt securing the control finger -arrow 1- ,

because is is coated with sealer.
– Move the control finger until the securing bolt is located in the
cut-out of the selector shaft -arrow 2- .
– Tighten bolt -arrow 4- to its correct torque.

– Fit the selector rod with ball joint to the control finger
-arrow 3- .
-arrow 2- .

Arosa 1997 ➤
– Fit the counter-hold for actioning the control cable and fit the
bolt -arrow- .
– Fit counter-hold bracket to the sub-frame -arrows- .

– Fit the drive shafts to the gearbox flanges using the correct
spanner from tool Kit XZN -U-40020- .
– Fit front exhaust pipe: ⇒ Rep. Gr. 26 ; Exhaust system com‐
ponents: removal and fitting .
– Fit sump insulation tray, if fitted: ⇒ Bodywork Repairs, instal‐
lation work, exterior; Rep. Gr. 50 ; Body, front .
– Fit the connector with its bracket, to the front of the cluch
housing.
– Fit the reversing light connector -arrow 1- .permitted

– Fit the connector bracket to its housing on the gearbox
-arrow 2- .
– Bolt up the earth cable.
– Fit the speedometer sender connector.
Note!
♦ If ther is a spring -arrow- between the clutch release lever and

the gearbox, remove it, otherwise the functioning of the ad‐
justment mechanism cannot be guaranteed.
♦ The spring is only needed to secure the clutch release lever
during transport.
– Fit the clutch cable to the gearbox: Clutch cables with auto‐
matic adjustment ⇒ page 14 . Clutch cables without automatic
adjustment (steering wheel on the right) ⇒ page 19 .
– Connect the earth battery strap.
– Check gearbox oil level ⇒ page 53 .
– Adjust the gearbox drive mechanism ⇒ page 40 .

Arosa 1997 ➤

Petrol engine vehicles
Aluminium cylinder block
Position Bolt Amount Tightening torque (Nm)

1 M8×65 1 18
2 M8×70 1 18
3 M8×160 1 18
4 M12×80 1 80
5 authorised by SEAT S.A. SEAT S.A does
permitted unless
9)
M7×12not guarantee or accept any liability with 1 9
6 M12×80 2 80
7 M12×80 1 80
9) Bolt securing the flywheel heat shield
Item A + B - dowel pegs

Cast iron engine block
Position Bolt Amount Tightening tor‐
que (Nm)
1 M8×65 1 18
2 M8×70 1 18
3 M8×160 1 18
4 M12×62 1 80
510) M7×12 1 9
6 M12×70 4 80
Vehicles with a diesel engine

Arosa 1997 ➤
Securing the gearbox to the engine

Position Bolt Amount Tightening tor‐
que (Nm)
1 M12×55 1 80
2 M12×70 1 80
3 M12×62 1 80
411) M7×12 1 9
512) M10×150 2 60
12) Additional bracket securing the starter motor to the gearbox

Pendulum support Nm
Nut -2- to bolt -1- 13) 40 + 90°
Bolt -3- 20 + 90°
13) Tighten the nut to the indicated torque, locking the hexagon bolt, so as not to
deform the rubber bush.
.
Always renew the nuts and bolts

Left-hand console to gearbox -arrows- 50 Nm
Cable guide bracket 25 Nm

Selection rod to gearbox bracket 25 Nm
Drive shaft to flanged shaft 45 Nm
Control finger to gearbox 20 Nm
Always renew
Counter hold bracket to sunframe 15 Nm
Securing counter hold to gearbox 20 Nm

Arosa 1997 ➤
3 Oil level for gears: checking

Checking gearbox oil level

Oil specification for
permitted gears
unless ⇒ page
authorised 1 S.A.
by SEAT . SEAT S.A does not guarantee or accept any liability with
– Remove oil level control bolt -arrow- .
Oil level is correct when the oil reaches the bottom edge of filling
hole.
– Tighten the gearbox oil level control bolt -arrow- to 25 Nm.
To completely fill the gearbox with new oil you must:
– Unscrew the oil level control bolt and top up to the lower edge
of the filling hole.
3. Oil level for gears: checking 53

Arosa 1997 ➤
4 Gearbox: dismantling and assem‐

bling
4.1 Assembly procedure
1 - Clutch housing
2 - 25 Nm
3 - Layshaft
⇒ page 91
4 - Input shaft
⇒ page 80
5 - Control rod with fork for 3rd
and 4th gears
6 - Control rod with fork for 1st
and 2nd gears
7 - Reverse gear shaft
8 - Reverse gear control rod
9 - Reverse gear
❑ Fit together with the
shaft
10 - Inversion lever
❑ Fit with the reverse gear
control rod
11 - 5th gear control rod
12 - Torx screw, 35 Nm
❑ For the reverse gear/
shaft
13 - Reversing light switch, 20
Nm
❑ For the control rods of
the 5th gear and reverse
❑ For the inversion lever and reverse gear
16 - 5th gear Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 - Plate spring respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ The concave side should face the 5th gear

❑ Always renew

Arosa 1997 ➤
19 - Retaining clip
20 - Fork for 5th gear
21 - Gasket
23 - Thrust washer for 5th gear
24 - Needle bearing bush
25 - Needle bearing
26 - 5th gear
27 - Syncromesh ring 5th gear
❑ The locking keys are in the syncromesh ring
28 - Spring
29 - Syncromesh hub 5th gear
30 - Safety ring
❑ Always renew
31 - Sliding sleeve for 5th gear
33 - 25 Nm Allen screw
❑ For securing the flanged shaft
34 - Left-hand flanged shaft
❑ Do not mix them up, the right-hand flanged shaft is different from the left ⇒ page 65
35 - Flanged shaft spring
36 - Thrust washer
37 - Conical ring
38 - Flanged shaft oil seal
❑ For the left-hand flanged shaft
❑ Left and right-hand oilseals have different diameters
❑ Replacement with gearbox fitted to vehicle ⇒ page 104
39 - Cap
40 - Connecting shaft
41 - Gearbox casing
❑ Assembly position of the oil collector ⇒ page 56
42 - Differential
43 - Gear lever console
44 - Spring
45 - Selector finger
46 - Bush
❑ For the gear lever console
47 - 15 Nm
48 - Flanged shaft oil seal
❑ For the right-hand flanged shaft
❑ Left and right-hand oilseals have different diameters
❑ Replacement with gearbox fitted to vehicle ⇒ page 104

Arosa 1997 ➤
49 - Right-hand flanged shaft

❑ Do not mix them up, the right-hand flanged shaft is different from the left ⇒ page 65
Assembly position of oil collector on the gearbox casing

– Insert the oil collector into the orifice at the same time
-arrow 1- and the groove -arrow 2- .
Assembly sequence ⇒ page 54

equipment required
♦ Pliers -A-81124-
♦ Bracket -AR-2203A-
♦ Electric blower -SAT 1416-
♦ Kit -T20022-

Arosa 1997 ➤
♦ Kit XZN -U-40020-
♦ Kit -U-40100-
♦ Kit -U-40200A-
♦ Turning tool -U-40203-
♦ Feeler gauge
4.1.1 Removal
– Fit the gearbox to column -AR-2203A- . Use drills No. 4 and
5.
– Drain gearbox oil. Unscrew oil drain plug from gearbox.

Arosa 1997 ➤
– Remove clutch release bearing -B- and release fork -A- .

– Remove guide bush -C- .
Note!
Remove the guide bush securing bolts with the correct diameter
of tool -U-40020- .
– Remove the right and left flanged shafts.

– Remove the flanged shafts with pressure springs, thrust wash‐
ers and conical rings.
– Unscrew the gearbox casing cover and remove the gasket.

– Bolt the connection finger or tool -U-40203- to the connection
shaft.
– Select 5th gear.
– Loosen the counter nut -arrow 1- located under the 5th gear
connection fork.
– Remove the dome headed bolt -arrow 2- and remove the con‐
nection fork with the 5th gear sliding sleeve.

Arosa 1997 ➤
– Fit the sliding sleeve of the 5th gear on the syncromesh body.
– Remove bolt -A- for the 5th gear. To lock it, select 5th gear by
hand by pushing the slider -arrow 1- and select 2nd gear with
the selector -arrows 2- and -3- .
– After selecting the gears, the input and layshafts are locked,
the body of the syncromesh and the gear cannot move and
thus it is possible to loosen the bolt.
– Remove 5th gear sleeve and remove 2nd gear.
– Remove safety ring -arrow- from the syncromesh body of the

5th gear.
Note!
Use tool -A-81124- to remove the safety ring.
– Remove the syncromesh body and the sliding 5th gear with
tool -U-40100/1- .
– Remove the needle bearing for sliding 5th gear.
– Remove 5th gearProtected

with tool -U-40100/1- .
The 5th gear bearing bush willtoonly be removed if the needle roller
bearing needs to be replaced, proceed as follows:
– Heat the bearing bush to about 100 °C with the electric blower
-SAT 1416- .

Arosa 1997 ➤
– Remove the needle bearing bush. Use tool -T20022- with

claws -T20022/44- .
– Remove the thrust washer located under the needle bearing
bush.
– Separate the clip -arrow- from the 5th gear control rod. Com‐
press with pliers and pull in the direction of the layshaft.
– Separate the speedometer sender -arrow- .
– Remove the bolts securing the clutch housing from the gear‐
box casing.
– Separate both casings by tapping with a plastic hammer. No
not damage the contact surfaces.
– Remove the differential from the gearbox casing.

Arosa 1997 ➤
– Remove the connection shaft cap -A- with tools -U-40200/25-

and -U-40200/21- .
– Remove the connection shaft with a drift.
– Remove the spring -arrow- between the selector finger -A- and
the gear console -B- .
– Remove the selector finger -A- .
– Remove the bolt -arrow- and remove the gear console and the
bush.

Arosa 1997 ➤
– Remove the reversing light switch -1- and the bolts -2- , -3-
and -4- .
– Remove the control rod for the 5th gear -1- and the reverse
gear control rod -2- together with the coupling rod -3- .
– Remove the reverse gear shaft from the gearbox casing from
the bottom; if necessary use tools -U-40200/3- and -
U-40200/10- .
– Remove input shaft -5- , control rod and fork for 3rd and 4th
gears -6- , the reverse gear shaft -1- , the reverse gear -2- , as
well as the secondary shaft -4- and the control rod with fork for
the 1st and 2nd gears -3- .

Arosa 1997 ➤
4.1.2 Installation
– Locate in their positions in the gearbox casing: the layshaft
-1- together with the control rod with forks for 1st and 2nd gears
-2- .
– Insert reverse gear -3- onto the reverse gear shaft -4- and fit
in its position in the gearbox casing.
– Lift the layshaft -1- slightly, together with the control rod with
fork for 1st and 2nd gears -2- and replace together with the
input shaft -3- and the control rod with fork for 3rd and 4th
gears -4- .
Note!
It will be necessary to lift the reverse gear slightly when lifting the
layshaft.
– Line up the theaded hole in the reverse gear shaft with its cor‐
responding hole in the gearbox casing.
– Secure the reverse gear shaft with the bolt -arrow- and tighten
to 35 Nm.
– Place the connection rod -1- beside the reverse gear control
rod -2- .
It will be necessary to keep the reverse gear slightly lifted.

Arosa 1997 ➤
– Secure the connection rod with the bolt -arrow- and tighten to
35 Nm.
– Fit the control rod for 5th gear -1- and bolt up to 35 Nm.
– Locate the control rods -A- in neutral position (all the control
rods must line up).
– Fit the gear console -B- with the bush and securing bolt
-arrow- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Line up the gear console
respect to-B- with theofcontrol
the correctness informationrods; to do this
fit the connection shaft -C- and tighten the bolt -arrow- to 15
Nm.
– Remove connection shaft -C- .
– Fit selector finger -1- in the gear console -2- .

Arosa 1997 ➤
– Fit the spring -arrow- between the selector finger -1- and the
gear console -2- .
– Locate the connection shaft -3- in the selector finger and the
gear console.
Fitting position
The step on the connection shaft should be facing the gear shafts.
– Check that the connection shaft -3- fits perfectly in the gear
console -2- .
– Insert cap -4- flush with the gearbox casing.
– Adjust the selector finger and the control bush when any of
these components have been replaced:
• Selector finger
• Control bush
• Selector rod or bracket
• Clutch housing
• Gearbox casing
Adjusting the selector finger and the control bush ⇒ page 77 .
– Fit the differential to the gearbox casing.
– Check that the magnet is not broken permitted
or cracked and place in
its housing in the gearbox casing.
– Secure the magnet with -AMV 100 200 03- paste.
– Thoroughly clean the contact surfaces of the clutch housing
and the gearbox casing. Apply a uniform layer (not too thick)
of -AMV 188 200 03- sealing paste.
– Fit the clutch housing to the gearbox casing.
– Check that the selector finger fits into the control bush.
– Bolt up the clutch housing to the gearbox casing to 25 Nm
tightening torque.
– Bolt up the reversing light switch to 20 Nm
– Fit thrust washer, pressure springs, conical rings and flanged

shafts
.
Note!
Do not mix up left and right-hand flanged shafts. They are not
interchangeable.
Item Flanged shaft Dimension “a”

1 left-hand side of gearbox casing 57 mm
2 right-hand side of gearbox casing 48 mm

Arosa 1997 ➤
– Fit articulation flange bolts with tool -T20005- to a tightening

torque setting of 25 Nm.
– Fit 5th gear onto the input shaft. Use tool -U-40200/20- .
Fitting position
The projection on the interior diameter of the gear should be fac‐
ing the gearbox casing.
– Fit up the new securing bolt with a new plate spring for the 5th
gear.
Fitting position permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
The concave side of the spring washer should be facing the 5th
gear.
– Do not tighten the securing bolt yet.
– Fit the thrust washer for 5th gear -1- onto the layshaft.
Assembly position
The projection in the internal diameter of the thrust washer should
be facing the roller bearing.
Fit the needle bearing bush -2- as described below:
– Heat the bush to about 100 °C with the electric blower -SAT
1416- , on a heating plate.
– Use tool -U-40200/15- to fit the bush.
– Fit the needle bearing.

Arosa 1997 ➤
– Fit the sliding 5th gear -1- .

– Fit the syncromesh -2- on the 5th sliding gear.
– Check that the spring -arrow- is fitted to the syncromesh ring.
If this is not the case, fit it.
Assembly position of 5th gear syncromesh hub

The highest collar dimension-a- and the sharpest bevel -arrow- ,
should be facing the sliding 5th gear.
– Fit 5th gear syncromesh hub to secondary shaft with tool -

U-40200/15- .
Note!
♦ The syncromesh locking keys -arrow- must coincide with the

housings in the hub.
♦ Once the syncromesh hub is fitted, check that the syncromesh
ring turns freely.
Find the correct 5th gear safety ring

There are several safety rings -2- of different thicknesses, to se‐
cure the 5th gear syncromesh hub -1- .
– Determine the thickness of the new ring -2- meauring the shaft
groove with a feeler gauge.
– Select the best fitting safety ring from the following table.
Thickness (mm) Spare no.
2.00 085 311 187
2.10 085 311 187 A
2.20 085 311 187 B
2.30 085 311 187 C
2.40 085 311 187 D
2.50 085 311 187 E
2.60 085 311 187 F

Arosa 1997 ➤
– Fit a new safety ring -1- making sure it is perfectly seated.

– Compress pin -2- and fit the control rod for the 5th gear.
– Fit the sliding sleeve onto the 5th gear syncromesh hub.
Assembly position
The pointed teeth -arrow A- should be facing the 5th gear, and
the tooth marks -arrow B- should coincide with the cut-outs in the
hub.
– Tighten bolt -A- for 5th gear to 40 Nm. To do this engage 5th
gear, moving the sliding sleeve down -arrow 1- and also the
2nd gear by turning the selector shaft -arrow 2- and pulling
outwards -arrow 3- .
– The input and layshafts will be locked as two gears are en‐
gaged; the syncromesh and 5th gear will not turn.
– Remove the sliding sleeve again.
– Fit the sliding sleeve with the fork for 5th gear.

Arosa 1997 ➤
– Loosen the locknut on the dome headed bolt -1- .

– Fit the dome headed bolt into its location in the gearbox casing.
Note!
If necessary, first clean the threaded hole with an M8×1 tap.
– Adjust the sliding sleeve and the fork for the 5th gear
⇒ page 69 .
Adjust the sliding sleeve and the fork for the 5th gear
– Select neutral (all the rods should be lined up).
– Coat the thread of the dome headed bolt with locking fluid -D
000 600 A2- .
– Loosen the locknut -1- on the dome headed bolt -2- .

– Turn the dome headed bolt -2- until the sliding sleeve is loca‐
ted at the same height as the syncromesh hub.
– Select 5th gear.
– Screw in the dome headed bolt -2- until the fork has no axial
play in the sliding sleeve groove.
– Loosen the dome headed bolt approx. 1/8 of a turn -2- to cre‐
ate the correct play between the sliding sleeve and the 5th
gear fork.
– Lock the dome headed bolt -2- with the locknut -1- tightening
it towards the gearbox casing.
Note!
On tightening the locknut -1- do not allow the dome headed bolt
-2- to move. Keep it immobile with a spanner.
– Deselect 5th gear.

– Check that the sliding sleeve is in neutral an the syncromesh
ring turns freely.
– Fit the gearbox casing cover gasket.
– Fit the cover to the gearbox casing and tighten the securing
bolts to 10 Nm.

Arosa 1997 ➤
5 Clutch housing: repairing

equipment required
♦ Kit -U-40020-

Arosa 1997 ➤
♦ Kit -U-40100-
5. Clutch housing: repairing 71

Arosa 1997 ➤
1 - 40 Nm
❑ For locking the selector
rod
2 - Dowel peg
❑ 2 units
3 - Outer track, roller bearing
❑ For input shaft
⇒ page 83
4 - Shim
❑ For input shaft
⇒ page 86
5 - Clutch release lever
6 - Plug with cap
7 - Vent tube
8 - Clutch housing
❑ In case of replacement:
Adjustment chart
⇒ page 118
❑ Adjust the selector fin‐
ger and the control bush
⇒ page 77
9 - Input shaft oil seal
10 - Guide bush
11 - 20 Nm Allen screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To secure the guide
bush
12 - Clutch release bearing
13 - Starter motor bush-bearing
14 - Guide bush
15 - Drive shaft with gear
❑ For speedometer
16 - Right-hand flanged shaft oil seal
❑ Replacement with gearbox in vehicle ⇒ page 104
17 - Metal bush
❑ For flanged shaft oil seal, ⇒ Item 16 (page 72)
❑ Can be replaced with geabox in vehicle

Arosa 1997 ➤
18 - Selector rod oil seal

❑ Lever it with tool -T20143- to remove
❑ Can be replaced with geabox in vehicle
19 - Selector rod bush-bearing, front
20 - Selector rod
❑ Assembly position: the bevel -arrow- arrow- should be facing the control bush, ⇒ Item 21 (page 73)
❑ Lubricate contact surfaces with MoS2 grease
❑ Adjust ⇒ page 77 , selector finger and control bush: adjusting
21 - Control bush
❑ Adjust ⇒ page 77 , selector finger and control bush: adjusting
22 - 25 Nm Allen screw
23 - Shim
❑ For differential
24 - Outer roller bearing track
❑ In case of replacement: ⇒ page 114
25 - Shim
❑ For lay shaft Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Determine thickness ⇒ page respect
100 to the correctness of information in this document. Copyright by SEAT S.A.
26 - Outer roller bearing track
❑ For layshaft
27 - Selector rod bush-bearing, rear
Removing the input shaft oilseal

– Removing the clutch release bearing.
– Removing the guide bush with the correct spanner from tool -
U-40020- .
– Remove the oil seal by levering it carefully with tool -
T20143/2- .

Arosa 1997 ➤
Fitting the input shaft oil seal

– Lubricate the oil seal and slide carefully onto the input shaft.
Assembly position:
2.5 mm below the surface of the casing.
Removing the starter motor bush-bearing

– Place tap from tool -U-40087- on the bush and screw as far as
it will go.
– Remove the bush-bearing with tool hammer of tool -U-40087- .
Fitting the starter motor bush-bearing

– Lubricate the bush-bearing before fitting.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Remove flanged shaft oil seal

– Remove the bush-bearing with tool hammer of tool -
U-40100/2- .

Arosa 1997 ➤
Fit flanged shaft oil seal

– Lubricate the oil seal conveniently.
– Fit oil seal with tool -U-40091- .
Note!
Tool -U-40091- has different diameters to fit different oil seals.

Select the correct one.
Removing the metal bush for the articulation flange oil seal
– Separate the bush by levering carefully with a screwdriver.
Note!
If the bush is worn or damaged, it must be replaced.
Fitting the metal bush for the flanged shaft oil seal
– Coat the contact surface of the bush with sealing paste.
Note!

Fitting the selector rod oil seal


Arosa 1997 ➤
Removing the front bush-bearing of the selector rod

– First remove the oil seal ⇒ page 74
– Remove the bush-bearing with tool -U-40204- -side B-.
Removing the front bush-bearing of the selector rod

– Remove the bush-bearing with tool -U-40204- -side A-.
Fitting the front bush-bearing of the ofselector
respect to the correctness informationrod
– Fit the bush-bearing with tool -U-40204- -side A-.

Assembly position:
The bush-bearing must be flush with the rear part of its housing.
Fitting the front bush-bearing of the selector rod

– Fit the bush-bearing with tool -U-40204- -side A-.
Assembly position:
The bush-bearing should be 10 mm below the clutch housing
surface.

Arosa 1997 ➤
6 Selector finger and control bush: ad‐

justing
♦ Adjustment tool -U-40201-
The selector finger and the control bush must be adjusted only
when any of the following components have been replaced:
• Selector finger
• Control bush
• Selector rod or locking element
• Clutch housing
• Gearbox casing
– Loosen bolt -1- and separate the slide -A- of tool -U-40201- .
– In the gearbox, measure the diameter of the
permitted unless spherical
authorised by SEAThead of S.A does not guarantee or accept any liability with
S.A. SEAT
the selector finger. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Place slide -A- with the same diameter as the spherical head,
over the spherical head of the selector finger -B- and secure
with the bolt -1- without tightening.
6. Selector finger and control bush: adjusting 77

Arosa 1997 ➤
– Locate tool -U-40201- on the gearbox casing and secure with

the two bolts -A- .
Note!
♦ First remove the slide -A- from tool -U-40201- .

♦ Use the hexagon bolts that secure both casings.
– Secure support -T20020- with a dial gauge.

– Locate the end of Protected
the dialby gauge bracket on the reverse gear
rod, with a pre-tension of 1 authorised
mm. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless
– Press the reverse gear control rod in the
-direction of the arrow- and adjust the dial gauge to “0” .
– Pres the reverse gear control rod in the opposite direction and
note the reading on the dial gauge (e.g.: 0.70 mm).
– Determine the average value of the movement of the reverse
gear control rod by dividing the meaured value by two:
Value average = 0.70 mm2 = 0.35 mm
– Press the control rod from beneath until the average value is
obtained (in this case 0.35 mm) and then secure the control
rod with bolt -2- .
– With hook -C- of the tool, move the selector finger towards the
inside of the reverse gear track.
– In this position, locate the slide -A- on the tool with the correct
spherical head. Fit bolt -1- without tightening.

Arosa 1997 ➤
– Locate tool -T20020- over tool -U-40201- with a dial gauge.

Locate the end of the dial gauge bracket on one side of the
spherical head -B- , with a pre-tension of 1 mm.
– Move the spherical head to one side -arrow- and adjust the
gauge to “0” .
– Move the spherical head again to its limit in the opposite di‐
rection and note the reading on the dial gauge (e.g.: 0.60 mm).
– Determine the average value of the movement of the selector
finger by dividing the obtained measurement by two:
Value average = 0.60 mm2 = 0.30 mm
– Secure the slide with bolt -1- in the position of the value ob‐
tained in the former operation (in this case 0.3 mm).
– Remove tool -U-40201- from the gearbox casing.
Note!
Do not change the position of the elements of tool -U-40201- .

Otherwise the adjustment of the selector finger and the control
sleeve would be wrong.
– On the clutch housing, loosen bolt -1- that secures the bush,
until this can move smoothly on the selector rod.
– Locate the selector rod in the central clamp -2- .
– Check that the centring bushes -A- and -B- are located cor‐
rectly in the clutch housing.
– Place tool -U-40201- turned 180° on the clutch housing.
Note!
♦ Tool -U-40201- must it perfectly into the two centring bushes

of the clutch housing.
♦ The spherical head of the slide -A- must be correctly housed
in the control bush.
– When all the elements are correctly fitted, tighten control bush
securing bolt -arrow- to the selector rod to: 35 Nm.
– Remove tool from clutch housing.
6. Selector finger and control bush: adjusting 79

Arosa 1997 ➤
35 – Gears, Shafts
1 Input shaft: dismantling and assembling

equipment required
♦ Pliers -A-81124-
♦ Kit -T20140-
♦ Kit -U-40100-
♦ Kit -U-40200 A-
Note!
♦ Whenever new gears are fitted consult the technical data ⇒ page 1 .
♦ The input shaft must be adjusted whenever elements have been replaced which could affect the position of
the roller bearings. Refer to Adjustment chart ⇒ page 118 .

Arosa 1997 ➤
1 - M8 Torx screw, 40 Nm
2 - Plate spring
3 - 5th gear
⇒ page 57 , assembly
sequence
4 - Washer
❑ Always 1 mm thick
❑ Fitted to gearboxes
manufactured from
07.97, except those
bearing the letters DQW
6 - Roller bearings
7 - Gearbox casing
❑ In gearboxes manufac‐
tured from 07.97, except
those bearing the letters
DQW, and due to wash‐
er ⇒ Item 4 (page 81) the
outer track of the roller
bearing fits 1 mm lower
8 - Input shaft
9 - Needle bearing
❑ Lubricate before fitting
10 - Sliding 3rd gear
❑ Remove ⇒ pagepermitted
84 unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ It is fitted together with the sliding sleeve and the 3rd and 4th gear syncromesh hub
11 - Syncromesh ring 3rd gear
❑ Checking for wear ⇒ page 84
12 - Safety ring
❑ Separation ⇒ page 84
13 - 3rd and 4th syncromesh assembly
❑ They are matching pairs
❑ Fitting the input shaft ⇒ page 85
14 - Safety ring
1. Input shaft: dismantling and assembling 81

Arosa 1997 ➤
16 - 4th gear
17 - Needle bearing
❑ Lubricate before fitting
18 - Stop washer
19 - Roller bearings
❑ Can be removed without tools
20 - Shim
❑ For the input shaft
22 - Clutch housing
23 - Spring
24 - Locking keys
25 - Sliding sleeve
26 - Syncromesh hub
❑ Identiifcation and assembly of hub ⇒ page 85
27 - Spring
Remove the outer track of the roller bearing respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!
Between the outer track of the roller bearing and the gearbox
casing a 1 mm thick washer is fitted.
Fit the outer track of the roller bearing
Note!
casing, fit first the 1 mm thick washer.

Arosa 1997 ➤
Removing the roller bearing

– Locate tool -U-40100/4- between the bearing and the input
shaft gear.
– When the bearing has moved, apply pressure with the press,
retighten the bolts of the tool to increase the contact surface
with the outer track.
Fitting the roller bearing

– Locate tool -U-40100/3- under the input shaft gear.
Remove the outer track of the roller bearing

– Remove the outer track of the roller bearing with tool -
T20140- .
– Procedure for extracting the outer ring ⇒ page 9 , General in‐
Fit the outer track of the roller bearing


Arosa 1997 ➤
Separate the safety ring

– Use tool -U-40200/26- .
Caution
Be careful when releasing the safety ring as it could sping out

and case harm.
Remove the 3rd gear and the 3rd and 4th gear syncromesh as‐
sembly
The 3rd gear is removed together with the 3rd and 4th gear syn‐
cromesh assembly.
– First remove the safety ring.
– Fit tool -U-40100/3- to the input shaft, under the 3rd gear.
with the inner track.
Note!
Tool -A-81124- can also be used.
Checking syncromesh ring wear

Do not exchange the syncromesh rings of the different gears.
– Before checking for wear, thoroughly clean the syncromesh
rings and their corresponding gears.
– Press the syncromesh ring onto the cone of the sliding gear
and measure dimension “a” with a feeler gauge.
Syncromesh ring Measurement “a” on Wear
a new syncromesh limit
3rd and 4th gears 1.1 to 1.7 mm 0.5 mm

Arosa 1997 ➤
Assemble the sliding sleeve and the syncromesh hub for 3rd and
4th gear
The 3rd and 4th gear syncromesh hub can be identified by a
groove -lower arrow- .
Assembly position:
The shorter teeth under the groove -lower arrow- face the 3rd
gear.
The upper groove -upper arrow- should be facing the 4th gear.
Assembling the sliding sleeve and the syncromesh hub

– The sliding sleeve if fitted by pushing it onto the syncromesh
hub.
– Insert the locking keys and fit the springs at 120° from each
other.
– The angled ends of the springs must locate in the inner hollow
of the corresponding locking keys.
Fitting the syncromesh assembly for 3rd and 4th gears

– Fit tool -U-40100/4- to the input shaft, under the 2nd gear.
– Locate tool -U-40200/20- on the 3rd and 4th gear syncromesh
assembly as far as it will go.
– The syncromesh locking keys must coincide with the housings
in the hub.
– Fit a new safety ring making sure it is correctly seated.

Arosa 1997 ➤
2 Input shaft: adjusting

equipment required
8010-
♦ Kit -T20140-
♦ Kit -U-40200A-
Adjust the input shaft when one of the following elements have
been replaced:
• Gearbox casing
• Clutch housing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• Input shaft
• Input shaft roller bearings
Refer to Adjustment chart ⇒ page 118 .

Arosa 1997 ➤
– Fit the outer track of the input shaft roller bearings into the
clutch housing, without the shim.
– Locate the input shaft in its housing in the gearbox casing.
Note!
In gearboxes manufactured from 07.97, except those bearing the

letters DQW, a 1 mm shim is fitted to the gearbox casing for the
outer track of the roller bearing. Check that the shim is fitted.
– Fit the clutch housing onto the gearbox casing and tighten the
securing bolts to 25 Nm.
2. Input shaft: adjusting 87

Arosa 1997 ➤
– Fit tool -T20020- on the gearbox casing with a dial gauge. Lo‐
cate the end of the dial gauge on the input shaft.
– Turn the input shaft to settle the roller bearings.
Note!
The adjustment to “0” of the dial gauge must be repeated every

time the measurement is carried out. Otherwise the dial gauge
will not return to the initial position.
– From the lower end of the gearbox, press the input shaft in the
direction of the dial gauge.
– Take note of the measurement obtained (e.g. 1.21 mm).
Note!
The dial gauge does not return to its initial position.
– Determine the thickness of the washer with the table

⇒ page 88 .
Shim tableProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Bearingrespect
play to the correctness of information inShim
Average value (mm) Thickness N° of spares

(mm)
0.66 0.650 085 311 391 AN
0.67 … 0.68 0.675 085 311 391 N
0.69 … 0.70 0.700 085 311 391 AP
0.71 … 0.73 0.725 085 311 391 P
0.74 … 0.75 0.750 085 311 391 AQ
0.76 … 0.78 0.775 085 311 391 Q
0.79 … 0.80 0.800 085 311 391 AR
0.81 … 0.82 0.825 085 311 391 R
0.83 … 0.85 0.850 085 311 391 AS
0.86 … 0.88 0.875 085 311 391 S
0.89 … 0.90 0.900 085 311 391 AT
0.91 … 0.93 0.925 085 311 391 T
0.94 … 0.95 0.950 085 311 391 BA
0.96 … 0.98 0.975 085 311 391 AA
0.99 … 1.00 1.000 085 311 391 BB
1.01 … 1.03 1.025 085 311 391 AB
1.04 … 1.05 1.050 085 311 391 BC
1.06 … 1.08 1.075 085 311 391 AC
1.09 … 1.10 1.100 085 311 391 BD
1.11 … 1.13 1.125 085 311 391 AD
1.14 … 1.16 1.150 085 311 391 BE

Arosa 1997 ➤
Bearing play Shim

Average value (mm) Thickness N° of spares
(mm)
1.17 … 1.18 1.175 085 311 391 AE
1.19 … 1.20 1.200 085 311 391 BF
1.21 … 1.23 1.225 085 311 391 AF
1.24 … 1.26 1.250 085 311 391 BG
1.27 … 1.28 1.275 085 311 391 AG
1.29 … 1.30 1.300 085 311 391 AN + AN
1.31 … 1.33 1.325 085 311 391 AN + N
1.34 … 1.36 1.350 085 311 391 AN + AP
1.37 … 1.38 1.375 085 311 391 AN + P
1.39 … 1.40 1.400 085 311 391 AP + AP
1.41 … 1.43 0.700 + 0.725 085 311 391 AP + P
1.44 … 1.46 0.700 + 0.750 085 311 391 AP + AQ
1.47 … 1.48 0.700 + 0.775 085 311 391 AP + Q
1.49 … 1.50 0.700 + 0.800 085 311 391 AP + AR
1.51 … 1.53 0.700 + 0.825 085 311 391 AP + R
1.54 … 1.56 0.700 + 0.850 085 311 391 AP + AS
1.57 … 1.58 0.700 + 0.875 085 311 391 AP + S
1.59 … 1.61 0.700 + 0.900 085 311 391 AP + AT
1.62 … 1.63 0.700 + 0.925 085 311 391 AP + T
1.64 … 1.66 0.700 + 0.950 085 311 391 AP + BA
1.67 … 1.68 0.700 + 0.975 085 311 391 AP + AA
1.69 … 1.70 0.700 + 1.000 085 311 391 AP + BB
– Remove the bolts that secure both casings and separate the
clutch housing.
– Separate the input shaft.
– Remove the outer track of the roller bearing with tool -

T20140- .
– Procedure for extracting the outer track ⇒ page 10 .
– Fit the outer track of the roller bearing in the clutch housing
with the correct shim (in this case 1.225 mm).
– Locate the input shaft in its housing in the gearbox casing.
bolts to 25 Nm.
– Carry out a measurement ⇒ page 89 .
Measurement
2. Input shaft: adjusting 89

Arosa 1997 ➤
cate the end of the dial gauge on the input shaft.
– Turn the input shaft to settle the roller bearings.
– From the lower end of the gearbox, press the input shaft in the
direction of the dial gauge -arrow- .
– The bearing play should be min. 0.01 ... max. 0.10 mm.
Note!
If no play can be measured, but the input shaft is free and can
turn easily, the adjustment is correct.

Arosa 1997 ➤
3 Layshaft: dismantling and assembling

equipment required
♦ Pliers -A-81124-
♦ Kit -T20140-
♦ Kit -U-40100-
♦ Kit -U-40200A-
Note!
♦ Whenever new gears or a new layshaft are fitted consult the technical data ⇒ page 1 .
♦ If the layshaft or the roller bearings are replaced, the layshaft must be adjusted ⇒ page 100 .
♦ The layshaft must be adjusted whenever elements have been replaced which could affect the position of
the roller bearings. Refer to Adjustment chart ⇒ page 118 .
3. Layshaft: dismantling and assembling 91

Arosa 1997 ➤
1 - Gearbox casing
❑ In gearboxes manufac‐
tured from 07.97, except
those bearing the letters
DQW, and due to wash‐
er ⇒ Item 2 (page 92)
the outer track of the
roller bearing fits 1 mm
lower
2 - Washer
❑ Fitted to gearboxes
manufactured from
07.97, except those
bearing the letters DQW
4 - Roller bearings
❑ Remove together with
1st gear ⇒ page 95
5 - Stop washer
6 - Sliding 1st gear
⇒ page 99
7 - Needle bearing
❑ For the sliding 1st gear
8 - Syncromesh ring
❑ Inner ring for 1st gear
❑ Checking for wear
⇒ page 97
❑ Check that the tabs show no signs of wear
9 - Outer ring for 1st gear
❑ Fit it to the 1st gear syncromesh ring, item 10
❑ Replace if it shows signs of wear or grooves
10 - Syncromesh ring 1st gear
❑ On fitting, the tabs on the ring must fit into their housings in the syncromesh assembly for 1st and 2nd
gear ⇒ Item 12 (page 92)
11 - Safety ring
❑ Location ⇒ page 96 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
12 - Syncromesh assembly for 1st and 2nd gear
❑ They are matching pairs
❑ Assembly of components ⇒ page 97 and ⇒ page 98

Arosa 1997 ➤
13 - Spring
14 - Sliding sleeve
15 - Syncromesh hub
16 - Locking keys
❑ 3 units
17 - Spring
18 - Syncromesh ring 2nd gear
19 - Outer ring for 2nd gear
❑ Fit to syncromesh ring ⇒ Item 20 (page 93)
❑ Replace if it shows signs of wear or grooves
20 - Syncromesh ring permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Inner ring for 2nd gear
❑ Check that the tabs show no signs of wear
21 - Sliding 2nd gear
22 - Safety ring
23 - Needle bearing
❑ For sliding 2nd gear
24 - 3rd gear
25 - Safety ring
26 - Safety ring
27 - 4th gear
❑ Assembly position: The identification groove should be facing the conical gears
28 - Layshaft
❑ Check that the ratio (number of teeth) is correct ⇒ page 1
31 - Shim
❑ For the layshaft

Arosa 1997 ➤
32 - Clutch housing
33 - Stop washer
❑ The step of the shim should be facing the roller bearing
34 - Needle bearing bush
❑ Removal if ony the needle roller bearing is replaced ⇒ page 60
❑ Removal together with 1st gear ⇒ page 95
❑ Fitting
35 - Needle bearing for gear, 5th gear
36 - Sliding 5th gear
38 - Spring
❑ Fit onto the 5th gear syncromesh ring
❑ Replace if it shows signs of wear
39 - Syncromesh hub 5th gear
❑ Removal, fitting and adjustment ⇒ page 54
40 - Sliding sleeve 5th gear
❑ Removal, fitting and adjustment ⇒ page 54
41 - Safety ring
Note!
casing a 1 mm thick washer is fitted.

Fitting the outer track of the roller bearing
Note!
casing, fit first the 1 mm thick washer.

Arosa 1997 ➤
Remove the 1st gear -4- with the roller bearing -3- , the stop
washer -2- , and the needle bearing bush for the 5th gear -1-
– Locate tool -U-40100/3- under the first gear.
Separate the safety ring

– Use tool -U-40200/26- .
Caution
Be careful when releasing the safety ring as it could sping out

and case harm.
Removing the 1st and 2nd gear syncromesh assembly

– After removing the safety ring, remove the 2nd gear and the
syncromesh assembly as a unit.
– Locate tool -U-40100/3-
Protectedunder the Copying
by copyright. 2nd gear.

– Locate tool -U-40100/4- under the bearing.
– Locate tool -U-40200/4- over the layshaft and remove the
bearing.
with the inner track.

Arosa 1997 ➤

– Locate tool -U-40100/3- under the attack gear.
– Place tool -U-40200/19- (side A) over the bearing and secure.

– Remove the layshaft outer roller bearing track from the clutch
housing, with tool -T20140- .
Note!
Tool -A-81124- can also be used.

Arosa 1997 ➤
Checking wear on inner ring for 1st and 2nd gear

– Press the syncromesh ring onto the cone of the sliding gear
and measure dimension “a” with a feeler gauge.
1st and 2nd gears 0.75 ... 1.25 mm 0.3 mm
Checking wear on syncromesh ring for 1st and 2nd gear

– Press syncromesh gear, external ring and internal ring against
the cone of the 2nd sliding gear and check dimension “a” with
a feeler gauge.
1st and 2nd gears 1.2 ... 1.8 mm 0.5 mm
Assembly position of external/internal rings and 2nd gear syncro‐

mesh
– Fit external ring -A- on 2nd gear.
Assembly position:
The angled tabs -arrow 1- must be facing the external ring -B- .
– Fit external ring -B- .
Assembly position:
The tabs -arrow 2- must fit into the cut-outs -arrow 3- of the sliding
gear.
– Fit syncromesh ring -C- .
Assembly position:
Theby cut-outs
Protected -arrow
copyright. Copying 4- fitorinto
for private the angled
commercial purposes, tabs -arrow
in part or in whole,1- of the
is not
external
permitted ring by
unless authorised -A- . S.A. SEAT S.A does not guarantee or accept any liability with
SEAT
Assembly of 1st and 2nd gear syncromesh components

– Fit the sliding sleeve -2- on the syncromesh hub -3- so that the
cut-outs of both components coincide.
– Insert the locking keys -4- and secure them with springs -1- at
120° from each other.

Arosa 1997 ➤
Assembly of 1st and 2nd gear syncromesh components

– The angled ends of the springs must locate in the inner hollow
of the corresponding locking keys.
Fitting the syncromesh assembly for 1st and 2nd gears

Assembly position:
The groove -1- for the jaw on the sliding sleeve should be facing
1st gear and the toothed part -2- of the sleeve facing 2nd gear.
– Turn syncromesh gear so that the cut-outs coincide with the
locking keys.
Assembly position of the 1st gear external ring

Assembly position:
The tabs -arows- should face the teeth of the reverse gear -A- .
Assembly position of the 1st gear external ring

Assembly position:
The tabs -1- should fit into the cut-outs -2- of the syncromesh ring
-B- .
– Fit the needle bearing.

Arosa 1997 ➤
Assembly position of the sliding 1st gear

Assembly position:
The cut-outs of the collar -arrows- should fit into the tabs of the
syncromesh ring ⇒ page 98

– Position the stop washer between the gear and the roller bear‐
ing ⇒ Item 5 (page 92) .

Arosa 1997 ➤
4 Layshaft: adjusting

equipment required
8010-
♦ Kit -T20140-
♦ Kit -U-40200A-
Adjust the layshaft when
to the one of the following elements have been
respect correctness of information in this document. Copyright by SEAT S.A.
replaced:
• Gearbox casing
• Clutch housing
• Layshaft
• Layshaft roller bearings
Refer to Adjustment chart ⇒ page 118 .

Arosa 1997 ➤
– Fit the outer track of the layshaft roller bearings into the clutch
housing, with a 0.75 mm thick shim.
– Locate the layshaft in its housing in the gearbox casing.
Note!
In gearboxes manufactured from 07.97, except those bearing the

letters DQW, a 1 mm shim is fitted to the gearbox casing for the
outer track of the roller bearing. Check that the shim is fitted.
4. Layshaft: adjusting 101

Arosa 1997 ➤
cate the end of the dial gauge on the lay shaft.
– Turn the layshaft to settle the roller bearings.
Note!
The adjustment to “0” of the dial gauge must be repeated every

time the measurement is carried out. Otherwise the dial gauge
will not return to the initial position.
– Pull the layshaft in the direction of the dial gauge.

Note!
The dial gauge does not return to its initial position.
Shim calculation table

The bearing tension is obtained by adding a constant pressure
value (0.2 mm) to the average value (0.3 mm) and the thickness
of the shim fitted (0.75 mm).
Washer fitted 0.75 mm
+ Measured value 0.30 mm
Shim thickness needed 1.25 mm
The following shims are available:
0.70 020 311 391 Q
0.75 020 311 391
0.80 020 311 391 A
0.85 020 311 391byB
permitted unless authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
0.90 020to311
respect 391 C of information in this document. Copyright by SEAT S.A.
the correctness
0.95 020 311 391 D
1.00 020 311 391 E
1.05 020 311 391 F
1.10 020 311 391 G
1.15 020 311 391 H
1.20 020 311 391 J
1.25 020 311 391 K
1.30 020 311 391 L
1.35 020 311 391 M
1.40 020 311 391 N
If the thickness needed is greater than those indicated on the ta‐
ble, two shims can be used.
clutch housing.
– Separate the layshaft.

Arosa 1997 ➤
– Remove the layshaft outer roller bearing track from the clutch
housing, with tool -T20140- .
– Remove the 0.75 mm thick shim from the clutch housing.
– Fit the outer track of the roller bearing in the clutch housing
with the correct shim (in this case 1.25 mm).
– Lubricate the roller bearings with gearbox oil.
– Locate the layshaft in its housing in the gearbox casing.
bolts to 25 Nm.
4. Layshaft: adjusting 103

Arosa 1997 ➤

1 Flanged shaft oil seals: removing and
installing
1.1 Flanged shaft oil seals: removing and

installing
(Gearbox fitted to vehicle)

equipment required
♦ Kit -U-40020-
♦ Kit -U-40100-
1.1.1 Removal
Note the general instructions for gearbox repairs ⇒ page 9 .
– Disconnect the negative terminal of the battery.

Arosa 1997 ➤
Note!
code.
– Separate the front exhaust pipe from the intermediate flange

and its supports: ⇒ Rep. Gr. 26 ; Exhaust system compo‐
nents: removal and fitting .
flange, with the correct spanner on tool -U-40020- .
– Pull driveshaft to one side and secure it, taking care that it is
not damaged.
– Drain gearbox oil. Unscrew oil drain plug from gearbox.
– Remove the flanged shaft bolt by threading two bolts into the
flange and immobilizing the shaft with a lever.
– Remove the flanged shaft with the spring, thrust washer and
conical ring.
– Remove the flanged shaft oilseal with tool -U-40100/2- . Acti‐

vate the hammer until the oil seal is removed.
Note!
Take care not to damage the oil seal housing in the gearbox.
1.1.2 Installation
1. Flanged shaft oil seals: removing and installing 105

Arosa 1997 ➤
Note!

– Fit the flanged shaft with the spring, thrust washer and conical
ring.
Note!
Do not mix up left and right-hand flanged shafts. They are not
interchangeable ⇒ page 65 .
– Fit articulation flange securing bolt. Use tool -T20005- and

tighten the bolt to 25 Nm.
– Fit driveshaft to gearbox flanged shaft and tighten bolts to 45
Nm.
– Fit front exhaust pipe: ⇒ Rep. Gr. 26 ; Exhaust system com‐
ponents: removal and fitting .
– Checking gearbox oil level ⇒ page 53 .

Arosa 1997 ➤
2 Differential: dismantling and assembling

equipment required
4002-
♦ Kit -T20022-
♦ Kit -T20140-
♦ Kit -U-40100-
♦ Kit -U-40200A-
Note!
♦ Heat the inner roller bearing track to 100 °C before fitting.

♦ The two roller bearings should be replaced together.
♦ Adjust the differential whenever the roller bearings are replaced ⇒ page 118 .

Arosa 1997 ➤
1 - Gearbox casing
2 - Shim S1
4 - Roller bearings
5 - Differential crown
⇒ page 111
❑ Install: refer to section
Code letters, group
numbers, ratios, filling
quantities ⇒ page 1
6 - Set of thrust washers
❑ Fit with gear oil
7 - Planet gear
8 - Threaded component
❑ To secure flanged shaft
oil seals
9 - Satellite
10 - Satellite shaft
❑ Remove with a drift
11 - Speedometer gear
❑ Remove levering with a screwdriver
14 - Shim S2
permitted unless authorised⇒
by page
SEAT S.A.114SEAT S.A does not guarantee or accept any liability with
15 - Clutch housing
16 - Bracket
❑ Secure the satellite shaft in the gearbox with the rivetted crown wheel
❑ It is secured with the rivets of the diffferential crown wheel ⇒ Item 19 (page 109)
17 - Split pin
❑ Fit to the centre of the shaft
18 - Differential casing
❑ If replaced, refer to Adjustment chart ⇒ page 118

Arosa 1997 ➤
19 - Rivet
❑ Only for production
❑ Drill ⇒ page 111
❑ Fit the crown wheel with bolts ⇒ page 111
20 - 20 Nm
21 - Differential crown wheel, rivetted or bolted
❑ Riveted in the factory
❑ Bolt assembly ⇒ page 111
Note!
The procedure and tools needed to remove the outer tracks of the
roller bearings are identical for the gearbox and clutch casings.
– Remove the outer roller bearing track from the clutch housing,
with kit -T20140- .
Note!
The procedure and tools needed to remove the outer tracks of the
roller bearings are identical for the gearbox and clutch casings.
Note!
The procedure and tools needed to remove the roller bearings are
identical for both sides of the differential box.
– Locate tool -U-40200/4- on the differential.

– Fit extractor -U-40100/1- on tool -U-40200/4- , making sure the
claws are inserted into the notches in the differential casing.
Remove the bearing.
If the bearing cage breaks on extraction, use toolunless
permitted -T20022-
authorisedto
byre‐
move the internal bearing ring. respect to the correctness of information in this document. Copyright by SEAT S.A.

Arosa 1997 ➤
Note!
The procedure and tools needed to fit the roller bearings are
identical for both sides of the differential casing.
– Heat the roller bearing to 100 °C with the -SAT 1416- electric
blower before fitting. Check the temperature with thet -SAT
4002- digital thermometer.
– Fit the speedometer actioning gear.
– Place tool -U-40200/19- -side B- over the bearing and fit it.
Fitting planet gears and satellites

– Coat the thrust washers with gearbox oil and fit in the differ‐
ential casing.
– Fit the planet gears -A- and secure with the flanged shafts
-B- .
– Insert one satellite and turn 180°.
– Fit the second satellite in the opposite position to the first.
– In this position, turn the satellites to the inside of the differential
casing by means of the flanged shafts, until they coincide with
the holes of the satellite shaft.
– Insert the satellite shaft until it goes through the first satellite.
– Fit the threaded components making sure they are correctly
seated.
– Fit the satellite shaft to its final position and fit
Protected by the circlip
copyright. to for private or commercial purposes, in part or in whole, is not
Copying
secure it. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

Arosa 1997 ➤
3 Differential crown: removing and in‐

stalling
3.1 Differential crown: removing and installing

equipment required
4002-
♦ Kit -U-40200A-
3.1.1 Removing
Note!
♦ Protect the roller bearings and gear for speedometer actioning

from damage and metal filings.
♦ Before and after drilling the rivets, thoroughly clean the differ‐
ential casing.
3. Differential crown: removing and installing 111

Arosa 1997 ➤
– Drill the rivet heads, on the opposite side to the speedometer

gear, with a 12 mm drill bit ∅.
– Remove the rivets from their holes with a drift.
– Heat the differential crown with the -SAT 1416- electric blower
to 120 °C. Check the temperature with the -SAT 4002- digital
thermometer.
– Place the differential casing in a press and seaparate the
crown from the case.
3.1.2 Installation
Before fitting the differential crown, consult the section Code let‐
ters, assignment of groups, ratios, filling amounts ⇒ page 1 .
Assembly position:
– The groove on the crown wheel should be facing the satellite
housing.
– Clean the contact surfaces of the crown and differential casing
thoroughly. Use a wire brush and a scraper. Do not use emery
cloth or sandpaper. The contact surfaces must be totally clean
and free from oil and grease.
Gearboxes with differential crown attached
– Cover the contact surfaces of the differential casing and the

crown wheel uniformly with locking agent -AMVby185
Protected 100Copying
copyright. 01- .for private or commercial purposes, in part or in whole, is not
Continued for all gearboxes respect to the correctness of information in this document. Copyright by SEAT S.A.
– Heat the differential crown with the -SAT 1416- electric blower
to 150 °C. Check the temperature with the -SAT 4002- digital
thermometer.

Arosa 1997 ➤
– Fit the differential crown onto the differential casing in the cor‐
rect assembly position ⇒ page 112 .
Note!
♦ To fit the crown correctly onto the differential casing work rap‐
idly without interruptions fitting it to the limit.
♦ If both components lock or jam on fitting, stop the assembly
process. Remove the crown and repeat the process from the
beginning.
– Once both components are assembled, continue pressing for

approx. 2 minutes, until the heat of the crown has been trans‐
ferred to the differential box.
Gearboxes with differential crown bolted on
– Bolt the differential crown and the differential casing together

with the special bolts, nuts and washers indicated in the Parts
catalogue: ⇒ Parts Catalogue .
– Tighten the differential crown to casing securing bolts to 70
Nm.
3. Differential crown: removing and installing 113

Arosa 1997 ➤
4 Differential: adjusting

equipment required
8010-
♦ Kit -T20140-
♦ Kit -U-40200A-
Adjust the differential when one of the following elements has

been replaced:
• Gearbox casing
• Clutch housing
• Differential casing
• Input shaft roller bearings
Refer to Adjustment chart ⇒ page 118

Arosa 1997 ➤
– Fit the outer track of the differential roller bearings into the
gearbox casing, with an S1 1 mm thick shim.
Note!
The roller bearings and their corresponding outer tracks are

matched pairs. Do not mix with other bearings.
– Fit the outer track of the differential conical roller bearings into
the clutch housing, without the S2 shim.
– Place the differential on the gearbox casing.
4. Differential: adjusting 115

Arosa 1997 ➤
cate the end of the gauge on the differential, interplacing tool
-U-40200/11- .
– Move the differential alternately in the
-direction of the arrows- .
Note!
When measuring do not turn the differential, because the roller

bearings may setle an the reading would be erroneous.
S2 shim calcuation table

The pre-tension of the bearing is obtained by adding a onstant
presure value (0.3 mm) to the obtained measurement value of S2
(in the example: 1.80mm).
Example:
Measured value 1.50 mm
S2 shim thickness 1.80
Protected mm Copying for private or commercial purposes, in part or in whole, is not
by copyright.
The shim needed will be determined by the following
respect table:

1.00 084 409 383 AE
1.40 084 409 383 AF
1.45 084 409 383 AG
1.50 084 409 383 AH
1.55 084 409 383 AJ
1.60 084 409 383 AK
1.65 084 409 383 AL
1.70 084 409 383 AM
1.75 084 409 383 AN
1.80 084 409 383 AP
1.85 084 409 383 AQ
1.90 084 409 383 AR
1.95 084 409 383 AS
2.00 084 409 383 AT
2.05 084 409 383 BA
2.10 084 409 383 BB
2.15 084 409 383 BC
2.20 084 409 383 BD
2.25 084 409 383 BE
2.30 084 409 383 BF
2.35 084 409 383 BG
2.40 084 409 383 BH
– Once the necessary S2 shim has been determined, remove
the dial gauge.
clutch housing.
– Separate the differential.

Arosa 1997 ➤
– Remove the outer roller bearing track from the differential cas‐
ing with tool -T20140- .
– Fit the S2 shim of the correct thickness (in this case 1.8 mm)
into the housing in the outer track of the differential roller bear‐
ing,
– Fit the differential outer roller bearing track to the clutch hous‐
ing, with tool -U-40200/10- and tool -U-40200/13- .
– Place the differential on the gearbox casing.
4. Differential: adjusting 117

Arosa 1997 ➤
5 Adjustment chart
Note!
If work is carried out on the gearbox, it will only be necessary to

adjust the input shaft, the layshaft and the differential when parts
have been replaced that directly influence the gearbox adjust‐
ment. To avoid unnecessary work check the following table.
Adjustment must be made to the

Input shaft Lay shaft Differential
⇒ page 86 ⇒ page 100 ⇒ page 114
Part replaced Gearbox casing x x x
Clutch housing x x x
Input shaft x
Layshaft (crown/pinion assembly) x
Differential casing x
Input shaft roller bearings x
Layshaft roller bearings x
Differential roller bearings x

Service
Workshop Manual
Alhambra 1996 ➤ , Alhambra 2001 ➤ ,
Altea 2004 ➤ , Altea XL 2007 ➤ ,
Altea XL Freetrack 2008 ➤ ,
Altea XL Freetrack 2009 ➤ ,
Arosa 1997 ➤ , Córdoba 1999 ➤ ,
Córdoba 2003 ➤ , Córdoba Vario 1999 ➤ ,
Exeo 2009 ➤ , Exeo ST 2009 ➤ ,
Ibiza 1999 ➤ , Ibiza 2002 ➤ ,
Ibiza 2008 ➤ , Inca 1996 ➤ ,
León 1999 ➤ , León 2006 ➤ ,
Toledo 1999 ➤ , Toledo 2005 ➤
Air conditioning permitted
with
Protectedrefrigerant R134a
Edition 01.2010

Service
Repair Group
00 - Technical data

Copyright © 2016 Seat S.A S01DCBXXX20

Alhambra 1996 ➤ , Alhambra 2001 ➤ , Altea 2004 ➤ , Altea XL 2007 ➤ , A ...
Air conditioning with refrigerant R134a - Edition 01.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Overview of air-conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Other means of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Principles of air-conditioning technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Vapour pressure table of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Coolant agent R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Air-conditioner operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.10 General aspects regarding workplace safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.11 Safety precautions for working on vehicles with air-conditioning and handling refrigerant
R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.12 Fundamental aspects for working on the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 15
2 General aspects regarding the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Parts of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Refrigerant circuit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Extraction and filling valve for the quick connection of the air-conditioning service station on
the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.4 Switches and senders in the refrigerant circuit and corresponding connections . . . . . . . . 27
2.5 Electrical components not fitted onto the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Refrigerant circuit pressures
Protected and
by copyright. temperatures
Copying . . . . .purposes,
for private or commercial . . . . .in. part
. . .or.in. whole,
. . . .is.not
............. 31
2.7 Refrigerant circuit with expansion valve . . . . . . . . . . . . . . . . . . . . . . . . .
. . ............. 32
2.8 Refrigerant circuit with choke and collecting tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Inspection and measurement work which can be carried out with a manometer . . . . . . . . 36
2.10 Equipment for loading and recycling of the refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.11 Repair instructions for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Legal texts and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Law regulating waste recycling and management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Refrigerant record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Important instructions regarding air-conditioner system repair . . . . . . . . . . . . . . . . . . . . . . 42
5 Working with the air conditioning service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Working with the service station SAT 4006D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Important notes on working with the air conditioning service station . . . . . . . . . . . . . . . . . . 44
5.3 Connecting the air conditioning service station for carrying out measurements and tests
........................................................................ 44
5.4 Emptying the refrigerant circuit with the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5 Emptying the refrigerant circuit with the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.6 Charging the refrigerant circuit with the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7 Fill the container of the air conditioning service station with refrigerant . . . . . . . . . . . . . . . . 50
5.8 Emptying the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6 Check for possible leaks in the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1 Locating leaks in the refrigerant circuit with the leak detector SAT 4012 . . . . . . . . . . . . . . 52
6.2 Locating leaks in the refrigerant circuit with the leak detector SAT 4007B . . . . . . . . . . . . 52
6.3 Tracing leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7 Cleaning the inner side of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 Cleaning the refrigerant circuit using the cleaning station SAT 4011 . . . . . . . . . . . . . . . . 60
7.2 Description and operation of the cleaning station SAT 4011 . . . . . . . . . . . . . . . . . . . . . . 63
7.3 Blow the refrigerant circuit out with compressed air, and then nitrogen. . . . . . . . . . . . . . . 66
Contents i
8 Cleaning refrigerant circuit of impurities using R134a refrigerant . . . . . . . . . . . . . . . . . . . . 69

8.1 Rinsing (cleaning) the refrigerant circuit using the refrigerant R134a . . . . . . . . . . . . . . . . 69
8.2 Application of the flush kit SAT 4009 with adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.3 Adaptation of refrigerant loading machines before SAT 4006D to rinse circuits with the Kit
SAT 4009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.4 Adapter for performing flush circuits VAS 6338/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9 Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.1 Possible complaints regarding the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10 Connecting the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1 To vehicles equipped with a connection on both the high and low pressure sides of the
refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11 Checking pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.1 Check the pressure in the refrigerant circuit (using the air conditioning service station) . . 97
11.2 Checking pressures on vehicles with restrictor and reservoir (with internally regulated
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
11.3 Checking pressures on vehicles with expansion valve and receiver (with internally regulated
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
11.4 Checking pressures on vehicles with restrictor, reservoir and air conditioner compressor
regulating valve N280 (with externally regulated compressor) . . . . . . . . . . . . . . . . . . . . . . 109
11.5 Checking pressures on vehicles with restrictor, reservoir and air conditioner compressor
regulating valve N280 (with externally regulated compressor) . . . . . . . . . . . . . . . . . . . . . . 114
12 Replacing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.1 Replace components of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.2 Replacing the air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
12.3 Replacing liquid tank or collecting tank and choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
13 Filling quantity for refrigerant R134a, refrigerant oil and authorised refrigerant oil . . . . . . 127
13.1 Top-up quantities of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
13.2 Refrigerant oils and the filling quantity of the authorised refrigerant oil . . . . . . . . . . . . . . . . 132
14 Verification equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
14.1 List of test equipment, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
15 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ii Contents
1 Overview of air-conditioning
(ERL001343; Edition 01.2010)
1.1 Introduction
This repair manual is aimed at providing the operators the basic
knowledge required to enable them to work in a qualified manner.
Note
After studying this manual, the operator should be qualified in the

area of vehicle air-conditioning, and should be able to apply the
acquired knowledge in practice.
This documentation is also intended for use by the persons in

charge of supervision and/or inspection.
Caution
When using tools or materials that have not been approved
(e.g. sealing additives), damage may be caused to the system
or it may be influenced.
Only tools and materials authorised by the manufacturer must
be used.
Warranty claims are invalid if tools or materials are used that
have not been approved.
1.2 Other means of information

♦ Service and Technical Manual with means of how to solve
current anomalies
♦ Repair manual for repair work specific to each model ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 .
cations
♦ Autodidactic programs
♦ Video programmes for training courses
♦ Catalogue of special tools / workshop trials
♦ Parts catalogue
♦ Service Organization: Volume 2
1. Overview of air-conditioning 1
1.3 Principles of air-conditioning technology
1.3.1 Physical principles:

The four known physical states of water also exist in air-condi‐
tioning refrigerants.
1- Gaseous state (invisible)
2- Evaporated state
3- Liquid state
4- Solid state
If water is heated in a container (heat absorption), one is able to

see water vapour rise. If this vapour is heated further by heat ab‐
sorption, it turns into an invisible gas. This process is reversible.
If heat is extracted from water in gaseous state, it first turns into
vapour, then into water, and finally into ice.
A - Heat absorption
B - Heat emission
1.3.2 Heat always flows from hot matter to

cold matter Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
All matter consists of a masspermitted
of moving molecules. The fast mov‐
ing molecules of a hot matter transfer some of their energy to the
cooler, slower moving molecules. By doing so, the movement of
the molecules of the hotter matter is slowed down, while the
movement of the molecules of the cooler matter is accelerated.
This process continues until the molecules of both matters move
at the same speed. They are then at the same temperature, and
the transfer of heat stops.
1.3.3 Pressure and boiling point

The boiling point of a liquid specified in the tables always makes
reference to a atmospheric pressure of 1 bar. Modifying the pres‐
sure of a liquid causes its boiling point to vary.
It is well known that water, for example, reaches its boiling point
at lower temperatures when the pressure is reduced.
From the vapour pressure curves for water and refrigerant R134a,
it can be seen that, for example, with a constant pressure, the
vapour turns into water (in the condenser) if the temperature de‐
creases, and that, for example, by decreasing the pressure, the
2 Rep. gr.00 - Technical data

refrigerant changes from a liquid state into a vapour state (evap‐

orator).
Pressure curve of water vapour
A - Liquid state
B - Gaseous state
C - Pressure curve of water vapour
1 - Liquid pressure in bar (absolute)
2 - Temperature in °C
Pressure curve of refrigerantpermitted
R134aunless
vapour
A - Liquid state
B - Gaseous state
D - Pressure curve of refrigerant R134a vapour
1 - Liquid pressure in bar (absolute)
2 - Temperature in °C
1.4 Vapour pressure table of refrigerant

R134a
The vapour pressure table for each refrigerant appears in the
technical documentation of the air-conditioners. The vapour pres‐
sure exerted on the liquid column in the tank can be found in the
table if the temperature of the tank is known.
Seeing as there is a vapour pressure table for each refrigerant, it
is possible to determine the kind of refrigerant by measuring its
pressure and temperature.
Note
In the case of absolute pressure, 0 bar is equal to an absolute

vacuum. Normal atmospheric pressure (positive pressure) is
equal to 1 bar absolute pressure. In general, most manometer
scales represent atmospheric pressure as 0 bar, meaning an ab‐
solute pressure of 1 bar (this can be recognised if there is a -1 on
the scale).
Temperature in °C Pressure in bar (positive pres‐

sure) R134a
-45 -0,61
-40 -0,49
-35 -0,34
-30 -0,16
-25 0,06
-20 0,32
-15 0,63
-10 1,00
Temperature in °C Pressure in bar (positive pres‐

sure) R134a
-5 1,43
0 1,92
5 2,49
10 3,13
15 3,90
20 4,70
25 5,63
30 6,70
35 7,83
40 9,10
45 10,54
50 12,11
55 13,83
60 15,72
65 17,79
70 20,05
75 22,52
80 25,21
85
Protected by copyright. Copying for private or 28,14
90 to the correctness of information in this document.
respect 31,34 Copyright by SEAT S.A.
1.5 Coolant agent R134a

The evaporation and condensation process is used in air-condi‐
tioners in vehicles. Matter with a low boiling point, called the
refrigerant, is used in this process.
The refrigerant used is tetrafluoroethane R134a, which reaches
its boiling point at a temperature of -26.5 °C with a vapour pres‐
sure of 1 bar.
1.5.1 Physical data of refrigerant R134a

Chemical formula CH2F–CF3 or CF3–CH2F
Chemical name Tetrafluoroethane
Boiling point at 1 bar - 26,5° C
Freezing point -101.6 °C
Critical temperature 100.6 °C
Critical pressure 40.56 bar (absolute)
1.5.2 Critical point

The critical point (critical temperature and critical pressure) is the
point above which the threshold between liquid and gas disap‐
pears.
When matter is above its critical point, it is always found in the
gaseous state.
At temperatures below the critical point, all types of refrigerant in
pressure vessels exhibit both a liquid and a gas phase, i.e. there
is a layer of gas above the liquid.
While there is gas in the tank apart from the liquid, the pressure
will depend on the ambient temperature ⇒ page 3 .

Note
Refrigerants may not be mixed. Only the specific refrigerant

specified for each air-conditioner may be used.
1.5.3 Environmental issues regarding refrig‐

erant R134a
♦ R134a is a chlorine-free hydrofluorocarbon (FHC)
♦ R134a’s atmospheric lifetime is less than that of refrigerant
R12.
♦ R134a has no negative impact on the ozone layer.
♦ R134a’s influence on the greenhouse effect is 10 times lower
than that of refrigerant R12.
1.6 Properties of refrigerant R134a
1.6.1 Commercial names and designations

Refrigerant R134a is currently available under the following com‐
mercial names:
♦ H-FKW 134a
♦ SUVA 134a
♦ KLEA 134a
Note
♦ Different commercial names may be used in other countries.

♦ Of the wide range of refrigerants available, only this particular
refrigerant may be used for motor vehicles. The designations
Frigen and Freon are trade marks. They are also used for re‐
frigerants which may not be used in motor vehicles.
1.6.2 Colour
In liquid or gaseous state, the refrigerant is colourless, like water.
The gas is invisible. Only the boundary line between the gas and
liquid is visible. (Liquid state in the rising tube of the charging cyl‐
inder or bubbles in an inspection hole). The refrigerant R134a
may appear coloured (cloudy) through an inspection hole. This
cloudiness is due to oil liberated partially by the refrigerant, and
is considered normal.
1.6.3 Vapourpermitted
pressure
In a closed container which is not completely full, the refrigerant

volatilises into vapour state on the surface. The amount that vol‐
atilises is transformed into liquid again due to the aggregation of
vapour particles. This state of equilibrium occurs under pressure,
and is commonly known as vapour pressure. The vapour pres‐
sure depends on the temperature ⇒ page 3 .
1.6.4 Physical properties of R134a

The vapour pressure curves of R134a and other refrigerants are
in certain regards very similar, and it is therefore not possible to
make a positive differentiation based only on pressure.
In the case of R134a, the compressor is lubricated with special

synthetic refrigerant oils, for example, PAG oils (polyalkylene gly‐
col oils).
1.6.5 Metal contact behaviour

In pure state, the refrigerant R134a is chemically stable and does
not attack iron or aluminium.
However, impurities in the refrigerant, such as chlorinated com‐
pounds, may cause certain metals and plastics to be attacked.
This may lead to blocking, leaks or sedimentation on the com‐
pressor piston.
1.6.6 Critical temperature / Critical pressure

The refrigerant R134a remains chemically stable up to a gas
pressure of 39.5 bar (which corresponds to a temperature of 101
°C). The refrigerant decomposes at higher temperatures (see
Flammability).
1.6.7 Water content

Only very small amounts of water are
authorised by soluble in the
SEAT S.A. SEAT S.A refrigerant.
permitted unless does not guarantee or accept any liability with
Otherwise, the refrigerant vapour
respect and theofwater
to the correctness vapour
information will mixCopyright
in this document. in by SEAT S.A.
any proportion.
Any water present in the refrigerant circuit is transported in drop
form. The desiccant or drying cartridge present in the reservoir
can absorb up to approx. 7 grammes of water. After absorbing
this quantity the desiccant is saturated and cannot hold any more
water. If any water remains in the refrigerant circuit, it will flow to
the nozzle of the expansion valve or throttle valve and freeze.
The air-conditioner will then stop cooling.
The water destroys the air-conditioner, seeing as, at high pres‐
sures and temperatures, acids are formed in combination with
other impurities.
1.6.8 Flammability
The refrigerant is non-flammable. On the contrary, it has a fire
retarding and extinguishing effect. The refrigerant is decomposed
by flames and incandescent surfaces. The refrigerant is also de‐
composed by UV light (caused by electric welding). This produces
toxic decomposition products which must not be inhaled. Mucus
irritation generally provides sufficient warning.
1.6.9 Filling factor

A container must have space for vapour, besides the space for
the liquid. The liquid expands as the temperature increases. This
reduces the space which can be occupied by the vapour. At a
certain moment, only liquid will remain in the container. There‐
after, only a slight increase in temperature will be sufficient to
generate high pressures in the container, seeing as the liquid tries
to expand further without any remaining space. The forces gen‐
erated by the pressure may be sufficient to cause the container
to burst. To prevent the container from being overfilled, the com‐
pressed gas regulations state the amount of refrigerant in kilo‐
grams allowed to fill a container according to its interior volume
in litres. This filling factor multiplied by the interior volume gives
the filling amount allowed. For the refrigerant used in vehicles, the
filling factor is 1.15 kg/l.

1.6.10 Leak detection

Leaks may appear in the refrigerant circuit, for example, due to
exterior damage. Due to the small amount of refrigerant which
may leak, small leaks may be detected, for example, with an
electronic leak detector or a leak detection additive which is add‐
ed to the refrigerant circuit.
Electronic leak detectors are capable of detecting leaks smaller
than 5 grams of refrigerant per year. (For each different refriger‐
ant, an electronic leak detector specifically designed to detect the
composition of the refrigerant in question must be used. For ex‐
ample, leak detectors for refrigerant R12 are not suitable to be
used for refrigerant R134a, seeing as it contains no chlorine
atoms, causing the detector not to react).
1.7 Refrigerant oil

The refrigerant oil is mixed with the refrigerant (at a approx. 20 to
40%, depending on the kind of compressor and the amount of
refrigerant), which continuously circulates through the circuit and
lubricates the moving parts.
Special synthetic refrigerant oils, for example, polyalkylene glycol
(PAG) oil, are use in combination with the refrigerant in air-con‐
ditioners which use R134a. This is necessary as mineral oil does
not mix with R134a. Moreover, the materials used in air-condi‐
tioners which use R134a may be attacked when the mixture flows
through the refrigerant circuit under high pressures and temper‐
atures, or if the lubricating film in the compressor is broken. The
use of unauthorized oils may cause the air-conditioner to break
down, and therefore only approved oils must be used.
⇒ Parts catalogue ETKA
Air conditioning oil for 134a in vehicles: PAG
Note
♦ Do not store refrigerant oil in open containers, as it is very

hygroscopic (water absorbent).
♦ Keep oil containers closed at all times.
♦ Do not reuse refrigerant oil. Dispose of as used oil from un‐
known source (see Waste, Environmental protection, Refrig‐
erant regulatory legislation (EC) 2037/2000).
♦ Diester oils are only for use in larger installations (not for air-
conditioners in vehicles).
1.7.1 Properties of the refrigerant oil

The most important properties are its great capacity to dissolve
in refrigerants, good lubricating properties, theauthorised
absence of acids,
permitted unless by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
and very low water content. Therefore, only respectspecific typesof of
to the correctness oils in this document. Copyright by SEAT S.A.
information
must be used. Consult the list of authorised refrigerant oils and
filling amounts ⇒ Rep. gr. 87 .
The PAG oils suitable for use with refrigerant R134a are very hy‐
groscopic, and cannot be mixed with other oils. For this reason,
open oil containers must be closed immediately to prevent hu‐
midity from entering. Moisture and acids promote ageing of re‐
frigerant oil, causing it to become dark, viscous and corrosive to
metals.
Note
♦ In refrigerant circuits designed for refrigerant R134a, only oil

authorised for use with the compressor must be used. (Ca‐
pacities ⇒ Rep. gr. 87 ).
♦ Due to its chemical properties, refrigerant oil must not be dis‐
posed of with engine or gear oils ⇒ Waste, Environmental
protection; Article 17 of Regulation (EC) 2037/2000 .
1.8 Comfort
One of the fundamental conditions required for driving with a clear
mind and safely is a feeling of comfort inside the vehicle. This
feeling of comfort can only be achieved by using the air-condi‐
tioner, especially under extreme temperatures and high air hu‐
midity. Naturally the comfort can also be increased by opening
the windows and the sliding roof or by setting the fan to a high
speed; however this leads to unpleasant side effects in the pas‐
senger compartment such as additional noise, air draughts, entry
of exhaust gases and unfiltered pollen (which can be very un‐
pleasant for people suffering from allergies).
By using an air-conditioner in conjunction with a properly-de‐
signed heating and ventilation system, a comfortable environ‐
ment can be created by adequately setting the temperature, air
humidity and air circulation inside the vehicle according to the ex‐
terior conditions. This can be done both with the vehicle stopped
or in motion.
Other important advantages of the air-conditioner are:
♦ The purity of the air that enters the vehicle (the humid fins of
the evaporator retain dust, for example, and expose of it to‐
gether with the condensed water).
♦ Temperature in a middle class car (e.g. during short trips, out‐
door temperature in shade 30 °C, and vehicle exposed to sun).
With air conditioning Without air condi‐
tioning
Top area 23 °C 42 °C
Chest area 24 °C 40 °C
Foot area 30 °C 35 °C
1.8.1 Environmental issues

Since 1992 approximately, new automotive air-conditioning sys‐
tems have gradually changed to using refrigerant R134a. This
refrigerant contains no chlorine, and therefore does not harm the
ozone layer.
Up to 1992 approximately, automotive air-conditioners used re‐
frigerant R12. As it contains chlorine atoms, this CFC is extremely
prone toProtected
destroying ozone,
by copyright. and
Copying also ortocommercial
for private contributing tointhe
purposes, green‐
house permitted
effect. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
There are programmes available to convert old installations which
still use R12 (harmful to the ozone layer).
For environmental protection reasons, refrigerant must not be re‐
leased in the atmosphere (Legal texts and guidelines).
⇒ page 39
1.9 Air-conditioner operation

The temperate inside the vehicle is determined by the heat radi‐
ated through the windows and by the heat transferred by metal

parts. In order to achieve that the temperature inside the vehicle

is comfortable for the occupants, some of the heat inside the ve‐
hicle must be evacuated.
Seeing as heat is diffused towards colder areas, a unit which
generates low temperatures is fitted inside the vehicle. Refriger‐
ant is constantly evaporated inside this unit. The heat required for
this process is extracted from the air which flows through the
evaporator.
The refrigerant, with the absorbed heat, is pumped away by the
compressor. Due to compression by the compressor, the heat
content and temperature of the refrigerant is increased. It is now
higher than the ambient air temperature.
The hot refrigerant with its heat content now flows to the con‐
denser. Due to the difference in temperature between the refrig‐
erant and the ambient air, the refrigerant now transfers the heat
to the ambient air through the condenser.
Hence, the refrigerant is the heat transporting medium. As it is
needed again, it flows back to the evaporator.
This is the reason why the principle on which all air-conditioners
is based is that of a refrigerant circuit. The differences are found
in the composition of the units.
1.10 General aspects regarding workplace

safety
♦ According to the current regulations and dispositions of the
legislation and professional trade unions.
♦ Observe the operating instructions regarding the work post ⇒
Environmental protection; Article 17 of Regulation (EC)
2037/2000 and Workplace safety (Service organization, Vol.
2, Chapter 6.12) , which must be on display at the refrigerant
work post.
1.10.1 Product properties

The refrigerant used in automotive air-conditioners belongs to the
new generation of refrigerants based on chlorine-free partially
fluorinated hydrocarbons (H–CF, R134a).
Regarding their physical behaviour, they are refrigerants liquefied
under pressure. They are subject to regulations regarding pres‐
surised vessels, and may only be used in duly authorised and
marked vessels for pressurised gases.
In order to guarantee their safe and correct application, there are
specific conditions which must be met.
1.10.2 Handling refrigerants

WARNING permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
There is a freezing hazard.

The refrigerant may escape in liquid or evaporated state.
Do not open containers which contain refrigerant.
When opening tanks or containers which contain refrigerant, their

content may escape in liquid or vapour state. The higher the pres‐
sure in the container, the more violent this reaction.
The pressure value depends on two conditions:
• The type of refrigerant inside the container. “The following rule

applies: The lower the boiling point, the higher the pressure.”
• The temperature value. “The following rule applies: The higher
the temperature, the higher the pressure.”
1.10.3 Use protective goggles

Wear protective goggles. They prevent refrigerant from coming
into contact with the eyes, which may cause serious injury due to
freezing.
1.10.4 Use protective gloves and apron

Refrigerants are extremely good grease and oil solvents. There‐
fore, if they come into contact with the skin, they eliminate the
protective greasy layer. This then causes the exposed skin to be
vulnerable to cold and harmful germs.
1.10.5 Do not let liquid refrigerant come into

contact with the skin
The heat produced on evaporation is removed from the surround‐
ing environment by the refrigerant. This is true even where the
surrounding environment is the skin. This may result in very low
temperatures. This leads to localised areas of freezing (boiling
point of R134a -26.5°C at atmospheric pressure).
1.10.6 Do not inhale refrigerant vapours
Note
In high concentrations, refrigerant vapours which escape mix with

the ambient air and displace the oxygen in the air needed when
breathing.
1.10.7 Smoking is strictly forbidden

The refrigerant may decompose due toof the heatinof

thisthe cigarette.
respect to the correctness information document. Copyright by SEAT S.A.
The substances produced consequently are toxic and must not
be inhaled.
1.10.8 Welding work on refrigerant installations

Before welding on vehicles (close to air-conditioner parts), the
refrigerant must be extracted by means of suction, and any re‐
mains must be eliminated by blowing with nitrogen.
The decomposition products of the refrigerant formed by the ef‐
fect of heat are not only toxic, but are also extremely corrosive
and may attack the piping and other parts of the installation. In
particular, hydrogen fluoride.
1.10.9 Penetrating odour

If a penetrating odour can be smelt, it means that decomposition
products have already been formed. Inhaling these substances
must be avoided at all costs, as doing so may cause serious
damage to respiratory tracts, the lungs and other organs.
1.10.10 First aid

• In the event of contact with the eyes or mucus, immediately
rinse with abundant running water and see an ophthalmolo‐
gist.

• In the event of contact with the skin, immediately remove all

wet clothing and rinse the affected parts of the skin with abun‐
dant water.
• In the event of inhaling refrigerant vapours in high concentra‐
tions, immediately take the affected person outdoors. Seek
medical assistance. In case of respiratory problems, adminis‐
ter oxygen. If the affected person has trouble breathing or
cannot breathe at all, tilt the head backwards placing one hand
behind the neck and apply artificial respiration.
1.10.11 Handling pressurised containers and

vessels
• Secure the containers to prevent them from falling.
Bottles stored upright must be secured to prevent them from fall‐
ing, and those lying flat must be secured to prevent them from
rolling.
• Do not drop or knock the containers over.
If dropped, the containers may be damaged, causing them to
break. The refrigerant will then evaporate rapidly, liberating con‐
siderable forces. Flying fragments of the bottle may cause serious
injury.
If transported improperly, the valves of the bottles may break. In
order to protect the valve, the bottles must always be transported
with the protective cap in position.
• The bottles must never be placed close to heating radiators.
Very high temperatures may be found in the vicinity of heating
radiators. High temperatures also mean high pressures, which
may exceed the admissible pressure of the container.
1.10.12 Do not expose to temperatures above

50 °C
In order to eliminate all hazards, the regulations regarding pres‐

surised vessels state that these vessels must not be exposed to
temperatures above 50 °C.
1.10.13 Do not heat in uncontrolled manner

Never heat the container with a flame. Localised overheating may
cause alterations in the material of the container, causing it to lose
resistance to pressure. Moreover, there is a risk that the refriger‐
ant may decompose due to localised overheating.
1.10.14 Close empty containers

Empty refrigerant containers must always be closed to prevent
humidity from entering. Moisture in metal containers leads to for‐
mation of rust, weakening the container wall material. Moreover,
the rust particles which enter the air-conditioning installation from
the container affect its operation.
1.10.15 Safety precautions for handling suction

and filling equipment
• Before connecting the filling equipment to the air conditioner,
ensure that all shut-off valves are completely closed.
• Before disconnecting the filling equipment from the air condi‐
tioner, ensure that the process has been completed, in order
prevent any refrigerant from escaping into the atmosphere.
• Once the refined refrigerant has been transferred from the fill‐
ing equipment to an external pressurised gas bottle, the man‐
ual shut-off valves on both the bottle and the filling equipment
must be closed.
• Do not expose the filling equipment to humidity or use it in wet
or humid environments.
• Ensure that the electrical power of the filling equipment is dis‐
connected before carrying out any maintenance work.
• Avoid using electrical power extension cords, in order to min‐
imise the risk of fire. If it is necessary to use an extension cord,
use a cable with a minimum cross-section of 2.5 mm2.
• In the event of fire, move the external bottle away.
• If oil sucked out from the air-conditioner is transferred from the
suction accumulator to the graduated container supplied, en‐
sure that it is later deposited in a container which can be
closed, seeing as the oil contains a small amount of refriger‐
ant. The refrigerant must not be dumped or disposed of into
the environment.
• When storing the service station, ensure that the wheels are
blocked.

1.11 Safety precautions for working on vehi‐

cles with air-conditioning and handling
refrigerant R134a
Air-conditioner service equipment A/C charging station - SAT
4006D-
WARNING
♦ Always keep an eye wash flask close to hand.

♦ If the refrigerant comes into contact with the eyes, imme‐
diately rinse them thoroughly for at least 15 minutes. Then,
apply eye drops and seek medical assistance immediate‐
ly, even if the eyes do not cause any pain.
♦ The medical assistance must be informed of the fact that
the freezing was caused by refrigerant R134a. If, despite
taking these safety precautions, other parts of the body
come into contact with the refrigerant, also rinse thor‐
oughly with cold water for at least 15 minutes.
♦ Work may only be carried out on the refrigerant circuit of
the air-conditioner in well ventilated areas. All air-extrac‐
tion installations in the workshop must be turned on.
♦ Do not store the refrigerant in deep or underground en‐
closures (e.g. basements), or on staircases leading down
to them, or window sills.
• Do not perform welding, brazing or soldering work on air-con‐

ditioning components filled with refrigerant. The same applies
to welding or soldering work on parts of the vehicle which may
cause parts of the air-conditioning to be heated. If any parts
are to be removed due to repairs in the paint oven or in its
preheating area, the parts may not reach temperatures in ex‐
cess of 80°C.
Reason:
Excessive heat causes extremely high pressures in the installa‐
tion, which may cause the pressure relief valve to open.
Solution:
– Empty the refrigerant circuit with the service station.
Note
Do not repair any damaged or leaking parts of the air-conditioner

by means of welding. They must always be replaced.
Always prevent heating containers

Protected (e.g. for
by copyright. Copying filling
privatecylinders
or commercialof the in part or in whole, is not
purposes,
service station) with refrigerant
permitted excessively,
unless authorised by SEAT S.A.and
SEAT do not not
S.A does expose
them to direct sunlight.respect to the correctness of information in this document. Copyright by SEAT S.A.
Solution:
– Never fill the container completely with liquid refrigerant. If too
little space is left for expansion (gas cushion), the container
will burst if the temperature rises, possibly with disastrous
consequences ⇒ page 5 .
Equipment and containers which contain air must under no cir‐
cumstances be filled with refrigerant.
Solution:
– Vacuum the equipment and containers before filling them with
refrigerant.

1.12 Fundamental aspects for working on the

refrigerant circuit
• The workplace specific guidelines must be observed ⇒ see
environment protection, Regulation for gases containing fluo‐
rine COM 492 (11.08.03), Service Organisation (30.11.02) .
Refrigerant for air conditioners / refrigerant oil: This informa‐
tion must be made available at the workplaces for refrigerants.
• Work with absolute cleanliness.
• When handling refrigerant and nitrogen, always wear protec‐
tive goggles and gloves.
• All air-extraction installations in the workshop must be turned
on.
• Only empty the refrigerant circuit using the air conditioning
service station; then the screw connection can be opened or
defective components can be replaced.
• Close any open units or flexible hoses with plugs, in order to
protect them from humidity and dirt. Plugs of different diame‐
ters can be found in the equipment kit - T20017A- .
• Use only tools and materials specially designed for refrigerant
R134a.
• Protect the refrigerant oil against humidity by closing the open
containers.
– Rinse the refrigerant circuit with nitrogen and the specific sol‐
vent for refrigerant R134a: ⇒ page 60
The refrigerant circuit must be rinsed with R134a in event of the
the following: ⇒ page 69
In vehicles without electromagnetic coupling on the compressor:
♦ Humidity or dirt have entered the refrigerant circuit (e.g. after
an accident).
♦ the refrigerant oil has turned dark or viscous.
♦ after replacing the air-conditioner compressor,
respectthere is too of information in this document. Copyright by SEAT S.A.
to the correctness
much refrigerant oil in the refrigerant circuit.
♦ The compressor has been replaced due to “internal” damage
(e.g. noise or lack of power).
In vehicles without electromagnetic coupling on the compressor:
Note
♦ The engine should only be started once the refrigerant circuit

has been assembled completely.
♦ If possible, the engine must only be started after the refrigerant
circuit has been filled.
♦ The compressor is always driven by means of the Poly-V belt
pulley / elastic coupling sleeve (it has no electromagnetic cou‐
pling):
♦ If the air-conditioner compressor locks, the overload protection
will come off the compressor shaft. Even if no buckling is visi‐
ble on the Poly-V belt pulley / overload protection, the com‐
pressor may still be locked. Another possibility is that there is
abrasive dust in the area of the pulley / overload protection.
♦ The compressor is equipped with a protected oil supply to
prevent any damage if the refrigerant circuit were to be empty.
This means that approx. 40 to 50 cm3 of refrigerant oil remains
in the air-conditioner compressor.
♦ Engine is not to be started unless refrigerant circuit has been
properly assembled. If, for example, the refrigerant piping has
not been connected to compressor, the compressor may over‐
heat if the engine is running (due to internal heating), and may
eventually be destroyed.
♦ The air-conditioner compressor regulating valve - N280- does
not work when the refrigerant circuit is empty and the com‐
pressor is operating at idling speed with the engine.
♦ If the engine must be started with the refrigeration circuit emp‐
ty:
♦ The refrigeration circuit must be assembled completely.
♦ There must be at least a quarter of the refrigerant oil required
by the refrigerant circuit in the compressor.
♦ The engine speed must not exceed 2,000 rpm.
♦ The engine must < run for about 10 minutes.
1.12.1 O-rings
♦ Use only O-rings which are resistant to refrigerant R134a and
to the corresponding refrigerant oils. The O-rings are no longer
colour coded. Either black or colour-coded O-rings may now
be used, without distinction.
♦ Ensure that the interior diameter of the O-rings is correct.
⇒ Rep. gr. 87
♦ The O-rings may Protected
only bebyused once.
♦ Before assembly, lubricate
respect tothe O-ringsofslightly
the correctness with
information in thisrefrigerant
oil (PAG oil).

Note
♦ When blowing out the parts with compressed air and nitrogen,
always use an appropriate device (workshop extraction sys‐
tem) to suck up the mixture of gas from the parts.
♦ Once the repair work has been completed, screw plugs (with
seals) into all the valve connections and service connections.
Putting the air-conditioner into service. Take the filling amounts

for the specific vehicle into account ⇒ Rep. gr. 87 .
Do not top up the refrigerant. Suck any refrigerant from the in‐
stallation and fill with new refrigerant.
1.12.2 Before putting the air-conditioner into

service after new filling
– When a new compressor is mounted or the refrigerant oil is
replaced (e.g. after blowing out the refrigerant circuit with com‐
pressed air), the compressor pulley must be turned 10 full
turns by hand before stating the engine. This avoids damage
to the compressor.
– In 5 and 10 cylinder diesel engines, turn the compressor 10
full turns by hand at the overload protection. Then, mount the
compressor. This avoids damage to the compressor.
– With the air-conditioner turned off ( electromagnetic coupling
for air-conditioner - N25-
respect and regulating
to the correctness valve
of information in thisfor air-condi‐
tioner compressor - N280- are not activated), start the engine.
– Once the engine starts idling at a stable speed, turn on the air-
conditioner and let it run for at least 10 minutes at maximum
cooling power.
2 General aspects regarding the refrig‐

erant circuit
2.1 Parts of the refrigerant circuit
Caution

be used.
• All refrigerant circuit components which are sent for quality

control must always be closed (use the original plugs from the
spare part).
• Replace any damaged or leaking components of the refriger‐
ant circuit. ⇒ page 122
• Up to now, all spare parts (compressor, collecting tank, liquid
tank, evaporator and condenser) have been filled with nitro‐
gen. This method is now being eliminated so that the pressure
compensation when the cap on a replacement part is un‐
screwed is only slight, if present at all.
2.1.1 Layout of the refrigerant circuit compo‐

nents and its influence on the high and
low pressure sides
The liquid tank condenser is found on the high pressure side, to‐
gether with the choke or expansion valve, as separation between
the high pressure side and the low pressure side of the liquid.
The high pressure is caused due to the choke or expansion valve
forming a narrowing where the refrigerant is accumulated, thus
leading to an increase in pressure and temperature.
Excessive pressure is produced if the circuit is filled with too much
refrigerant or refrigerant oil, the condenser is dirty, the radiator
breaks down, the system is blocked, or there is humidity in the
refrigerant circuit (freezing of the choke or expansion valve).
The evaporator, the collector tank and thepermitted
evaporator tempera‐
ture sensor are found on the low pressure side, together
respect with theof information in this document. Copyright by SEAT S.A.
to the correctness
compressor, as separation between the high pressure side and
the low pressure side of the gas.
A drop in pressure may occur in the system due to a loss of re‐
frigerant, a fault in the choke or expansion valve (no narrowing),
a fault in the compressor, or freezing of the evaporator.

2.1.2 Air-conditioner compressor with electro‐

magnetic coupling
The air-conditioner compressor is driven by the vehicle engine
using a Poly-V belt.
An electromagnetic coupling on the air-conditioner compressor
provides direct transmission between the belt pulley and the air-
conditioner compressor (crankshaft) when the air-conditioner is
turned on.
A short-circuit fuse mounted on the compressor pulley activates
the electromagnetic coupling if the compressor turns with difficul‐
ty, protecting the belt transmission against excessive load.
The air-conditioner compressor sucks in refrigerant gas from the
evaporator, compresses it and transfers it to the condenser.
Note
♦ The air-conditioner compressor contains refrigerant oil which

may be mixed with refrigerant R134a at any temperature.
♦ The manufacturer’s label specifies the refrigerant to be used
for the specific air-conditioner compressor installed. A regu‐
lating valve adjusts the pressure in the low pressure side within
the specified technical range (characteristic regulation curve).
♦ In order to prevent the air-conditioner compressor from being
damaged if the refrigerant circuit is empty, the electromagnetic
coupling is disconnected, and the air-conditioner compressor
regulating valve - N280- is not activated (the compressor op‐
erates at idling speed with the engine).
2. General aspects regarding the refrigerant circuit 19

2.1.3 Air-conditioner compressor without

electromagnetic coupling
The air-conditioner compressor is driven by the vehicle engine
using a Poly-V belt.
An overload protection device mounted on the air-conditioner
compressor pulley is activated if the compressor turns with diffi‐
culty, protecting the belt transmission against excessive load.
The air-conditioner compressor sucks in refrigerant gas from the
evaporator, compresses it and transfers it to the condenser.
Note
♦ The air-conditioner compressor contains refrigerant oil which

may be mixed with refrigerant R134a at any temperature.
♦ The refrigerant should be specified on the model label that has
to be used for the respective air conditioner compressor fitted.
A regulating valve adjusts the pressure in the low pressure
side within the specified technical range (characteristic regu‐
lation curve).
♦ On this air-conditioner compressor, the regulating valve is ac‐
tivated from the exterior.
♦ The engine should only be started once the refrigerant circuit
has been assembled completely. ⇒ page 15
♦ The compressor is equipped with a protected oil supply to
prevent any damage if the refrigerant circuit were to be empty.
This means that approx. 40 to 50 cm3 of refrigerant oil remains
in the air-conditioner compressor.
2.1.4 Condenser
The condenser transfers heat from the compressed refrigerant
gas to the ambient air.
During permitted
this process, the refrigerant
unless authorised gasS.A
by SEAT S.A. SEAT condenses, turning
does not guarantee into
liquid. respect to the correctness of information in this document. Copyright by SEAT S.A.

2.1.5 Evaporator
The liquid refrigerant evaporates inside the evaporator coils. The
heat required for this process is extracted from the air which flows
past the evaporator fins. The air is cooled down. The refrigerant
evaporates, and is sucked in by the compressor, together with the
heat absorbed.
A choke or expansion valve is used to control the amount of re‐
frigerant which enters the evaporator. In installations equipped
with an expansion valve, the flow is controlled in such as way that
only gaseous refrigerant exits the outlet of the evaporator.
2.1.6 Collecting tank

In order to ensure that the compressor only sucks in gaseous re‐
frigerant, the collecting tank collects the mixture of gas and va‐
pour which comes from the evaporator. The vapour is turned into
gaseous refrigerant.
The refrigerant oil which constantly flows through the refrigerant
circuit does not remain inside the collecting tank, as there is an
extraction borehole for the oil.
Any humidity which may have entered the refrigerant circuit dur‐
ing assembly is retained by a filter (desiccant bag) located in the
tank.
The compressor sucks in gaseous refrigerant with oil.
Note
♦ The collecting tank must be replaced if the refrigerant circuit

has remained open for a prolonged period of time (longer than
the repair time) and humidity has entered, or if required due to
any other circumstance.
♦ Plugs -A- and -B- must only be removed immediately before
assembly.
♦ If the collecting tank remains open, the desiccant bag is soon
saturated with humidity, rendering it useless.
♦ During assembly, also take note of the arrow indicating the
flow direction.

2.1.7 Choke
The choke creates a narrowing. This narrowing restricts the flow,
thereby separating the refrigerant circuit into the high and low
pressure sides. Before reaching the choke, the refrigerant is hot
and under high pressure. After passing through the choke, the
refrigerant is cold and under low pressure. There is a strainer be‐
fore the narrowing to collect any dirt. There is also a fine mesh
after the narrowing which atomises the refrigerant before it rea‐
ches the evaporator.
Note
♦ The arrow -A- located on the choke points towards the evap‐
orator.
♦ It must be replaced whenever the circuit is opened.
♦ Take note of the different versions.
⇒ Rep. gr. 87
⇒ Parts catalogue
2.1.8 Liquid tank

The tank collects the liquid drops, and constantly leads them to‐
wards the expansion valve. Any humidity which may have entered
the refrigerant circuit during assembly is retained by a desiccant
bag inside the liquid tank.
Note
♦ Replace the fluid tank in case the refrigerant circuit had been
opened for a longer period (longer that the usual repair period)
and humidity has entered or in event a replacement is neces‐
sary due to a certain complaint. ⇒ page 122
♦ The plugs must only Protected
be removed immediately
by copyright. before
Copying for private assem‐
bly. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If the liquid tank remains open, the desiccant bag is soon sa‐
turated with humidity, rendering it useless.
♦ During assembly, also take note of the arrow indicating the
flow direction.
New tanks are mounted directly onto the condenser, and are
equipped with a desiccant cartridge.
Note
♦ Replace the desiccant cartridge in case the refrigerant circuit

had been opened for a longer period (longer that the usual
repair period) and humidity has entered or in event a replace‐
ment is necessary due to a certain complaint. ⇒ page 122
♦ The desiccant cartridge must only be removed from its pack‐
aging immediately before assembly.
♦ If the packaging remains open, the desiccant cartridge is soon
saturated with humidity, rendering it useless.

2.1.9 Expansion valve

The expansion valve controls the flow and atomises the refriger‐
ant as it passes through, such that the vapour does not turn into
gas until it leaves the evaporator, according to its heat content.
2.1.10 Quick-release couplings on refrigerant

line
WARNING
Only release and open the quick-release couplings after com‐

pletely discharging the refrigerant circuit.
Note
♦ To remove refrigerant line -D- use release tool for air condi‐
tioner pipes -T40149/- to open retaining ring -A- ⇒ Air condi‐
tioning; Rep. gr. Protected
87 . by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ After removing the corresponding refrigerant
respect to the correctness line
of information it is
in this neces‐
sary to replace the quick-release coupling connections -B- and
-G- together with the associated support ring -E- or -H- and O-
ring -F- or -J-. ⇒ Air conditioning; Rep. gr. 87 and ⇒ Parts
catalogue .
A - Retaining ring (in quick-release coupling, high-pressure side)

B - Quick-release coupling with retaining ring (“high-pressure
side”)
C - Refrigerant line with internal heat exchanger
D - Refrigerant line (“high-pressure side”)
E - Support ring (“high-pressure side”)
F - O-ring (“high-pressure side”)
G - Quick-release coupling with retaining ring (“low-pressure
side”)
H - Support ring (“low-pressure side”)
J - O-ring “low pressure side”

2.1.11 O-rings
The O-rings seal the unions and joints between the different com‐
ponents of the refrigerant circuit.
Only O-rings which are resistant to refrigerant R134a and to the
corresponding refrigerant oils must be used. This is guaranteed
by using genuine spare parts.
⇒ Parts catalogue
O-rings:
• Use once only.
• Note the correct diameter -a- and -b-.
• Moisten with refrigerant oil before fitting.
Note
O-rings for circuits using refrigerant R134a are no longer colour

coded. Either black or colour-coded O-rings may now be used,
without distinction.
⇒ Rep. gr. 87
2.1.12 Piping and flexible hoses of the refriger‐

ant circuit
The mixture of refrigerant oil and refrigerant R134a corrodes cer‐
tain metals (e.g. copper) and alloys and dissolves certain hose
materials. For this reason, only genuine spare parts must be
used.
Piping and flexible hoses are joined by means of screw joints or
special plug-in couplings.
Note
Observe the specified tightening torque for the screw joints, and
use the release tools supplied for the plug-in couplings.
2.1.13 Pressure relief valve

The pressure relief valve
respect iscorrectness
to the locatedofon the compressor
information in this document.or on the
liquid tank.
The valve opens at a pressure of approx. 38 bar and closes again
once the pressure has dropped (approx. 30 bar).
Not all the refrigerant is released.
Depending on the version, it is equipped with a transparent plastic
disc which is broken when the valve reacts.

2.2 Refrigerant circuit configuration

2.2.1 Refrigerant circuit with expansion valve
and one evaporator
1- Evaporator
2- Expansion valve
3- Suction, charging and measuring valve
4- Liquid tank with desiccant bag / desiccant cartridge
5- Condenser
6- Air conditioning compressor
Note
The arrows indicate direction of refrigerant flow.
2.2.2 Refrigerant permitted
circuit with
unless choke
authorised by SEATand col‐
lecting tank
1- Air conditioning compressor
2- Condenser
3- Choke
4- Evaporator
5- Collecting tank with desiccant bag
Note
2.2.3 Refrigerant circuit with expansion valve

and two evaporators
1- Evaporator
2- Expansion valve
3- Suction, charging and measuring valve
4- Sight glass
5- Liquid tank with desiccant
6- Condenser
7- Compressor
8- Solenoid valve for refrigerant circuit
9- Expansion valve
10 - Second evaporator
Note

2.3 Extraction and filling valve for the quick

connection of the air-conditioning serv‐
ice station on the refrigerant circuit
♦ Torque wrench - V.A.G 1783- (2 … 10 Nm) with "insertable
ratchet 1/4 Inch" - VAS 6234-
WARNING

If refrigerant circuit has not been evacuated, refrigerant may
escape.
Extract the refrigerant before opening the refrigerant circuit. If
the refrigerant circuit does not open after sucking the refriger‐
ant out, within 10 minutes, pressure may be accumulating in
the circuit due to re-evaporation. Suck the refrigerant out of the
circuit again.
• Only valves and connections which are resistant to refrigerant

R134a and to the corresponding refrigerant oils must be used.
• Different connections (exterior diameter) for high and low
pressure sides.
• Always replace plugs.
Position in the vehicle.
See the repair manual of the respective vehicle ⇒ Rep. gr. 87 .
2.3.1 Suction and charging valve with Schrad‐

er valve
Note
♦ Torque wrench - V.A.G 1783- with "insertable ratchet 1/4 Inch"

- VAS 6234-
♦ Socket - T10364- for releasing the element of the Schrader
valve ⇒ page 149
A - Service connection (welded)

B - Element of the
Protected Schrader
by copyright. valve
Copying (2.4or±commercial
for private 0.2 Nm)purposes, in part or in whole, is not
C - O-ring (belonging
respect to theto the valve)
D - Plug with seal

2.3.2 Suction and charging valve, high pres‐

sure side
Note

- VAS 6234-
♦ Socket - T10364- for releasing the valve element
⇒ page 149
1- Cone with exterior or interior thread

2- O-ring: 10.8 mm; 1.8 mm Differenciation: black or coloured
3- Suction and charging valve with groove for O-ring, and ex‐
terior or interior thread M8 x 1 for cap
4- O-ring for sealing cap: 10.8 mm; 1.8 mm Differenciation:
black or coloured
5- Upper connector cover
2.3.3 Suction and charging valve, low pres‐

sure
Protected sideCopying for private or commercial purposes, in part or in whole, is not
by copyright.
Note

- VAS 6234-
♦ Socket - T10364- for releasing the valve element
⇒ page 149
1- Cone with exterior thread and groove for O-ring

2- O-ring: 7,6 mm; 1.8 mm Differenciation: black or coloured
3- Suction and charging valve with interior thread M8 x 1 for
cap
4- O-ring for sealing cap: 7,6 mm; 1.8 mm Differenciation:
black or coloured
5- Upper connector cover
2.4 Switches and senders in the refrigerant

circuit and corresponding connections
Note
Switching pressures, disassembly and assembly of switches, as

well as layout of switches and versions. See specific refrigerant
circuit for vehicle.
⇒ Rep. gr. 87

2.4.1 Air-conditioner high pressure switch -

F23-
Operation:
Increases the refrigerant liquid fan speed if the refrigerant circuit
pressure increases (approx. 16 bars).
2.4.2 High pressure switch for electromagnet‐

ic coupling - F118-
Operation:
Turns the air-conditioner compressor off if the pressure in the re‐
frigerant circuit is excessive (approx. 32 bar).
2.4.3 Low pressure switch for air conditioning

system - F73-
Operation:
In therespect
eventtoof
thepressure
correctness ofloss in the
information refrigerant
in this circuit,byswitches
document. Copyright SEAT S.A. the
air conditioner compressor off (at approx. 2 bar).

2.4.4 Valve connections for switches in refrig‐

erant circuit
WARNING

escape.
Extract the refrigerant before disassembling valve -C-. If the
refrigerant circuit does not open after sucking the refrigerant
out, within 10 minutes, pressure may be accumulating in the
circuit due to re-evaporation. Suck the refrigerant out of the
circuit again.
• Different thread for switches on high and low pressure sides.

• Only valves and O-rings which are resistant to refrigerant
R134a and to the corresponding refrigerant oils must be used.
A - Connection (welded)
B - O-rings
C - Valve (with O-ring)
2.4.5 Air-conditioner pressure switch - F129-

This pressure switch has 3 functions:
1. Increases the refrigerant liquid fan speed if the refrigerant cir‐
cuit pressure increases (approx. 16 bars).
2. Switches off air-conditioning when pressure is too high (approx.
32 bars - e.g. resulting from insufficient engine cooling).
3. Switches off air-conditioning when pressure is too low (approx.
2 bars - e.g. resulting from loss of refrigerant).
Note
The air-conditioner pressure switch - F129- replaces the air-con‐

ditioner high pressure switch - F23- , the air-conditioner low
pressure switch - F73- and the high pressure switch for the elec‐
tromagnetic coupling - F118- .

2.4.6 High-pressure sender - G65-

This high pressure sender - G65- is installed instead of the air-
conditioner pressure switch - F129- .
The high pressure sender generates a rectangular signal or a da‐
tagram when voltage is applied. This signal changes according
to the pressure in the installation.
With this signal, the connected control units (refrigerant fan con‐
trol unit, engine control unit air-conditioner control unit and dis‐
play, Climatronic - E87- , or else the Climatronic control unit -
J255- , etc.) calculate the pressure of the refrigerant circuit, and,
according to this pressure, activate the refrigerant and engine
fans, the air-conditioner electromagnetic coupling - N25- , or ad‐
just the activation of the air-conditioner compressor regulating
valve - N280- .
2.4.7 Refrigerant pressure and temperature

sender - G395-
WARNING

escape.
Extract the refrigerant before disassembling the refrigerant
pressure and temperature sender - G395- . If the refrigerant
circuit does not open after sucking the refrigerant out, within
10 minutes, pressure may be accumulating in the circuit due
to re-evaporation. Suck the refrigerant out of the circuit again.
This refrigerant pressure and temperature sender - G395- is in‐

stalled instead of the high pressure sender - G65- or the air-
conditioner pressure switch - F129- .
The pressure signal is continuously monitored, while the temper‐
ature signal is only monitored if the temperature rises above 0 °
C.
This information is used by the Climatronic control unit - J255- to
accordingly activate the refrigerant fans and the air-conditioner
compressor regulating valve - N280- .
2.4.8Protected Compressor
by copyright. Copying for control valve,
private or commercial air incondition‐
ing - correctness
N280-of information in this document. Copyright by SEAT S.A.
respect to the
The regulating valve is mounted onto the compressor. It is acti‐

vated by the air-conditioner control unit and display, Climatronic
- E87- , or else by the Climatronic control unit - J255- . The reg‐
ulating valve is used to control the pressure in the low pressure
side, thereby regulating the temperature in the evaporator.
Note
The air-conditioner compressor regulating valve - N280- forms

part of the air-conditioner compressor, and cannot be replaced
separately.

2.5 Electrical components not fitted onto the

refrigerant circuit
2.5.1 Refrigerant fan control unit - J293-
Note
Different models exist.
This control unit connects and disconnects the electromagnetic

coupling, and thereby the air-conditioner compressor. It connects
the refrigerant fans, and calculates the pressure of the refrigerant
circuit in vehicles equipped with a high pressure sender - G65- or
a refrigerant pressure and temperature sender - G395- .
2.5.2 Evaporator outlet temperature sender -

G263- or evaporator temperature sen‐
sor - G308-
Operation:
The evaporator permitted
outlet temperature sender - G263- or the evapo‐
rator temperature sensor
respect-toG308- calculate
the correctness the temperature
of information after by SEAT S.A.
in this document. Copyright
the evaporator. This value is sent to the air-conditioner control
unit, and serves as reference signal for controlling the compres‐
sor. This prevents that the evaporator ices-up
2.6 Refrigerant circuit pressures and tem‐

peratures
WARNING
When working on the refrigerant circuit, the current general

safety regulations and pressurised vessel regulations must be
observed.
The refrigerant circuit pressures and temperatures depend on the

current service states (e.g. engine speed, refrigerant fan speed
1, 2 or 3, engine temperature, compressor on or off), as well as
on the effects of environmental factors (e.g. ambient temperature,
air humidity, cooling power required).
In vehicles equipped with a air-conditioner compressor regulating
valve - N280- , the pressure in the low-pressure side is regulated
by activating the valve.
For this reason, the values specified in the following table are
merely approximations. They are calculated based on an engine
speed of between 1500 and 2000 rpm for 20 minutes, and an
ambient temperature of 20 °C.

The connections supplied for the manometer bank used to meas‐

ure the pressure are located on the specific refrigerant circuit of
the vehicle.
⇒ Rep. gr. 87
At a temperature of 20 °C and with the engine stopped, a pressure
of 4.7 bar is set in the refrigerant circuit.
2.7 Refrigerant circuit with expansion valve

A - Low-pressure side of refrigerant circuit.
B - High-pressure side of refrigerant circuit.
Component Refrigerant Pressure (bar excess pressure) Temperature in °C
aggregation
state
-1- Evaporator, from inlet to Vapour approx. 1.2 bar approx. -7 ?
outlet
(approx. 1.8 bar) (approx. -1° C)
-2- air-conditioner compres‐ Gas approx. 1.2 bar approx. -1 ?
sor, side A
(approx. 1.8 bar) (approx. +1° C)

Component Refrigerant Pressure (bar excess pressure) Temperature in °C

aggregation
state
-3- air-conditioner compres‐ Gas approx. 14 bar approx. +65°C
sor, side B
-4- Condenser Gas, vapour, approx. 14 bar approx. +55 ? at outlet
liquid
-5- liquid tank Liquid approx. 14 bar approx. 55 ?
-6- Extraction and filling valve, Liquid approx. 14 bar approx. 55 ?
side B
-7- expansion valve Liquid, expan‐ approx. 14 bar approx. 55 °C, is reduced to
sion into va‐ -7 °C
pour
-8- Extraction and filling valve, Gas approx. 1.2 bar approx. -7 ?
side A
(approx. 1.8 bar) (approx. -1° C)
1) 1. On AC circuits with regulating compressor the pressure is maintained at an absolute pressure of approx. 2 bars (corresponding to
gauge pressure of approx. 1 bar). regardless of changes in the heat transfer and differences in the engine speed. However this applies
only for the compressor output range. If the performance limits of the compressor are exceeded, the pressure increases.
2) 2. The temperature is maintained within the regulation range of the compressor in the refrigerant circuits by the regulating compressor,
in spite of the changing transfer of heat and the different engine speeds. However this applies only for the compressor output range. If the
performance limits of the compressor are exceeded, the temperature increases.
Note
♦ Air conditioning compressors that do not regulate their power

by themselves will be switched off by the respective controller
at an evaporation temperature less than 0°C via the compres‐
sor regulation valve of the air conditioning - N280- .
♦ In vehicles equipped with a air-conditioner compressor regu‐
lating valve - N280- , the pressure in the low-pressure side is
regulated by activating the valve.

HD - High pressure side of the refrigerant circuit.
ND - Low pressure side of the refrigerant circuit.

1 - Evaporator
2 - Expansion valve
3 - High pressure switch/sen‐
sor
❑ The versions are differ‐
ent depending on the
vehicle.
4 - Service connection for the
high-pressure side
5 - Liquid tank
vehicle.
6 - Condenser
7 - Pressure relief valve
8 - Compressor, high-pressure
side permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
9 - Compressor, low-pressure
side
10 - Primary volume
11 - Service connection for the
low-pressure side
2.8 Refrigerant circuit with choke and collecting tank

A – Low-pressure side of refrigerant circuit.

B – High-pressure side of refrigerant circuit.
Component Refrigerant
respect toag‐ Pressure
the correctness (bar excess
of information pres‐CopyrightTemperature
in this document. by SEAT S.A. in °C
gregation state sure)
-1- air-conditioner compressor, Gas up to 20 bar up to 70 °C
side B
-2- Condenser From gas to va‐ up to 20 bar up to 70 °C
pour to liquid
-3- choke From liquid to Side B up to 20 bar, side A Side B up to 60 °C, side
vapour over 1.5 bar A over -4 °C
-4- evaporator From vapour to over 1.5 bar over -4 °C
gas
-5- collecting tank Gas
-6- air-conditioner compressor, Gas
side A
On side A, the pressure is retained at approx. 2 bar by the “reg‐
ulating” compressor, even with different engine speeds. However,
this is only valid within the power range of the compressor. If the
power limits of the air-conditioner compressor are exceeded.
⇒ page 97

Note
In vehicles equipped with a air-conditioner compressor regulating

valve - N280- , the pressure in the low-pressure side is regulated
by activating the valve.
2.9 Inspection and measurement work

which can be carried out with a manom‐
eter
Manometer reading
1- Temperature scale for refrigerant R134a, CF3–CH2F or
CH2F–CF3.
2- Pressure scale
The manometers may have one or more temperature
permitted scales
unless authorised by SEATto‐S.A. SEAT S.A does not guarantee or accept any liability with
gether with the pressure scale. The values for the R134a scale
are assigned according to the vapour pressure table. As different

refrigerants produce different vapour pressures at the same tem‐
perature, each temperature scale is identified for the correspond‐
ing refrigerant.
2.9.1 Manometers allow the following inspec‐

tion and measurement work to be car‐
ried out
a – Pressure and temperature measurement in the refrigerant cir‐
cuit
♦ The high-pressure manometer is used to measure the pres‐
sure and temperature which, while the air-conditioner is con‐
nected, evenly spread from the compressor outlet, through the
condenser, up to the narrowing (choke or expansion valve).
♦ The low-pressure manometer is used to measure the pressure
and temperature which, while the air-conditioner is connected,
evenly spread from the narrowing (choke or expansion valve),
through the evaporator, up to the compressor inlet.
Note
The relationship between pressure and temperature specified on

the manometers is only valid for the areas of the refrigerant circuit
which contain liquid or vapour, not gas. In gaseous state, the
temperature is approx. between 10 °C and 30 °C greater than that
stated by the manometer.
b – Checking for presence of refrigerant in closed container

A closed container or a refrigerant circuit contains refrigerant
R134a if the temperature stated by the manometer is equal to the
temperature of the refrigerant (the liquid present adopts the tem‐
perature of the environment).
A closed container or a disconnected refrigerant circuit is empty
if the temperature stated by the manometer is below the temper‐
ature of the refrigerant.

Note
The relationship between pressure and temperature specified on

the manometers is no longer valid when no liquid is present, and
the only pressure created is due to the presence of gas.
2.10 Equipment for loading and recycling of

the refrigerant
Different equipment is available on the market for the extraction
by vacuum, cleaning and filling of the refrigerant of vehicle air
conditioners.
2.10.1 Classification of suction systems into

groups
Group 3:
Mobile suction and charging systems for charging pressurised
gas tanks fixed to the system.
The refrigerant or the mixture of refrigerant and refrigerant oil is
charged into the pressurised gas tanks which are permanently
joined or fixed to the mobile systems. According to Regulation
COM (2003) 492 regarding fluorinated gases (11/08/03), in this
case, the pressurised gas tanks must beProtected
equivalent to pressur‐
ised tanks. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
The charging systems do not require:

♦ a permit
♦ or an inspection by experts, seeing as the gas is charged into
pressurised gas tanks equivalent to pressurised tanks. (None‐
theless, the system used to charge the pressurised gas tanks
to be delivered to third parties from these pressurised tanks
does require the corresponding permit and is subject to com‐
pulsory inspections).
Note
In the case of service and recycling equipment used in automotive

workshops, these suction and charging equipment do not require
a permit (Group 3), but may only be handled by duly qualified
personnel. The handling and maintenance of the equipment is
described in the corresponding manufacturer’s documentation.
2.10.2 Charging systems which do not require

a permit
Charging systems which do not require a permit are charging
systems in which the pressurised gases are charged into mobile
pressurised gas tanks which are exclusively used by the company
itself.
Observation:
Certain service equipment is charging systems which do not re‐
quire a permit. When working with this equipment, the refrigerant
is not charged into mobile pressurised gas tanks, but into a fixed
charging cylinder with a visible level gauge and float switch.

Recommendation:
When charging surplus refrigerant to cover own demand, it is ad‐
visable to use a portable charging cylinder with a visible level
gauge and a pressure relief valve.
When charging pressurised gases into other pressurised gas
tanks, observe the TRG 402 (Technical Regulations regarding
Pressurised Gases).
2.11 Repair instructions for refrigerant circuit
WARNING
When working on the refrigerant circuit, the current general

safety regulations and pressurised vessel regulations must be
observed.
Caution
When using tools or materials thatauthorised
permitted unless have bynot SEATbeen approved
(e.g. sealing additives), damagerespectmay
to the be caused
correctness to the system
be used.
Special tools and accessories:

In order to guarantee a correct and professional repair of an air-
conditioner system:
• special tools and material are required (see the list under
⇒ page 142 ).
• The basic notes on the leak detector device must be taken into
account ⇒ page 51 .
• Special knowledge is required.
Note
Refrigerant may not be released into the environment

⇒ page 39 .

3 Legal texts and regulations
Note
♦ The laws and regulations applicable in each case are those of

each particular country, or else, the following in the case of the
European Union.
♦ Different and/or additional laws and regulations may be appli‐
cable in other countries or continents.
♦ Please refer to the responsible authorities.
♦ The effect of the change in climate can already be recognised
worldwide. This is why the climate protection is one of the most
important tasks for humans. This, however, represents a ma‐
jor challenge for all concerned.
♦ In the so-called Kyoto Protocol, amongst others, the global
goals are defined for the protecting the climate. In this protocol,
besides the targets for reducing the carbon dioxides, the target
has also been determined for reducing greenhouse gases
containing fluorine, such as the refrigerant R134a due to its
intensive greenhouse
Protected by effect.
3.1 Laws and regulations

European Regulation (EC) Nº 2037/2000

(1) The use and sale of CFCs is forbidden.
(2) Calendar for banning the use and manufacture of HCFC
equipment.
(3) CFCs and HCFCs will be recovered for destruction or recycling
during service or maintenance operations on the equipment, or
before its disassembly or destruction.
(4) Member states will take measures to promote the recovery,
recycling or destruction of CFCs and HCFCs.
(5) Member states will determine the minimum qualification re‐
quired by the personnel involved.
(6) All feasible measures will be taken to prevent CFCs and
HCFCs from leaking or escaping. In particular, fixed equipment
with a refrigerant load greater than 3 kg will be controlled.
Training and certification programmes will be established for per‐
sonnel involved in the carrying out of leak inspections, recovery,
recycling and destruction of refrigerants
Directive (EC) no. 842/2006
Guideline 2006/40/EC
Maintenance and repair work on the refrigerant circuit of the air
conditioning system
All persons that carry out maintenance and repair work on the air
conditioning system of the vehicle must have participated on a
course or training program and have been provided with instruc‐
tions (proof of training is required). Other or extended directives
may apply outside the European Union.
TRG 402 (Using the filling stations)
• over the age of 18 years,
3. Legal texts and regulations 39

• who possess the required knowledge and experience,

• and who can be expected to carry out their tasks in a reliable
manner.
The personnel must be trained before commencing their activi‐
ties, and periodically thereafter, at least once a year, in matters
regarding
• special hazards involved with handling pressurised gases,
• safety regulations, in particular the relevant TRG,
• measures to be taken in case of faults, disasters or accidents,
• handling fire extinguishing equipment and protective equip‐
ment,
• handling and maintenance of charging stations, based on the
handling instructions.
Transformation of a refrigerant R12 circuit into a refrigerant
R134a circuit, and repair (Retrofit)
Note
♦ Due to the situation of the environment and the resulting laws

derived, the manufacture of refrigerant R12 will be suspended,
and it will no longer be available. Refrigerant R134a has been
developed to substitute refrigerant R12.
♦ Air-conditioner systems designed and built to operate with re‐
frigerant R12 cannot and must not simply be charged with
refrigerant R134a. In order to guarantee that the air-condition‐
er operates perfectly after a transformation, certain compo‐
nents of the refrigerant circuit must be replaced.
Refrigerant record
According to the environmental statistics law, it is compulsory to
keep a record of refrigerants used.
For this reason, automotive workshops will have to inform the re‐
spective National Statistical Institute on the use of refrigerants.
Therefore, it is advisable to keep a record sheet ⇒ Service Or‐
ganisation Manual
3.2 Law regulating waste recycling

permitted unlessand
management
The legal regulations regarding the handling and elimination of

refrigerant and refrigerant oil waste must be included in the pro‐
tection law on waste immissions, recycling and management.
⇒ Environmental Protection (EC) Nº 2038/2000 (see Page 25 of
Official Journal) Consult the competent authorities.
3.2.1 Elimination of refrigerants and refriger‐

ant oils
Refrigerant
The refrigerant to be eliminated must be placed in appropriate
containers, which must be duly marked, for its recycling, taking
into account the admissible filling mass.
Refrigerant oil
Used refrigerant oils from installations which contain halogenated
hydrocarbons must be eliminated as waste subject to special
control. They may not be mixed with other oils or materials. They

must be stored and eliminated correctly in compliance with the

national directives.
Sources in other countries may be obtained from the responsible
authorities.
3.3 Refrigerant record
Note
♦ The following laws and guidelines listed apply for the member
states of the EC. Other or extended guidelines may apply in
countries outside the European Union.
♦ Please refer to the responsible authorities.
The quantities used for the operating and maintenance must be

documented (Refrigerant manual, ⇒ SEAT-ServiceNet, Guide‐
lines, Service Guidelines; Environment Protection; Immission
Protection ), so that you are able to provide proof when requested
by the responsible authorities. Due to a guideline of the European
Parliament from 2005, inspection sheets are no longer required
in the EC. Other guidelines may apply for countries that do not
belong to the EC.
3. Legal texts and regulations 41

4 Refrigerant circuit
4.1 Important instructions regarding air-con‐

ditioner system repair
• An air-conditioner system designed to operate with refrigerant
R12 cannot be used with refrigerant R134a, without first car‐
rying out modifications to the refrigerant circuit.
• Refrigerant oils specially designed for refrigerant circuits
which use R134a and for those which use R12 must never be
mixed.
• Service stations which come into contact with a specific re‐
frigerant must only be used with that specific refrigerant.
• Circuit components designed for use with refrigerant R134a
are marked by means of inscriptions and/or green labels, or
are manufactured (e.g. using different threads) in such a way
that it is impossible to confuse them with components de‐
signed to operate with refrigerant R12.
• There is an information plate in the engine compartment, lock
carrier plate or plenum chamber which specifies the refrigerant
used.
• Different refrigerants must under no circumstances be mixed.
Note
If work is to be carried
Protected out on theCopying
by copyright. refrigerant
for private circuit, take
or commercial into ac‐
count the information contained
permitted unless authorisedin
bychapters
SEAT S.A. SEAT“Safety
S.A doesmeasures”
and “Basic aspects for working
respect on theofrefrigerant
to the correctness circuit”.

5 Working with the air conditioning

service station
Caution
♦ If there is a suspicion that chemical substances have been

filled into the refrigerant circuit of the vehicle for the pur‐
pose of sealing leaks, the vehicle must not be connected
to the air conditioning service station and the refrigerant
must not be extracted.
♦ Chemical substances used to seal leaks build up deposits
in the refrigerant circuit which impair the function of the air
conditioner and lead to malfunction of the air conditioner
(and your air conditioning service station).
♦ The client must be informed that their air conditioning sys‐
tem contains substances that have not been authorised
by SEAT. You are not permitted to extract nor repair such
air conditioning systems.
Note
♦ SEAT refuses the use of chemical substances for sealing the

leaks in refrigerant systems.
♦ Chemical substances used to seal leaks in refrigerant circuits
usually react with the ambient air or the humidity in the ambient
air. They cause deposits in the refrigerant circuit (and in the
air conditioning service station), cause malfunctions at valves
and other components if they come into contact with them.
These deposits cannot be completely
Protectedremoved from the
by copyright. Copying com‐
ponents affected. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ In most cases, you are not able to see if chemical substances
are used for sealing the leaks in refrigerant systems. In most
cases, the necessary sticker that should be applied for the
purpose of informing about this substance is usually not at
hand. Therefore great care is required on vehicles where the
past records are unknown.
♦ Containers are available at accessory dealers that should sep‐
arate the chemical substances (for sealing leaks). As SEAT
refuses the use of such substances, they cannot provide any
information to the use of such filters and their efficiency at this
point.
5. Working with the air conditioning service station 43

5.1 Working with the service station SAT

4006D
5.2 Important notes on working with the air
conditioning service station
The following must be observed when working with the service
stations (e.g. with the air conditioning service station - 4006D- ):
• The installed filters and desiccants must be replaced at the
latest when the service time stated in the respective instruc‐
tions manual is reached.
• Only refrigerant oils authorised for the specific refrigerant cir‐
cuit of the vehicle must be used.
⇒ Parts catalogue
Under the following circumstance, the refrigerant sucked out must
not be reused in the station, even after it has been purified.
• If the compressor was damaged, leading to the refrigerant de‐
composing due to overheating.
• If there are dark and sticky sediments in the refrigerant circuit
(which can only be detected after opening the installation).
• If there is any doubt about the composition of the refrigerant
extracted from the refrigerant circuit.
In such cases it is always necessary to empty the service station.
If necessary, clean system and replace filter and dryer as well as
refrigeration oil.
The contaminated refrigerant can be stored in so-called recycling
bottles for processing or correct disposal and sent back the re‐
frigerant supplier (see the country specific legal guidelines, dif‐
ferent or extended standards are possible).
Commercially available service stations can be classified into two
groups:
♦ A. Service stations where the extracted refrigerant is cleaned
for re-use (so-called extraction and recycling stations), such
as the air conditioning service station. - SAT 4006D- .
♦ B. Service stations which extract the extracted refrigerant and
deposit it into recycling bottles (to be treated at large scale at
specialised plants). These installations are known as suction
systems.
5.3 Connecting the air conditioning service

station for carrying out measurements
and tests
• Depending on the type of tools chosen, there may beunless
permitted differ‐
ences in the work process. The specific handling instructions
for each tool must be taken into account.
Note
Basically, the work process must be carried out exactly as de‐

scribed in the instructions manual of the air-conditioning service
station - SAT 4006D- .
In order to prevent air or humidity from entering the refrigerant

circuit through the charging hoses, they must be connected as
follows:

– Switch ignition OFF.

– Connect the service station to the electrical power source.
– Remove the caps from the service connections or valve con‐
nections (on the specific refrigerant circuit of the vehicle).
⇒ Rep. gr. 87
– Remove the filling hoses.
Note
Connect the charging hoses with quick couplings to the service

connections on the refrigerant circuit.
Caution
The valves may not be opened on the high pressure and vac‐
uum side if the engine is running. Otherwise, severe damage
may be caused between the high pressure and vacuum side
of the refrigerant circuit caused by a “short circuit” when the air
conditioner of the air conditioner compressor is switched on.
– Only turn the handwheel in the quick connector adapter far

enough until the valve has been opened safely in the service
coupling (observe the pressure gauge, do not apply excessive
pressure to the valve).
– Start the engine and perform the planned measurements or
checks.
– Compare the values obtained with the required measurement
values ⇒ page 97
– Before removing the quick connector,
Protected close the Copying
by copyright. connection
for privateby
turning the handwheel outwards.
5.4 Emptying the refrigerant circuit with the

service station
• Depending on the type of tools chosen, there may be differ‐
ences in the work process (the specific handling instructions
for each tool must be taken into account).
• The refrigerant circuit must be emptied if any parts of the re‐
frigerant circuit are to be disassembled, if there is any doubt
about the amount of refrigerant in the circuit or if required by
the safety measures.
• All fundamental instructions for working with the air-condition‐
ing service station can be obtained from the respective oper‐
ating instructions of the air-conditioning service station.
Emptying:
– Connect the air-conditioning service station to the service con‐
nections of the vehicle when observing the respective operat‐
ing instructions ⇒ Rep. gr. 87 and put into operation.

Note
♦ Take into account that, besides the refrigerant, some refriger‐

ant oil may also be sucked out of the refrigerant circuit. In order
to ensure that the compressor is correctly lubricated, new re‐
frigerant oil must be added to the circuit ⇒ Rep. gr. 87 .
♦ In vehicles without electromagnetic coupling on the compres‐
sor (using the compressor regulation valve of the air condi‐
tioning - N280- ), the engine < should run 10 minutes long with
empty and closed refrigerant circuit (the air conditioner com‐
pressor always runs along as well). In the process, the engine
speed must be max. 2000 rpm.
♦ The engine can be started in vehicles with electromagnetic
coupling on the compressor, because the air conditioner pres‐
sure switch - F129- or the high-pressure sender - G65- (checks
if refrigerant is in the refrigerant circuit) separates the electro‐
magnetic coupling when no refrigerant is located in the refrig‐
erant circuit.
5.5 Emptying the refrigerant circuit with the

service station
• Basically, the work process must be carried out exactly as de‐
scribed in the instructions manual of the service station.
• The operation with the service station - SAT 4006D - is de‐
scribed here.
Before filling the refrigerant circuit with refrigerant, the circuit must
be extracted 45 minutes long when using one evaporator and 60
minutes long (without air) using two evaporators. Any humidity is
also extracted from the circuit.
Leaks can be detected when extracting the refrigerant.
Vacuuming:
Caution
♦ The engine must not be started during the extraction proc‐

ess and asProtected
long by ascopyright.
the refrigerant circuit
Copying for private is empty.
♦ If the refrigerant circuit
respect is emptyofand
to the correctness the engine
information is started,
damage can be caused to the air conditioner compressor.
♦ Only start the engine after the refrigerant circuit has been
filled.

– If necessary, correct the amount of refrigerant oil inside the
refrigerant circuit, see the corresponding Repair Manual for
the vehicle ⇒ Rep. gr. 87 .
– Check the amount of refrigerant present in the service station.
– Connect the charging hoses of the service station to the re‐
frigerant circuit on the vehicle by means of quick coupling
adaptors (see the specific refrigerant circuit of the vehicle).
⇒ Rep. gr. 87
– Turn the wheel on the quick coupling adaptors until the service
coupling valves are completely open (do not force the valve).

Note
If the pressure needs to be measured after charging the installa‐

tion in vehicles which only have a service connection on one side
of the refrigerant circuit, a valve adaptor and hose with a valve
opener must be used.
– Start the emptying process on the service station. The refrig‐

erant is extracted automatically (if necessary, observe the time
setting for the extraction).
When the emptying process has completed, the leak inspection
of the refrigerant circuit is started. The vacuum in bar per second
is monitored.
If the vacuum is not maintained, proceed as follows:
– Re-initiate the vacuum phase on the air conditioning service
station. The refrigerant is extracted automatically (if necessa‐
ry, observe the time setting for the extraction). Observe the
vacuum indicator for a while. The filling can be carried out only
after the vacuum continues.
♦ When a larger leak is at hand that results in a large quantity of
air entering when extracting that the air conditioning service
station cannot generate sufficient vacuum or when the vac‐
uum indicator displays that air enters immediately after turning
off the service station and the vacuum is reduced,
– the leak on the refrigerant circuit must be detected as follows:

Note
♦ A larger leak can, e.g. be determined by building up a pressure

of max. 15 bar with clean and dry compressed air or with ni‐
trogen ⇒ page 60 . When the leak is large enough you can
hear a noise at the location of the leak that is caused by the
air or the by the gas escaping from here.
♦ The compressed air or the nitrogen is inserted into the refrig‐
erant circuit via the service connection to which the quick
connection adapter for the service connection had previously
been connected.
♦ The quick connector for the service connection can, for ex‐
ample be connected to the compressed air equipment of the
workshop using a prepared filling hose -A- (e.g. with a 5/8"-18
UNF thread, depending on the thread of the quick connection
adapter) and a suitable adapter -B- ⇒ page 142 . To ensure
that no oil and no impurities can enter the refrigerant circuit of
the air conditioning via the compressed air equipment, a com‐
bined fine filter can be used for the compressed air system,
oil, dirt and water separator as they are implemented in paint
systems. They are mounted between the compressed air sys‐
tem and the filling hose -A- ⇒ Workshop equipment cata‐
logue .
♦ Using a pressure gauge battery with pressure regulator for ni‐
trogen (max. pressure 15 bar) -1-, a compressed gasS.A. cylinder
filled with nitrogen -3- can be connected tocorrectness
respect to the the service con‐ in this document. Copyright by SEAT S.A.
of information
nection of the refrigerant circuit using a filling hose -2- (e.g.
with a 5/8"-18 UNF thread) - (to which the quick connection
adapter for the service connection had previously been con‐
nected). ⇒ page 51
– Slowly increase the pressure in the refrigerant circuit up to

maximum 15 bar.
WARNING
♦ Maximum permissible operating pressure 15 bar

♦ when performing the leak detection with nitrogen, only
work with a pressure regulator for nitrogen cylinders.
– The leaking location is detected by the noise that is caused by

the gas escaping at this position.
– Repair the leaking location.
– Repeat the extraction procedure and observe the vacuum in‐
dicator for several hours. The filling can be carried out only
after the vacuum continues.
♦ When a smaller leak is at hand where only a small quantity of
air enters and the air conditioning service station cannot gen‐
erate sufficient vacuum, the vacuum indicator display does not
rise or only rises very slowly after turning off the service sta‐
tion. This is an indication that the air only enters through a
small leak and that the vacuum is reduced due to this.
– Fill 100 g of refrigerant in the circuit and search for the leaking
location using an electronic leak detector and remedy
⇒ page 52 or refill refrigerant with UV contrast agent and
search for the leaking location on the refrigerant circuit using
the leak detector SAT 4012 and remedy ⇒ page 52 .
– When necessary, extract the refrigerant circuit ⇒ page 45 .

– Extract the refrigerant circuit and observe the vacuum indica‐

tor for several hours. The filling can be carried out only after
the vacuum continues.
5.6 Charging the refrigerant circuit with the

service station
• Basically, the work process must be carried out exactly as de‐
scribed in the instructions manual of the service station.
• Before charging the refrigerant, correct the amount of refrig‐
erant oil inside the refrigerant circuit ⇒ Rep. gr. 87 .
• The total amount of refrigerant can be charged at either the
low or high pressure side.
Charging the circuit with refrigerant
– Vacuum the refrigerant circuit with the service station
⇒ page 46 .
– Turn the wheel on the quick coupling adaptor (close).
– Allow the charging hose to fill with refrigerant.
– Turn the wheel on the quick coupling adaptor (do not force the
valve), and charge the circuit with the specified amount of re‐
frigerant.
– Remove the air conditioning service station.
Turn on the air conditioner after filling.
Note
If the air conditioner compressor has been removed, turn the pul‐
ley for the poly V-belt / the free wheel approx. 10 times by hand
before turning on the first time. This prevents that the air condi‐
tioner compressor is not damaged by a surge of liquid when
turning on the air conditioner for the first time (when oil has en‐
tered the air conditioner compressor, it will be pressed out by the
rotation).
– Start the engine with the compressor disconnected (version

with electromagnetic coupling).
– Set the compressor to its lowest power setting, "Econ" mode
or A/C disconnected (version with regulating valve without
electromagnetic coupling).
– Wait for the engine to start idling at a stable speed.
– Switch on compressor
Protected and allowCopying
by copyright. system to run
for private at idle for
or commercial at in part or in whole, is not
purposes,
least 2 minutes.
– If necessary, check the pressures in the refrigerant circuit with

the service station.
– Switch off the engine.
– Turn the wheel on the quick coupling adaptor (close).
– Remove the hoses from the refrigerant circuit.
– Replace the protective caps.

5.7 Fill the container of the air conditioning

service station with refrigerant
• Basically, the procedure must be carried out as described in
the instruction manual of the air-conditioning service station.
• A description of how to charge each air-conditioner system
with a determined amount of refrigerant is given. To make sure
that neither insufficient nor too much refrigerant has been filled
(both would influence the cooling output) the refrigerant has
been mounted an a scale.
5.8 Emptying the service station
Note
♦ If the service station needs to be emptied (e.g. after vacuuming

refrigerant with impurities), all filters and desiccants must al‐
ways be replaced (remove the filters and desiccants form their
airtight packaging only immediately before they are to be
mounted,Protected
in order to minimise the amount of humidity absor‐
bed). permitted unless
♦ The bottles in which the used refrigerant (with impurities) is to

be stored are called “recycling bottles”.

♦ Before filling them with refrigerant for the first time, the recy‐
cling bottles must always be vacuumed (refrigerant bottles
which contain air must never be filled with refrigerant).
♦ Do not mix different types of refrigerants (mixed refrigerants
cannot be treated, and must be disposed of as waste). If there
is any doubt regarding the composition of the contents of a
bottle, the company in charge of recycling the refrigerant must
be informed.
WARNING
♦ When filing recycling bottles (pressurised gas containers),

all applicable regulations, technical regulations and cur‐
rent laws must be observed.
♦ The recycling bottles must under no circumstances be
overfilled (the gas cushion in overfilled recycling bottles
may be insufficient to compensate for expansion of the
liquid caused by heat. This may result in the bottle burst‐
ing).
♦ For your own safety, use only recycling bottles equipped
with a safety valve.
♦ The recycling bottles must be weighed on a calibrated
scale during the filling process. ??The maximum permit‐
ted charge quantity is 75 % (fill factor 0.75) of the charge
weight shown on the recycling bottle (the possibility can‐
not be excluded that that along with the refrigerant, refrig‐
erant oil is drawn into the recycling bottle).

6 Check for possible leaks in the refrig‐

erant circuit
Note
♦ This Workshop Manual describes two different procedures for

detecting leaks in the refrigerant circuit. These procedures
have been proven and lead to reliable results when exposed
to the different operating conditions with the correct and com‐
plaint related application.
♦ Smaller leaks can be detected using an electronic leak detec‐
tor or a UV leak detection lamp.
♦ There are several solutions on offer in retail markets for leak
detection on refrigerant circuits. These methods do not always
produce satisfactory results and, if the instructions for use are
not observed strictly, some AC circuit components, which are
in order, can be evaluated as leaky. Moreover certain methods
can cause damage or subsequent damage to the AC circuit.
♦ Components where a leak is detected must not be repaired,
they must be replaced using genuine spare parts.
♦ A leaking refrigerant circuit must not be filled with refrigerant.
This is why the refrigerant circuit must be extracted before fill‐
ing and checked for leaks in the process ⇒ page 46 .
Caution
♦ If there is a suspicion that chemical substances have been

filled into the refrigerant circuit of the vehicle for the pur‐
pose of sealing leaks, the vehicle must not be connected
to the air conditioning service station and the refrigerant
must not be extracted.
♦ SEAT disapproves of the use of chemical substances
(leak stop additives) for sealing leakage in AC circuits.
♦ Chemical substances used to seal leaks build up deposits
in the refrigerant circuit which impair the function of the air
conditioner and lead to malfunction of the air conditioner
(and your service station).
♦ The client must be informed that their air conditioning sys‐
tem contains substances that have not been authorised
by SEAT. You are not permitted to extract nor repair such
air conditioning systems.
Note
Chemical substances (sealing additives) used to seal leaks in re‐
frigerant circuits usually react with the ambient air or the humidity
in the ambient air; the deposits chemical substances build up in
refrigerant circuits (and your service station) cause malfunctions
at valves and other components if they come into contact with
them. These deposits cannot be completely removed from the
components affected (even by flushing). Therefore the refrigerant
circuit can only be serviced by renewing all components that have
come into contact with the chemical substances.
6. Check for possible leaks in the refrigerant circuit 51

6.1 Locating leaks in the refrigerant circuit

with the leak detector - SAT 4012-
Note
Small leaks may be detected for example using an electronic leak

detector.
To ensure that as little refrigerant as possible does not escape to

the environment when searching for leaks as possible, proceed
in the following way to perform a complete extraction of the re‐
frigerant circuit:
– Extract the refrigerant circuit using the air conditioning service
station ⇒ page 45 .
Note
♦ If a larger leak is detected when extracting, the leak position

must be determined and remedied as described ⇒ page 45 .
♦ If no leak or a very small leak is detected when extracting that
the leak position cannot be determined, proceed as follows:
♦ Currents of air quickly disperse refrigerant gas. Draughts must
therefore be avoided during leak detection.
♦ When the refrigerant circuit is completely empty, charge it with
approx. 100 g refrigerant.
Leak location: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Use the leak detector according to the corresponding instruc‐
tions manual.
– Keep the detection point below the area of the suspected leak.
Depending on model, if the number of clicks increases or a siren
type sound is given out then this means a leak has been detected
(see the relevant instructions).
6.2 Locating leaks in the refrigerant circuit

with the leak detector - SAT 4007B-
Note
Small leaks may be visually located, for example, with a fluores‐

cent medium, such as the leak detection additive - SAT 4007B- .

Leak location:
– When the refrigerant circuit is completely empty, fill with 100
grammes of refrigerant, with the a/c load station replaced by
SAT 4006D - SAT 4006C- .
– Add leak detection additive - SAT 4007/2- to the refrigerant
circuit, and inspect the refrigerant circuit with an UV lamp UV
lamp - replaced by SAT 4007B/3 - SAT 4007/3- .
Note
The leak detection additive may remain inside the refrigerant cir‐
cuit.

6.3 Tracing leaks in refrigerant circuit
6.3.1 Searching for leaks on the refrigerant

circuit using the leak detection system
VAS 6201A
Note
♦ Certain leaks are difficult or even impossible to find using an

electronic leak detector. Such leaks can be detected using the
VAS 6201A leak detector.
♦ Refrigerant circuit leaks result in a loss of refrigerant oil to‐
gether with the refrigerant. This oil generally remains in the
vicinity of the leak location. Adding a small quantity of fluores‐
cent fluid to the refrigerant circuit makes this oil visible under
UV light. The fluid (PAG oil containing an additive which shows
up under UV light) is poured into the refrigerant circuit and
becomes distributed with the refrigerant oil when the air con‐
ditioner is switched on.
♦ It is necessary to operate the air-conditioning system for at
least 60 minutes (AC compressor running) to ensure that the
additive is distributed uniformly in the entire AC circuit.
The refrigerant
♦ permitted oil by
unless authorised containing theS.Aadditive,
SEAT S.A. SEAT whichorshows
does not guarantee accept anyup un‐with
liability
der UV light, can either be filled directly into the open circuit or
pumped in with the circuit charged using the hand pump VAS
6201/1 (from the leak detection system VAS 6201A) via the
service connection on the vacuum side.
♦ If the leak detection additive is applied via the service con‐
nection on the low-pressure end with the refrigerant circuit
charged, a small quantity of additive remains in the service
connection. This is to be carefully removed so as to avoid
subsequent erroneous leak detection.
♦ If a component forming part of a circuit into which the leak
detection additive is poured has to be renewed, thoroughly
clean joints with other components after assembling refriger‐
ant circuit. These leak detector additive residues at the con‐
nection points could be evaluated erroneously as leakage
when searching for leaks later.
♦ When extracting a refrigerant circuit, refrigerant oil and there‐
fore leak detection additive enter the air conditioning service
station. The refrigerant oil will be separated from refrigerant in
the oil separator of the air conditioning service station and ex‐
tracted from the air conditioning service station using the
extraction equipment. Do not pour the refrigerant oil drained
off back in. It is to be replaced with fresh refrigerant oil.
♦ Observe the following if leak detection fluid has already been
poured into a refrigerant circuit in the course of previous repair
work: Only add new leak detection fluid if refrigerant oil is re‐
placed. If only some of the refrigerant oil has been renewed,
just add the corresponding quantity of leak detection fluid. If,
for example, 100 ml of refrigerant oil has been replaced on a
vehicle containing 250 ml, only add 1 ml (cm3) of leak detection
additive.
♦ Certain materials and their compounds (e.g. oxidation prod‐
ucts on aluminium components, anti-corrosion waxes) also
show up under UV light.

Tools and other items required: VAS 6201A

1- Manual pump with cartridge - VAS 6201/1-
2- Cartridge - VAS 6201/2-
3- Cleaning solution - VAS 6201/3-
4- UV leak detection lamp - VAS 6201/4-
5- UV protective goggles - VAS 6201/6-
6- Sticker - VAS 6201/7-
7- Filler tube
VAS 6201/8
8- Protective gloves - VAS 6201/9-
Pouring in leak detection additive with refrigerant circuit empty
The cartridge -A- contains 15.4 ml of leak detection additive (one
unit -B- corresponds to 2.5 ml).
– Mount the hand pump - VAS 6201- Pos. -1- with the cartridge
Pos. -2- -VAS 6201/2- .
– Mount the filling tube - VAS 6201/8- ( ⇒ page 55 Pos. -7-) to
the hand pump.
– Open the service valve of the hand pump.

The leak detection additive can be filled into the empty refrigerant
circuit through an open connection.
– Separate a connection position on the refrigeration circuit that
is easy to access.
– Cover the area around the connecting position with film or ab‐
sorbent paper.
– Hold the pipes upwards.
– Screw in the screw knob of the hand pump in until leak detec‐
tion additive exits from pipe.
– 2,5 ± 0.5 ml (Millilitre = cm3) Fill leak detection additive in the
refrigeration circuit.
Note
If a repair leak detection fluid has already been filled in a refrig‐

erant circuit during a previous leak detection, proceed as follows:
Only fill the new leak detection additive when the refrigerant oil is
replaced. If only some of the refrigerant oil has been renewed,
just add the corresponding quantity of leak detection additives. If,
for example, in a vehicle with 250 ml refrigerant oil, 100 ml is re‐
placed, only 1 ml (cm3) of leak detection additive can be filled.
– Replace the O-ring for the separated connecting position.

– Reassemble the refrigerant circuit.
– Apply a sticker near to the service connection that provides
information that leak detection additive has been filled into this
refrigerant circuit.
– Extract and charge the refrigerant circuit as described.
– Switch the air conditioner on:
Note
♦ To enable the leak detection additive to be distributed through‐

out the entire refrigerant circuit, the air conditioner must re‐
main switched on for at least 60 minutes (the air conditioner
compressor must run). Depending on the size of the leak, the
leak can already be detected during this period.
♦ Depending on the size and location of the leak, it may take
several days before the refrigerant oil with leak detection ad‐
ditive escapes.
– Find leaks on the refrigerant circuit using the UV leak detection

lamp VAS 6196/4.

Pouring in leak detection additive with refrigerant circuit charged
Note
♦ If a repair leak detection fluid has already been filled in a re‐

frigerant circuit during a previous leak detection, proceed as
follows: Only fill the new leak detection additive when the re‐
frigerant oil is replaced. If only some of the refrigerant oil has
been renewed, just add the corresponding quantity of leak de‐
tection additives. If, for example, in a vehicle with 250 ml
refrigerant oil, 100 ml is replaced, only 1 ml (cm3) of leak de‐
tection additive can be filled.
♦ A small quantity of the leak detection additive remains in the
service connection. Carefully remove these residues so that
these residues are not mistakenly perceived as a leak with
future leak detections.
The cartridge -A- contains 15.4 ml of leak detection additive (one

unit -B- corresponds to 2.5 ml).

– Remove the sealing cap of the service connection of the vac‐
uum side of the refrigerant circuit.
– Mount the hand pump - VAS 6201- Pos. -1- with the cartridge
-2- -VAS 6201/2- .
Note
Ensure that hose on hand pump is completely filled with leak de‐
tection additive.
– Connect the quick connector tot he service connection on the

vacuum side and open the service connection by screwing in
the handwheel. Hold hose pointing upward and screw knob on
hand pump in until leak detection additive exits from filler pipe.
– Cover the area around the service connection with film or ab‐
sorbent paper.
– By screwing in the screw knob on hand pump 2.5 ± 0.5 ml
(Millilitre = cm3) Fill leak detection additive in the refrigeration
circuit.

– Slacken the quick connector and remove from the service

connection.
– Remove the residues of the leak detection additive from the
service connection with, e.g. paper.
– Connect the service connection with the sealing cap.
– If required, clean the surroundings of the service connection
using a suitable cleaning solvent.
– Apply a sticker near to the service connection that provides
information that leak detection additive has been filled into this
Note
♦ To enable the leak detection additive to be distributed through‐

out the entire refrigerant circuit, the air conditioner must re‐
main switched on for at least 60 minutes (the air conditioner
compressor must run). Depending on the size of the leak, the
leak can already be detected during this period.
♦ Depending on the size and location of the leak, it may take
several days before the refrigerant oil with leak detection ad‐
ditive escapes.
– Find leaks on the refrigerant circuit using the UV leak detection

lamp VAS 6196/4.
Find leaks on the refrigerant circuit using the UV leak detection
lamp VAS 6196/4.
WARNING
Never look into UV lamp.
Never point UV lamp at other people.
Note
♦ It is necessary to operate the air-conditioning system for at

least 60 minutes (AC compressor running) to ensure that the
additive is distributed uniformly in the entire AC circuit.
♦ Depending on the magnitude and location, it may take several
days for sufficient refrigerant oil and additive to emerge to
clearly identify the leak.
♦ In the event of leaks at the evaporator, the additive may be
washed out with the condensate and emerge via the conden‐
sate drain. As on most vehicles the evaporator is not acces‐
sible without considerable effort, checking the condensate
drain for example can provide an indication of evaporator leak‐
age. This does however require the additive to have been in
the refrigerant circuit for a lengthy period (several days).
♦ The safety goggles are not only designed to provide eye pro‐
tection. They also make the additive more readily visible under
UV light.
♦ Depending on the accessibility of various parts of the refriger‐
ant circuit, it may be necessary to remove certain vehicle
components (e.g. bumper or air cleaner).

– Move the vehicle to a dark area in the workshop (the effect of

the UV lamp is reduced at daylight or with intensive lighting).
– Check accessibility of various parts of the refrigerant circuit
and remove components in area of refrigerant circuit which
would block view of refrigerant circuit components (e.g. noise
insulation and bumper).
– Use eye protection.
– Connect UV-lamp to 12 V battery (vehicle battery). Take care
to ensure correct polarity of connections.
– Switch on UV lamp and illuminate components of refrigerant
circuit. Locations at which leakage has resulted in the emer‐
gence of refrigerant, refrigerant oil and thus also leak detection
additive show up under UV light (fluorescent).

7 Cleaning the inner side of the refrig‐

erant circuit
7.1 Cleaning the refrigerant circuit using the

cleaning station - SAT 4011-
It is necessary to work as cleanly as possible to prevent moisture
and other contamination such as old refrigeration oil from getting
into the circuit. This saves refrigerant and unnecessary installa‐
tion time and avoids unnecessary environmental pollution. For
this purpose it is necessary to flush the circuit with R134a refrig‐
erant or blow it out with nitrogen and a special solvent approved
by the equipment manufacturer and SEAT.

Note
Additional information: ⇒ Service Manual for the cleaning station
Note
♦ For use in the washing mode the unit must be supplied with
compressed air at a minimum pressure of 6 bars and maxi‐
mum pressure of 8 bars from a compressed air circuit with
dehumidifier.
♦ The sweeping of the refrigerant circuit using nitrogen usually
requires considerably more skilled labour than rinsing with
R134a refrigerant. When rinsing with R134a refrigerant, clean‐
ing of components is usually more thorough and for this reason
a rinse should be done for each complaint (sweeping with ni‐
trogen is done for specific complaints and components)
♦ When blowing out with nitrogen and solvent ensure that the
operating pressure does not exceed 12 bars (this corresponds
to the pressure in a charged AC circuit at an ambient temper‐
ature of approx. 60 °C; use pressure reduction valves, if
required.
WARNING
♦ Use only pressure reduction valves for nitrogen bottles

(minimum operating pressure 8 bars and max. operating
pressure 12 bars).
♦ The solvent solution which comes out of the filtered com‐
ponents should be collected in the container in which it
was transported.
♦ The safety regulations must be closely observed for the
correct use of the unit.
Note
Do not blow nitrogen through the hose clip, the expansion valve,
the compressor or liquid tanks and collectors. ⇒ page 69
– If the condensers have been fitted with a dehydration cartridge

integrated in the liquid tank, remove this cartridge
– First blow out the old refrigerant oil and any dirt with com‐
pressed air, and then eliminate any humidity in the compo‐
nents with nitrogen.
– Adapters for connecting the pressure hose to the refrigerant
circuit and ⇒ Heating, air-conditioning or ⇒ air-conditioning
⇒ page 79
So that oil or humidity from the compressed air system does not
enter into the refrigerant circuit, note the following points.
⇒ page 148
– If the refrigerant pipes are permitted
fitted with a connection thread or
bolt use the adaptors from the refrigerant circuit adapter
respect to the correctness of informationkit - document. Copyright by SEAT S.A.
in this
V.A.G 1785- ( Adapter - V.A.G 1785/1- to Adapter - V.A.G
1785/8- ) to connect the filling hoses 5/8" -18 UNF (some of
these adapters are also included in the adapter kit, set for
SEAT vehicles - SAT 4009- . ⇒ page 79
7. Cleaning the inner side of the refrigerant circuit 61

– For refrigerant pipes lacking the threads or connection (for the

connection of adapters) use the adaptors from the adapter kit,
set for SEAT vehicles - SAT 4009- or an air pistol with a com‐
mercial type rubber tip..
Note
The refrigerant circuit should only be swept using nitrogen if it may

not be rinsed or if the rinsing operation is too complicated for the
specific components (sweeping may also be used to quickly elim‐
inate for example small impurities and dirt in the refrigerant pipes).
The refrigerant circuit (or specific components) must be swept (if

rinsing is not possible or inconvenient):
– If there is dirt or any other impurities in the circuit.
– If, after vacuuming an airtight refrigerant circuit, the vacuum is
not maintained (there is humidity in the refrigerant circuit which
builds up pressure).
– If the refrigerant circuit has remained open longer than nec‐
essary for assembly (e.g. after an accident).
– If, based on pressure and temperature measurements in the
refrigerant circuit, there may be humidity in the circuit.
– If there is any doubt regarding the amount of refrigerant in the
– if the compressor has to be changed due to internal damage
(for example noise or lack of power),
– if required by the Repair Manual following replacement of cer‐
tain components.
7.1.1 General procedure for cleaning the cool‐

ing circuit
Note
♦ For those vehicles where the refrigerant pipes do not have a

thread for connection of the adapter V.A.G - 1785- . To sweep
specific components the use of the Adapter kit, SEAT pas‐
senger vehicles - SAT 4009- is recommended.
♦ The evaporator must be blown out through the low-pressure
piping connection (large diameter), ensuring that the expan‐
sion valve or choke has been
permitted unless authorised disassembled.
♦ The components must always be blown out in the opposite

direction to that of the refrigerant flow.

♦ Inspect the expansion valve. Replace if any dirt or corrosion
is found.
♦ If there are dark or sticky sediments that cannot be removed
using using R134a refrigerant, then sweep these components
with nitrogen and solvent or replace the components.
♦ Thin, light grey sediments inside the piping do not negatively
affect the performance of the components.
♦ After the blowing-out process, always replace the liquid tank
or the collecting tank and the choke. If the condensers have
been fitted with a dehydration cartridge integrated in the liquid
tank, replace this cartridge

After sweeping the refrigerant circuit:

– Replace, depending on the vehicle, these components (hose
clip and collector tank, expansion tank and liquid tank or even
dehydration cartridge) ⇒ Heating, air-conditioning or ⇒ Air-
conditioning and ⇒ Spare parts catalogue
– Depending on the complaint the compressor may need to be
replaced ⇒ Heating, air-conditioning or ⇒ Air-conditioning and
⇒ Spare parts catalogue or the refrigerant machine oil must
be emptied from the removed compressor (replace compo‐
nents of the refrigerant circuit) then refill with the quantity of
refrigerant machine oil specified (special oils and oil quantities
for refrigerant machines)
Note
♦ Replacement compressors come with the specific amount of

oil for refrigerant machines. For machines with two evapora‐
tors, if necessary, add the required amount of refrigerant
machine oil to the circuit ⇒ Heating, air-conditioning or ⇒ Air-
conditioning and (special oils and oil quantities for refrigerant
machines).
♦ If the compressor is not to be replaced then the amount of
refrigerant machine oil must be corrected (empty to move the
refrigerant machine oil then put the correct quantity into the
compressor or the refrigerant circuit) (replace components of
the refrigerant circuit) and (approved refrigerant machine oils
and filling quantities).
– Reassemble the refrigerant circuit ⇒ Heating, air conditioning .

– Start up the air conditioning according to the specifications ⇒
Heating, air conditioning .
7.2 Description and operation of the clean‐

ing station - SAT 4011-
Additional information: ⇒ Service Manual for the cleaning station
Remove the refrigerant from the circuit using the a/c loading sta‐
tion - SAT 4006D- .
The cleaning station - SAT 4011- has a control panel with two
areas:
WARNING
♦ Use only pressure reduction valves for nitrogen bottles

(minimum operating
Protected pressure 8 barsforand
by copyright. Copying privatemax. operating
pressure 12 bars).
♦ The safety regulations must be closely observed for the

correct use of the unit.

Zone -A- of the panel for cleaning with nitrogen:

1- Nitrogen input tap to component to be cleaned
Check that the tap on the external nitrogen tank is open, and there
is a maximum output pressure of 12 bar.
Open the tap -IN- until the manometer shows a pressure reading
of 12 bar, then close the tap. Once pressurised, if the pressure
has not changed after 10 minutes, then there are no leaks.
2- Nitrogen output tap from component to be cleaned
Depressurise the circuit by opening the output tap -OUT-.
3- Manometer for nitrogen pressure in the circuit
-Min - Max- operating pressure for washing and flushing circuit:
-8-12 bars-
If the manometer reading changes, the circuit is not leakproof.
Zone -A- of the panel for cleaning with solvent:
1- Solvent viewing window
It is possible to see through the window whether the solvent is
clean or carrying particles.
If it is very dirty it should be dismounted and clean
2- Tap for circuit flush or purge -Flush- o -Purge-
The purge tap is closed when no more particles are observed in
the solution.
In position -B- or -C- the vacuum pump will start to operate to fill
the machine with solvent.
The numerical field is the operating range for the flushing opera‐
tion; Position -2- leave in this position for ten minutes, then
continue with Position -5-, again for at least 10 minutes, then con‐
tinue with Position -0-. The flushing procedure is then concluded
properly. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3- Manometer for the circuit wash or purge pressure
-Min - Max- operating pressure for washing and flushing circuit:

-6-8 bars-
Connection area for solvent inlet/outlet: rear

1- Air/solvent separator
Solvent should be treated as hazardous waste, and the regula‐
tions applicable in your region or country must be observed.
2- Solvent input to component or circuit to be cleaned
Solvent input with a fluid impulse system.
3- Solvent output from the component or circuit which is being
cleaned
Circuit closed, in operating position
4- Return to tank tap
On completion of the operation the solvent must be drained from
the machine to the recipient.

Connection area for nitrogen inlet/outlet: rear

1- Nitrogen input to circuit or component
Execution of nitrogen sweep at pressure between -6÷12 bar- in
order to drag away any possible traces of solvent and humidity
that may remain in the component or circuit after the purge phase.
2- Nitrogen output from circuit or component
Circuit closed, in operating position
Connection area for inlet/outlet for filling: side of unit

1- Level of solvent
Do not fill with more than 20 litres, this could cause malfunctions.
2- Solvent filling and drainage connection
Recommended minimum operating level -10 litres-.
Solvent should be treated as hazardous waste, and the regula‐
tionsunless
permitted applicable
authorisedin yourS.A.
by SEAT region
SEAT S.Aordoes
country mustorbe
not guarantee observed.
On completion of the operation the solvent must be drained from
the machine to the recipient.
3- Compressed air connection
The operating pressure should be limited to a pressure between
-min. 5 bars- and -max. 8 bars-.
4- Input connection from nitrogen tank to equipment
Check that the tap on the external nitrogen tank is open, and there
is a maximum output pressure reading on the pressure control of
-12 bar-.
5- Operating zone selector switch
The selection switch has three possible positions: -CHARGE-
Switch on intake pump to fill unit with solvent.
-STOP- when it is not to be used, disconnected from the com‐
pressed air circuit.
-WORK- operating or wash position.
6- External filter
Replace filter regularly, at least every 10 times a not very dirty
circuit is cleaned, and every 3 washes if the circuits are very dirty.
It should be treated as hazardous waste, and the regulations ap‐
plicable in your region or country must be observed.
When replacing, check that it is not pressurised, that is, it is not
under pressure and the machine is disconnected from the com‐
pressed air installation.
7- Nitrogen discharge connection
The sweep stage is not finished until nitrogen also comes out
through the nitrogen discharge connection.

Input and output hose connections:

1- Red hose connection with the tool
connect to rear of equipment -OUT NITRO- and to the service
connection of the corresponding system to be cleaned, low pres‐
sure end.
Ensure that cone is connected properly, leakage is possible if in‐
stalled incorrectly. Replace rubber cone when worn.
2- Black hose connection with the tool
connect to rear of equipment -IN NITRO- and to the service con‐
nection of the corresponding system to be cleaned, high pressure
end.
Ensure that cone is connected properly, leakage is possible if in‐
stalled incorrectly. Replace rubber cone when worn.
7.3 Blow the refrigerant circuit out with com‐

pressed air, and then nitrogen.
• Compressed air must be used to remove humidity and other
impurities from the refrigerant circuit. Nitrogen must be used
to eliminate the humidity from the refrigerant circuit.
• The sweeping of the refrigerant circuit using compressed air
and nitrogen usually requires considerably more labour than
rinsing with R134a refrigerant. When rinsing with R134a re‐
frigerant, cleaning of components is usually more thorough
and for this reason a rinse should be done for each complaint
(sweeping with compressed air is carried out for specific com‐
plaints and components)
The sweeping of the components is only applied
Protected in the
by copyright. following
cases. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If there is no possibility of rinsing the refrigerant circuit using
the refrigerant R134a.
♦ When dirt and other impurities are located in the different com‐
ponents of the refrigerant circuit.
♦ If the vacuum display does not remain stabile when extracting
refrigerant circuit (there is humidity in the refrigerant circuit
which builds up pressure).
♦ If the refrigerant circuit has remained open longer than nec‐
♦ If, based on pressure and temperature measurements in the
♦ When this requests for the replacement of certain components
of the vehicle in the specific Repair Manual ⇒ Heating, air
conditioning .
Note
♦ When sweeping the refrigerant circuit using compressed air

and nitrogen, the degree of purity is not reached than when
rinsing with R134a refrigerant. When rinsing using the refrig‐
erant R134a, the refrigerant oil is released and cleaning the
component is more effective.
♦ When sweeping, the maximum operating pressure of 15 bar
must not be exceeded (when necessary, also use a pressure
reducer for the compressed air).

WARNING
♦ Nitrogen may escape from the bottle in an uncontrolled

manner.
♦ Use only pressure reducers for nitrogen gas cylinders
(maximum working pressure 15 bar).
♦ The mixture of gas blown out of the components must be
sucked up with the appropriate extraction installations.
– Always sweep the component in the opposite direction tot he

flow of refrigerant.
Do not blow compressed air or nitrogen through the choke, ex‐
pansion valve, compressor, or the liquid and collecting tanks.
– With condensers where a cartridge is mounted in the integra‐
ted container, the cartridge must be removed.
– First blow out the impurities from the container using com‐
pressed air and then the humidity using nitrogen.
– Fit the adapter for connecting the pressure hose to the refrig‐
erant circuit ⇒ Heating, air conditioning .
So that no oil nor humidity from the compressed air system does
not enter into the refrigerant circuit, note the following points:
♦ The compressed air must be cleaned and dehydrated by
means of a compressed air cleaning device. Insert the filter
and dehumidifier (part of the scope of promotion of the tools
for painting work) ⇒ Workshop equipment andby special toolsS.A does not guarantee or accept any liability with
permitted unless authorised SEAT S.A. SEAT
catalogue . respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ For refrigerant lines with thread connection or union nut, use

the adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- ) for
connecting the filling hose 5/8" -18 UNF. These adapters are
part of the Adapter set for refrigeration - VAS 6338/1- and the
Adapter sets for refrigerant circuits for commercial vehicles -
VAS 6338/50- .
♦ For refrigeration lines without thread or union nut, use the
Adapter set for refrigeration - VAS 6338/1- or the Adapter sets
for refrigerant circuits for commercial vehicles - VAS 6338/50-
or a commercially available compressed air pistol with rubber
nozzles.
Note
♦ The compressed air and nitrogen flowing out of the component

must be captured using a suitable device (e.g. workshop ex‐
traction unit).
♦ Certain impurities and the old refrigerant do not allow them‐
selves to be removed at all or to be removed from certain parts
of the refrigerant circuit. Such impurities can only be elimina‐
ted by rinsing then with refrigerant R134a.

7.3.1 Blowing out the refrigerant circuit
Note
♦ For vehicles where no adapter for connecting the refrigerant

line is connected, a compressed air gun with rubber nozzle
can be used for blowing through the components. When doing
so, take special care not to damage any connections (crushing
or scratching).
♦ The evaporator must be blown out through the low-pressure
piping connection (large diameter), ensuring that the expan‐
sion valve or choke has been disassembled.
♦ Always sweep the component in the opposite direction tot he
flow of refrigerant.
♦ Inspect the expansion valve. Replace if any dirt or corrosion
is found.
♦ If there are dark and sticky sediments which cannot be re‐
moved with compressed air in any components, they must be
replaced.
♦ Minimum residues of grey paint on the inside of the refrigerant
lines do not influence the function of the component.
♦ After the blowing-out process, always replace the liquid tank
or the collecting tank and the choke. In condensers with inte‐
grated driers, the drier cartridge or drier must be replaced.

8 Cleaning refrigerant circuit of impuri‐

ties using R134a refrigerant
8.1 Rinsing (cleaning) the refrigerant circuit

using the refrigerant R134a
• Work as cleanly as possible to prevent moisture and other
contamination (such as abrasion particles from wear or de‐
fective compressor) as well as old refrigeration oil from getting
into the circuit. This saves refrigerant and unnecessary instal‐
lation time and avoids unnecessary environmental pollution.
For this purpose flush the circuit with R134a refrigerant.
The refrigerant circuit must be rinsed:
– If there is dirt or any other impurities in the circuit.
– If, after vacuuming an airtight refrigerant circuit, the vacuum is
not maintained (there is humidity in the refrigerant circuit which
builds up pressure).
– If the refrigerant circuit has remained open longer than nec‐
– If, based on pressure and temperature measurements in the
– If there is any doubt regarding the amount of refrigerant in the
– if the compressor has to be changed due to internal damage
(for example noise or lack of power),
– if required by the Repair Manual following replacement of cer‐
tain components.
Necessary tools
♦ Air conditioning service station with rinsing equipment - SAT
4006D- (with this air conditioning service station, there is an
additional function “refrigerant circuit rinsing” and the required
rinsing equipment for the refrigerant circuits) ⇒ Workshop
equipment and special tools catalogue
♦ Adaptors kit, set for SEAT vehicles - SAT 4009- ⇒ page 144
and ⇒ Catalogue of workshop equipment and special tools
Preparation work
– Draining the refrigerant circuit
– Remove the compressor ⇒ Heating, air-conditioning or ⇒ Air-
conditioning
For vehicles with hose clip and collector tank
– Remove the hose clip (for certain vehicles) and reconnect the
pipes ⇒ Heating, air-conditioning or ⇒ Air-conditioning
– Remove the collector tank (for certain vehicles) and reconnect
the pipes (using the adapters and the filling hose belonging to
the Adapter kit, set for SEAT vehicles - SAT 4009- ,
⇒ page 144 ⇒ Heating, air-conditioning or ⇒ Air-conditioning
8. Cleaning refrigerant circuit of impurities using R134a refrigerant 69

Note
Actually the catch reservoir should also be flushed, however due

to its large internal volume, it contains a great deal of liquid re‐
frigerant. Draining this refrigerant would cause the catch reservoir
to ice up highly, the refrigerant would evaporate very slowly and
significantly slow down evacuation.
For vehicles with expansion valve and liquid tank

– Remove the liquid tank (for certain vehicles, not necessary for
all vehicles) and reconnect the pipes (using the adapters and
the filling hose belonging to the Adapter kit, set for SEAT ve‐
hicles - SAT 4009- , ⇒ page 144 ⇒ Heating, air-conditioning
or ⇒ Air-conditioning
Note permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
The liquid tank may be rinsed depending on the version (the de‐
hydration cartridge within must be removed), ⇒ Heating, air-
conditioning or ⇒ Air-conditioning
– For vehicles fitted with the dehydration cartridge in the con‐

denser liquid tank (for certain vehicles) remove the dehydra‐
tion cartridge and reseal the hole in the liquid tank ⇒ Heating,
air-conditioning or ⇒ Air-conditioning
– Remove the expansion valve for certain vehicles and fit the
corresponding adapter from the Adapter kit, set for SEAT ve‐
hicles - SAT 4009- , ⇒ Heating, air-conditioning or ⇒ Air-
conditioning .

Note
♦ If the Adapter kit, set for SEAT vehicles - SAT 4009- does not
include a suitable adapter for the expansion valve, then the
expansion valve may be widened (the used expansion valve
must often be replaced and is no longer required).
♦ Before widening remove the regulation elements and then drill
the expansion valve using a suitable drill bit (diameter 6 mm
for example).
♦ Expansion valves exist with different versions and with differ‐
ent structures. In case of the version -A- remove for example
the parts -B-, -C- and -D-. For the component -D- the part
-E- (regulation element) must be removed. The expansion
valve must then be drilled in the area -F- using a suitable drill
bit
♦ For the version -G- remove the parts -H-, -I- and -K- then drill
the zone -L- using a suitable drill bit.
♦ Clean the widened expansion valve and remove the remains
(shavings)
♦ Now fit the parts -B-, -C- and -D- for the version-A- or the part
-H- for the version -G-
Note
For vehicles equipped with two evaporators, the second evapo‐

rator circuit must be separated from the first evaporator and they
must be rinsed separately ⇒ Heating, air-conditioning or ⇒ Air-
conditioning .
Rinsing
– Check the quantity of refrigerant in the air-conditioning service
station; there must be at least 7kg of the refrigerant R134a
filled.
Note
30 minutes before the first rinsing, switch on the heater connected

to the refrigerant tank. This increases the pressure in the refrig‐
erant tank and accelerates the filling of the rinsing circuit.
permitted–unless
Extract the container for
S.Aold
doesoil on the air conditioning
any liability withservice
authorised by SEAT S.A. SEAT not guarantee or accept
respectstation.
– Connect the feed hose (high-pressure side) of the air-condi‐

tioning service station using the adapter to the low pressure
pipe going to compressor (this is the widest pipe).
– Connect the return hose (vacuum side or intake side) of the
air-conditioning service station to the output of the rinsing
equipment for the refrigeration circuit.
– Connect the input of the refrigerant circuit rinsing equipment
using the adapter to the high-pressure pipe going to the com‐
pressor (this is the thinnest pipe).

Note
♦ Components should always be rinsed in the opposite direction

of flow of refrigerant in the air-conditioning system during nor‐
mal operation. ⇒ page 74
♦ When flushing, impurities from the refrigerant circuit ingress
into the refrigerant circuit flushing attachment and the air con‐
ditioner service station, where they are retained in the built-in
filters and dryer. Depending on the nature of the impurities,
these components are to be replaced more frequently in line
with the operating instructions for the air conditioner service
station or the refrigerant circuit flushing attachment (refrigerant
circuit flushing attachment filter after approx. 5 to 10 flushing
cycles depending on the level of contamination of the refrig‐
erant circuits flushed).
♦ Depending on the nature of the dirt (oil used by refrigerant
machines and particles created by wear and abrasion of the
compressor) deposits are made on the spy hole of the refrig‐
erant circuit rinsing equipment. If necessary, clean the spy
hole after rinsing and, for monitoring purposes, rinse the re‐
frigerant circuit one more time (one rinsing cycle is sufficient
this time).
♦ The liquid refrigerant cannot be driven at the necessary speed
through the expansion valve, hose clip and dehydration bags
in certain liquid tanks; for this reason these components must
be removed from circuit and replaced with adapters if neces‐
sary ⇒ Heating, air-conditioning or ⇒ Air-conditioning
♦ Adapter for the connection of the air conditioning service sta‐
tion and for connecting certain components of the refrigerant
circuit.
– Activate the air-conditioning service station and rinse the re‐

frigerant circuit (for about 1 or 1.5 hours for each of three
cycles)
Note
♦ The rinsing must be carried out exactly asProtected

described in the
instructions manual of the air-conditioning service
permitted unlessstation.
♦ Depending on the version of the air conditioning service sta‐

tion, the container for the old oil only has a volume of approx.
125 cm3. If a unit with a greater quantity of refrigeration oil is
to be flushed, it may be necessary to empty the reservoir for
old oil after completing the first flushing cycle.
♦ Observe the refrigerant that flows back into the air conditioning
service station The circuit can be considered to be clean only
when the refrigerant flowing back into the AC service station
is transparent and fully colourless in the observation window
in the flushing device for AC circuits.
♦ For rinsing, all of the refrigerant machine oil in the circuit is
washed out (except for minimum residues for example in the
evaporator f that may be disregarded).
♦ For particularly intense soiling of the refrigerant circuit, rinsing
maybe required twice (2 rinsing cycles with three rinsing op‐
erations each cycle).

Work process of rinsing (the sequence is automatic and complies

with the programming of the air conditioning service station).
♦ After switch-on, the flushing circuit (refrigerant circuit with con‐
necting hoses and refrigerant circuit flushing attachment) is
initially evacuated and the refrigerant circuit checked for leaks
(Manual switching may be necessary depending on the ver‐
sion of the air conditioning service station.)
♦ The emptied refrigerant circuit is loaded from the high-pres‐
sure side of the air-conditioning service station (in the opposite
direction to normal flow of the air-conditioning through the low
pressure side of the refrigerant circuit of the vehicle) with a
specific quantity of refrigerant (for example 5 kg) or until the
refrigerant circuit and the spy holes of the refrigerant circuit
rinsing equipment are filled to a maximum with liquid refriger‐
ant (according to the air-conditioning service station version
refrigerant may not flow for a short time).
♦ Once specified quantity of refrigerant has been loaded into the
system, depending on the version of the air-conditioning serv‐
ice station and the refrigerant circuit rinsing equipment, the
heating for the printing equipment is activated (only if the re‐
frigerant is expelled from the refrigerant circuit rinsing equip‐
ment in a gaseous form).
♦ After evacuating the refrigerant, switch off the heater for the
flushing device for AC circuits (if present). Depending on the
version the AC circuit may be evacuated again, and after
evacuation the AC service station separates the refrigeration
oil evacuated from the circuit.
♦ The refrigerant filling process, vacuuming (and evacuation) is
repeated 2 times (that is, it is completed three times in all).
♦ After the third extraction, the rinsing circuit is emptied depend‐
ing on the air-conditioning service station.
– After completion of the flushing cycle, check the observation
window in the flushing device for AC circuits. If contamination
is present it may be necessary to clean the flushing device for
AC circuits or the AC service station in conformance with the
operating instructions and flush again for purposes of check‐
ing (one flushing operation of approx. 30 minutes is sufficient).
– Check pressure in AC circuit. Pressure should not be present
in the circuit (if necessary relieve again momentarily).
– Remove
Protected by copyright. the connection
Copying of the vehicle
for private or commercial topart
purposes, in the air-conditioning
or in whole, is not
service station on the refrigerant circuit (the circuit must not
have overpressure).
– Replace, depending on the vehicle, these components (hose
clip and collector tank, expansion tank and liquid tank or liquid
tank dehydration cartridge) ⇒ Heating, air-conditioning or ⇒
Air-conditioning and ⇒ Spare parts catalogue
– Depending on the complaint the compressor may need to be
replaced ⇒ Heating, air-conditioning or ⇒ Air-conditioning and
⇒ Spare parts catalogue or the refrigerant machine oil must
be emptied from the removed compressor (replace compo‐
nents of the refrigerant circuit) then refill with the quantity of
refrigerant machine oil specified (special oils and oil quantities
for refrigerant machines)

Note
♦ Replacement compressors come with the specific amount of

oil for refrigerant machines. For machines with two evapora‐
tors, if necessary, add the required amount of refrigerant
machine oil to the circuit ⇒ Heating, air-conditioning or ⇒ Air-
conditioning and (special oils and oil quantities for refrigerant
machines).
♦ If the compressor is not to be replaced then the amount of
refrigerant machine oil must be corrected (empty to move the
refrigerant machine oil then put the correct quantity into the
compressor or the refrigerant circuit) (replace components of
the refrigerant circuit) and (approved refrigerant machine oils
and filling quantities).
– Reassemble the refrigeration circuit ⇒ Heating, air-condition‐

ing or ⇒ Air-conditioning .
– Empty and fill the refrigerant circuit as specified and
– Start the air-conditioning according to the specifications ⇒
Heating, air-conditioning or ⇒ Air-conditioning and
8.1.1 Connecting diagram of different rinsing

circuits
Note
♦ The arrows in the figures show the flow direction of the refrig‐
erant when rinsing (when rinsing, the refrigerant flows in the
opposite direction than with the normal operation of the air
conditioner, therefore the high pressure side of the air-condi‐
tioning service station is connected to the vacuum connection
of the refrigerant circuit to the compressor).
♦ These basic circuit diagrams show a refrigerant circuit with a
hose clip and collector tank and a refrigerant circuit with an
expansion valve, liquid tank and second evaporator (optional
additional equipment for certain vehicles)
♦ Depending on the assembly of the air-conditioning service
station, a check valve may be between the refrigerant circuit
and the air-conditioning service station (used to establish the
correct direction of refrigerant flow when rinsing).
Refrigerant circuit with choke and collecting tank
Note
For vehicles with a hose clip and collector tank, remove the hose
clip and the collector tank and reconnect the pipes that were dis‐
connected in order to remove the hose clip. The pipe connections
from the removed collector tank are interconnected using two
adapters and the filling tube (from
permittedthe Adapter
unless authorisedkit, for S.A.
by SEAT SEATSEATve‐
hicles - SAT 4009- ) respect to the correctness of information in this document. Copyright by SEAT S.A.

1 - Air conditioning service sta‐

tion
❑ With an electric module
and a rinsing program,
e.g. Air conditioning
service station with rins‐
ing equipment - SAT
4006D- or Air condition‐
ing service station with‐
out rinsing equipment -
SAT 4006C- with at‐
tachment SAT 4009
❑ If an AC service station
without flushing pro‐
gramme is used, this
procedure must be per‐
formed manually (evac‐
uate, flush 3 times with
at least 4 kg of refriger‐
ant evacuate refrigerant
again).
2 - Refrigerant hose of the air
❑ of the high-pressure
side of the air-condition‐
ing service station (red
in most cases) to the
connection on the vac‐
uum side of the com‐
pressor on the refriger‐
ant circuit (larger circuit)
3 - Connection adapters for the
low pressure side of the refrig‐
erant circuit
ent depending on theProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
vehicle. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Belong to the Adapter
kit, set for SEAT vehicles - SAT 4009-
4 - Connection adapters for the low pressure side of the refrigerant circuit
❑ The versions are different depending on the vehicle.
❑ On the refrigerant pipe from the compressor to the collector tank
5 - Connection to the collector tank
❑ On the refrigerant pipe from the compressor to the collector tank
6 - Adapter to bridge the removed collector tank
❑ Belong to the Adapter kit, set for SEAT vehicles - SAT 4009- ⇒ page 79
7 - Refrigerant filling hose
❑ Belong to the Adapter kit, set for SEAT vehicles - SAT 4009-
8 - Adapter to bridge the removed collector tank
9 - Connection to the collector tank

10 - Evaporator
11 - Location of the hose clip
❑ Hose clip removed
❑ Remove the hose clip ⇒ Heating, air-conditioning or ⇒ Air-conditioning
12 - Bolted joint on the refrigerant pipe
❑ After the hose clip is removed tighten ⇒ Heating, air-conditioning or ⇒ Air-conditioning
13 - Condenser
14 - Connection for the high pressure side of the refrigerant circuit
15 - Connection adapters for the high pressure side of the refrigerant circuit
16 - Filling tube for refrigerant circuit rinsing equipment
❑ From the connection to the high-pressure side from the compressor on the refrigerant circuit (thinnest
diameter) to the input of the refrigerant circuit rinsing equipment.
17 - Refrigerant circuit rinsing equipment
❑ Structures may differ depending on the machine evolution, for example refrigerant circuit rinsing equip‐
ment - Kit SAT 4009- for machines preceding the -SAT 4006D-
❑ with filter, observation window, safety valve, refrigerant reservoir, etc. (depending on version)
❑ Depending on the air-conditioning service station and architecture and the refrigerant circuit rinsing
equipment, there may be a retention valve fitted to the output of the refrigerant circuit rinsing equipment
(used to establish the correct direction of refrigerant flow when rinsing).
18 - Refrigerant hose of the air conditioning service station
❑ of the vacuum side of the air-conditioning
Protected service
by copyright. Copying station
for private (bluepurposes,
or commercial in most cases)
in part to the
or in whole, is notoutlet of the rinsing
equipment for the refrigerant circuit
Refrigerant circuit with expansion valve, liquid tank and second

evaporator
Note
♦ This diagram of basic circuits shows the refrigerant circuit with

an expansion valve, liquid tank and second evaporator (addi‐
tional optional equipment for certain vehicles).
♦ On vehicles with expansion valve and receiver, the expansion
valve is removed and replaced with an adapter. Depending on
the vehicle, the receiver is also removed and the pipe con‐
nections to the receiver are connected using two adapters and
a filler hose.
♦ For vehicles fitted with only one evaporator, the components
from item “16”are not fitted or not needed.

1 - Air conditioning service sta‐

tion
❑ With an electric module
and a rinsing program,
e.g. Air conditioning
service station with rins‐
ing equipment - SAT
4006D- or Air condition‐
ing service station with‐
out rinsing equipment -
SAT 4006C- with at‐
tachment SAT 4009
❑ If an AC service station
without flushing pro‐
gramme is used, this
procedure must be per‐
formed manually (evac‐
uate, flush 3 times with
at least 4 kg of refriger‐
ant evacuate refrigerant
again).
2 - Refrigerant hose of the air
❑ of the high-pressure
side of the air-condition‐
ing service station (red
in most cases) to the
connection on the vac‐
uum side of the com‐
pressor on the refriger‐
ant circuit (larger circuit)
3 - Connection adapters for the
low pressure side of the refrig‐
erant circuit
vehicle.
❑ Belong to the Adapter
kit, set for SEAT vehicles - SAT 4009- ⇒ page 79
4 - Connection adapters for the low pressure side of the refrigerant circuit
5Protected
- Adapter for removed
by copyright. expansion
Copying for private valve
❑respect
permitted The
unless versions
authorised are
by SEAT different
S.A. SEAT S.Adepending onorthe
does not guarantee acceptvehicle.
any liability with
6 - Evaporator
7 - Connection to the liquid tank
❑ There are no vehicles with a dehydrator cartridge in the condensation liquid tank or with a liquid tank
included in the condenser ⇒ Heating, air-conditioning or ⇒ Air-conditioning .
8 - Adapter to bridge the removed liquid tank
9 - Refrigerant filling hose
❑ For example filling tube (belonging to Adapter kit, for SEAT vehicles - SAT 4009- )

10 - Condenser
❑ If the condenser is fitted with a liquid tank including a dehydrator cartridge then this cartridge must be
removed (reseal the liquid tank close to the condenser following removal) ⇒ Heating, air-conditioning or
⇒ Air-conditioning
❑ If the liquid tank is directly fitted to the condenser, then it can be removed and the liquid tank replaced
after rinsing ⇒ Heating, air-conditioning or ⇒ Air-conditioning
11 - Connection for the high pressure side of the refrigerant circuit
12 - Connection adapters for the high pressure side of the refrigerant circuit
13 - Filling tube for refrigerant circuit rinsing equipment
❑ From the connection to the high-pressure side from the compressor on the refrigerant circuit (thinnest
diameter) to the input of the refrigerant circuit rinsing equipment.
14 - Refrigerant circuit rinsing equipment
❑ These are different versions and different structures, for example refrigerant circuit rinsing equipment
❑ with filter, observation window, safety valve, refrigerant reservoir, etc. (depending on version)
❑ Depending on the air-conditioning service station and architecture and the refrigerant circuit rinsing
equipment, there may be a retention valve fitted to the output of the refrigerant circuit rinsing equipment
(used to establish the correct direction of refrigerant flow when rinsing).
15 - Refrigerant hose of the air conditioning service station
❑ of the vacuum side of the air-conditioning service station (blue in most cases) to the outlet of the rinsing
equipment for the refrigerant circuit
16 - Adapter for sealing the output of the second evaporator
❑ Only necessary for vehicles with the optional “second evaporator”
17 -permitted
Adapter forauthorised
unless sealing the output
by SEAT S.A. SEATofS.Athe
doessecond evaporator
18 - Connection on the low pressure side of the refrigerant circuit to the second evaporator
19 - Connection on the high pressure side of the refrigerant circuit to the second evaporator
20 - Adapter for the expansion valve removed on the second evaporator
21 - Second evaporator

8.2 Application of the flush kit - SAT 4009-

with adapters
• Depending on the type of tools chosen, there may be differ‐
ences in the work process. The specific handling instructions
for each tool or adapter must be taken into account.
WARNING
Always keep an eye wash flask close to hand.

If the refrigerant comes into contact with the eyes, immediately
begin thorough rinsing of the eyes for 15 minutes.
Then, apply eye drops and seek medical assistance even if the
eyes do not cause any pain.
The medical assistance must be given
permittedall of authorised
unless the details of S.A.
by SEAT theSEAT S.A does not guarantee or accept any liability with
refrigerant causing the problem. respect to the correctness of information in this document. Copyright by SEAT S.A.
WARNING
Before installation, the air-conditioning station should be dis‐

connected from the electricity supply.
– Connect the red tube (high-pressure area)-1-, on the side of

the valve rod, to the station coupling-2- after removing the
plastic cap.
– Connect the other end of the red tube to the part of circuit to
be cleaned, using the kit SAT 4009 and the elements required
for the work.

The universal bridge -1- is an example of connection, with the

rubber joint -2- connected to the tube diameter.
On the low pressure side (blue tube) -1- the refrigerant flows
through the air conditioning circuit to be cleaned in liquid form and
follows the connection to the cleaning filter.
At the input -1- the refrigerant flows, by the spy hole -3- where the
level of impurities can be observed.
– This filter removes the particles from the refrigerant which is
then returned to the machine by the rapid connection -2- .
8.3 Adaptation of refrigerant loading ma‐

chines before SAT 4006D to rinse cir‐
cuits with the Kit SAT 4009
Refrigerant loading machines supplied by SEAT after the model
SAT 4006D, have the Kit SAT 4009 included.
Machines prior to the model SAT 4006D supplied by SEAT re‐
quire installation of the Kit SAT 4009 for rinsing of R134a refrig‐
erant circuits.
Note
♦ Additional information ⇒ Instructions manual of the machine

itself.
♦ Additional information ⇒ Fitting the cleaning kit from the man‐
ufacturer.
♦ Catalogue of tools and utilities.
WARNING
Before installation, the air-conditioning station should be dis‐

connected from the electricity supply.
– Ensure that the content of the cleaning kit isrespect
complete.

♦ Case with support or adapter SAT 4009D ⇒ page 79
♦ Connection pipes
♦ Connection kit with ball valve.

♦ Filter with attachment bracket.

Fitting
– Remove the front and top plate from the refrigerant station
134a.
– Insert the socket -1- into the circuit so that the -T- is as shown,
after the red tap-2- on the refrigerant cylinder. The refrigerant
is liquid in this area.
– Tighten the remaining connections and extract them from the
two holes-1- and -2-
– Fit the handle -B- to the valve with the correct screw.
– Carefully tighten the Schraeder valve-A- with the correspond‐
ing spanner.
Fit the bracket and the filter:
– Carefully tighten the filter attachment bracket to the frame us‐

ing the four bolts.
– Tighten the filter attachment bracket with the two nuts and
bolts.
– Fit the filter to the bracket -1- previously fitted to the machine.

8.4 Adapter for performing flush circuits -

VAS 6338/1-
♦ The following table shows the different adapters necessary for
the connection of the air conditioning service station to the re‐
frigerant circuit for rinsing and to bridge the fluid tank or the
collector tank and the expansion valve (specific to certain ve‐
hicles).
♦ With a filler hose with connections 5/8 -18 UNF (short version
e.g. filler hose - VAS 6338/31- ) join the two adapters mounted
on the collector tank or the dismounted fluid tank (included in
the adapter kit for SEAT passenger vehicles - VAS 6338/1- ).
♦ If a refrigerant circuit is not going to be mounted immediately
after flushing, leave the adapters in the connectors and plug
the connectors in the adapters using the hoods - VAS 6338/30-
(from the adapter kit for SEAT passenger vehicles - VAS
6338/1- ).
♦ Depending on the version of air conditioning compressor and
the manufacturing period, different connection and sealing
techniques are used in the refrigerant circuit ⇒ Heating, air
conditioning .
Block or screw connection

Screw connections -A-
Block connections-B-

Block connections with different types of seal

Block connections with radial seal -A- (with plastic or metal guide
-B-)
– Block connections with axial seal -C-

Ibiza 1993; Cordoba 1994; Inca 1995; Arosa 1996

Vehicle Adapters re‐ Adapters required for Others
quired for the re‐ the refrigerant hoses to
frigerant hoses the fluid tank
to the air condi‐
tioning compres‐
sor
Ibiza Adapter - VAS – Dismount the tank – Re‐
1993 ► 6338/14- and bridge the re‐ place
Cordo‐ frigerant hoses. the ex‐
ba 1994 ♦ Adapter - VAS pan‐
► 6338/28- sion
valve
♦ Adapter - VAS with
6338/29- the
– After flushing, fit a adapt‐
new fluid tank. er -
VAS
6338/1
9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.


to the air condi‐
tioning compres‐
sor
Inca ♦ Adapter - – Dismount the tank – Re‐
1995 ► VAS 6338/4- and bridge the re‐ place
Arosa Low-pres‐ frigerant hoses. the ex‐
1996 ► sure end ♦ Adapter - VAS pan‐
6338/28- sion
♦ Adapter - valve
VAS 6338/2- ♦ Adapter - VAS with
or adapter - 6338/29- the
VAS adapt‐
6338/14- high – After flushing, fit a er -
pressure end new fluid tank.
VAS
6338/1
9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing,
Protected by copyright. Copying for private or commercial purposes, in part fitwhole, is not
or in
a new
expan‐
sion
valve.
Ibiza ♦ Adapter - – Remove the dehy‐ – Re‐
2002 ► VAS drator cartridge and place
Cordo‐ 6338/12- plug the fluid tank. the ex‐
ba 2003 Low-pres‐ pan‐
► sure end – After flushing, fit a sion
new dehydrator valve
♦ Adapter - cartridge. with
VAS 6338/2- the
High pres‐ adapt‐
sure end er -
VAS
6338/3
4- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.

Toledo 1995; Leon 1996; Arosa 2000; Inca 2000; Arosa 1997;
Cordoba Vario 1997
to the air condi‐
tioning compres‐
sor
Toledo Adapter - VAS – Dismount the tank – Re‐
1995 ► 6338/14- and bridge the re‐ place
Leon frigerant hoses. the ex‐
1996 ► ♦ Adapter - VAS pan‐
6338/28- sion
valve
♦ Adapter - VAS with the
6338/29- adapter
– After flushing, fit a - VAS
new fluid tank. 6338/1
9- (or
an ex‐
pan‐
sion
valve
en‐by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
larged of information in this document. Copyright by SEAT S.A.
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.
Arosa ♦ Adapter - – Dismount the tank – Re‐
Cordo‐ Low-pres‐ frigerant hoses. the ex‐
ba Vario sure end ♦ Adapter - VAS pan‐
1997 ► 6338/28- sion
♦ Adapter - valve
VAS 6338/2- ♦ Adapter - VAS with the
or adapter - 6338/29- adapter
VAS - VAS
6338/14- high – After flushing, fit a
pressure end 9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.


to the air condi‐
tioning compres‐
sor
Arosa ♦ Adapter - – Dismount the tank – Re‐
2000 ► VAS and bridge the re‐ place
Inca 6338/12- frigerant hoses. the ex‐
2000 ► Low-pres‐ ♦ Adapter - VAS pan‐
sure end 6338/28- sion
valve
♦ Adapter - ♦ Adapter - VAS with the
VAS 6338/2- 6338/29- adapter
High pres‐ - VAS
sure end – After flushing, fit a
9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.

Toledo 1999; Leon 1999; Altea 2004; Toledo 2005; Leon 2006
to the air condi‐
tioning compres‐
sor
Toledo ♦ Adapter - – Dismount the tank – Re‐
Leon Low-pres‐ frigerant hoses. the ex‐
1999 ► sure end pan‐
– 2 adapters - VAS sion
♦ Adapter - 6338/2- and join valve
VAS 6338/2- with hose - VAS with the
High pres‐ 6338/31- . adapter
sure end - VAS
– After flushing, fit a 6338/1
new fluid tank. 9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.
Altea ♦ Adapter - Liquid tank – Re‐
2004 ► VAS – Flush sweeping is place
Altea XL 6338/12- possible. the ex‐
2007 ► Low-pres‐ pan‐
Altea sure end – After flushing, fit a sion
Free‐ new fluid tank. valve
track ► ♦ Adapter - with the
VAS 6338/3- adapter
High pres‐ - VAS
sure end 6338/1
8- (or
an ex‐
pan‐to the correctness of information in this document. Copyright by SEAT S.A.

respect
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.


to the air condi‐
tioning compres‐
sor
Toledo ♦ Adapter - Liquid tank – Re‐
6338/12- possible. the ex‐
Low-pres‐ pan‐
sure end – After flushing, fit a sion
new fluid tank. valve
♦ Adapter - with the
VAS 6338/3- adapter
High pres‐ - VAS
sure end 6338/1
8- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.
Leon ♦ Adapter - Liquid tank – Re‐
6338/12- possible. the ex‐
Low-pres‐ pan‐
sure end – After flushing, fit a sion
new fluid tank. valve
♦ Adapter - with the
VAS 6338/3- adapter
High pres‐ - VAS
sure end 6338/1
8- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.

Alhambra 1996;
Note
On vehicles with additional evaporator (Alhambra) it is necessary

to flush the front and rear AC circuits separately. The front refrig‐
erant circuit must be sealed with adapter - V.A.G 1785/1- , the
adapter - 1785/3- and caps -VAS 6338/30-.


frigerant hoses to the fluid tank and addi‐
the air condition‐ tional evaporator
ing compressor
Alham‐ ♦ Adapter - VAS – As no adapter is yet – Re‐
bra 6338/7- Low- available for the place
1996 pressure end tank, it should re‐ the ex‐
until main mounted and pan‐
May ♦ Adapter - VAS flushed. The flush sion
2000 ► 6338/2- High time will increase valve
Infor‐ pressure end by approximately (for
mation 30 minutes due to front
about the additional vol‐ and
the ume. rear
adapter – If the refrigerant is circuit)
for the still not clean after with
tank the third flush, con‐ the
(dehy‐ tinue flushing until adapt‐
drator) the refrigerant ap‐ er -
was not pears clean on VAS
availa‐ passing the obser‐ 6338/3
ble on vation window. 5- (or
com‐ – After flushing, fit a an ex‐
pletion new fluid (dehydra‐ pan‐
of this tor) tank. sion
report. ♦ Adapter - V.A.G valve
1785/7- low pres‐ en‐
sure hose for addi‐ larged
tional evaporator with a
drill)
♦ Adapter - V.A.G
1785/5- high pres‐ – After
sure hose for addi‐ flush‐
tional evaporator ing, fit
♦ Adapter - V.A.G a new
1785/3- with hood - expan‐
VAS 6338/30- to sion
plug front refriger‐ valve.
ant circuit.
♦ Adapter - V.A.G
1785/1- with hood -
VAS 6338/30- to
plug front refriger‐
antto circuit.


frigerant hoses to the fluid tank and addi‐
the air condition‐ tional evaporator
ing compressor
Alham‐ ♦ Adapter - VAS – Remove the dehy‐ – Re‐
bra 6338/7- Low- drator cartridge and place
1996 pressure end plug the fluid tank. the ex‐
after – After flushing, fit a pan‐
June ♦ Adapter - VAS new dehydrator sion
2000 ► 6338/2- High cartridge. valve
pressure end ♦ Adapter - V.A.G (for
1785/7- low pres‐ front
sure hose for addi‐ and
tional evaporator rear
circuit)
♦ Adapter - V.A.G with
1785/5- high pres‐ the
sure hose for addi‐ adapt‐
tional evaporator er -
♦ Adapter - V.A.G VAS
1785/3- with hood - 6338/3
VAS 6338/30- to 5- (or
plug front refriger‐ an ex‐
ant circuit. pan‐
sion
Protected by copyright. Copying forvalve
♦ permitted
Adapter - V.A.G private or commercial purposes, in part or in whole, is not
1785/1- with hood - en‐

VAS 6338/30- to larged
plug front refriger‐ with a
ant circuit. drill)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.
Ibiza 2008:
Vehicle Adapters re‐ Adapters required for Other re‐
quired for com‐ reservoir/receiver con‐ quire‐
pressor connec‐ nections ments
tions
Ibiza – Compressor Collecting tank – Restric‐
2008 ► manufacturer – Screw connection tor re‐
“Denso” at inlet Adapter - moved,
♦ Adapter - VAS 6338/9- pipe
VAS con‐
6338/12- – Block connection nec‐
(low-pres‐ with axial seal at tions
sure side) outlet Adapter - re-as‐
VAS 6338/10- sem‐
♦ Adapter - bled
VAS 6338/2- – Remove the dehy‐
(high-pres‐ drator cartridge and – After
sure side) plug the fluid tank. flush‐
ing, fit a
– After flushing, fit a new ex‐
new dehydrator pan‐
cartridge. sion
valve.

Exeo 2009, Exeo ST 2009:

Vehicle Adapters re‐ Adapters required for Other re‐
quired for com‐ reservoir connections quire‐
pressor connec‐ ments
tions
Exeo – Compressor Reservoir with differ‐ – Restric‐
2009 ► manufacturer ent connection ver‐ tor re‐
Exeo ST “Denso” (bloc sions moved,
2009 ► k connections ♦ Version “1” pipe
with radial con‐
and axial – Block connections nec‐
seal) with axial seal at in‐ tions
♦ Adapter - let and outlet re-as‐
VAS ♦ Adapter - VAS sem‐
6338/12- 6338/10- (2x re‐ bled
(low-pres‐ quired)
sure side) – After
flush‐
♦ Adapter - ing, fit a
VAS 6338/2- new ex‐
(high-pres‐ pan‐
sure side) sion
valve.
– Compressor ♦ Version “2”
manufacturer
“Denso” (bloc – Block connections
k connections with radial seal at
with radial inlet and outlet
and axial ♦ Adapter - VAS
seal) ⇒ Air- 6338/8- (2x re‐
conditioning; quired)
Rep. gr. 87
♦ Adapter -
VAS
6338/12-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/3-
(high-pres‐
sure side)

9 Complaints
9.1 Possible complaints regarding the re‐

frigerant circuit
Note
♦ The air-conditioner operates correctly if air is blown out

through the vents on the instrument panel at a temperature of
7 °C or lower.
♦ Climatronic setting “LO”.
♦ Air-conditioner setting “AC”; “max.”; “cold”.
9.1.1 Test requirements

• The self-diagnosis does not detect any fault with the vehicle
information, measurement and diagnosis system - VAS
5051A- through the “Guided fault location”, in the measure‐
ment value block no deactivation condition is observed for the
air-conditioner compressor (only for vehicles with “Air-condi‐
tioning” self-diagnosis).
⇒ Rep. gr. 87
9.1.2 Possible complaints
Note
♦ For all complaints marked with a * “Check pressures”.

♦ For vehicles fitted with two evaporators, when the complaint
concerns one evaporator check the pressures in the refriger‐
ant circuit.
♦ Refrigeration has completely failed. *

♦ Refrigeration power insufficient at any vehicle speed and/or all
engine speeds *
♦ Refrigeration nonexistent or insufficient after several kilome‐
tres. **
♦ No refrigeration or insufficient refrigeration in one or both
evaporators (for vehicles with two air-conditioning units).** * *
♦ The air-conditioner compressor, the air-conditioner electro‐
magnetic coupling - N25- , or the air-conditioner compressor
regulating valve - N280- is deactivated by the air-conditioner
low-pressure switch - F73- , the electromagnetic coupling
high-pressure switch - F118- , the air-conditioner pressure
switch - F129- , or by the air-conditioner control unit and dis‐
play, Climatronic - E87- or the Climatronic control unit - J255-
due to a too high or too low pressure.*
♦ Nonexistent fresh air intake or considerable reduction after
several kilometres (evaporator frozen).
Protected*by copyright. Copying for private or commercial purposes, in part or in whole, is not
The following complaints may also occur:
The air conditioner compressor is noisy

– Retighten the bolts securing the compressor and the com‐
pressor support with a torque wrench.

– Check the tension of the refrigerant pipes, they should not be

in contact with any other components and must be free from
tensions or twisting (if necessary, correct alignment).
Noises are heard immediately after turning on the air-conditioner
and/or when turning or braking the vehicle (refrigerant knocking):
– Empty the refrigerant circuit, vacuum it and recharge (exces‐
sive refrigerant in circuit).
Note
♦ Excessive refrigerant oil in the circuit may also give rise to this
complaint (e.g. the amount of refrigerant oil was not compen‐
sated for after replacing the compressor). With such com‐
plaints, rinse the refrigerant circuit using the refrigerant R134a.
⇒ page 69
♦ The refrigerant must be extracted from the air conditioner
compressor (replace the O-ring) via the oil drain plug. To make
the extraction easier, the pulley for the Poly-V-belt or the clutch
plate of the magnetic clutch must be turned by hand. Then the
entire quantity of refrigerant oil must be filled into the refriger‐
ant circuit according to the ⇒ specific repair manual of the
vehicle (50 g direct in the air conditioner compressor).
An air-conditioner which otherwise operates correctly, spatters

water through the vents (on the instrument panel or in the foot‐
well).
– Check that the condensation drainage tube is correctly laid,
and that it is not squashed or kinked.
– Check the water condensation output valve, it should not be
blocked by wax or underbody protection and must close per‐
fectly.
– Check the cover of the plenum chamber, and ensure that it is
not damaged and is mounted correctly (no water must enter
the evaporator).
– Check the drains of the plenum chamber; ensure that these
are not blocked (for example by dead leaves).
9. Complaints 95
10 Connecting the service station
10.1 To vehicles equipped with a connection

on both the high and low pressure sides
of the refrigerant circuit
10.1.1 Service stations connection to carry out

measurements and inspections
– Attach the quick coupling adaptors to the charging hoses of
the service station (wheels or manual shut-off valves not
open).
– Connect the service station and vacuum the charging hoses
(only necessary if there is air inside the charging hoses).
– Disconnect the service station.
– Unscrew the caps from the service connections (with valve).
– Connect the service station to the service connections of the
refrigerant circuit on the vehicle with the quick coupling adap‐
tors.
– Turn the wheel on the quick coupling adaptors until the refrig‐
erant circuit connection valvesunlessare completely
authorised open
by SEAT S.A. SEAT(check
S.A does the
permitted not guarantee or accept any liability with
manometer; do not over-pressurise the valves).
– Carry out the planned inspections and measurements.

11 Checking pressures
11.1 Check the pressure in the refrigerant cir‐

cuit (using the air conditioning service
station)
Note
♦ Checking the cooling performance. The air-conditioner oper‐

ates correctly if air is blown out through the vents on the
instrument panel at a temperature of 7 °C or lower.
♦ Climatronic setting “LO”.
♦ Air-conditioner setting “AC”; “max.”; “cold”.
♦ Valve connections and service connections to carry out meas‐
urements and inspections.
11.1.1 Test requirements

• The radiator and condenser are clean (if necessary, clean
them).
• The thermal protection insulation of the expansion valve is in
order and correctly mounted. See the repair manual of the ve‐
hicle in question ⇒ Rep. gr. 87 .
• The Poly-V belt is in good condition and properly tensed. The
compressor and alternator belts are in good condition and
properly tensed. See the repair manual of the respective ve‐
hicle ⇒ Rep. gr. 87 .
• All air ducts, covers and seals are OK and properly installed.
• No faults have been detected during the electrical system and
vacuum system fault location. See the repair manual of the
respective vehicle ⇒ Rep. gr. 87 .
• The air-conditioner self-diagnosis does not detect any fault
with the vehicle information, measurement and diagnosis sys‐
tem - VAS 5051A- through the “Guided fault location”, in the
measurement value block no deactivation condition is ob‐
served for the air-conditioner compressor (only for vehicles
with “Air-conditioning” self-diagnosis).
• The air flow through the dust and pollen filter is not obstructed
by dirt. See the repair manual of the respective vehicle ⇒ Rep.
gr. 87 .
• The heater and the air conditioner do not obtain additional air
at full speed from the fresh air blower. The evaporator and
heater do not obtain additional air at full speed from the fresh
air blower. See the repair manual of the respective vehicle ⇒
Rep. gr. 87 .
• The air duct flaps of the heater and the air conditioner reach
their end position. See the repair manual of the respective ve‐
hicle ⇒ Rep. gr. 87 .
• The fresh air intake ductspermitted
belowunless
the bonnet and
authorised by SEATinS.A.
theSEAT
pas‐S.A does not guarantee or accept any liability with
senger compartment, as well as thetocorresponding
respect drain in this document. Copyright by SEAT S.A.
the correctness of information
valves, are in good condition. See the repair manual of the
vehicle in question ⇒ Rep. gr. 87 .
• Engine at operating temperature
11. Checking pressures 97

• The vehicle should not be in direct sunlight.

• Ambient temperature above 15°C
• Open all instrument panel vents.
• While the engine is running and the air-conditioner is set at
maximum cooling power:
⇒ Rep. gr. 87
Set the air-conditioner to maximum cooling power.
Setting on the air-conditioner control unit and display, Climatronic
- E87- :
– Set the operating mode “Auto” (air-conditioner compressor
activated).
– Select the temperature setting “LO” for the driver and front
passenger side.
Setting on the heater controls:
– A/C button and Rec (air recirculation) button depressed.
– The temperature selector rotating control is at the end position
“cold”.
– The fresh air blower rotating control is set to position “4”.
• The Protected
refrigerant fan/sCopying
by copyright. - V7-forare running
private (at least
or commercial speed
purposes, in part or1).*
in whole, is not
Note
In some versions, the fan only starts running after the pressure in
the refrigerant circuit has surpassed a preset value.
• The fresh air blower - V2- is running at maximum speed.

• The air recirculation/fresh air flap set to position “Air recircu‐
lation”/ closes the air retention flap and opens the air recircu‐
lation flap (within 1 minute after starting the vehicle).*
• The refrigerant shut-off valve is closed.*
• The valves of the valve unit and pump are closed (and the
refrigerant recirculation pump is not running).*
11.1.2 Checking pressures

– Connect the air conditioning service station.
– Read off pressure on pressure gauges; two results are possi‐
ble.
♦ The pressure in the refrigerant circuit is lower than that indi‐
cated in the table.
♦ The pressure in the refrigerant circuit is equal to or higher than
that indicated in the table.
Ambient temperature (in °C) Pressure in refrigerant circuit in
bar
+15 °C 3,9
+20 °C 4,7
+25 °C 5,6
+30 °C 6,7
+35 °C 7,8

Ambient temperature (in °C) Pressure in refrigerant circuit in

bar
+40 °C 9,1
+45 °C 10,5
Note
♦ The temperature of the refrigerant circuit components must be

equal to the ambient temperature.
♦ If any of the refrigerant circuit components are hotter or colder,
the pressure is different to the values in the table.
♦ In the case of absolute pressure, 0 bar is equal to an absolute
vacuum. Normal atmospheric pressure (positive pressure) is
equal to 1 bar absolute pressure. In general, most manometer
scales represent atmospheric pressure as 0 bar, meaning an
absolute pressure of 1 bar (this can be recognised if there is
a -1 on the scale).
♦ In vehicles equipped with a high-pressure sender - G65- in
which the pressure measured is displayed in the measure‐
ment value block, the measured pressure must coincide with
the values in the table.
⇒ Rep. gr. 87
The pressure in the refrigerant circuit is lower than that indicated
in the table.
Insufficient refrigerant in the circuit.
– Determine refrigerant circuit leaks .
– Check the pressure relief valve.
If the pressure relief valve has been activated:
– Check radiator fan control.
– Check for constricted refrigerant pipe and hose cross-sections
caused
Protected by inadequate
by copyright. bending
Copying for private radii. purposes, in part or in whole, is not
or commercial
– Check
respect for
to theany external
correctness damage
of information in thison the refrigerant
document. piping
Copyright by SEAT S.A. and
hoses.
– Clean the refrigerant circuit (rinse with refrigerant R134a or
sweep with compressed air or nitrogen).
The pressure in the refrigerant circuit is equal to or higher than
that indicated in the table.
– Start engine.
– Adjust air conditioning for maximum refrigeration capacity.
Note
If the low-pressure switch was disassembled when connecting

the air-conditioning service station, bridge the electrical connec‐
tions of the corresponding plug to measure the pressure.
• The air-conditioner compressor is driven with the engine

through the air-conditioner electromagnetic coupling - N25- .
• The air-conditioner regulating valve - N280- is activated by the
Climatronic control unit - J255- .
⇒ Rep. gr. 87

If the compressor is not driven while the engine is running, or if

the regulating valve is not activated:
– Locate and eliminate the cause, e.g. by consulting the air-
conditioner fault memory.
– Take the test requirements into account.
– Check the power supply of the air-conditioner electromagnetic
coupling - N25- . If correct, repair the electromagnetic cou‐
pling.
– Check the activation of the air-conditioner compressor regu‐
lating valve - N280- .
⇒ Rep. gr. 87 .
11.1.3 Continuation of test depending on layout

of AC circuit
♦ Checking pressures on vehicles with restrictor and reservoir
(with internally regulated compressor) ⇒ page 100
♦ Checking pressures
Protected on
by copyright. vehicles
Copying with
for private expansion
or commercial valve
purposes, and
in part or inre‐
whole, is not
ceiver (with internally regulated compressor) ⇒ page 104
♦ Checking pressures on vehicles with restrictor, reservoir and

air conditioner compressor regulating valve - N280- (with ex‐
ternally regulated compressor) ⇒ page 109
♦ Checking pressures on vehicles with restrictor, reservoir and
air conditioner compressor regulating valve - N280- (with ex‐
ternally regulated compressor) ⇒ page 114 .
11.2 Checking pressures on vehicles with re‐

strictor and reservoir (with internally
regulated compressor)
Note
♦ Connect the air conditioning service station.

♦ Observe test requirements ⇒ page 97 .
– Set engine speed of 2000 rpm.

– Observe the pressure display (e.g. pressure gauge equip‐
ment) of the air conditioning service station.
Note
♦ The switching pressures of the refrigerant circuit switches are

specific to the vehicle.
♦ The valve connection for the low-pressure switch or the evap‐
orator must only be used on vehicles with no service connec‐
tion on the low-pressure side and with a non-accessible
connection on the compressor or collecting tank (measure‐
ment precision). Applies only for certain vehicles ⇒ heater and
air conditioning; Rep. gr. 87 or ⇒ air conditioning; Rep. gr.
87 .
11.2.1 Theoretical values:

High-pressure side:
Increasing by a maximum of 20 bars from the initial pressure
(when connecting the manometers).

Low-pressure side:
Decreasing to the value of the diagram from the initial pressure
A - High pressure (measured at the service connection) in bar.
B - Low pressure (measured at the valve connection of the com‐
pressor or the collecting tank) in bar.
C - Acceptable tolerance range.
D - Low pressure (measured at the valve connection of the low-
pressure switch or at the service connection) in bar.
E - Acceptable tolerance range
Possible difference in permitted
relation to authorised by SEATPossible
unless S.A. SEAT S.Acause
does notof fault or accept any liability with
guarantee Fault elimination
specification
• The high pressure remains con‐ Insufficient refrigerant in the circuit. – Find leak with leak de‐
stant or increases only slightly tector and eliminate.
(above the pressure with the en‐
gine stopped), – Recharge the refriger‐
ant circuit.
• Low pressure drops to value in
graph or below
• Required cooling output is not at‐
tained
• High pressure normal,

• low pressure equal to value of the
diagram,
tained

• low pressure too low (see dia‐
gram),
tained
Note
Clean the refrigerant circuit (rinse with refrigerant R134a or sweep

with compressed air or nitrogen).

Possible difference in relation to Possible cause of fault Measures to be taken

specification
• High pressure only increases Compressor defective – Clean refrigerant cir‐
slightly above pressure with en‐ cuit (flush with refrig‐
gine stopped erant R134a or blow
out with compressed
• the low pressure decreases only air and nitrogen ).
slightly,
• Required cooling output is not at‐ – Renew compressor.
tained
Possible difference in relation to Possible cause of fault Fault elimination

specification
• The high pressure rises above Narrowing or blockage in the refrigerant cir‐ – Feel AC circuit with
the specification, cuit. hand to determine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is nottemperature differ‐
• Low pressure drops permitted
to value in
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability withences.
graph or below respect to the correctness of information in this document. Copyright by SEAT S.A.
• Required cooling output is not at‐ • If temperature differ‐

tained ences are percepti‐
ble on a component:
– Renew hose or pipe
if kinked or constric‐
ted.
– In the event of clog‐

ging, clean refriger‐
ant circuit (flush with
refrigerant R134a or
blow out with com‐
pressed air and nitro‐
gen ).
• If no fault is found.
– Clean refrigerant cir‐
cuit (flush with refrig‐
erant R134a or blow
out with compressed
air and nitrogen ).
• High and low pressure normal at Humidity in the refrigerant circuit. – Check receiver (with
first dryer), replace, if re‐
quired. Then drain
• the high pressure rises above the AC circuit for at least
specification, 3 hours (see note).
• Low pressure drops to value in
graph or below – Clean refrigerant cir‐
• Required cooling output is not at‐ erant R134a or blow
tained out with compressed
air and nitrogen ).
• High and low pressure normal at
first
• After lengthy operating period,
low pressure drops excessively
(evaporator ices up)

Note
♦ If problem involving moisture in refrigerant circuit only occurs

after a lengthy operating period or only infrequently (low pres‐
sure drops below specification and evaporator ices up), it is
sufficient to replace the dryer in the receiver (adjust quantity
of refrigerant oil). Subsequently, evacuate refrigerant circuit
for at least 3 hours.
♦ It is not initially necessary to clean the refrigerant circuit (flush
with refrigerant R134a or blow out with compressed air and
nitrogen ) when this problem occurs. Normally, there is only a
small quantity of moisture in the system which can be removed
by lengthy evacuation.

specification
• High pressure normal, Compressor defective – Clean refrigerant cir‐
• low pressure too low (see dia‐ erant R134a or blow
gram), out with compressed
• Required cooling output is at‐ air and nitrogen ).
tained
– Renew compressor.
Note
Observe the following regarding fault “High pressure normal, low

pressure too low”: This fault may cause the evaporator to ice up
or the low pressure switch - F73- to shut off the compressor al‐
though the amount of refrigerant in the circuit is OK.
Possible difference in relation to Possible
permitted cause
unless authorised of fault
by SEAT Fault
S.A. SEAT S.A does not guarantee elimination
specification respect to the correctness of information in this document. Copyright by SEAT S.A.
• High pressure normal or too high, Too much refrigerant in the circuit. – Suck the refrigerant
out of the refrigerant
• low pressure too high (see dia‐ circuit.
gram),
• Compressor noise (particularly • If quantity of refriger‐
after switch-on) ant extracted roughly
corresponds to ac‐
• Required cooling output is not at‐ tual capacity:
tained
• The amount of refrig‐
erant sucked out is
considerably more
than the specified fill‐
ing amount.
– Recharge the refrig‐
erant circuit.
– Repeat test.


specification
• High and low pressure normal Too much refrigerant oil in circuit – Drain the refrigerant
circuit.
tained – Clean refrigerant
circuit (flush with re‐
frigerant R134a or
blow out with com‐
pressed air and ni‐
trogen ).
• High and low pressure normal
• Compressor noise (particularly
after switch-on)
• Required cooling output is at‐
tained
Note
♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor
was renewed.
♦ If there is too much refrigerant oil in the circuit, discharge com‐
pressor and renew reservoir. After cleaning
Protectedthe refrigerant
circuit (flush with refrigerant R134a or blow out with com‐
pressed air and nitrogen ), add the correct amount of refriger‐

ant oil to the circuit ⇒ page 132 .
11.3 Checking pressures on vehicles with ex‐

pansion valve and receiver (with inter‐
nally regulated compressor)
Note


Note
♦ The switching pressures and version of the refrigerant circuit

switches are specific to the vehicle.
♦ The pressures should be measured at the service connec‐
tions. This point on the connections varies depending on the
specific vehicle model ⇒ heater, air conditioning; Rep. gr. 87
or ⇒ air conditioning; Rep. gr. 87 .


High-pressure side:
Increasing by a maximum of 20 bars from the initial pressure
Low-pressure side:
A - High pressure in bar.
B - Low pressure in bar.
C - Acceptable tolerance range.
Possible difference in rela‐ Possible cause of fault Measures to be taken

tion to specification
• The high pressure re‐ Insufficient refrigerant in the circuit, or – Suck the refrigerant out of the re‐
mains constant or in‐ expansion valve faulty. frigerant circuit.
creases only slightly
(above the pressure • If quantity
respect to the correctness of information in this document. Copyright of refrigerant
by SEAT S.A.extracted
with the engine stop‐ roughly corresponds to actual ca‐
ped), pacity:
• Low pressure drops to – Replace the expansion valve.
value in graph or below
– Recharge the refrigerant circuit.
• Required cooling output
is not attained – Repeat test.
• High pressure normal, • If quantity of refrigerant extracted is
substantially less than specified ca‐
• low pressure equal to pacity:
value of the diagram,
– Find leak with leak detector and
• Required cooling output eliminate.
is not attained
– Repeat test.
Note
If no fault can be found and air conditioner operation is not OK

when test is repeated, clean refrigerant circuit (flush with refrig‐
erant R134a or blow out with compressed air and nitrogen ).

Possible difference in rela‐ Possible cause of fault Fault elimination

• The high pressure rises ♦ Narrowing or blockage in the refrig‐ – Feel AC circuit with hand to deter‐
above the specification, erant circuit. mine temperature differences.
• Low pressure drops to ♦ Expansion valve faulty. • If temperature differences are per‐
value in graph or below ceptible on a component:
• Required cooling output – Renew hose or pipe if kinked or
is not attained constricted.
– In the event of clogging, clean re‐

frigerant circuit (flush with refriger‐
ant R134a or blow out with com‐
pressed air and nitrogen and renew
expansion valve if applicable).
– Clean refrigerant circuit (flush with
refrigerant R134a or blow out with
compressed air and nitrogen and
renew expansion valve if applica‐
ble).
– Repeat test.
Note
If, after cleaning (flushing with R134a refrigerant or blowing out

with compressed air or nitrogen) the AC circuit still does not op‐
erate properly, replace the expansion valve.
Possible difference in rela‐ Possible cause of fault Measures to be taken

• High and low pressure ♦ Expansion valve faulty. – Replace receiver (with dryer) and
normal at first drain AC circuit for at least 3 hours
♦ Humidity in the refrigerant circuit. (see note).
• After some time, high
pressure increases – Inspect the expansion valve. Re‐
above specification and place if any dirt or corrosion is
low pressure drops to found.
• Required cooling output – Clean refrigerant circuit (flush with
is not attained refrigerant R134a or blow out with
compressed air and nitrogen ).
• High and low pressure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
normal at first permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• After lengthy operating
period, low pressure
drops excessively
(evaporator ices up)

Note

Possible difference in relation to Possible cause of fault Fault elimination

specification
• High pressure normal or too ♦ Too much refrigerant in the – Suck the refrigerant out of the re‐
high, circuit. frigerant circuit.
• low pressure too high (see dia‐ ♦ Expansion valve or compres‐ • If quantity of refrigerant extracted
gram), sor faulty. roughly corresponds to actual ca‐
• Required cooling output is not pacity:
attained – Replace the expansion valve.
after switch-on) – Recharge the refrigerant circuit.
– Repeat test.
• The amount of refrigerant sucked

out is considerably more than the
specified filling amount:
– Repeat test.
Note
If operation of the air conditioning system is not OK when the test

is repeated, re-fit old expansion valve and clean refrigerant circuit
(flush with refrigerant R134a or blow out with compressed air and
nitrogen ). Replace the compressor and liquid tank.

specification
• High pressure only increases Compressor defective – Clean refrigerant circuit (flush with
slightly above pressure with refrigerant R134a or blow out with
engine stopped
•respect
theto low pressure decreases
– Replace the compressor and liq‐
only slightly, uid tank.
• Required cooling output is not
attained


specification
• High pressure normal, Expansion valve or compressor – Replace the expansion valve.
faulty.
• low pressure too low (see dia‐ – Recharge the refrigerant circuit.
gram),
• Required cooling output is at‐ – Repeat test.
tained
Note
♦ If operation of the air conditioning system is not OK when the

test is repeated, re-fit old expansion valve and clean refriger‐
ant circuit (flush with refrigerant R134a or blow out with com‐
pressed air and nitrogen ). Replace the compressor
Protected and
by copyright. liquid
tank. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ When this fault occurs, it is possible for the evaporator to ice

up even when the proper quantity of refrigerant is present in
the circuit.

specification
• High and low pressure normal Too much refrigerant oil in circuit – Drain the refrigerant circuit.
• Required cooling output is not – Clean refrigerant circuit (flush with
attained refrigerant R134a or blow out with
• High and low pressure normal
after switch-on)
• Required cooling output is at‐
tained
Note

was renewed.
pressor and renew receiver. After cleaning the refrigerant


strictor, reservoir and air conditioner
compressor regulating valve - N280-
(with externally regulated compressor)
Note


Note
♦ Switching pressures for actuation of air conditioner compres‐

sor regulating valve - N280- and radiator fans - V7- are vehicle-
specific.
♦ The pressures should be measured at the service connec‐
tions. This point on the connections varies depending on the
specific vehicle model ⇒ heater, air conditioning; Rep. gr. 87
or ⇒ air conditioning; Rep. gr. 87 .

High-pressure side:
Increasing by 20 bar from the initial pressure (when connecting
the manometers).

Low-pressure side:
A - Low pressure (measured at the service connection) in bar ab‐
solute pressure.
B - Control current for air conditioner compressor regulating valve
- N280- in amps
C - Acceptable tolerance range
Note
♦ Under unfavourable conditions (very high ambient tempera‐

tures, high humidity), pressure on high-pressure end may
increase to max. 29 bar.
♦ The control current -B- is indicated in the measurement value
block.
♦ The high pressure is indicated in the measurement value block
⇒ Rep. gr. 87 .
♦ The low pressure is adjusted according to the control current
for the air-conditioner compressor regulating valve - N280-
within the tolerance margin in the compressor power range.
tures, high humidity), compressor output may not always be
sufficient to attain the specified value.
♦ The specified service current for the regulating valve must be
greater than 0.3 A to ensure that the regulating valve is prop‐
erly activated.
♦ At the “maximum cooling power”setting, the control current is
set to approximately 0.8 A (indicated in the measurement val‐
ue block) ⇒ Rep. gr. 87 .
vacuum. Normal atmospheric pressure is equal to 1 bar ab‐
solute pressure. In general, most manometer scales represent
atmospheric pressure as 0 bar, meaning an absolute pressure
of 1 bar (this can be recognised if there is a -1 on the scale).
• The high pressure re‐ ♦ The control for the AC compres‐ – Check control for AC compressor
mains constant or increa‐ sor regulating valve - N280- is regulating valve - N280- .
ses only slightly (above defective.
the pressure with the en‐ – Find leak with leak detector and elim‐
gine stopped), ♦ Insufficient refrigerant in the cir‐ inate.
cuit.
• Low pressure drops to – Recharge the refrigerant circuit.
is not attained

• low pressure too low (see
diagram),
is not attained


• low pressure too low (see
diagram),
is not attained
Note
Clean the refrigerant circuit (rinse with refrigerant R134a or sweep

with compressed air or nitrogen).
Possible difference in relation Possible cause of fault Measures to be taken

to specification
• High pressure only increa‐ ♦ The control for the AC compres‐ – Check control for AC compressor
ses slightly above pres‐ sor regulating valve - N280- is regulating valve - N280- .
sure with engine stopped defective.
• the low pressure decrea‐ ♦ Compressor defective
Protected by copyright. Copying for private orrefrigerant R134a
commercial purposes, ororblow
in part out
in whole, is notwith
ses only slightly, permitted unless authorised by SEAT S.A. SEATcompressed air and
S.A does not guarantee nitrogen
or accept any liability).with
• Required cooling output is
not attained – Renew compressor.
• The high pressure rises ♦ The control for the AC compres‐ – Check control for AC compressor
above the specification, sor regulating valve - N280- is regulating valve - N280- .
defective.
• Low pressure drops to val‐ – Feel AC circuit with hand to deter‐
ue in graph or below ♦ Narrowing or blockage in the re‐ mine temperature differences.
frigerant circuit.
not attained • If temperature differences are per‐
ceptible on a component:
– Renew hose or pipe if kinked or con‐
stricted.
– If clogged use compressed air and

nitrogen in the AC circuit.
refrigerant R134a or blow out with

to specification
• High pressure and low ♦ The control for the AC compres‐ – Check control for AC compressor
pressure normal. After a sor regulating valve - N280- is regulating valve - N280- .
while, the high pressure defective.
rises above the specifica‐ – Replace receiver (with dryer) and
tion, ♦ Humidity in the refrigerant circuit. drain AC circuit for at least 3 hours
(see note).
• Low pressure drops to val‐
ue in graph or below – Clean refrigerant circuit (flush with
• Required cooling output is refrigerant R134a or blow out with
not attained compressed air and nitrogen ).


to specification
• High and low pressure
normal at first
• After lengthy operating pe‐
riod, low pressure drops
excessively (evaporator
ices up)
Note

♦ A problem with evaporator output temperature sender - G263-
can also cause icing-up of refrigerant circuit. In the event of
such complaints it is also necessary to take into consideration
the reading block for the evaporator output temperature sen‐
sor - G263- ⇒ Vehicle diagnostic tester; in the “guided diag‐
nostic mode ” of the air conditioning and ⇒ heater, air
conditioning; Rep. gr. 87 or ⇒ air conditioning; Rep. gr. 87 .
Possible difference in relation Possible cause of fault
Measures to be taken
to specification
• High pressure normal, ♦ The control for the AC compres‐ – Check control for AC compressor
sor regulating valve - N280- is regulating valve - N280- .
• low pressure too low (see defective.
diagram), – Clean refrigerant circuit (flush with
♦ Compressor defective refrigerant R134a or blow out with
attained compressed air and nitrogen ).
Note
If the fault “high pressure normal, low pressure too low” occurs, it
is necessary to observe the following: It is possible for the evap‐
orator to ice up even though the quantity of refrigerant in the circuit
is OK. Check the reading from the evaporator output temperature
sensor - G263- and control for the AC compressor regulating
valve - N280- . If the reading from the AC evaporator temperature
sensor - G263- is not OK; the evaporator can ice up and the cool‐
ing capacity not achieved ⇒ Vehicle diagnostic tester; in the
“guided diagnostic mode ” of the air conditioning and ⇒ heater,
air conditioning; Rep. gr. 87 or ⇒ air conditioning; Rep. gr. 87 .


to specification
• High pressure normal or ♦ The control for the AC compressor reg‐ – Check control for AC com‐
too high, ulating valve - N280- is defective. pressor regulating valve -
N280- .
• low pressure too high (see ♦ Too much refrigerant in the circuit.
diagram), – Suck the refrigerant out of the
• Compressor noise (partic‐ refrigerant circuit.
ularly after switch-on)
• If quantity of refrigerant ex‐
• Required cooling output is tracted roughly corresponds
not attained to actual capacity:
• The amount of refrigerant

sucked out is considerably
more than the specified filling
amount:
– Recharge the refrigerant cir‐
cuit.
– Repeat test.
permitted•unless
High and bylow pressure ♦notThe control foranythe ACwith compressor reg‐ – Check control for AC com‐
authorised SEAT S.A. SEAT S.A does guarantee or accept liability
respectnormal ulating
to the correctness of information in this document. valve
Copyright - N280-
by SEAT S.A. is defective. pressor regulating valve -
N280- .
• Required cooling output is ♦ Too much refrigerant oil in circuit
not attained – Drain the refrigerant circuit.
• High and low pressure – Clean refrigerant circuit (flush
normal with refrigerant R134a or blow
out with compressed air and
• Compressor noise (partic‐ nitrogen ).
ularly after switch-on)
attained
Note

was renewed.
pressor and renew reservoir. After cleaning the refrigerant


strictor, reservoir and air conditioner
compressor regulating valve - N280-
(with externally regulated compressor)
Note

♦ If a problem is only encountered at one evaporator on vehicles
fitted with two evaporators, check the pressures in the refrig‐
erant circuit. If these are OK, check the pipe connection be‐
tween the problematic evaporator and the outlet of the pipe
connection at the refrigerant pipe junction (for cross-sectional
constriction or clogging). If no fault is found, discharge the re‐
frigerant circuit and re-fill it with the specified quantity of re‐
frigerant. Check pressures and performance of air condition‐
ing system again If the subject of the complaint is still present,
replace the expansion valve in front of the evaporator in ques‐
tion ⇒ heater, air conditioning; Rep. gr. 87 or ⇒ air condi‐
tioning; Rep. gr. 87 .

Note
♦ The switching pressures to activate the air-conditioner com‐

pressor regulating valve - N280- and the refrigerant fans - V7-
are specific to the vehicle.
♦ The pressures must be measured on the service connections.
The position of these connections are different according to
the vehicle ⇒ Rep. gr. 87 .
11.5.1 Theoretical values

High-pressure side:
Increasing by a maximum of 20 bar from the initial pressure (when
connecting the manometers).

Low pressure:
A - Low pressure (measured at the service connection) in bar ab‐
solute pressure.
B - Control current for air conditioner compressor regulating valve
- N280- in amps
C - Permissible tolerance range (valid for compressor operation
percentage between 10 ... 90 %)
Note

tures, high humidity), pressure on high-pressure end may
increase to max. 29 bar.
♦ The control current -B- is indicated in the measurement value
block.
♦ The high pressure measured by the high-pressure sender -
G65- is indicated in the measurement value block ⇒ Rep. gr.
87 .
♦ The low pressure is adjusted according to the control current
for the air-conditioner compressor
Protected by copyright. regulating
Copying for valve purposes,
private or commercial - N280-in part or in whole, is not
within the tolerance margin in the compressor power range.
tures, high humidity), compressor output may not always be
sufficient to attain the specified value.
♦ The specified service current for the regulating valve must be
greater than 0.3 A to ensure that the regulating valve is prop‐
erly activated.
♦ At the “maximum cooling power” setting, the control current is
set to between approximately 0.65 A and 0.8 A (depending on
the vehicle, it is indicated in the measurement value block) ⇒
Rep. gr. 87 .
vacuum. Normal atmospheric pressure is equal to 1 bar ab‐
solute pressure. In general, most manometer scales represent
atmospheric pressure as 0 bar, meaning an absolute pressure
of 1 bar (this can be recognised if there is a -1 on the scale).

to specification
• The high pressure remains ♦ The control for the AC compressor reg‐ – Check control for AC com‐
constant or increases only ulating valve - N280- is defective. pressor regulating valve -
slightly (above the pressure N280- .
with the engine stopped), ♦ Insufficient refrigerant in the circuit.
– Suck the refrigerant out of
• Low pressure drops to val‐ ♦ Expansion valve faulty. the refrigerant circuit.
ue in graph or below
• Required cooling output is • If quantity of refrigerant ex‐
not attained tracted is substantially less
than specified capacity:
• High pressure normal, – Find leak with leak detector

and eliminate.
• low pressure equal to value
of the diagram, – Recharge the refrigerant cir‐
• Required cooling output is cuit.
not attained
– Repeat test.


to specification
• High pressure normal, • If quantity of refrigerant ex‐
tracted roughly corresponds
• low pressure too low (see to actual capacity:
diagram),
– Replace the expansion
• Required cooling output is valve.
not attained
cuit.
– Repeat test.
Note
♦ Clean the refrigerant circuit (rinse with refrigerant R134a or

sweep with compressed air or nitrogen).
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- and the actuation of the air conditioner
compressor regulating valve - N280- . If measured value of
evaporator output temperature sender - G263- is not OK,
evaporator may ice up or cooling output may not be attained.
♦ If, after replacing the expansion valve, operation of the air
conditioning system is not OK when the test is repeated (re-fit
old expansion valve), clean refrigerant circuit (flush with re‐
frigerant R134a or blow out with compressed air and nitro‐
gen ). Replace the compressor and liquid tank.
♦ When this fault occurs, it is possible for the evaporator to ice
up even when the proper quantity of refrigerant is present in
the circuit.
♦ If the expansion valve is faulty (constantly closed or does not
open enough), the air-conditioner compressor regulating valve
- N280- is activated at maximum power, and the low pressure
drops to or below the value of the diagram (the air-conditioner
compressor sucks refrigerant from the low-pressure side). But,
as the refrigerant cannot flow through the expansion valve, the
cooling power cannot be achieved, and the pressure may also
not increase or only increase slightly, seeing as there is no
energy transformation.

to specification
• High pressure only increa‐ ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
ses slightly above pressure ulating valve - N280- is defective. tioner compressor regulating
with engine stopped valve - N280-
♦ Compressor defective
• the low pressure decreases – Clean refrigerant circuit
only slightly, (flush with refrigerant R134a
• Required cooling output is or blow
Protected by copyright. Copying for private or commercial purposes, out
in part with
or in compressed
whole, is not
not attained air
permitted unless authorised by SEAT S.A. SEAT S.A does not guaranteeand or nitrogen ). with
accept any liability


to specification
• The high pressure rises ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
above the specification, ulating valve - N280- is defective. tioner compressor regulating
valve - N280-
• Low pressure quickly drops ♦ Narrowing or blockage in the refriger‐
to value in graph ant circuit. – Feel AC circuit with hand to
• Required cooling output is ♦ Expansion valve faulty. determine temperature dif‐
not attained ferences.
• If temperature differences
are perceptible on a compo‐
nent:
– Renew hose or pipe if kinked
or constricted.
– In the event of clogging,

clean refrigerant circuit (flush
with refrigerant R134a or
blow out with compressed air
and nitrogen ).

cuit.
– Repeat test.
– Clean refrigerant circuit
(flush with refrigerant R134a
or blow out with compressed
air and nitrogen ).

cuit.
– If function is not OK, repeat

test:
– Replace the expansion valve

and the liquid tank.
Note
♦ In this case, the evaporator may ice up although the correct

quantity of refrigerant is present in the refrigerant circuit.
as the refrigerant cannot flow through the expansion valve, the S.A does not guarantee or accept any liability with
permitted unless authorised by SEAT S.A. SEAT
cooling power cannot be achieved, respect
and the pressure
to the may
correctness of also in this document. Copyright by SEAT S.A.
information


to specification
• High and low pressure nor‐ ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
mal at first ulating valve - N280- is defective. tioner compressor regulating
valve - N280-
• the high pressure rises ♦ Humidity in the refrigerant circuit.
above the specification, – Clean refrigerant circuit
• Low pressure drops to val‐ (flush with refrigerant R134a
ue in graph or below or blow out with compressed
air and nitrogen ).
not attained
• High and low pressure nor‐ – Renew receiver with dryer.

mal at first
– rain AC circuit for at least 3
• After lengthy driving time, hours.
low pressure drops below
specification (evaporator – Recharge the refrigerant cir‐
ices up) cuit.
– Repeat test.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ If this incident occurs only after a prolonged service period or
occasionally (the low pressure drops to below the specification
and the evaporator freezes), only the desiccant needs to be
replaced (located in the liquid tank). The amount of refrigerant
oil must be compensated for. The refrigerant circuit must now
be vacuumed for at least 3 hours.
♦ In principle it is not necessary to blow out the refrigerant circuit
with compressed air and nitrogen in the event of this com‐
plaint, seeing as there is generally only a small amount of
humidity in the system which may be eliminated by vacuuming
the circuit for a prolonged period of time.


to specification
• High pressure normal, ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
ulating valve - N280- is defective. tioner compressor regulating
• low pressure too low (see valve - N280-
diagram), ♦ Expansion valve or compressor faulty.
• Required cooling output is ♦ Compressor defective – Clean refrigerant circuit
attained (flush with refrigerant R134a
air and nitrogen ) (not always
necessary, refer to notes).


cuit.

test:
– Recharge the refrigerant
cir‐
cuit.
– Repeat test.
Note
♦ In the case of the problem “High pressure normal, vacuum too

low” the following must be observed: Error, the evaporator
may freeze, or the cooling power is not achieved.
♦ Check the measurement value of the evaporator outlet tem‐
perature sender - G263- or the evaporator temperature sender
- G308- and the controlling of the air conditioning system com‐
pressor regulating valve - N280- . If the value measured by the
high-pressure sender - G65- is incorrect, the evaporator may
freeze or the cooling power is not achieved.
♦ If the air-conditioner compressor regulating valve - N280- is
faulty (the regulating valve is not activated, but the compressor
operates correctly), it is not necessary to blow out the refrig‐
erant circuit. In this case, replacing the air-conditioner com‐
pressor is sufficient (compensate for the amount of refrigerant
oil in the new air-conditioner compressor).
⇒ Rep. gr. 87


to specification
• High pressure normal or too ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
high, ulating valve - N280- is defective. tioner compressor regulating
valve - N280-
• low pressure too high (see ♦ Too much refrigerant in the circuit.
diagram), – Suck the refrigerant out of
♦ Expansion valve faulty.
• Compressor noise (particu‐ the refrigerant circuit.
larly after switch-on) ♦ Compressor defective
• If quantity of refrigerant ex‐
• Required cooling output is tracted roughly corresponds
attained to actual capacity:

cuit.

test:
• The amount of refrigerant

sucked out is considerably
more than the specified filling
amount:
cuit.
– Repeat test.
Note
♦ If the air-conditioner compressor regulating valve - N280- is

faulty (the regulating valve is not activated, but the compressor
operates correctly), it is not necessary to blow out the refrig‐
erant circuit. In this case, replacing the air-conditioner com‐
pressor is sufficient (compensate for the amount of refrigerant
oil in the new air-conditioner compressor).
was renewed.
♦ When the air conditioner compressor must not be replaced,
the refrigerant of the compressor must be extracted (replace
the O-ring) via the oil drain plug. From the entire filling quantity
of refrigerant oil that is specified in the ⇒ specific repair manual
of the vehicle , 50 g is filled direct into the air conditioner com‐
pressor and the rest in the refrigerant circuit.


to specification
• High and low pressure nor‐ ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
mal ulating valve - N280- is defective. tioner compressor regulating
valve - N280-
• Required cooling output is ♦ Too much refrigerant in the circuit.
attained – Drain the refrigerant circuit.
♦ Expansion valve faulty.
– Clean refrigerant circuit
(flush with refrigerant R134a
air and nitrogen ).
• High and low pressure nor‐ – Add correct quantity of refrig‐
mal erant oil to circuit (see note).
• Compressor noise (particu‐ – Recharge the refrigerant cir‐
larly after switch-on) cuit.
attained – If function is not OK, repeat
test:
– Replace the expansion

valve.

cuit.
– Repeat test.
Note
♦ Overfilling with refrigerant oil may occur if, for example, the
compressor has been renewed without adjusting the quantity
of refrigerant oil.
♦ If expansion valve is defective (permanently open), evaporator
temperature is no longer regulatedrespect

suchtothat only refrigerant
in gas form exits from the evaporator. Under certain usage
conditions, liquid droplets may then be drawn in by the com‐
pressor and cause noise (liquid cannot be compressed).
pressor and renew receiver. After cleaning the refrigerant
pressed air and nitrogen), add the correct amount of refriger‐

12 Replacing components
12.1 Replace components of the refrigerant

circuit
• All refrigerant circuit components which are sent for quality
control must always be closed (use the original plugs from the
spare part).
• Compressor parts, collected tank, liquid tank, evaporators and
condenser are, until now, filled with nitrogen gas. This filling
will now gradually be stopped, or else the pressure of the ni‐
trogen will be so low that the gas will not be heard escaping
when the component is first opened.
• In vehicles without an electromagnetic coupling on the com‐
pressor, the engine must only be started if the refrigerant
circuit is completely assembled (the compressor operates
constantly at the same time).
• To prevent damage to the air conditioner compressor when
the refrigerant circuit is empty, air conditioning system com‐
pressor regulating valve - N280- (without electromagnetic cou‐
pling), it is equipped with a protected oil supply. This means
that approx. 40 to 50 cm3 of refrigerant oil remains in the air-
conditioner compressor. ⇒ page 15
Note permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ As spare parts in the spare parts catalogue are stored at dif‐

ferent locations over longer periods, when opening for the first
time (also genuine spare parts of the same series) gas may
escape in some cases and not in other cases. For this pur‐
pose, carefully remove the caps of the connections on the
genuine parts to allow the nitrogen gas to escape slowly.
♦ The refrigerant circuit contains a choke and a collecting tank,
or else an expansion valve and a liquid tank.
♦ Close any open connections and hoses (to prevent humidity
from entering).
♦ Always replace the choke.
The collecting tray / liquid container, the dryer bag or the dryer
cartridge must not be replaced when the following conditions are
fulfilled:
• After an accident, the collecting / liquid tank have not been
damaged.
• The repair is carried out in a brief period of time (no longer than
standard repair time) and no humidity has entered. The vehicle
is not over 5 years old.
The collecting tray / liquid container or the dryer cartridge must
be replaced when the following conditions are fulfilled:
• The refrigerant circuit has been opened and the vehicle is over
5 years old.
• The refrigerant circuit has been open for an indefinite period
of time (slow leak).
• The repair time is longer than usual, and humidity has entered.
• After blowing through with compressed air / nitrogen or rinsing
with the refrigerant R134a, the collecting tray / liquid container
or the dryer cartridge must always be replaced. Keep the gen‐

uine spare parts in their original packing as long as possible

to prevent them from getting wet.
• The air-conditioner compressor is blocked.
• The collecting / liquid tank is damaged (accident).
Caution
Handling the refrigerant oil ⇒ SEAT-ServiceNet, Guidelines,

Service Guidelines; Environment Protection .
The used refrigerant oil will be handled in the same way as old
oil with unknown origin.
12.1.1 The refrigerant circuit was completely

empty
– Disassemble the faulty component.
– Remove the air conditioning compressor.
– Unscrew the oil drain plug on the air conditioner compressor
(replace the O-ring).
Note
♦ The “Denso” (“Nippondenso”) compressor has a seal instead

of an O-ring on the oil drain plug, which must always be re‐
placed ⇒ Parts catalogue
♦ To accelerate the draining of the refrigerant oil, turn the com‐
pressor via the pulley of the Poly-V-belt or via the electromag‐
netic coupling disc.
♦ Extract the refrigerant from the air conditioner compressor,
handling the refrigerant oil ⇒ SEAT-ServiceNet, Guidelines,
Service Guidelines; Environment Protection .
♦ Then fill air conditioner compressor with a quantity of fresh
refrigerant oil corresponding to quantity of refrigerant oil in
original compressor ⇒ Rep. gr. 87 .
♦ Use different types and amounts of refrigerant oil for different
air-conditioner compressors ⇒ Rep. gr. 87 .
♦ In order to guarantee the lubrication of the compressor when
it is put into service, it must be filled with at least 80 cm3 of
refrigerant oil. The remaining refrigerant oil may be filled into,
for example, the new collecting tank or liquid tank ⇒ Rep. gr.
87 .
♦ If any dirt has entered the compressor while the refrigerant
circuit is open (e.g. after an accident), the compressor must
be replaced.
♦ Blow out the refrigerant circuit out with compressed air and
then with nitrogen.
– Replace liquid tank or collecting tank and choke.

– Assemble, vacuum and recharge the refrigerant circuit.
12.1.2 There is still refrigerant in the refrigerant

circuit
– Drain the refrigerant circuit.
12. Replacing components 123

– Remove the damaged component, blow out with compressed

air and collect and possible escaping refrigerant.
– Fill the new component with the same amount of new refrig‐
erant oil as the amount blown out previously (plus 20 cm3 in
the evaporator, plus 10 cm3 in the condenser and in the re‐
frigerant piping and hoses).
– Replace the choke.
– Assemble, vacuum and charge the refrigerant circuit.
12.2 Replacing the air conditioner compres‐

sor
12.2.1 If it is not necessary to clean (rinse) the

refrigerant circuit, e.g. after external
damage resulting from an accident
– Remove the compressor oil drain plug.
The “Denso” (Nippondenso) compressor has a seal instead of an
O-ring on the oil drain plug, which must always be replaced.
⇒ Parts catalogue
– To facilitate draining the refrigerant oil, turn the compressor by
the electromagnetic coupling disc.
– Blow out the old refrigerant from the air conditioner compres‐
sor. Handling the refrigerant oil ⇒ SEAT-ServiceNet, Guide‐
lines, Service Guidelines; Environment Protection .
– Unscrew the oil drain plug on the old air conditioner compres‐
sor (replace the O-ring), turn the compressor around so that
the refrigerant oil can run out and only fill with the same amount
that has run out (of the old compressor).
Note
♦ If, e.g. 70 cm3 has been extracted from the defective com‐
pressor and 220 cm3 from the genuine part compressor (a
small quantity of refrigerant remains in the compressor), in this
case, 70 cm3 of refrigerant oil has been filled into the new
compressor (the refrigerant oil can be used that has been ex‐
tracted from the compressor replaced).
♦ If a larger volume of refrigeration oil was drained from the de‐
fective compressor (more than 80 cm3), the remaining oil can
also be filled into the evaporator or into the collecting tray /
liquid container ⇒ Rep. gr. 87 .


12.2.2 Leaking or due to internal damage (e.g.

noises or loss of power)
Note
With internal damage (in the air conditioner compressor), rinse

the refrigerant circuit using the refrigerant R134a ⇒ page 69 .
– Replace collecting tray / dryer cartridge and the expansion

valve or the liquid tank and choke.
12.3 Replacing liquid tank or collecting tank

and choke
12.3.1 After cleaning the refrigerant circuit, e.g.

due to moistness (the refrigerant circuit
was
Protected by copyright. Copyingleft open
for private over a
or commercial longer
purposes, in partperiod)
or in whole, is or
not dirt
having entered

– Eliminate the cause of the fault.
– Inspect the expansion valve. Replace if any dirt or corrosion
is found.
– Remove the compressor oil drain plug.
Note
The “Denso/Nippondenso” compressor has a seal instead of an

O-ring on the oil drain plug, which must always be replaced ⇒
Parts catalogue .
– To facilitate draining the refrigerant oil, turn the compressor by

the electromagnetic coupling disc.
– Blow out the old refrigerant from the air conditioner compres‐
sor. Handling the refrigerant oil ⇒ SEAT-ServiceNet, Guide‐
lines, Service Guidelines; Environment Protection .
– Then fill air conditioner compressor with a quantity of fresh
refrigerant oil corresponding to quantity of refrigerant oil in
original compressor ⇒ Rep. gr. 87 .
12. Replacing components 125

Note

♦ In order to guarantee the lubrication of the compressor when
it is put into service, it must be filled with at least 80 cm3 of
refrigerant oil. The remaining refrigerant oil may be filled into,
for example, the new collecting tank or liquid tank ⇒ Rep. gr.
87 .
♦ If any dirt has entered the compressor while the refrigerant
circuit is open (e.g. after an accident), the compressor must
be replaced.
– Replace liquid tank or collecting tank and choke.

12.3.2 If the refrigerant does not have to be

cleaned (e.g damaged in an accident),
no refrigerant has escaped and no in‐
gress of moisture and dirt into refrigerant
circuit
– Disassemble the fluid tank or collecting tank.
– Clean any dirt in the liquid tank or collecting tank.
– Weigh the disassembled liquid tank or collecting tank.
Note
♦ Fill the new liquid tank or collecting tank with as much refrig‐
erant oil as necessary to reach the weight of the disassembled
tank.
♦ Assemble the new fluid tank or collecting tank.
– Assemble, vacuum permitted
and charge the refrigerant
unless authorised by SEAT S.A.circuit.

13 Filling quantity for refrigerant R134a,

refrigerant oil and authorised refrig‐
erant oil
13.1 Top-up quantities of refrigerant R134a
Note
♦ When filling refrigerant circuits, always fill the high pressure

side to the limit of the upper tolerance (there is refrigerant left
in the filler hoses).
♦ The compressor correspondence (“Zexel”, “Sanden” or “Den‐
so / Nippondenso”) can be found in the ⇒ Parts catalogue and
in ⇒ Heating, air conditioning or ⇒ air conditioning
Note
Modified refrigerant circuits (from R12 to R134a) should be filled

to the level shown in the Repair Manual “Air conditioning using
R12 refrigerant”. ⇒ Air conditioning using R12 refrigerant (The
repair manual is only available in printed format).
13.1.1 Top-up quantities for Arosa (1H_) 1997►

Refrigerant circuit characteristics:
• Expansion valve
• Liquid by
Protected tank
• “Sanden”
respect to compressor with magnetic
the correctness of information coupling
Vehicle type Production time Top-up quantity in grammes Differences in this refriger‐
ant circuit
Arosa to 09.00 750 + 50 • Condenser with part
number 6N0 820 413.
after 06.00 750 + 50 • Condenser with part

number 6X0 820 413
and index“A”.
Note
To prevent alteration to the refrigeration capacity of the air con‐

ditioner, only chokes with an opening of the same diameter should
be fitted.
13.1.2 Top-up quantities for Ibiza 93, Cordoba

(6K_) 1993►, ► 2001
• Expansion valve
• Liquid tank
13. Filling quantity for refrigerant R134a, refrigerant oil and authorised refrigerant oil 127
• “Sanden” compressor with magnetic coupling ⇒ Heating, air

conditioning and ⇒ Parts catalogue
Vehicle Production time Top-up quantity in Differences in this refrigerant circuit
type grammes
Ibiza 93 from 05.93 850 + 30 • Left-hand guide
Cordoba from 06.94 900 + 30
• Right-hand guide
Note
At the start of production only “Fa Denso” compressors were fit‐

ted. In models made since 1993, compressors manufactured by
“Sanden” have also been fitted ⇒ Heating, air conditioning and
⇒ Parts catalogue .
13.1.3 Top-up quantities for Inca (6K_) 1995►

• Expansion valve
• Liquid tank
Vehicle type Production time Top-up quantity in Differences in this refrigerant circuit
grammes
Inca Since 07.95 850 + 30 • Left-hand guide
900 + 30
Note
At the start of production, only “SD7- V16” type compressors

manufactured by “Sanden” were fitted.
13.1.4 Top-up quantities for Cordoba Vario (6K_) 1997►

• Drip tray
• “Denso” compressor with magnetic coupling ⇒ Heating, air
grammes
Cordoba Vario Since 05.97 850 + 30 • Left-hand guide
900 + 30
13.1.5 Top-up quantities for Toledo (1L_) 1994►, ►1999

• Drip tray


grammes
Toledo From 10.94 850 ± 30 • Left-hand guide
to 09.98 900 ± 30 • Right-hand guide
Note
If the condenser that is fitted is replaced by a condenser with an‐

other part number, the top-up quantity given on the label attached
to the vehicle should be checked, and where necessary correc‐
ted, or another label showing the correct top-up quantity should
be stuck on top ⇒ Heating, air conditioning and ⇒ Parts cata‐
logue .
13.1.6 Top-up quantities for Toledo 99, Leon 2000 (1M_) 1999 ►
• Drip tray
• “Denso” compressor with magnetic coupling.
Vehicle Production time Top-up quantity in Differences in this refrigerant circuit
type grammes
Toledo From 10.98 onwards 750 + /-50 • none
1999 "
Leon 2000 From 11.99 onwards 750 + /-50 • none
Note
At the start of production, only “7 SEB - 16” type compressors

manufactured by “Denso” were fitted. ⇒ Air conditioning and ⇒
Parts catalogue
13.1.7 Top-up quantities for Ibiza, Cordoba, Cordoba Vario (6K_) 1999►
• Drip tray
• “Denso” or “Zexel” compressor with magnetic coupling ⇒
Heating, air conditioning and ⇒ Parts catalogue
grammes
Ibiza Since 05.99 750 + /- 50 • none
Cordoba
Cordoba
Vario
13.1.8 Top-up quantities for Ibiza, Cordoba (6L_) 2002 ►

• Choke
• Drip tray
• “Denso” or “Zexel” compressor without magnetic coupling and
with Compressor regulating valve, air conditioning - N280- ⇒
Air Conditioning and ⇒ Parts catalogue
grammes
Ibiza 2002 From 11.01 550+ /- 25 • none
Cordoba 2003
13.1.9 Filling quantities for the Altea, Altea XL, Toledo 2005, Altea Freetrack (5P_)
2004 ►
• Choke (painted red) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Drip tray respect to the correctness of information in this document. Copyright by SEAT S.A.
• “Sanden”, “Zexel” or “Denso” compressor with compressor

regulating valve, air conditioning - N280- (without magnetic
coupling).
• Compressors as of CW 45/06 on all petrol and diesel engines
with air conditioning, the compressors are installed depending
on the destination country or sales region: countries with cold
climate 140 cm3, other countries 160 cm3.
Vehicle Production time Top-up quantity in grammes Differences in this refrigerant circuit
type
Altea From 04.04 525 + / - 25 • Choke painted red.
Toledo From 09.04
2005 From 09.06
Altea XL
Altea
Freetrack
Note
♦ Chokes with varying diameter openings are available as spare

parts. (yellow-coloured 1.54 mm, red-coloured 1.42 mm).
♦ Depending on the manufacturer, the colour red on the choke
may be replaced by orange.
♦ To prevent alteration to the refrigeration capacity of the air
conditioner, only chokes painted red should be fitted.
♦ According to the version, different compressors are fitted ⇒
Air conditioning and ⇒ Parts catalogue .
13.1.10 Top-up quantities for Leon 2006 (1P_) 2005 ►

• Choke (painted red)
• Drip tray
• “Sanden”, “Zexel” or “Denso” compressor with compressor
regulating valve, air conditioning - N280- (without magnetic
coupling).

• Compressors as of CW 45/06 on all petrol and diesel engines

with air conditioning, the compressors are installed depending
on the destination country or sales region: countries with cold
climate 140 cm3, other countries 160 cm3.
Vehicle type Production time Top-up quantity in grammes Differences in this refrigerant circuit
Leon 2006 As of 04.05 525 ± 25 • Choke painted red.
Note

♦ To prevent alteration to the refrigeration capacity of the air
conditioner, only chokes painted red should be fitted.
♦ According to the version, different compressors are fitted ⇒
Air conditioning and ⇒ Parts catalogue .
13.1.11 Filling quantities for Inca (6J_) 2008►

• Choke
• Drip tray
• Compressor“Thick” without magnetic coupling and with Com‐
pressor regulating valve, air conditioning - N280- ⇒ Climate
control and ⇒ Parts catalogue
grammes
Ibiza 2008 From 08.08 500 ± 15 • none
13.1.12 Top-up quantities for Alhambra (7M_) 1996►

• Expansion valve
• One or two evaporators
• “Sanden” compressor with magnetic coupling ⇒ air condition‐
ing and ⇒ Parts catalogue
grammes
Alhambra
♦ Vehicle Until 05.00, brand 950 +50 • one evaporator
with one SD7-V16
evapora‐
tor
♦ Vehicle Until 05.00, brand 1350 +50 • two evaporators

with two SD7-V16
evapora‐
tors
grammes
♦ Vehicle Until 06.00, brand 700 + 50 • one evaporator
with one SD7-V16
evapora‐
tor
♦ Vehicle Until 06.00, brand 1050 + 50 • two evaporators

with two SD7-V16
evapora‐
tors
♦ Vehicle From 00.06, San‐ 950 +25 • two evaporators

with two den brand
evapora‐
tors
13.1.13 Top-up quantities for Exeo, Exeo ST (3R_) 2009 ►

• Restrictor (yellow or red-coloured)
• Drip tray
• “Denso” compressor with air conditioning system compressor
regulating valve - N280- (without magnetic clutch)
Vehicle Production time Top-up quantity in grammes Differences in this refrigerant circuit
type
Exeo From 12.08 500 ± 15 • Yellow or red-coloured restrictor
Exeo ST from 03.09
Note

♦ When installed, compressors from “Denso” (“6 SEU 14” and
“7 SEU 17”). ⇒ Air conditioning; Rep. gr. 87 and ⇒ Electronic
parts catalogue
13.2 Refrigerant oils and the filling quantity of

the authorised refrigerant oil
Note
♦ PAG (polyalkylene glycol) oil is extremely hygroscopic (water

absorbent), and therefore
authorised byall open containers should
guaranteebe im‐ any liability with
permitted unless SEAT S.A. SEAT S.A does not or accept
mediately resealed.
♦ PAG oil in containers which have been open for any length of
time should not be used.

13.2.1 Authorised refrigerant oils
Note
♦ Oils used for the R12 refrigerant are not suitable for the R134a
refrigerant.
♦ The compressor manufacturer “Nippondenso” has changed its
name to “Denso”.
♦ The special oil, only for use in R134a coolant circuits, can no
longer be obtained on the refrigerant oil market.
♦ Refrigerant oils specially adapted to the respective compres‐
sor are therefore available through the spare parts programme
⇒ Parts catalogue .
♦ The use of other refrigerant oils may cause the installation to
break down, given that they are not always miscible with the
R134a refrigerant and therefore their circulation (to lubricate
the compressor) is not guaranteed.
♦ Different refrigerant oils for “Zexel”-, “Denso”- and “Sanden”
compressors. ⇒ Parts catalogue
♦ The refrigerant oils that are used together with the “Denso”
compressor (formerly known as “Nippondenso”) (G 052 300
A2) are also included in the Retrofit-Kit repair kit (part number
4A0 298 107 A) ⇒ Parts catalogue .
♦ For refrigerant circuits with “Zexel” or “Sanden” compressors,
refrigerant oil with part number G 052 154 A2 ⇒ Parts cata‐
logue should be used.
♦ For refrigerant circuits with “Zexel” compressors, in addition to
refrigerant oil G 052 154 A2, refrigerant oil G 052 200 A2 in‐
cluded in the Retrofit–Kit (part number 4A0 298 107) may also
be used ⇒ Part number .
13.2.2 Top-up quantities for refrigerant oils
Note
♦ The compressor correspondence (“Zexel”, “Sanden” or “Den‐
so”) can be found in the relevant vehicle repair manual ⇒
Heating, air conditioning or ⇒ Air conditioning and in the parts
catalogue ⇒ Parts catalogue
♦ For “Zexel”, “Denso” and “Sanden” compressors, the quantity
of refrigerant oil given on the spare compressor is equivalent
to the total quantity of oil. If the compressor is replaced, the
quantity of oil in the new compressor should be corrected (an
incorrect quantity of refrigerant oil will cause damage to the
compressor).
♦ When pouring the refrigerant oil from the replacement com‐
pressor (or the faulty compressor), a small amount of oil is
usually left in the compressor (20 to 30 cm3); this quantity of
refrigerant oil does not effect the working of the compressor,
and can therefore be ignored (it remains in all compressors).
♦ Following initial switch-on, the refrigerant oil is distributed
throughout the entire refrigerant circuit.
♦ Quantity of top-up refrigerant oil in the event of replacement
of faulty components of the refrigerant circuit. ⇒ Heating, air
conditioning , ⇒ Air conditioning and ⇒ Parts Catalogue
13.2.3 Top-up quantities for Arosa (1H_) 1997►

• Expansion valve
• Drip tray
• “Sanden” compressor with magnetic coupling for air condi‐
tioning - N25- ⇒ Heating, air conditioning and ⇒ Parts cata‐
logue
Vehicle type Production time Total quantity of oil in refrig‐ Compressor brand
erant circuit in cm3
Arosa From 03.97 100 SD7B10
From 06.00 120 Electromagnetic clutch
SD6V12
Electromagnetic clutch
Note
♦ All of the oil required for the refrigerant circuit is located in the
replacement compressor. If the compressor is replaced, the
amount of oil in the compressor must be corrected according‐
ly.
♦ As the compressor always operates together with the engine
and the total quantity of refrigerant oil is located in the com‐
pressor, the engine should only be started if the circuit has
been completely fitted. ⇒ Heating, air conditioning
♦ This compressor is available as a replacement compressor
with different top-up quantities of oil, therefore the exact part
number should be checked. ⇒ Parts catalogue
13.2.4 Top-up quantities for Ibiza 93, Cordoba (6K_) 1993►, ► 2001
• Expansion valve
• Liquid tank
• “Sanden” or “Denso” compressor with magnetic coupling for
air conditioning - N25- ⇒ Heating, air conditioning and ⇒ Parts
catalogue Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Vehicle type Production timerespect toTotal quantity
the correctness of oil inin refrig‐
of information this document. CopyrightCompressor
by SEAT S.A. brand
Ibiza 93 Since 05.93 115 DIAVIA
Electromagnetic clutch HARRISON
Cordoba From 06.94 115 DIAVIA
Electromagnetic clutch HARRISON
Note
ly.
♦ At the start of production only “Sanden” compressors were fit‐
ted. ⇒ Heating, air conditioning and ⇒ Parts catalogue

13.2.5 Top-up quantities for Inca (6K_) 1995►

• Expansion valve
• Liquid tank
• Compressors from a variety of manufacturers with magnetic
coupling for air conditioning - N25- ⇒ Heating, air conditioning
and ⇒ Parts catalogue
Vehicle Production time Total quantity of oil in refrigerant cir‐ Compressor brand
type cuit in cm3
Inca Since 07.95 115 SD7V16
Electromagnetic
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with clutch
Note
ly.
♦ Depending on the date of manufacture and the engine, differ‐
ent compressors are fitted.
♦ This compressor is available as a spare part with different
quantities of top-up oil,; therefore the oil quantity in the com‐
pressor and the exact part number should be checked ⇒
Heating, air conditioning and ⇒ Parts number .
♦ It is possible that the manufacturer has attached a plate to the
compressor showing the part number and quantity of oil in the
compressor.
13.2.6 Top-up quantities for Cordoba Vario (6K_) 1997►

• Expansion valve
• Drip tray
• “Sanden” compressor with magnetic coupling for air condi‐
tioning - N25- ⇒ Heating, air conditioning and ⇒ Parts cata‐
logue
Cordoba Since 05.97 115 Electromagnetic clutch
Vario
Note
All of the oil required for the refrigerant circuit is located in the
amount of oil in the compressor must be corrected accordingly.
13.2.7 Top-up quantities for Toledo (1L_) 1994►, ►1999

• Expansion valve
• Drip tray
catalogue
Toledo From 10.94 onwards 115 SD7V16
Electromagnetic clutch
Note
ly.
♦ Different makes of compressor are fitted in the Toledo, de‐
pending upon the engine and production date. ⇒ Heating, air
13.2.8 Top-up quantities for Toledo 99, Leon 2000 (1M_) 1999 ►
• Expansion valve
• Drip tray
catalogue
Vehicle type Production time Total quantity of oil in refrigerant cir‐ Compressor brand
cuit in cm3
Toledo 99 " From 10.98 on‐ 135 + / - 15 SD7V16
wards Electromagnetic clutch
Leon From 11.99 on‐ 135 + / - 15 SD7V16
wards Electromagnetic clutch

Note
ly.
♦ Different makes of compressor are fitted in the Toledo 99 and
Leon 2000, depending upon the engine and production date.
This compressor is available as a replacement compressor
with different top-up quantities of oil, therefore the exact part
number should be checked. ⇒ Air conditioning and ⇒ Parts
catalogue
compressor.
13.2.9 Top-up quantities for Ibiza, Cordoba, Cordoba Vario (6K_) 1999►
• Expansion valve
• Drip tray
air conditioning - N25- ⇒ Air conditioning and ⇒ Parts cata‐
logue
Vehicle type Production time Total
permitted unlessquantity ofSEAT
authorised by oil in
S.A.refrig‐ Compressor
SEAT S.A does not guarantee brand
respecterant cm3
circuit inof information
to the correctness in this document. Copyright by SEAT S.A.
Ibiza Since 05.99 135 SD7V16

Cordoba Electromagnetic clutch
Cordoba
Vario
Note
ly.
♦ Different makes of compressor are fitted in the models, de‐
pending upon the engine and production date. This compres‐
sor is available as a replacement compressor with different
top-up quantities of oil, therefore the exact part number should
be checked. ⇒ Air conditioning and ⇒ Parts catalogue
13.2.10 Top-up quantities for Ibiza, Cordoba (6L_) 2002 ►

• Expansion valve
• Drip tray
• “Sanden”, “Denso” or “Zexel” compressor with compressor
regulating valve, air conditioning - N280- ⇒ Air conditioning
Vehicle type Production time Total quantity of oil in re‐ Compressor brand
frigerant circuit in cm3
Ibiza 02 From 11.01 140 Depending on the engine ver‐
Cordoba 03 From 02.02 120 sion:
Denso SD7V16
Denso
Note
ly.
♦ As of model year 2002 compressors without magnetic cou‐
pling and with AC control valve are installed depending on
engine (different oil quantities). ⇒ Air conditioning and ⇒ Parts
catalogue
13.2.11 Filling quantities for the Altea, Altea XL, Toledo 2005, Altea Freetrack (5P_)
2004 ►
• Expansion valve
• Drip tray
• “Sanden” compressor, “Denso” compressor or “Zexel” with
compressor regulation valve, air-conditioning unit - N280- ,
“Valeo”, ⇒ air-conditioning units and ⇒ Spare parts catalogue
cuit in cm3
Altea From 04.04 140+ / -10 Denso
Toledo 2005 From 01.05 110 + /-10 Sanden
Altea XL From 04.04 120+ /-15 Zexel
Altea Free‐ From 09.06 Valeo
track From 10.09 120+ /-15 Delphi
110+ /-10
Note
ly.
♦ Different makes of compressor are fitted in the Altea and Tol‐
edo models, depending upon the engine and production date.
♦ This compressor is available as a replacement compressor in
different versions, therefore the exact part number should be
checked. ⇒ Air conditioning and ⇒ Parts catalogue
compressor.

13.2.12 Top-up quantities for Leon 2006 (1P_) 2005 ►

• Expansion valve
• Drip tray
• “Sanden”, “Denso” or “Zexel” compressor with compressor
regulating valve, air conditioning - N280- ⇒ Air conditioning
cuit in cm3
Leon 2006 From 04.05 140 + /-10 Denso
From 04.05 110 + /-10 Sanden
From 07.05 120+ /-15 Zexel
From 04.05 Denso
From 10.09 90+ /-10 Delphi
110+ /-10
Note
ly.
♦ Different makes of compressor are fitted in the Altea and Tol‐
edo models, depending upon the engine and production date.
♦ This compressor isauthorised
permitted unless available as S.A.
by SEAT a replacement
SEAT S.A does notcompressor in any liability with
guarantee or accept

compressor.
13.2.13 Filling quantities for Inca (6J_) 2008►

• Expansion valve
• Drip tray
• Compressor, “Thick” with compressor regulating valve, cli‐
mate control - N280- ⇒ Climate control and ⇒ Parts Catalogue
Vehicle type Production time Total quantity of oil in re‐ Compressor brand
frigerant circuit in cm3
Ibiza 08 From 08.08 80 + /-10 Denso 6SEU12C
From 10.09 110 + /-10 Denso 6SEU14C
90 + /-10 Delphi 6CVC140
Note
quantity of oil in the 1K0 820 803 compressor must be correc‐
ted accordingly.
♦ As of model year 2008 compressors without magnetic cou‐
pling and with AC control valve are installed depending on
engine (different oil quantities). ⇒ Air conditioning and ⇒ Parts
catalogue
13.2.14 Top-up quantities for Alhambra (7M_) 1996►

• Expansion valve permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• Drip tray
air conditioning - N25- ⇒ Air conditioning and ⇒ Parts cata‐
logue
Vehicle type Production time Total quantity of oil in refrig‐ Compressor / component brand
Alhambra Electromagnetic clutch
♦ Vehicle From 06.95 135±15 • one evaporator
with one
evapora‐
tor
♦ Vehicle From 01.96 135*+105**=240±15 • two evaporators

with two
evapora‐ • * Contains the quantity supplied
tors from spares
• ** Should be added to the circuit
Note
ly.
♦ SD7-V16 compressor from Sanden, reference G052 154 A2
♦ This compressor is available as a replacement compressor in
13.2.15 Top-up quantities for Exeo, Exeo ST (3R_) 2009 ►

• Choke
• Drip tray

• “Denso” compressor with air conditioner compressor regulat‐

ing valve - N280- (without magnetic clutch) ⇒ Air conditioning;
Rep. gr. 87 and ⇒ Electronic parts catalogue
Vehicle type Production time Total quantity of oil in refrigerant Compressor brand
circuit in cm3
Exeo From 12.08 90 + /-10 Denso 6 SEU 14
Exeo ST from 05.2009 120 + / - 10 Denso 7 SEU 17
Note
ly.
♦ On the Exeo model different compressors are installed de‐
pending on the engine version. As replacement compressors
of this type are available with different refrigeration oil capaci‐
ties, it is important to observe the exact part number ⇒ Air
conditioning; Rep. gr. 87 and ⇒ Electronic parts catalogue .
♦ The compressor may have been fitted at the factory with a
rating plate indicating the part number and the quantity of re‐
frigerant oil in the compressor.
14 Verification equipment and tools
14.1 List of test equipment, tools and materi‐

als
Note
This list provides a general overview of the verification equipment,

tools and materials required to correctly repair the refrigerant cir‐
cuit.
Caution

be used.
14.1.1 Tools and materials which may be ac‐

quired from the distribution centre or im‐
porter
Overview Page
Air-conditioning service station - ⇒ page 144
SAT4006D- , other service stations ⇒ SAT
Workshop equipment catalogue with pro‐
gram for rinsing the refrigerant circuit with
refrigerant R134a.
Leak detecting spray - SAT 4007B- ⇒ page 145
Filling valve R134a and R12 - SAT 4007/1- ⇒ page 145
Leak detection additive - SAT 4007/5- ⇒ page 146
Release tool - SAT 1795- ⇒ page 146
Cleaning station - SAT 4011- for rinsing the ⇒ page 144
circuit with solvent product for the refrigerant
circuit with refrigerant R134a.
Electronic leak detector - SAT 4012- ⇒ page 145
Rinse set - SAT 4009- , adapter set for con‐ ⇒ page 144
necting the air-conditioning service station to
the refrigerant circuit and for bypassing cer‐
tain components when rinsing or blowing
out.
Rinse set - VAS 6338/1- , adapter set for no figure
connecting the air-conditioning service sta‐
tion to the refrigerant circuit and for bypass‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ing certain components when rinsing or permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
blowing out.
Release tool - VAS 6127/3- ⇒ page 147
Counterhold - T20017A- ⇒ page 147
Extractor - T20017A- for electromagnetic ⇒ page 147
coupling (Sanden compressor)

Overview Page
Extractor for electromagnetic coupling - ⇒ page 148
T20017A- (Kit)
Rinse set - SAT 4009- with program for rins‐ ⇒ page 144
ing the refrigerant circuit with refrigerant
R134a.
Adaptor kit for refrigerant - V.A.G 1785 -10- ⇒ page 148
R134a circuit
Combined fine filter unit for compressed air no figure
system, and oil, dirt and water separators
commonly found in painting plants ⇒ Work‐
shop device catalogue
O-rings ⇒ parts catalogue no figure
Refrigerant oil ⇒ Spare parts catalogue no illustration
14.1.2 Commercially available tools and materials

Overview Page
Fin comb ⇒ page 149
Charging hoses 5/8”-18 UNF with valve opener ⇒ page 150
Connection parts for refrigerant bottles and seal for quick coupling connection ⇒ page 150
or screw connection 5/8” - 18 UNF
Valve caps 5/8”-18 Protected
UNF by copyright. Copying for private or commercial purposes, in part or in whole, is not ⇒ page 150
Manometer bank with pressure relief valve for nitrogen
⇒ page 150
Quick coupling adaptor for service connections, 2 units included with the serv‐ ⇒ page 151
ice station
Open end spanner. The spanner widths correspond with the screw connec‐ no figure
tions of the refrigerant hoses.
Valve opener for charging hoses. no figure
Joint nozzle for conical surface seal 5/8” - 18 UNF no figure
Compressed-air gun with rubber nozzle no figure
Valve opener for Schrader valves no figure
Manual shut-off valve 5/8” - 18 UNF no figure
Recycling bottle for refrigerant R134a no figure
Digital thermometer ⇒ page 145
Protective gloves, no figure no figure
Protective goggles ⇒ page 146
Refrigerant R134a with pressurised bottle (contents according to demand) no figure
Nitrogen with pressurised bottle no figure
Clamp spanner (oil filter) as retention tool for Poly-V belt pulley no figure
14.1.3 Proprietary tools

Overview Page
Charging hose with connection for workshop ⇒ page 151
compressed-air system
14. Verification equipment and tools 143

14.1.4 Tools and materials which may be ac‐

quired from the distribution centre or im‐
porter
Air-conditioning filling station - SAT 4006D- with the rinsing kit -
SAT 4009- (and other service stations that may be presently
supplied)
⇒ Workshop device catalogue
♦ Work processes: The verification, vacuuming (recycling),
emptying and charging operations must be carried out ac‐
cording to the corresponding instructions manuals.
♦ Filters and desiccants must be replaced at the latest once the
service period specified in the instructions manual has ex‐
pired, and whenever the station is emptied (ensure that there
are sufficient spare filters. Available from the manufacturer,
see instructions manual).
♦ Other service stations not mentioned here may also be used.
⇒ Workshop device catalogue
♦ The following familiar individual units are united in this service

station: Filling cylinder, pressure measurement battery, vac‐

uum pump, shut-off valves and filling hoses.
♦ This service station includes a quick coupling (for service con‐
nections on the high and low pressure sides).
– Adaptors for air-conditioning refrigerant pipes, all models

⇒ page 79
Cleaning station - SAT 4011- with nitrogen + solvent

Work processes: The verification, vacuuming (recycling), empty‐
ing and charging operations must be carried out according to the
corresponding instructions manuals.
Filters and desiccants must be replaced at the latest once the
service period specified in the instructions manual has expired,
and whenever the station is emptied (ensure that there are suffi‐
cient spare filters. Available from the manufacturer, see instruc‐
tions manual).
– For all models:
Rinse set - SAT 4009- or -VAS 6338/1-

– For all models:

Digital thermometer - SAT 4002-

– For all models:
Electronic leak detector - SAT 4012-

– Kit:
Leak detector spray for air conditioners - SAT 4007B- 0 -VAS

6201-
– Injector for introduction of the fluorescent liquid, spare:
R134a and R12 injector - SAT 4007/1-

– Spare:

Fluorescent substance - SAT 4007/5-

– It may be used with either refrigerant R12 or R134a, without
distinction.
Protective goggles and UV lamp - SAT4007B/3 y SAT4007B/4-

– Tools for releasing the quick-release connectors on the refrig‐
erant lines: Tools for Alhambra model
Release tool - SAT 1795-
1- blue 1/2 inch
2- black 5/8 inch
3- red 3/8 inch
4- white 3/4 inch
– Application:
Release tool - SAT 1795-

– Tools used for the Ibiza 2002 / Cordoba 2003 model:

Release tool - VAS 6127/3-

1- Green DN 8 for high pressure lines
2- Black NW 13 for vacuum lines
– Application:
Release tool - VAS 6127/3-

– Releasing the air-conditioning compressor pulleys with the
electromagnetic clutch.
Retention tool for coupling disc (for air-conditioner

Protected compressor
manufactured by “Sanden”) permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– For all models including compressor with electromagnetic

clutch:
Extractor (for air-conditioner compressor manufactured by “San‐

den”)
For Sanden compressor (with threaded holes electromagnetic
coupling disc)

Electromagnetic coupling extractor kit - T20017A- (with conical

plugs to prevent dirt or humidity from entering the components)
– Counter hold or dolly for the extraction of the compressor cou‐
pling disk nut.
– Pulley bearing extraction and assembly tool
Composed of cone-shaped plugs of different diameters used to
seal the refrigerant circuit if this needs to be opened for repairs,
for all models.
– Adapter
Magnetic coupling puller V.A.G 1719 (for “Zexel” compressor)
Refrigerant circuit adaptor kit - V.A.G 1785-

♦ Adaptor for blowing out refrigerant circuit with compressed air
and nitrogen
A - Thread 5/8"-18 UNF for conical surface seal
B - Connection nut (for screw connection with O-ring)
♦ M18 x 1.5 VAG 1785/1
♦ M20 x 1.5 VAG 1785/2
♦ M 24x1,5 V.A.G 1785/3
♦ M 28x1,5 V.A.G 1785/4
B - Threaded sleeves for O-rings
♦ M18 x 1.5 VAG 1785/5

♦ M20 x 1.5 VAG 1785/6
♦ M 24x1,5 V.A.G 1785/7
♦ M 28x1,5 V.A.G 1785/8

Valve adaptor
B - Interior thread for valve opener M10 x 1.25 VAG 1785/9 (for
valve connections on high-pressure side), M12 x 1.5 VAG
1785/10 (for connections on low-pressure side)
Note
♦ A Schrader valve is screwed into connection -A-.

♦ A valve opener must be installed in the filler hose connection.
Adapter set for service connection V.A.G 1786

A - Adapter with union nut - V.A.G 1786/1- (only for connections
with small valve core at low-pressure side)
B - Filler hose with union nut 5/8"-18 UNF(short version)
C - Adapter with service connection - V.A.G 1786/2-
Note
For connections with large valve core (standard on “Zexel” com‐

pressors, gradual change to small valve core from 10.94 on‐
wards), adapter V.A.G 1785/10 should be used (remove valve
from adapter V.A.G 1785/10 or install valve opener in filler hose
-B-).
Socket - T10364- for valves of the service connections HD/ND

side (high / low pressure) in the refrigerant circuit.
14.1.5 Commercially available tools and mate‐

rials
Fin comb
– Spare:

Charging hoses
Thread 5/8” - 18 UNF
Note
♦ Use charging hoses of different colours, 1800 mm long.

♦ Have spare valve openers and seals ready.
Connection parts for refrigerant bottles and seal for quick coupling
connection or screw connection 5/8” - 18 UNF
Valve plug with spare seals (for thread 5/8” - 18 UNF)

The seals may also be used for the charging hoses.
Manometer bank with pressure relief valve for nitrogen (max. re‐
duction pressure: 15 bar)
1- Pressure gauge set with pressure reduction
2- Pressure hoses (interior diameter 5 mm, length 2 meters)
with accessories for hoses
3- Nitrogen gas cylinder
4- Hose accessory
Note
To connect to the refrigerant circuit adaptor kit - V.A.G 1785- with

thread 5/8” - 18 UNF

Service connection quick coupling adaptor

♦ High-pressure side with nominal diameter 16 mm
♦ Low-pressure side with nominal diameter 13 mm
Note
This quick connector is included in the scope of supply of the air

conditioning service station.
14.1.6 Proprietary tools

Charging hose with connection for workshop compressed-air sys‐
tem
A - Charging hose 5/8”-18 UNF** (large interior diameter version)
B - Connection for workshop compressed-air system** (use only
with filter)
** Commercially available tools and materials

15 Glossary

Arosa Current Flow Diagram No. 42 / 1
Airbag
From June 1999
Different location for relays and fuses, provision of multiple connectors, see "Positioning Points" chapter
1 2 3 4 5
6 7 8 9
5 11 1
1 1 6 1
1
6 7 8 12
13 5
18 720
2 3 9 22
9 10 14 21 23
4
87 30 30
N97--0073
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 03.2000
30 30
75x 75x Control unit for Airbag, coil spring for airbag/return spring
with slip ring, airbag igniter - driver side, igniter 1 for airbag
- passenger side
F138 Coil spring for airbag/return spring with slip ring
J17 Fuel pump relay (01259-4433)
J234 Control unit for Airbag (01321)
J491 Control unit for fuel shut-off (Crash)
N95 Airbag igniter - driver side (00588)
N131 Igniter 1 for airbag - passenger side (00589)
J17/3 J491/5 N199 Side airbag igniter, driver's side (01217)
T16/7
** * N200 Side airbag igniter, passenger's side (01218)
0.5 0.5 0.5 T2d 2 way connector
gr/ws gr/ge gr/ge T4r 4 way connector, under driver seat
T4s 4 way connector, under passenger seat
B159 T4z 4 way connector
T16 16 way connector
A125 T34 34 way connector
44 Earth point, A pillar left, bottom

0.5 0.5
gr/ws gr/ge
109 Earth connection, in airbag wiring loom
199 Earth connection -3-, in dash panel wiring loom

K
T34/9 J234 T34/34
A125 Connection (crash signal), in dash panel wiring harness

T34/6 T34/10 T34/11 T34/13 T34/14 T34/4 T34/3 T34/2 T34/1
B159 Connection (diagnosis), in interior wiring harness
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
br ws ws/sw ge sw/ge ge/gn ge/bl ge/br ge/gr
* Only vehicles with diesel engine
** Only petrol engines
T2d/1 T2d/2 T4z/1 T4z/2 T4r/2 T4r/1 T4s/2 T4s/1
N131 N199 N200

F138
N95 ws for
Protected by copyright. Copying = private
whiteor commercial purposes, in part or in whole, is not
swSEAT
permitted unless authorised by = S.A.
black
ro of=information
respect to the correctness red in this document. Copyright by SEAT S.A.
br = brown
T4z/3 gn = green
0.5 0.5 bl = blue
br br gr = grey
109 44 199 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--41342
rs = pink
Edition 03.2000
30 30
75x 75x Control unit for Airbag, control unit with display unit in dash
panel insert, side airbag crash sensor, driver's side
D Ignition/starter switch
G179 Side airbag crash sensor, driver's side (01221)
G180 Side airbag crash sensor, passenger's side (01222)
H1 Horn/dual tone horn (00906)
J234 Control unit for Airbag (01321)
J285 Control unit with display unit in dash panel insert (01317)
B163
K75 Air bag warning lamp
26 S11 Fuses in fuse box
0.5 1.5
S226 br/ro sw
S226 Fuse in fuse box
5A T4r 4 way connector, under driver seat
0.5 4
sw sw 26a T4s 4 way connector, under passenger seat
11
0.5 T32 32 way connector
sw S11 T34 34 way connector
D/15 B135
15A
11a 34 Earth point, under driver's seat
0.35 0.35 1.5
ge/ws sw sw/ge
35 Earth point, under front passenger seat

T32/6 T32/1
H1
44 Earth point, A pillar left, bottom
109 Earth connection, in airbag wiring loom

T34/5 J234 Protected by copyright. Copying for private or commercialJpurposes,
T34/30
285 in part or in whole, is not
B102 Earth connection, in front left interior wiring loom
T34/20 T34/21
K75 B135 Connection -1- (15a), in interior wiring harness

0.5 0.5
gn br
T32/9
B163 Positive connection -1- (15), in interior wiring harness
1 1
G179 G180
2 2
ws = white
0.5 0.5 sw = black
sw sw
ro = red
br = brown
T4r/3 T4s/3 gn = green
0.5 0.5 0.5 0.5 0.35 2.5 bl = blue
br br br br br br
gr = grey
109 109 34 109 35 B102 44 li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--40922
rs = pink
Edition 03.2000
Basic equipment
From July 2000
Relay locations on relay carrier:
11 10 9 8 7
6 5 4 3 2 1
97-40408
7 - X contact relief relay (100)

8 - Automatic intermittent wash/wipe relay (19)
Note:
♦ The number in brackets behind the part designation denotes the control number on the housing.
Edition 09.2002
Position of fuses in fuse box:
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 A - pourple permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Edition 09.2002
Battery, ignition/starter switch, X contact relief relay, terminal 30
junction box
31 30
A Battery
7 J59 B Starter
X 75x D Ignition/starter switch
J59 X contact relief relay
SA1 Fuse -1- in fuse box/battery
T6h/4 T6h/3 T6h/2 T6h/1 SA2 Fuse -2- fuse box/battery
203
203
SA3 Fuse -3- fuse box/battery
1 1 6 2.5
6 SA4 Fuse -4- fuse box/battery
ro
br sw/ge sw ro SA5 Fuse -5- fuse box/battery
A32 71
150
SA9 Convertible -9- in fuse box/battery
4 6 4
ro ro ro
SB16 Fuse -16- in fuse box
T10 10-pin connector, green, connector point
TV2 Terminal 30 junction box
D 30 502 501
1 Earth strap, battery - body
TV2
X 15 unless
50 permitted S by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
P authorised
500 Copyright by SEAT S.A.
respect to the correctness of information in this document. 2 Earth strap, gearbox - body
2.5 2.5 4 1 0.5
sw/ge ro/sw sw ge br/ro
16a 500 Screw connection -1- (30), on relay plate

66 77 186
186 113
113
T10/1 SB 16
5A
41 501 Screw connection -2- (30), on relay plate
2.5
ro/sw 16b
0.5 0.35 10 502 Screw connection -1- (30a), on relay plate

B/30 B/50 br/ro br/ro ro
B158 A32 Positive (+) connection (30), in dash panel wiring harness
25
sw
B158 Connection (S), in interior wiring harness
+
* T5f/1 T5f/2 T5f/3 T5f/4 T5f/5 1 2 3 4 * For all models, does not apply to AMF, 4-pin connector, T4a
A SA 5 SA 6 SA 7 SA 8 SA 9 SA 1 SA 2 SA 3 SA 4
30A 30A 20A 10A 30A 110 A 80A 50A 50A
ws = white
-- sw = black
ro = red
br = brown
gn = green
25 25 bl = blue
sw sw
gr = grey
1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--43443
rs = pink
Edition 09.2002
Immobiliser control unit, immobiliser reading coil
D2 Immobiliser reading coil
J... Engine control units
J234 Airbag control unit
J362 Immobilizer control unit
SB28 Fuse -28- in fusebox
T10a 10-way connector, red, in the wiring harness interconnection
T10n 10-way connector, grey, in the wiring harness interconnection
76 Earth point, near gearbox control
A38 Positive connection-2- (15a), in instrument panel wiring harness
J 234 J 234
T75/74 J... J... T75/75 A76 Connection (diagnosis cable K), instrument panel wiring harness
J... 0.35 0.35
or/sw or/br A121 Connection (High-Bus), instrument panel wiring harness
34 32
* T10n/4 T10n/5
206
206 0.5 0.35 0.35 0.5 0.5 0.35 0.35 A122 Connection (Low-Bus), instrument panel wiring harness
ws/ge or/sw or/sw or/sw or/br or/br or/br
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not * W self-diagnosis line
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with A122
T10a/7 in this document. Copyright A121
respect to the correctness of information by SEAT S.A.
1 0.5 0.5 0.5
ro ws/ge or/sw or/br
30 W CAN--H CAN--L
T10x/10 T10x/7 J362 T10x/2 T10x/1
T3/1 T3/2 T3/3 T10x/9 T10x/3 T10x/8

31 15a K
0.5
sw
A38
1 0.5
sw gr/ws
28b
SB 28
7.5A
28a
ws = white
D2 1
sw = black
1
br sw ro = red
br = brown
gn = green
185
185
b
bl = blue
A76
gr = grey
76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42706
rs = pink
Edition 09.2002
Control unit with warning lamps on the instrument panel,
diagnostic interface for data bus, warning lamp for yellow
triangle symbol
J285 Control unit with warning lamps on instrument panel
J533 diagnostic interface for data bus
K63 Warning lamp for 'yellow triangle' symbol
SB10 Fuse -10- in the fusebox
J... T10b 10-way connector, blue, in the wiring harness interconnection
T16 16-way connector, in the instrument panel, in the center. Auto-
diagnostic connection centre
T10b/9
A27 Connection (speed signal), instrument panel wiring harness
0.5
gn/ws
26 20 201
201 9
A76 Connection (diagnosis cable K), instrument panel wiring harness
A27
*
0.35 0.35 0.35 0.35 0.35
* Only vehicles without central locking
or/br or/sw gn/ws bl/br br/ro
CAN--L CAN--H
T32a/20 T32a/19 T32/3 T32/21 T32/30
Kpermitted
63
J533of information in this document. Copyright
respect to the correctness J285by SEAT S.A.
T32/25 T32a/28 T32a/27 T32/23 T32/1

CAN--L CAN--H 198
198
0.35 0.35 0.35 0.35 0.5 0.35

gr gn sw ro ro sw
11b 10b
T16/14 T16/6
192
192
SB 11 SB 10
5A 7.5A ws = white
T16/7 T16/4 T16/16
11a 10a
sw = black
K 31
ro = red
0.5 0.5 0.5 0.5 0.5 br = brown
gr/ws br ro ro ro
gn = green
b A76
* bl = blue
84 205
205 gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--45698
rs = pink
Edition 09.2002
headlights warning lamp, alternator warning lamp,
airbag warning lamp, ABS warning lamp, left-hand side
flasher warning lamp, digital clock, odometer
C Alternator
H3 Buzzer (01023-3444)
J285Control unit with warning lamps on the instrument panel
(01317)
K1 Headlight warning lamp
K2 Alternator warning lamp
C/D+ K47 ABS warning lamp
K65 Left-hand side flasher warning lamp
0.5 K75 Airbag warning lamp
bl K94 Left-hand side flashr warning lamp
108
108 T10 10-way connector, green, in the wiring harness
interconnection
T10a/3 T10a 10-way connector, red, in the wiring harness interconnection
Y2 Digital clock
0.35 0.35 Y4 Odometer
bl ws
249 Earth
Protected by copyright. Copying for private or commercial purposes, in partconnection -2-,
or in whole, is notinterior wiring harness
T32/12 T32/17 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
* Only vehicles without ABS
** Only diesel vehicles without ABS
K2 K1 *** Only vehicles without airbag
Y2 H3 K47
J285
K94 K65 K75

Y4
T32/2 T32/18 T32/24 T32/9 T32/6 T32/19
0.35 0.35 0.35

gn/sw sw/ws ge
122
122 115
115 206
206 199
199 131
131 136
136
T10/10
ws = white
*** sw = black
ro = red
2.5 0.5 0.5 0.5 0.35 0.35 0.35 0.5 0.5
br br br br br br br ge br br = brown
gn = green
249 * ** bl = blue
gr = grey
157
157 156
156
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
or = orange
97--42003
rs = pink
Edition 09.2002
Control unit with warning lamps on the instrument
panel, handbrake control switch, brake fluid level
switch, sidelights warning lamp, brake system warning
lamp, digital display illumination
F9 Handbrake control switch (01114)
F34 Brake fluid level switch
J285 Control unit with warning lamps on the instrument panel
(01317)
c K4 Sidelights warning lamp
d K19 Warning lamp for safety belt warning system (00665)
e K118 Warning lamp for brake system
142
142 131
131 83 135
135 L75 Digital display illumination
T10c 10-way connector, black, in the wiring harness
0.5 1 1 0.5 0.35 0.35 0.35 interconnection
gr/bl gr/bl gr/bl gr/bl gr/gn gr/ro gr/ge
61 Earth point, C strut left
B145 B160
B102 Earth connection, interior wiring harness, front left
0.35 0.35 0.5 0.5
gr/bl br/bl br/ge br/ge
T32/20 T32/14 T32/26 T32/27 T32/29

B145 Positive connection (58b), interior wiring harness
Connection (brake system monitoring), interior wiring

B160
T10c/6 harness
L75 K4 K118
J285 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
0.5
bl/br
1 1
K19
F9 F34
2 2
203
203 198
198 181
181 1
0.5 0.5 1 1 0.5 0.5

br br br br br br/sw
ws = white
sw = black
167
167
ro = red
B102
br = brown
2.5 gn = green
br bl = blue
gr = grey
61
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42004
rs = pink
Edition 09.2002
Lighting switch, fog lights switch, lighting switch light bulb
E1 Lighting switch
E7 Fog light switch
L9 Lighting switch light bulb
T10c 10-pin connector, black, in interconnection station
81 Earth connection -1-, in dash panel wiring harness
c
g A3 Positive (+) connection (58), in dash panel wiring harness
e
A40 Positive connection -1- (30), in dash panel wiring harness
156
156
0.35 0.5 0.5

gr/gn gr/gn gr/gn
124
124
A3
1.5
ws/ge
99 111
111 107
107 106
106 59 156
156
T10c/8
0.35 0.5 0.35 0.5 2.5 1.5 2.5 1.5 1.5
gr/ge gr/ge gr/ro gr/ro ws/sw gr/gn ge ws/ge gr/ws 1 0.5
gr/bl gr/bl
58L 58R 56 58 B 56b NL NSL TFL 58b
T17/13 T17/14 T17/4 T17/16 T17/6 T17/7 T17/8 T17/9 T17/3 T17/17
E1 T17/15
30
T17/1
X
E7 T17/2
NL/NSL
L9 T17/10
31
1.5 2.5 1.5 0.5

ro sw/ge gr/ws br
A40
3 139
139
4 1.5
ro ro ws = white
sw = black
ro = red
11 109
109 br = brown
gn = green
bl = blue
gr = grey
81
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--41733
rs = pink
Edition 09.2002
Number plate lighting, left rear turn signal bulb, left tail
light bulb, left brake light bulb, high brake light bulb, right
tail light bulb, right reverse light bulb, right brake light
bulb
M2 Tail light bulb, right
M4 Tail light bulb, left
M6 Turn signal bulb, rear left
f M8 Turn signal bulb, rear right
g
219
219 M9 Brake light bulb, left
M10 Brake light bulb, right
M17 Reversing light bulb, right
0.5 1 M25 High level brake light bulb
gr/gn sw/ro L20 Rear fog light bulb
SB2 Fuse -2- on fuse holder
2a
T5b 5-pin connector, brown, in C pillar, left
T10d/7 T10a 10-pin connector, red, in interconnection station
SB 2
5A T10d 10-pin connector, white, in interconnection station
X Number plate light
2b
0.5 1
52 Earth point, in tailgate/boot lid, left
gr/gn sw/ro
B131
218 Earth connection -1-, in tailgate/boot lid wiring harness
114
114 99 190
190 112
112 121
121
B109 Earth connection, in rear left interior wiring harness
B131 Connection (54), in interior wiring harness

1 1
sw/ro sw/bl
B132 B132 Connection (number plate lights), in interior wiring harness
Protected by copyright. Copying for private or T
commercial
5b/2 T10a/2
0.5 0.5 1.5 0.5 0.5 1 1 1 1 0.5 0.5
gr/gn gr/gn gr/ws sw/ws gr/sw sw/ro sw/ro sw/ro sw/bl gr/ro sw/gn
NSL BLL 58L 54 54 RFL 58R BLR

1 1 T6a/1 T6a/2 T6a/6 T6a/5 2 T6/1 T6/6 T6/2 T6/5
X
L20 M6 M4 M9 M25 M10 M17 M2 M8
ws = white
2 2 T6a/3 T6a/4 1 T6/3 T6/4
sw = black
31 31 31 31 ro = red
br = brown
0.5 0.5 1.5 1.5 2.5 1 1.5 1.5 2.5 gn = green
br br br br br br br br br bl = blue
gr = grey
B109 B109 B109 B109 52 218 B109 B109 52 li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
or = orange
97--41734
rs = pink
Edition 09.2002
Headlight dipper/flasher switch, left side light bulb, front
left turn signal bulb, right side light bulb, front right turn
signal bulb, twin filament bulb/sealed beam insert, left
E4 Headlight dipper/flasher switch
L1 Twin filament bulb/sealed beam insert, left
L2 Twin filament bulb/sealed beam insert, right
M1 Side light bulb, left
75 72
M3 Side light bulb, right
M5 Turn signal bulb, front left
2.5 1.5 M7 Turn signal bulb, front right
ws/sw ro SB4 Fuse -4- on fuse holder
56 30 SB5 Fuse -5- on fuse holder
T5d/3 T5d/5
E4 SB13 Fuse -13- on fuse holder
T5d/2 T5d/4
56b
T10b 10-pin connector, blue, in interconnection station
78 56a T10c 10-pin connector, black, in interconnection station
2.5 2.5 1.5 1.5
72 113
113 110
110 ge ge ws ws 74 114
114 108 Earth connection -2-, in front left wiring harness
0.5 0.5 1.5 A9 0.5 0.5

gr/ge gr/ge ws 102
102 gr/ro gr/ro
1.5 2.5 131 Earth connection -2-, in engine compartment wiring harness
ge ge
4a 13a 44a 45a 12a 5a
A9 Positive (+) connection (56 b), in instruments wiring harness
SB 4 SB 13 SB 44 SB 45 SB 12 SB 5
5A 10A 15A 15A 10A 5A
4b 13b 44b 45b 12b 5b A95 Connection -1- (56a), in dash panel wiring harness
0.5 0.5 1.5 1.5 1.5 1.5 0.5 0.5

gr/sw gr/sw ws/sw ge/sw 159
159 163
163 ge ws gr/ro gr/ro B167 Connection (56b), in interior wiring harness
A95
T10b/6 T10b/4 T10b/5 T10c/5 T10b/
90 1.5 7
1.5 1 1 1.5 0.35 97 B247 Connection -2- (56b), in interior wiring harness
ws
116
116 ge/sw ge/sw ge ge ws
119
119
T10c/4
1 0.5 1.5 1.5 B247 B167 1.5 53 1.5 0.5 1
sw/ws gr/sw ws/sw ge/sw ge ws gr/ro sw/gn
BLL 58 56a 56b 56b 56a 58 BLR
T8d/3 T8d/4 T8d/8 T8d/6 T8e/6 T8e/8 T8e/4
Protected T8e/3 Copying for private or commercial purposes, in part or in whole, is not
by copyright.
ws = white
M5 M1 L1 L2 M3 M7 sw = black
ro = red
br = brown
T8d/2 T8e/2
31 31 gn = green
2.5 2.5 bl = blue
br br gr = grey
108 131
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--41735
rs = pink
Edition 09.2002
Parking light switch, turn signals switch, turn signal bulb,
left side, turn signal bulb, right side, fog light bulb, left,
fog light bulb, right
E2 Turn signal switch (00886)
E19 Parking light switch
L22 Fog light bulb, left
L23 Fog light bulb, right
6 M18 Side turn signal bulb, left
h M19 Side turn signal bulb, right
1 0.5 T10b 10-pin connector, blue, in the interconnection station
gr sw/ge T10c 10-pin connector, black, in the interconnection station
P 49a
T7a/5 T7a/2
12 Earth point, in engine compartment, left
E19
108 Earth connection -2-, in front left wiring harness
T7a/4
PL
T7a/6
PR E2 T7a/3
L
T7a/7
R
131 Earth connection -2-, in engine compartment wiring harness
0.5 0.5 0.5 0.5
gr/ge gr/ro sw/ws sw/gn 43
Positive (+) connection (right turn signal), in dash panel
A5
wiring harness
100
100 112
112
0.35
sw/gn Positive (+) connection (left turn signal), in dash panel wiring
A6
harness
A6 A5
Connection (turn signal, right) in engine compartment wiring
D57
harness
0.5 0.5 0.35 0.5 0.5 0.5 0.5
sw/ws sw/ws sw/ws sw/ws sw/gn sw/gn sw/gn Connection (turn signal, left) in engine compartment wiring
D58
harness
79
127
127 89 46 T10b/8 T10c/1 128
128 98
0.5 0.5 1.5 D59 Connection (fog light), in engine compartment wiring harness
sw/ws sw/gn ws/ge
D58 D57 D59

0.5 1 0.5 1 1.5 1.5
sw/ws sw/ws sw/gn sw/gn ws/ge ws/ge
99 112
112
2 2 1 1
ws = white
M18 M19 L22 L23 sw = black
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ro = red
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with br = brown
1 1 in this document. Copyright by SEAT S.A.2 2
respect to the correctness of information gn = green
0.5 0.5 1.5 1.5 bl = blue
br br 4 br br
br gr = grey
131 131 12 108 108 li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--41736
rs = pink
Edition 09.2002
Emergency flasher switch, rear window heating switchflasher
relay, warning lamp emergency lights, rear window heating
warning lamp, rear window heating switch light, heated rear
window
E3 Emergency flasher switch
E15 Rear window heating switch (00973)
J1 Flasher relay
i K6 Emergency lights warning lamp (00910)
h
204
204 K10 Rear window heating warning lamp (00911)
A80 L39 Rear window heating switch light
SB7 Fuse -7- in fuseholder
0.5 1 1 2.5 1.5
sw/ge ro sw/ge sw/ge sw/ge SB43 Fuse -43- in fuseholder
T5b 5-way connector, brown, in strut C, left-hand side
14a 7a 48a 43a Z1 Rear heated window (00975)
SB 14 SB 7 SB 48 unless
permitted SB 43authorised by SEAT S.A. SEAT S.A does not guarantee 61 orEarth
accept point, C strut
any liability with left
10A 7.5A 20A respect
15A to the correctness of information in this document. Copyright by SEAT S.A.
14b 7b 48b 43b

58 60 209
209 218 Earth connection, tailgate wiring harness
1 0.5 1 0.5 0.5 2.5 1.5

ro/ge sw/gr gr/bl gr/bl gr/bl bl gr/ws A80 Connection -1- (X), in the instrument panel wiring harness
1/49a E3 7/30a 6/75a 4/58b 8 J1 80

* Only vehicles without electric and heated mirrors
1/58b K10 5/75a
L39 E15
2/31 6/+
2.5
*
3/L 2/R 5/31
K6 sw
T5b/1
0.5 0.5 0.5 0.5 2.5
sw/ws sw/gn br br sw
+
113
113 120
120 49 50
Z1
-- ws = white
184
184 90 sw = black
ro = red
br = brown
2.5 1.5 1 2.5 gn = green
br br br br bl = blue
gr = grey
61 218
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42009
rs = pink
Edition 09.2002
Fresh air ventilator switch, warning lamp for fresh air and
circulating air functions, fresh air blower, servo-motor for
fresh/circualting air flap, additional resistance for fresh air
ventilator with thermal overload fuse
E9 Fresh air ventilator switch
E159 Fresh and circulating air flap switch
K114 Warning lamp for fresh and circulating air functions
i A80 L16 Fresh air regulation light
N24 Additional resistance for fresh air ventilator with thermal overload
1 2.5 0.5 4
sw/ge sw/ge ge/bl sw/ro fuse
6a 50a 9a A61 SB9 Fuse -9- in fuseholder
SB 6 SB 50 SB 9 6 2.5 SB50 Fuse -50- in fuseholder
15A 15A 5A sw sw/ge T4j 4-way connector, behind instrument panel
6b 50b 9b V2 Fresh air blower (01273-4124)
4 49a V154 Servo-motor for fresh/circulating air flap
1 1.5 0.5
sw/ge sw/gr ge/bl SB 49 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
45 S.AEarth point, behind instrument panel
25A permitted unless authorised by SEAT S.A. SEAT does not guarantee or accept any liability with
57 respect to the correctness of information in this document. Copyright by SEAT S.A.
186
186 171
171 160
160 49b
0.5 2.5 162 Earth connection, in ventilator motor wiring harness
gr/bl sw/ro
188
188
T4j/3 T4j/1 A61 Positive connection (X), in the instrument panel wiring harness
0.5 0.5 2.5

gr/bl sw/bl sw/bl A80 Connection -1- (X), in the instrument panel wiring harness
58b Xa
T8m/3 K114 T8m/5 E159 E9 T6t/2
L66 Connection, in heater blower wiring harness

L16
T8m/4 T8m/7 T8m/8 T6t/1 T6t/3 T6t/4 T6t/5
0.5 0.5 0.5 2.5 2.5 2.5 2.5

br bl/ge ws/ro ge gn ws/sw bl
L66
2.5 2.5
ge ge
2 1
1 4 1 3 2
ws = white
V154 M V2 M N24 sw = black
2 ro = red
3 br = brown
0.5 2.5 2.5 gn = green
br br br bl = blue
gr = grey
162 45
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
or = orange
97--42010
rs = pink
Edition 09.2002
Switches and instruments - lighting control, beam
adjuster, beam adjuster motor, left, beam adjuster motor,
right
E20 Switches and instruments - lighting control
E102 Headlight range control adjuster
i SB50 Fuse -50- on fuse holder
A80 T10b 10-pin connector, blue, in the interconnection station
0.5 1 2.5
V48 Headlight range control motor, left
ge/bl sw/ge sw/ge V49 Headlight range control motor, right
9a 6a 50a
76 Earth point, near selector mechanism
SB 9 SB 6 SB 50
5A 15A 15A 81 Earth connection -1-, in dash panel wiring harness
9b 6b 50b
76
1 1.5 131 Earth connection -2-, in engine compartment wiring harness
sw/ge sw/gr
0.5 0.5
gr/gn 186
186 A36 Connection (75a), in dash panel wiring harness
ge/bl
j
58 56b
T6e/3 T6e/4 A36
A80 Connection -1- (X), in dash panel wiring harness
E20 E102
T6e/5 T6e/1 T6e/2
58b 31 G
0.5 0.5 0.5

gr/bl br ro/bl
84 105
105 106
106
T10b/1
1 0.5 0.5 1
ge/sw ro/bl ro/bl ge
+ G G +
T8d/5 T8d/1 T8e/1 T8e/5
V48 V49
T8d/7 T8e/7 ws = white
31 31 Protectedsw = black
ro authorised
permitted unless = red by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
br = brown
2.5 0.5 0.5 gn = green
br br/bl br/bl bl = blue
gr = grey
76 81 131 131 li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
or = orange
97--41739
rs = pink
Edition 09.2002
Intermittent wash/wipe relay, intermittent windscreen
31
wiper switch, rear window wiper switch, rear window and
windscreen washer pump, windscreen wiper motor
J31 8
E22 Intermittent wiper switch
53M 75a 53S J T
E34 Rear wiper switch
J31 Automatic intermittent wash/wipe relay
T10c 10-pin connector, black, in the interconnection station
T9/4 T9/2 T9/8 T9/5 T9/1 T9/6 T10d 10-pin connector, white, in the interconnection station
V Windscreen wiper motor
1 1 1.5 1 0.5 1 1 V59 Windscreen and rear window washer pump
br gn sw/gr gn br/sw gn gn
57 Earth point, left rear pillar

T10c/
10
1
gn
1 131 Earth connection -2-, in engine compartment wiring harness
V59
2
k A36 Connection (75a), in dash panel wiring harness
A36 l
1
gn/sw
j B102 Earth connection, in front left interior wiring harness
T10c/9
1.5 1.5 1 1 1 1
sw/gr sw/gr sw/gr gn/sw gn/sw bl
53C
75a 53S J T
T5c/2 T5c/3 T5c/5 T4b/2 T4b/1 T5e/5
181
181 W E34
21 O
T5c/4 E22 53b
T5c/1
T
T4b/4 T4b/3 T5e/1
H
53e 75a 31
O
1
sw/gr
1
gn/sw
1
gn/ge
J 1.5
br
1.5
sw/gr
T10d/ T10d/10 T10d/9 T10d/2

3
171
171
1 1 1 1 ws = white
gn sw/gr gn/sw gn/ge sw = black
4/53 1/75a 3/53e 2/53b rois not=
Protected by copyright. Copying for private or commercial purposes, in part or in whole, red
br with= brown
V permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability
gn =
respect to the correctness of information in this document. Copyright by SEAT S.A. green
5/31 bl = blue
1 2.5 gr = grey
B102 131 br 57 br 81 li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
or = orange
97--41740
rs = pink
Edition 09.2002
Rear window wiper motor, reverse lights switch, dual
tone horn, horn plate
F4 Reversing light switch
H Horn plate (00889)
H1 Dual tone horn (00906)
A2 T5a 5-pin connector, brown, in tailgate/boot lid
T5b 5-pin connector, in C pillar, left
1 4 1.5 1.5 0.5 2.5 T10d 10-pin connector, white, in interconnection station
sw sw sw sw sw sw
V12 Rear window wiper motor (00919)
26a 29a 27a
20 5
A104 57 Earth point, left rear pillar
SB 26 SB 29 SB 27
5A 5A 5A
1.5
26b 29b 27b
sw 98 Earth connection, in tailgate/boot lid wiring harness
19a
*
165
165 0.5 1 0.35
218 Earth connection -1-, in tailgate/boot lid wiring harness
k
sw sw sw SB 19
l 15A
19b
1 1 1 145
145 36 A2 Positive (+) connection (15), in dash panel wiring harness
bl gn/sw sw/ge
1.5
sw/ge
T5b/5 T5b/3 T5b/4 T10d/4 A104 Positive connection -2- (15), in dash panel wiring harness
T10d/5 * Only vehicles without central lock
1 1 1 1
bl gn/sw sw/ge sw/ro
1.5
sw/ge
T5a/5 T5a/3 T5a/4 1
1
1 1 1
bl gn/sw sw/ge
F4 H1
2 2
T4i/2 T4i/3 T4i/4 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 1.5 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
V12 sw/bl br/sw respect to the correctness of information in this document. Copyright by SEAT S.A.
T4i/1 96 T10d/1
1.5 ws = white
br/sw
sw = black
T7a/1 ro = red
br = brown
T5a/1 H gn = green
1 1.5 1.5 2.5 bl = blue
br br br br
gr = grey
98 218 57 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
or = orange
97--41741
rs = pink
Edition 09.2002
Front interior lighting, door contact switch, driver's side,
door contact switch, passenger side, tailgate/boot lid
release switch
E165 Tailgate/boot lid release switch (01141)
F2 Door contact switch, driver side (01169)
F3 Door contact switch, front passenger's side (01707)
T5 5-pin connector
217
217
T5a 5-pin connector, brown, in tailgate/boot lid
T5g 5-pin connector, black, in C pillar, left
0.5
T10f 10-pin connector, black, in A pillar, lower passenger side
ro T10g 10-pin connector, black, in A pillar, lower driver's side
W Interior light, front
T5/1
0.5 98 Earth connection, in tailgate/boot lid wiring harness
ro
2/30a
249 Earth connection -2-, in interior wiring harness
W 59
B102 Earth connection, in front left interior wiring harness

1/31 3/TK
0.5 0.5 0.35

br br/ws br/ws B154 Connection -1- (DC), in interior wiring harness
T5/3 T5/2 T5g/5
respect * S.A.
to the correctness of information in this document. Copyright by SEAT Only vehicles without central lock
0.5 0.5
br/ws br/ws
B154
0.5
*
0.5 0.35 0.5
br br/ws bl/br br/ws
T10f/9 48 T10g/9 T5a/2
0.5 0.5 0.5

br/ge br/ge br/ws
2 2 1
F3 F2 E165
1 1 2
0.5 0.5 0.5 ws = white

br br br sw = black
ro = red
T10f/10 T10g/10 br = brown
gn = green
0.5 0.5
bl = blue
br br gr = grey
B102 249 B102 98 li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
or = orange
97--41742
rs = pink
Edition 09.2002
Brake light switch, cigarette lighter, cigarette lighter illumination
F Brake light switch (00526-2131)
J104 ABS with EDL control unit
J217 Automatic gearbox control unit
L28 Cigarette lighter light bulb
A52 T10d 10-pin connector, white, in interconnection station
T16 16-pin connector, black
U1 Cigarette lighter
2.5 1 0.5 0.5 1 1.5 1
ro ro ro ro ro ro ro 81 Earth connection -1-, in dash panel wiring harness
7 129
129 11a 10a 15a 46a 15
SB 11 SB 10 SB 15 SB 46
5A 7.5A 10A 15A
11b 10b 15b 46b A52 Positive connection -2- (30), in dash panel wiring harness
0.5 0.35 0.5 1 1.5 D73 Positive connection (54), in engine compartment wiring harness
ro ro ro ro/ge ro
* Only vehicles with ABS
36 38 199
199 T10d/6 136
136 ** Only vehicles with automatic gearbox
0.35 1 0.5
or/br ro/ge gr/bl
CAN--L 2 3
1
T16/14 T16/16
F U1 L28
T16/4 T16/7 T16/6
K CAN--H 4
1
0.5 0.5 0.35 1 1.5

br gr/ws or/sw sw/ro br
D73
25 34 1 1 1
sw/ro sw/ro sw/ro
ws purposes,
Protected by copyright. Copying for private or commercial = whitein part or in whole, is not
** * permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
sw = black
ro = red
J217 J
104 91
br = brown
T45a/21 T25/18
gn = green
bl = blue
gr = grey
81 238 li = purple
ge = yellow
211 212 213 214 215 216 217 218 219 220 221 222 223 224
or = orange
97--41743
rs = pink
Edition 09.2002
1.0 l - Motronic/37 kW, engine code letters AUC

From July 2000
1.4 l - Motronic/44 kW, engine code letters ANW

From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
2 - Fuel pump relay (167)

Warning:
♦ The brackets after the names of the relays refers to the control number on the housing.
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 09.2001
Battery, starter, alternator, voltage regulator, ignition/starter
switch, terminal 30 junction box, X contact relief relay
31 30
A Battery (00532)
7 J59 B Starter
X 75x C Alternator
C1 Voltage regulator
T6h/4 T6h/3 T6h/2 T6h/1 E1 Lighting switch
31 99
E1 E19 Parking light switch
0.5 1 6 T17/15 6 J59 X contact relief relay
br sw/ge sw/ge ro
SA2 Fuse -2- on battery fuse holder
2.5 1.5 1.5 SA1 Fuse -1- on battery fuse holder
A61 ro ro/bl ro T5s 5-pin connector, in the transmission
A32 A40 T10 10-pin connector, green, in interconnection station
T10a 10-pin connector, red, in interconnection station
4 6 4
ro ro ro TV2 Terminal 30 junction box
D 30 502 501 1 Earth strap, battery body
TV2 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 Earth strap, gearbox - body
X 50 15 P S respect to the correctness of information in this document. Copyright by SEAT S.A.
500
2.5 2.5 4 1 0.5
sw/ge ro/sw sw gr br/ro 500 Screw connection -1- (30), on relay plate
E
1
25 E 19 136
136
145
145 27 501 Screw connection -2- (30), on relay plate
T17/1 T7a/5
A41
2.5 0.35 502 Screw connection -1- (30a), on relay plate
ro/sw bl
T10/1 T10a/3 A32 Positive connection (30), in dash panel wiring harness
2.5 10 0.5 1
ro/sw ro bl sw/ge
T5s/1 T5s/2 T5s/3

2.5 25 16 0.5 0.5 A41 Positive (+) connection (50), in dash panel wiring harness
ro/sw sw sw bl gn
50 30 + 2 1 B+ D+ W A61 Positive connection (X), in dash panel wiring harness
SA 2 SA 1 G C ws = white
B A 80 A 110 A
sw = black B102 Earth connection, in front left interior wiring harness
M
C1 ro = red
br = brown
--
gn = green
25 25 bl = blue
sw sw gr = grey
B102 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--41745
rs = pink
Edition 09.2001
Motronic control unit, ignition transformer, coolant
temperature sender, plug cap, spark plugs
G2 Coolant temperature sender
J220 Motronic control unit
N152 Ignition transformer
P Plug cap
Q Spark plugs
A2 SB24 Fuse -24- in fusebox
2.5 1.5 0.5 1.5 4 SB34 Fuse -34- in the fusebox
sw sw sw sw sw
A104 34a 24a 36a
T10 10-way connector, green, in the wiring harness interconnection
5
T10d 10-way connector, white, in the wiring harness interconnection
0.5
sw SB 34 SB 24 SB 36 T10n 10-way connector, grey, in the wiring harness interconnection
10A 5A 15A
10 Plenum chamber earthing point
30a 34b 24b 36b
1.5 0.5 1.5
sw ws/ge sw
SB 30 220 Earth connection (sender earth), engine wiring harness
5A
30b
T10/4 T10n/10 T10/8 14
0.5 1 1.5 1 A2 Positive connection (15), instrument panel wiring harness

sw/ge sw sw sw/ge
T10d/8 103
103 T80/27 J220 T80/11
A104 Positive connection -2- (15), dash panel insert wiring harness
1 0.5 * Only on ANW and AUD vehicles with automatic gearbox

sw/ge sw/ge ** Only on vehicles without automatic gearbox
T80/57 T80/71 T80/74 T80/54
38 101
101 130
130
1.5 0.5 0.5 0.5 0.5

sw gn/br gn/ge ge/ro bl/gr
N152 or accept1 any liability

permitted unless authorised by SEAT S.A. SEAT 2 S.A does not guarantee 3 with
respect to the correctness of information in this document. Copyright by SEAT S.A. 2 3
G62 G2
1 4
4
1 1 1 ws = white
2.5 2.5 br/ws br/ws br/bl sw = black
br br ro = red
P
* ** br = brown
59
Q 121
121 gn = green
bl = blue
a
gr = grey
10 220
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42302
rs = pink
Edition 09.2001
Motronic control unit, PAS pressure switch, engine revolution
sender, Hall sender, exhaust gas recirculation potentiometer,
exhaust gas recirculation valve
F88 PAS pressure switch
G28 Engine revolution sender
G40 Hall sender
G212 Exhaust gas recirculation potentiometer
A52 J293 Radiator fan control unit
2.5 0.5 1 1 N18 Exhaust gas recirculation valve
ro ro ro ro
T10c 10-way connector, black, in the wiring harness interconnection
15a 31a T10d 10-way connector, white, in the wiring harness interconnection
7 149
149 85 T14 14-way connector, engine
SB 15 SB 31 0.5 J293 J293 J293 J217 T14a 14-way connector, brown, engine
10A 10A
ws T14c/2 T14c/3 T14c/3 T68/30
15b 31b 220 Earth connection (sender earth), engine wiring harness
2 * *
1 1 0.5 0.5 0.5 1
ro/ge ro/sw ro/ws gn/bl gn/bl sw/ro
F88 A52 Positive connection -2- (30), instrument panel wiring harness
L5 D161
T10d/ T10c/7 1
**
6
1 1 0.5 0.5 0.5
ro/ge ro ws/sw ro/ws bl D101 Connection -1-, engine bay wiring harness
105
105 * Connection (radiator fan run-on cycle), in the engine bay wiring
J220 T80/15 T80/49 T80/17 T80/42 D161
harness
T80/60
L5 by copyright.
Protected Connection-1-,
Copying air conditioning
for private wiringpurposes,
or commercial harnessin part or in whole, is not
T80/62 T80/53 T80/67 T80/78 T80/69
0.5 0.5 0.5 0.5 1 0.5 *
respect Only
to vehicles with
the correctness air conditioning
bl ge ws sw li gn/br ** Only on ANW and AUD vehicles with automatic gearbox
*** Only on ANW and AUD vehicles without automatic gearbox
T14a/ T14a/ T14/5
13 14
1 0.5 0.5
T3/2 T3/3 li gn/br br/ws
2 5 6 4
G40 G28 N18 ***

3 1 1
G212 2
1 0.5
T3/1 sw/ge gn/li
123
123 46 44
ws = white
T14a/12 T14/11 sw = black
ro = red
0.5 0.5 0.5 0.5 0.5 0.5 1 0.5 1
br/ws br/ws sw gr gn/li ge sw/ge gn/li br/sw br = brown
D101 gn = green
16 bl = blue
a
gr = grey
220
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42708
rs = pink
Edition 09.2001
Motronic control unit, inlet air temperature sender, inlet
manifold pressure sender, accelerator position sender,
sender -2- for the accelerator pedal position
G42 Inlet air temperature sender
G71 Inlet manifold pressure sender
G79 Accelerator pedal position sender
G185 Sender -2- for the accelerator pedal position
T14 14-way connector, engine
150
150 151
151
0.5 0.5
ws/gn ws/bl
T80/16 J220 T80/12
T80/70 T80/56 T80/6 T80/45 T80/19 T80/7 T80/33 T80/8
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

ge/sw ws/br gn/sw ge/li br/li ro/li gn/li sw/li
T14/10 T14/12
0.5 0.5
ge/sw ws/br
4 2 1 6 5 3 4 2
G71 G42 G185 G79

3 1
0.5 0.5
gn/li br/ws
ws = white
T14/9 T14/4 sw = black
ro = red
0.5 0.5 br = brown
gn/li br/ws Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
gn unless
permitted = green
bl respect
= blue
34 30
gr = grey
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--42018
rs = pink
Edition 09.2001
Motronic control unit, throttle valve control unit, throttle valve
control (electric accelerator control), angle sender -1- for
throttle valve (electric accelerator control)
G186 Throttle valve control (electric accelerator control)
G187 Angle sender -1- for throttle valve control (electric accelerator
control)
control)
J104 Control unit for ABS with EDS
J 217 J 104 J 104 J 217 J220 Motronic control unit
T68/16 T25/10 143
143 T25/11 T68/15 145
145 J338 Throttle valve control unit
0.5 0.5 T14 14-way connector, engine
or/br or/sw T14a 14-way connector, brown, engine
T10n/5 T10n/4 10 Plenum chamber earthing point
0.35 0.35 0.35 0.35 0.35 0.35

or/br or/br or/br or/sw or/sw or/sw 167 Earth connection -4-, engine bay wiring harness
D160 D159
D159 Connection (High-Bus), engine bay wiring harness
0.35 0.35
or/br or/sw
CAN--L CAN--H
T80/32 J220 T80/31 D160 Connection (Low-Bus), engine bay wiring harness
* Only on ANW and AUD vehicles with automatic gearbox

T80/2 T80/28 T80/61 T80/68 T80/55 T80/75 T80/80 T80/66
** Only on vehicles without automatic gearbox
0.5 0.5 0.5 0.5 1 1

gr/ge sw/ro ws/sw ro/ws ro/gr ro/bl
T14a/7 T14a/ T14a/ T14/8 T14a/ T14/6

10 4 8
0.5 0.5 0.5 0.5 1 1
1 2 4 3 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
18
J338 G186 respect to the correctness of information in this document. Copyright by SEAT S.A.
6 5
G187 G188
** * * * ** ws = white
sw = black
2.5 2.5 2.5 2.5 2.5
br br br br br ro = red
br = brown
gn = green
bl = blue
167
gr = grey
10 10 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42709
rs = pink
Edition 09.2001
Motronic control unit, knock sensor I, injector, cylinder 1,
injector, cylinder 2, injector, cylinder 3, injector, cylinder 4
G61 Knock sensor I (00524-2142)
J362 Immobiliser control unit
N30 Injector, cylinder 1 (01249-4411)
T10 10-pin connector, green, in the interconnection station
T10a 10-pin connector, red, in the interconnection station
T10b 10-pin connector, blue in the interconnection station
T10n 10-pin connector, grey, in the interconnection station
J362 T14 14-pin connector, in the engine
136
136 142
142 128
128 T10x/7 T14a 14-pin connector, brown, in the engine
Earthing connection (screened), in engine compartment wiring
0.5 0.35 0.35 0.5 200
gn/ws ge/gr ge/gr ws/ge harness
D95 Connection (injectors) in engine compartment wiring harness

T10b/9 T10n/7 T10a/7
* Self-diagnosis wire W
0.5 0.35 0.5
*
gn/ws ge/gr ws/ge
W
T80/5 T80/30 J220 T80/29
T80/63 T80/77 T80/79 T80/59 T80/73 T80/65 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
0.5 0.5 1 1 1 1 respect to the correctness of information in this document. Copyright by SEAT S.A.
200 gn/ro gr gr/sw gr/gn gr/ro gr/bl
T14/7 T14a/5 T14a/6 T14a/9 102

102
0.5 0.5 1 1 1 1 1
sw bl gr/sw gr/gn gr/ro gr/bl ro/ge
T14a/ T14a/ T14a/1 T10/5

3 2
N30 2 N31 2 N32 2 N33 2
0.5 0.5 0.5 1
sw bl gr ro/ge
1 1 1 1 ws = white
T14a/11
sw = black
1 1 1 1 1 ro = red
2 1 ro/ge ro/ge ro/ge ro/ge ro/ge br = brown
gn = green
D95 bl = blue
G61 gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42303
rs = pink
Edition 09.2001
Motronic control unit, lambda probe, lambda probe after
catalyst, lambda probe heater, lambda probe heater 1, after
catalyst
G39 Lambda probe (00525-2342)
G130 Lambda probe after catalyst (00699)
Z19 Lambda probe heater
Z29 Lambda probe heater 1, after catalyst
D102 Connection -2-, in engine compartment wiring harness
E30 Connection (87a), in engine wiring harness

147
147
0.35
gn
T10a/8
0.5
gn/bl
T80/41 J220
T80/21 T80/47 T80/13 T80/46 T80/20 T80/1 T80/34 T80/35

1 0.5 1 0.5 0.35 1.5 0.5 0.35
D102 ws sw br bl gr/ws br/ro gr gr/ro
0.5 0.5
ws ws
T4c/3 T4c/4 T4c/2 T6q/1 T6q/5 T6q/4 T6q/2 T6q/6

35
1 1 1
gr sw ws
Z29 G39
103
103
ws = white
G130 Z19
Protected by copyright. Copying for private or commercial
sw =
black
1 1
respect to the correctness of information in this document. Copyright by SEAT S.A.ro = red
ws ro/ge
br = brown
T4c/1 T10a/4 T6q/3 gn = green
1 1 1.5 bl = blue
ws/ro ws/ro E30 ws/ro gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
or = orange
97--42304
rs = pink
Edition 09.2001
Motronic control unit, fuel pump relay, brake light switch,
30 15 brake pedal switch, speedometer sender, active charcoal
filter system electrovalve 1
J17
2 F Brake light switch
87F T F63 Brake pedal switch
G22 Speedometer sender
J17 Fuel pump relay
T6i/1 T6i/2 T6i/5 T6i/3
M9 Brake light bulb, left
4 4 0.5 0.5
ro/bl ro/sw ro/ge sw
M25 High level brake light bulb
A99 A2
N80 Activated charcoal filter system solenoid valve I (pulsed)
8 T10 10-way connector, green, in the wiring harness interconnection
1.5 1 1 0.5 1
ro/bl ro/sw ro/sw sw sw T10a 10-way connector, red, in the wiring harness interconnection
3a 1a 27a 28a
116
116 T14 14-way connector, engine
SB 3 SB 1 SB 27 SB 28
10A 10A T10a/9 5A 7.5A
12 Earth point in engine bay, on the left
3b 1b 27b 28b
0.35 1
1 1 0.5 sw sw
ro/ge ro/ge ro/ge 82 Earth connection -1-, front left wiring harness
144
144
A38
83 91 137
137
0.5 0.35 A2 Positive connection (15), instrument panel wiring harness
J220 T80/26 sw/gr ws/bl
A38 Positive connection -2- (15a), in instrument panel wiring harness

T80/14 T80/51 T80/23
T10/2 T10c/3
0.5 1 1 0.5 0.5
gn/ge li/gn sw/ro sw/gr ws/bl A99 Connection -1- (87), in the instrument panel wiring harness
D73 T14/2 T14/1 D73 in part

Protected by copyright. Copying for private or commercial purposes, Positive connection
or in whole, is not (54), engine bay wiring harness
1 1 0.5 0.5
sw/ro sw/ro sw/gr respect to the correctness of information in this document. Copyright by SEAT S.A.
ws/bl
2 1 2 1 2
N80 F63 F T10d/7 G22

1 2 1 3
0.5 1 1 1 1
sw/ge sw ro/ge sw/ro br
ws = white
sw = black
17 21 32 M9 T14/3 ro = red
M10 br = brown
M25 gn = green
4 1 bl = blue
br br
gr = grey
12 82
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--42710
rs = pink
Edition 09.2001
Fuel level indicator sender, fuel pump (pre-supply pump),
coolant level indicator sender, oil pressure switch 0,3 bar
F22 Oil pressure switch 0,3 bar
G Fuel level sender
G6 Fuel pump (pre-supply pump)
G32 Coolant level sender
b T10c 10-way connector, black, in the wiring harness interconnection
c
d 61 Earth point, C strut left
e
B109 Earth connection, interior wiring harness, rear left

101
101
1.5 0.35 0.35

ro/bl ro/bl bl/sw
40a
SB 40 T10c/2 T10a/6
15A
40b
1.5 0.35 0.35 0.5 0.5

ro/ge li/swby copyright. Copying br/ws
Protected bl/ro
for private or commercial purposes,bl/sw
1 2 T10a/1 1 1
G6 G G32 F22
4 3 2 ws = white
sw = black
1.5 0.5 1 0.5
br br/ws br/ws br/sw ro = red
br = brown
gn = green
2.5 bl = blue
br 26 29
B109 gr = grey
61
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42023
rs = pink
Edition 09.2001
Control unit with warning lamps on dash panel insert, fuel
gauge, coolant temperature gauge, speedometer, oil
pressure warning lamp,coolant temperature/level warning
lamp
G1 Fuel gauge
G3 Coolant temperature gauge
G21 Speedometer
b
c
16a
d K3 Oil pressure warning lamp
e K28 Coolant temperature/level warning lamp
SB 16 K105 Fuel level indicator lamp
5A
26 13 73
16b
0.5 0.5 0.5 0.5 0.5 T10a 10-way connector, red, in the wiring harness interconnection
ge/ro bl gn/ws br/ro br/ro

T10/3 T10a/3 A27 B158 7
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

bl/sw ro/bl br/ws ge/ro li/sw bl gn/ws br/ro 238 Earth connection-1-, interior wiring harness
T32/10 T32/22 T32/7 T32/8 T32/5 T32/12 T32/3 T32/30

249 Earth connection -2-, interior wiring harness
G3 G1
K3 K2 A27 Connection (speed signal), instrument panel wiring harness
J285
B158 Connection (S), interior wiring harness
K28 K105
G21
T32/13 respect to the T32/9
T32/1 T32/24
0.35 0.35 0.35 0.35

ge/gr sw br br
78 107
107
249 ws = white
2.5 sw = black
br ro = red
br = brown
238
gn = green
2.5 bl = blue
br gr = grey
76 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42305
rs = pink
Edition 09.2001
Control unit with warning lamps in the dash panel, revolution
counter, exhaust gas warning lamp (EOBD), electronic accelerator
control warning lamp (EPC)
G5 Rev. counter
K83 Exhaust gas warning lamp (EOBD)
K132 Electric accelerator control warning lamp (EPC)
30
A121 Connection (High-Bus), instrument panel wiring harness

0.5
ro
11a
A122 Connection (Low-Bus), instrument panel wiring harness
SB 11
5A
77 111
111 91
11b
0.35 0.35 0.35 0.35

ge/gr ws/bl gn ro
T32a/15 T32/28 T32/11

Protected by copyright.T32/23
K132
J285
K83
G5
T32a/20 T32a/19 T32/ T32a/10
CAN--L CAN--H 32
0.35 0.35 0.35 0.35

or/br or/sw ws/gn ws/bl
A122 A121
T10n/ T10n/6 ws = white
3
0.5 0.5 0.5 0.5 0.5 0.5 sw = black
or/br or/br or/sw or/sw ws/gn ws/bl ro = red
br = brown
gn = green
J 362
62 67 J362
47 52
bl = blue
T10x/1 T10x/2
gr = grey
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 152 153
or = orange
97--45705
rs = pink
Edition 09.2001
1.4 l - Marelli 4LV/74 kW, engine code letters AUB

From July 2000
Different relay, fuse and multi-way connector allocation: see section on "Fitting locations".
11 10 9 8 7
6 5 4 3 2 1
97-40408 respect to the correctness of information in this document. Copyright by SEAT S.A.

7 - X-contact relief relay (100)
Note:
♦ in brackets, after the component designation, appear the production control numbers on the housing.
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2001
Battery, starter motor, alternator, voltage regulator, ignition and
starter switch, terminal 30 junction box, X-contact relief relay
31 30
A Battery (00532)
7 J59 B Starter motor
X 75x C Alternator
D Ignition and starter switch
T6h/4 T6h/3 T6h/2 T6h/1 E1 Lights switch
1 1 6 6 J59 X-contact relief relay
br sw/ge sw ro
29 99 E1/15 SA2 Fuse -2- in fuse box/battery
A61
T5s 5-pin connector, in the transmission
2.5 4 2.5
ro ro/bl ro TV2 Terminal 30 junction box
A32 A40 1 Earthing strap, battery - bodywork

4 6 4
ro ro ro
2 Earthing strap, gearbox - bodywork
D 30 502 501
TV2 61 Earthing point, C pillar, left

X 50 15 P S
500
2.5 2.5 4 1 0.5 500 Screwed union -1- (30), on the relay plate
501 Screwed union -2- (30), on the relay plate

E1/1 25 E 19 140
140
T7a/5
T10/1 152
152 27
502 Screwed union -1- (30a), on the relay plate
2.5 10 0.5 0.35
ro/sw ro Protected by copyright.
bl Copying
sw/gefor private or commercial purposes, in part or in whole, is not
respect to the correctness of information in this document. Copyright by SEAT A32
S.A. Positive connection (30), in dash panel wiring harness
T5s/1 T5s/2 T5s/3
2.5 25 16 0.5 0.5 A40 Positive connection -1- (30), in dash panel wiring harness
ro/sw sw sw bl gn
50 30 + 2 1 B+ D+ W
A61 Positive connection (X), in dash panel wiring harness
B102 SA 2 SA 1 G C
B A 80A 110A
B102 Earthing connection, in interior wiring harness, front left
ws = white
M
C1 sw = black
-- ro = red
br = brown
2.5 25 25 gn = green
br sw sw bl = blue
gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42026
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), coolant
temperature sender, ignition transformer, spark plug
connector, spark plugs
G2 Coolant temperature sender (01039)
G62 Coolant temperature sender (00522-2312)
J537 Control unit for Marelli 4LV (injection system)
P Spark plug connector
A2 Q Spark plugs
2.5 1.5 0.5 1.5 4
sw sw sw sw sw SB30 Fuse -30- in fuse box
A104 34a 24a 36a SB36 Fuse -36- in fuse box
5 T5l 5-pin connector, in the engine
0.5
sw SB 34 SB 24 SB 36 T10 10-pin connector, green, in the interconnection station
10A 5A 15A
T10d 10-pin connector, white, in the interconnection station
30a 34b 24b 36b T10n 10-pin connector, grey, in the interconnection station
1.5 0.5 1.5 T14 14-pin connector, in the engine
sw ws/ge sw
SB 30 T14a 14-pin connector, brown, in the engine
5A
T10/4 T10n/10 T10/8 14
30b 10 Earthing point, in the plenum chamber
0.5 1.5 1 1.5 0.35
sw/ge sw sw sw sw/ge
Earthing connection -1-, in the engine compartment wiring
85
harness
T10d/8 103
103 T121/4 J537 T121/28
A2 Positive connection (15), in the dash panel wiring harness
1 0.5
sw/ge sw/ge
T121/ T121/103 121
121 T121/93
102 A104 Positive connection -2- (15), in dash panel wiring harness
0.35 0.35 1 0.35
35 100
100 gn/br gn/ge br/ws bl/gr
T5l/4 T14a/ T14a/12 T5l/2 T14/3

11
1 0.5
Protected by copyright. 0.5
Copying for private1 or commercial purposes,
0.5 in part or in whole, is not
sw permitted unlessgn/br gn/ge
authorised br/ws S.A does notbl/gr
by SEAT S.A. SEAT guarantee or accept any liability with
2 N152respect to the1 correctness
3 of information in this document. Copyright by SEAT S.A.
2 3
G62 G2
1 4
4
2.5 0.5 0.5 ws = white
br ge/ro br/ws sw = black
ro = red
P
T5l/5 T14/4 br = brown
Q gn = green
2.5 0.5 bl = blue
br ge/ro
a
gr = grey
10 85
131
131 li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42306
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), hall sender,
potentiometer for exhaust gas recirculation, exhaust gas
recirculation valve
G40 Hall sender (00515-2113)
G212 Potentiometer for exhaust gas recirculation (00556)
J293 Coolant fan controlunit (00831)
N18 Exhaust gas recirculation valve (01265-4312)
A52 SB37 Fuse -37- in fuse box
2.5 0.5 1 1.5 T10a 10-pin connector, red, in the interconnection station
ro ro ro ro
15a 37a T14 14-pin connector, in the engine
7 149
149
SB 15 SB 37 J293 J293 J293 85 Earthing connection -1-, in the engine compartment wiring harness
10A 15A
T14c/8 T14c/2 T14c/3
15b 37b
* * * 220 Earthing connection, (sender earth), in engine wiring harness
0.5 0.5
1 1.5 bl ro/ws
ro/ge ro
D157 L5 A52 Positive connection -2- (30), in dash panel wiring harness
T10d/ T10a/5
6
1 1.5 0.35 0.35 0.35
ro/geCopying
Protected by copyright. ro for private or commercialblpurposes, in part
ro/ws gn/bl
or in whole, is not D101 Connection -1-, in engine compartment wiring harness
105
105 * Copyright by *SEAT S.A.
J537
T121/3 T121/40 T121/61 T121/41 Connection (air conditioner ON), in engine compartment wiring
D157
harness
T121/86 T121/98 T121/ T121/100 L5 Connection -1-, in air conditioner wiring harness
114
0.35 0.35 1 0.35
gn/br ge li gn/br * Only vehicles with air conditioning
T14/1
0.5 0.5
gn/br br/sw
2 5 6 4
G40 N18
3 1 1
G212 2
0.5 1 0.5
ro/ws sw/ge gn/li
49 47 123
123 ws = white
16 ro = red
0.5 0.5 0.35 0.5 1 1 0.5
br = brown
br/ws br/ws gn/li gn/li D101 br/sw br/sw br/sw gn = green
bl = blue
a b
gr = grey
85 220
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42028
rs = pink
Edition 09.2001
Marelli 4LV control unit (injection system), engine revolution
sender, inlet air temperature sender, inlet manifold pressure
sender, accelerator position sender, sender -2- for the
accelerator pedal position
220 Earth connection (sender earth), engine wiring harness
149
149 150
150
0.35 0.35
ws/gn ws/bl
T121/47 Protected by J
537copyright. Copying forT121/30
T121/ T121/ T121/108 T121/109 T121/85 T121/ T121/ T121/ T121/ T121/ T121/
87 82 72 34 33 36 35 73
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
ws sw/ws ge/sw ws/br gn/sw ge/li br/li ro/li gn/li sw/li
T3/1 T3/2 T14/10 T14/12

0.5 0.5
ge/sw ws/br
4 2 1 6 5 3 4 2
G28 G71 G42

3 1
0.5 0.5 G185 G79
gn/li br/ws
ws = white
sw = black
T3/3 T14/11 ro = red
0.35 0.35 0.5
br = brown
br/sw br/bl gn/li gn = green
bl = blue
b
34 29 gr = grey
220
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--45732
rs = pink
Edition 09.2001
Marelli 4LV (injection system) control unit, throttle valve control
unit, throttle valve control (electric accelerator control), angle
sender -1- for throttle valve (electric accelerator control)
control)
control)
J338 Throttle valve control unit
J 104 J 104 J537 Control unit for Marelli 4LV (injection system)
T25/10 143
143 T25/11 145
145 T10n 10-way connector, grey, in the wiring harness interconnection
T14a 14-way connector, brown, engine
0.5 0.5
or/br or/sw 10 Plenum chamber earthing point
T10n/5 T10n/4
0.35 0.35 0.35 0.35
or/br or/br or/sw or/sw
D160 Connection (Low-Bus), engine bay wiring harness

D160 D159
0.35 0.35
or/br or/sw
CAN--L CAN--H
T121/58 J537 T121/60
T121/1 T121/2 T121/91 T121/ T121/ T121/ T121/117 T121/118

92 83 84
2.5 2.5 0.35 0.35 0.35 0.35 1 1

br br ro/gr sw/ro ws/sw ro/ws gr/ge ro/bl
T14a/7 T14a/ T14a/ T14a/ T14a/8 T14a/1

10 4 3
0.5 1 1 0.5 0.5 0.5
ro/gr sw/ro ws/sw ro/ws gr/ge ro/bl
1 2 4 3
J338 G186
6 5
G187 G188
ws = white
sw = black
ro
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not = red
br = brown
gn = green
bl = blue
gr = grey
10 10
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42712
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), knock
sensor I, cylinder 1 injector, cylinder 2 injector, cylinder
3 injector, cylinder 4 injector
G61 Knock sensor I (00524-2142)
N30 Injector cylinder 1 (01249-4411)
T5l 5-way connector, in the engine
T10 10-way connector, green, in the wiring harness
interconnection
J 362 T10b 10-way connector, blue, in the wiring harness
136
136 142
142 128
128 T10x/7
interconnection
T10n 10-way connector, grey, in the wiring harness
0.5 0.35 0.35 0.5
gn/ws ge/gr ge/gr ws/ge
interconnection
T14 14-way connector, in the engine
T14a 14-way connector, brown, in the engine
T10b/9 T10n/7 T10a/7
* 200 Earth connection (screened), engine bay wiring harness
0.35 0.35 0.35
gn/ws ge/gr ws/ge
W D95 Connection (injectors) wiring harness engine bay

T121/54 T121/48 J537 T121/43
* W auto-diagnosis line
T121/ T121/106 T121/96 T121/97 T121/88 T121/89

99
0.35 0.35 0.35 0.35 0.35 0.35

sw gr gr/sw gr/gn gr/ro gr/bl
102 with
102
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability
respect to theT14a/2
correctness T14a/5 in this document.
of information T14a/6 CopyrightT14a/9
by SEAT S.A.
0.35 0.35 1 1 1 1 1
T14/8 T14/7 T14/6 T10/5

N30 2 N31 2 N32 2 N33 2
0.5 0.5 0.5 1
sw bl gr ro/ge
1 1 1 1 ws = white
T5l/1
sw = black
1 1 1 1 1 ro = red
gn = green
D95 bl = blue
G61 gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--45733
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), Lambda probe,
Lambda probe after catalytic converter, Lambda probe
heating, heating for Lambda probe 1, after catalytic converter
G130 Lambda probe after catalytic converter (00699)
Z29 Heater for Lambda probe 1, after catalytic converter
E30 Connexion (87a), engine wiring harness
147
147
0.35
gn
T10a/8
0.35
gn/bl
T121/37 J537
T121/ T121/69 T121/63 T121/ T121/5 T121/ T121/ T121/ T121/51

68 81 70 71 52
0.35 0.35 0.35 0.35 1 0.35 0.35 0.35 0.35

gn sw br ws/gr br/ro gr/ro sw gn gr/ws
T4c/3 T4c/4 T4c/2 T10n/2 T6q/1 T6q/5 T6q/4 T6q/3 T6q/6
1 1 1
gr sw ws
Z29 Z19 G39

103
103
G130 ws = white
1 1
ws ro/ge sw = black
ro = red
T4c/1 T10a/4 T6q/2 T14a/13 br = brown
gn = green
1.5 1.5 1.5 1.5 bl = blue
ws/ro ws/ro ws/ro ro/gn
gr = grey
E30
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
or = orange
97--42308
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), fuel pump
30 15 relay, brake light switch, brake pedal switch,
speedometer sender, activated charcoal filter solenoid
J17
2 valve 1
87F T F Brake light switch (00526-2131)
F63 Brake pedal switch
G22 Speedometer sender (01086)
T6i/1 T6i/2 T6i/5 T6i/3
4 4 0.5 0.5 J537 Control unit for Marelli 4LV (injection system)
M9 Left brake light bulb
M10 Right brake light bulb
A99 A2 M25 High brake light bulb
8
1.5 1 1 0.5 1
N80 Activated charcoal filter solenoid valve 1 (01247-4343)
ro/bl ro/sw ro/sw sw sw (frequency)
3a 1a 27a 28a
116
116
SB 3 SB 1 SB 27 SB 28 SB27 Fuse -27- in fuse box
10A 10A T10a/9 5A 7.5A SB28 Fuse -28- in fuse box
3b 1b 27b 28b
1 1 0.35 0.35 1 T14 14-pin connector, in the engine
ro/ge ro/ge ro/ge sw sw
144
144 T10d 10-pin connector, white, in the interconnection station
A38
83 91 139
139
J537 T121/65 0.5 0.35 12 Earthing point in the engine compartment, on the left
sw/gr ws/bl
T10/2 T10c/3 82 Earthing connection -1-, in the wiring harness, front left
T121/64
permitted unless authorised by SEAT S.A. SEAT S.AT121/55 T121/56
0.35 0.35 0.35 0.5 0.5
gn/ge li/gn sw/ro sw/gr ws/bl A2 Positive connection (15), in the dash panel wiring harness
D73 T14/14 T14/13 A38 Positive connection -2- (15a), in dash panel wiring harness
1 1 0.5 0.5
sw/ro sw/ro sw/gr ws/bl
A99 Connection -1- (87), in dash panel wiring harness
2 1 2 1 2
N80 F63 F T10d/7 G22 D73

Positive connection (54), in engine compartment wiring
harness
1 2 1 3
0.5 1 1 1 1 Positive connection -2- (15a), in engine compartment wiring
sw/ge sw ro/ge sw/ro br ws = white D136
harness
sw = black
17 D136 32 M9 T14a/14 ro = red
M10 br = brown
1 1 M25 1 gn = green
sw sw 4
br
br
bl = blue
gr = grey
113
113 21 82 12
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--42033
rs = pink
Edition 09.2001
Fuel gauge sender, fuel pump (pre-supply pump),
coolant shortage sender, oil pressure switch 0.3 bar,
intake manifold preheating heater element
F22 Oil pressure switch 0.3 bar (00772-3114)
G Fuel gauge sender (00771-3113)
G32 Coolant shortage sender
N51 Intake manifold preheating heater element
b SB40 Fuse -40- in fuse box
c
T5l 5-pin connector, in the engine
d
e
T14 14-pin connector, in the engine
102
102 101
101
12 Earthing point in the engine compartment, on the left
1 1.5 0.35 0.35

sw ro/bl ro/bl bl/sw 61 Aerthing point, C pillar, left
40a
108 Earthing connection -2-, in the front wiring harness, left
T5l/3 SB 40 T10c/2 T10a/6
15A Earthing connection -2-, in the engine compartment wiring
131
40b
harness
1
sw/ge
B109 Earthing connection, in interior wiring harness, rear left
1
N51
2
1 1.5 0.35 0.35 0.5 0.5

br ro/ge li/sw br/ws bl/ro bl/sw
T14/9
1
br 1 2 1 1
G6 G T10a/1 G32 F22

4 authorised by SEAT
permitted unless 3 2
respect to the correctness of information in this document. Copyright by SEAT S.A. ws = white
2.5 1.5 0.5 1 0.5 sw = black
br br br/ws br/ws br/sw
ro = red
br = brown
108 B109
gn = green
26 42 bl = blue
6 2.5
br br gr = grey
12 61
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42309
rs = pink
Edition 09.2001
pressure warning lamp, coolant temperature/level warning
lamp
G1 Fuel gauge
G21 Speedometer
b
c
K3 Oil pressure warning lamp
16a
d K28 Coolant temperature/level warning lamp
e K105 Fuel level indicator lamp
SB 16 SB16 Fuse -16- in the fusebox
5A
26 73
16b
0.5 0.5 0.5 0.5 A27 Connection (speed signal), instrument panel wiring harness
ge/ro gn/ws br/ro br/ro
T10/3 A27 B158

7 B158 Connection (S), interior wiring harness
0.35 0.35 0.35 0.35 0.35 0.35 0.35
bl/sw ro/bl br/ws ge/ro li/sw gn/ws br/ro
T32/10 T32/22 T32/7 T32/8 T32/5 T32/3 T32/30
G3 G1
K3
Protected by copyright. Copying for private or commercial purposes, in partJor in whole, is not
285
K28 K105
G21
T32/13 T32/1
0.35 0.35
ge/gr sw
78 107
107
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42035
rs = pink
Edition 09.2001
counter, alternator warning lamp, exhaust gas warning lamp
(EOBD), electric accelerator control warning lamp (EPC)
G5 Rev. counter
30 K132 Electric accelerator control warning lamp (EPC)
0.5 T10a 10-way connector, red, in the wiring harness interconnection
ro
11a 13
SB 11 0.5
5A bl
11b
238 Earth connection-1-, interior wiring harness
77 111
111 91
T10a/3
0.35 0.35 0.35 0.35 0.35 249 Earth connection -2-, interior wiring harness
ge/gr ws/bl gn ro bl
T32a/15 T32/28 T32/11 T32/23 T32/12 A121 Connection (High-Bus), instrument panel wiring harness

K132 K2
J285
K83
G5
T32a/20 T32a/19 T32/ T32a/10 T32/9 T32/24

CAN--L CAN--H 32
0.35 0.35 0.35 0.35 0.35 0.35

or/br or/sw ws/gn ws/bl br br
A122 A121 249

3
0.5 0.5 0.5 0.5 0.35 0.35 2.5 sw = black
or/br or/br or/sw or/sw ws/gn ws/bl br ro = red
br = brown
238
gn = green
J362 62 67 J362 47 52
bl = blue
T10x/1 T10x/2 2.5
br gr = grey
76 li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 152 153
or = orange
97--42713
rs = pink
Edition 09.2001
1.4 l/55 kW diesel injection engine, engine codes AMF

From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408

3 - Fuel shut- off control unit (405)
Note:
Edition 02.2003
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 A - beige permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
3 A - purple
Edition 02.2003
31 30
B Starter
7 J59 C Alternator
X 75x C1 Voltage regulator
E1 Lighting switch
T6h/4 T6h/3 T6h/2 T6h/1 E19 Parking light switch
1
br
1
sw/ge
6
sw 16 93 E1/15 34
6
ro
T14b 14-pin connector, on engine
2.5 2.5 2.5 1.5 TV2 Terminal 30 junction box
A61 ro ro ro ro
A32 A40
4 6 4
ro ro ro 2 Earth strap, gearbox - body
D 30 502 501
61 Earth point, left C-pillar
TV2
X 50 15 P S
500 A32 Positive (+) connection (30), in dash panel wiring harness
2.5 2.5 4 1 0.5 10
sw/ge ro/sw sw ge br/ro ro
A40 Positive (+) connection -1- (30), in dash panel wiring harness
E1/1 21 E 19 130
130
T7a/5 A61 Positive (+) connection (X), in dash panel wiring harness
120
120 45
0.5 Protected
0.35 by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with heater
* Only models with additional
bl br/ro
60 97 ** Only
respect to the correctness of information in this document. models
Copyright without
by SEAT S.A.additional heater
T10/1 T14b/ T14b/4
5
* * **
2.5 25 10 6 25 16 0.5 0.5
ro/sw sw ro ro sw sw bl br/ro
B102
50 30 + 4 3 2 1 B+ D+ W
SA 4 SA 3 SA 2 SA 1 G C
B 80A 50A 80A 150A
* ws = white
110A ** sw = black
M
C1 ro = red
-- br = brown
2.5 A gn = green
br 25 25 bl = blue
sw sw gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--43444
rs = pink
Edition 02.2003
Direct injection diesel control unit, fuel cut-off control unit
(collision), engine revolution sender, fuel gauge sender
30 31 DA
G28 Engine revolution sender (00513-2111)
J491 3 G81 Fuel temperature sender (00539-2311)
* J234 Airbag control unit (01321)
CRASH 15 15DA
J248 Direct injection diesel control unit
T9c/3 T9c/6 T9c/5 T9c/2 T9c/4 T9c/8 J491 Fuel cut-off control unit (collision)
J 362
0.5
br
0.5
ro
0.5
gr/ge
0.5
sw
1
sw ** 1
sw
1
sw
T10x/7
A52
0.5
T10b 10-way connector, blue, in the wiring harness
A125 32b ws/ge interconnection
2.5 1 0.5
ro ro gr/ge SB 32 T10b/10 T10a/7 76 Earth point, near gearbox control
10A
15a
7 32a
J 234 *** 81 Earth connection -1-, instrument panel wiring harness
SB 15 T75/72 1 0.35 0.35
10A sw sw ws/ge
15b A104 W A2 Positive connection (15), instrument panel wiring harness

T121/37 J248 T121/16
1 2.5
ro/ge sw A52 Positive connection -2- (30), instrument panel wiring harness
A2 T121/ T121/110 T121/ T121/
102
Protected by copyright.103
Copying111
78 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 0.35
A104 Positive connection -2- (15), instrument panel wiring harness
0.35respect to the correctness of information in this document. Copyright by SEAT S.A.
sw br/sw ws
5 A125 Connection (impact signal), instrument panel wiring harness

F27
0.35 0.35 0.35 0.35 Connection (screened), in the direct injection diesel wiring
F27
sw br sw/ge li harness
* Only vehicles with airbag
T3/3 T3/2 T3/1 ** Only vehicles without airbag
*** W auto-diagnosis line
81 1
G28 G81
2
ws = white
2.5 sw = black
br ro = red
br = brown
gn = green
bl = blue
gr = grey
76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--45771
rs = pink
Edition 02.2003
Direct injection diesel control unit, fuel pump relay,
85 87 coolant temperature sender, intake manifold pressure
sender, intake air temperature sender, supercharging
J17
2 pressure limiter electro-valve
86 30a G2 Coolant temperature sender (01039)
T6j/5 T6j/3 T6j/1 T6j/2
0.5 0.5 4 4 J17 Fuel pump relay (01259-4433)
gn sw/ge ro/bl ro/ge J248 Direct injection diesel control unit
138
138 117
117 N18 Exhaust gas recirculation valve (01265-4312)
24a 40b N75 Supercharging pressure limiter electro-valve (01262-4442)
0.35 0.35
gn ro/ge SB24 Fuse -24- in fuseholder
SB 24 SB 40 SB40 Fuse -40- in fuseholder
5A 15A
T10a/10 T10a/8 T10/6 T10 10-way connector, green, in the wiring harness
24b 40a interconnection
0.35 0.5 0.5 1.5 0.35 0.35
gn sw/ge ws/ge ro gn ro/ge T14b 14-way connector, in the engine
91 72 10 100
100
T121/80 J248 T121/27 T121/40
T121/ T121/73 T121/ T121/71 T121/61 T121/62 T121/112 T121/

52 31 104
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

br/bl bl/ge li/ro sw/ge br/ws ro/bl bl/br br/bl
T14b/13 T14b/11
0.5 0.5
ge/ro br/bl
2 G72 G71 3 2 2 3 G62 G2 1
N18 N75
1 4 1 1 4 2
0.5 0.5 0.5
permitted 0.5
sw/ge sw/ge ws/gr respect to the
br/ws
ws = white
sw = black
90 91 T14b/14 T14b/12 ro = red
0.5 1
br = brown
ge/ro br gn = green
bl = blue
124
124 109
109 gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42311
rs = pink
Edition 02.2003
Diesel direct injection system control unit, air mass meter,
unit injector solenoid valve, cylinder 1, unit injector solenoid
valve, No. 2 cyl., unit injector solenoid valve, No. 3 cyl.
G70 Air mass meter
J248 Diesel direct injection system control unit
N240 Unit injector solenoid valve, No. 1 cyl.
91 SB37 Fuse -37- in fuse box
T8b 8-pin connector
1 T10a 10-pin connector, red, coupling station
sw/ge
10 Earth point, in plenum chamber
2
14
G70 D95 Connection (injectors), in engine compartment wiring harness
4 3 5
0.35 0.35 0.35 0.35

br/ro ro/gn br/bl br/ro F26 Connection -2-, in diesel direct injection system wiring harness
T121/38 J248 T121/30 T121/49 T121/68
T121/116 T121/118 T121/121 T121/114 T121/1 T121/2 T121/ T121/

4 5
2.5 2.5 2.5 2.5 1.5 1.5

br/ge br/gn br/ws br/ro sw/ws sw/ws 2.5 2.5
br br
F26
T8b/3 T8b/5 T8b/2 T8b/6

2.5
sw/ws
T10a/4
1.5 1.5 1.5 1.5 1.5
ro ge ws br sw/ws
37b Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 2 2 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
N240 N241 N242 SB 37
15A ws = white
1 1 1
37a
sw = black
ro = red
1.5 1.5 1.5 1.5 br = brown
br br br sw/ge gn = green
D95 bl = blue
93
gr = grey
10 10
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--45772
rs = pink
Edition 02.2003
Diesel direct injection system control unit, high and low heat
output relay, idling switch, accelerator pedal position sender,
coolant heating elements
F8 Kick-down switch
F60 Idling switch
J104 130
130 J
104 128
128
J359 Low heat output relay
T25/11 T25/10
J360 High heat output relay
0.5 0.5
or/sw or/br Q7 Coolant heating elements
134
134
S109 Coolant heater element fuse
T10n/4 T10n/5 S143 Coolant heater element fuse 2
0.5 S265 Coolant heater elements fuse 3
gn/ws 0.35 0.35 0.35 0.35 T10b 10-pin connector, blue, coupling station
or/sw or/sw or/br or/br
T10n 10-pin connector, grey, coupling station
T10b/9 D159 D160
Positive (+) connection -1- (30a), in engine compartment wiring
D78
0.35 0.35 0.35 harness
ws or/sw or/br
CAN--H CAN--L
T121/20 J248 T121/7 T121/6 D98 Connection (glow plugs), in engine compartment wiring harness
Positive (+) connection (high bus), in engine compartment wiring

D159
T121/22 T121/21 T121/ T121/ T121/ T121/ T121/ T121/ harness
51 63 70 50 12 69
0.35 0.35 Positive (+) connection (low bus), in engine compartment wiring
sw/br * D78 sw/bl D160
6 6 harness
ro 10 ro 0.35 0.35 0.35 0.35 0.35 0.35
ro br/bl ws/bl gn/ws gr/ro ge/gn gr/bl * Only models with additional heater
30a 30a
T6b/5 T6b/1 T6c/1 T6c/5
*
J359 6 *
J360
T6b/3 T6b/2 T6c/2 T6c/3
87a GK RV 87a
0.5 6 0.5
sw/ge sw/ro sw/ge
D98
88 6 6 6 90
sw ro/ws ro
1 1 1 6 1 5 3 2 4
* * *
S109 S143 S265
40A 40A 40A
ws = Protected
white by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 2 2
F60 F8 G79 sw =permitted
black unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 4 4 ro = redrespect to the correctness of information in this document. Copyright by SEAT S.A.
sw ws ro br = brown
gn = green
Q7 bl = blue
gr = grey
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70 or = orange
97--45773
rs = pink
Edition 02.2003
Diesel direct injection system control unit, brake light switch,
clutch pedal switch, cruise control system brake pedal
switch/diesel direct inj. system
F Brake light switch
F36 Clutch pedal switch
F47 Cruise control system brake pedal switch (diesel direct injection
system)
F268 Additional heater, heater element contact switch
J293 Radiator fan control unit
J293 J293 M9 Brake light bulb, left
T14c/8 T14c/3
* * M25 High level brake light bulb
0.5 0.35 T4j 4-pin connector, behind dash panel
bl gn/bl T10 10-pin connector, green, connector point
95
T10a 10-pin connector, red, connector point
D157
T10d 10-pin connector, white, connector point
*
0.35 0.35
ge/bl bl 45 Earth point, behind dash panel
T121/42 J248 T121/34 T121/29

162 Earth connection, in blower motor wiring harness
T121/66 T121/65 T121/32 T121/15

*** **
B131 Positive (+) connection (54), in engine compartment wiring
D73
harness
0.35 0.35 1 1 0.35 0.35 0.35
ws/ro sw/ge sw/ro sw/ro sw/ro sw/ro ws/ge
Connection (air conditioner, on), in engine compartment wiring
D157
harness
T10d/7 D73 T10a/9
* Only models with air conditioner
1 *** 1 ** 0.35 ** Only models with ABS
ws/sw sw/ro ws/gn
*** Only models without ABS
2 1 2
M9 T4j/2
F36 F47 M10 F
1
M25 1
0.5
li
2
0.5 0.5 1 2
br/bl ws/ge ro/ge
F268 ws = white
Protected by copyright. Copying for private or commercial purposes, in part1or in whole, is not sw = black
T10/8 T10d/6
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ro = red
0.5
1 0.5
br = brown
ws/ge ro/ge br gn = green
2.5 bl = blue
32 17 br 162 gr = grey
45 li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84 or = orange
97--43447
rs = pink
Edition 02.2003
Diesel direct injection system control unit, terminal 30 voltage
supply relay, glow plugs relay, Hall sender, glow plugs -
engine
G40 Hall sender
J52 Glow plugs relay
J317 Terminal 30 voltage supply relay
N79 Heater element (crankcase breather)
N239 Intake manifold flap change-over valve
T10a/5 Q6 Glow plugs - (engine)
2.5 2.5
ro ro
J317 2/30a
8 F25 Connection -1-, in diesel direct injection system wiring harness
9/85 6/87
52 73 7 * Only models with additional heater
0.35 2.5 1.5 0.35 6

sw/li sw/ge sw/ge ge/bl ro
T 30a
J248 T121/18 T6e/5 T6e/1
T10/5
J52
T121/ T121/109 T121/81 1 T6e/3 T6e/2
101 sw/ge 87a G
0.35 0.35 0.35 23a

br/sw gn/li ro/bl
1 6
0.5
sw/ge SB 23 sw/ge ro
T3k/3 T3k/2 5A
2 23b
G40 N239 31 1
sw/ge
1
35 37
T3k/1 T10/4
0.5 0.5 0.5 0.5 1
sw/ge sw/ge sw/ge sw/ge sw/ge
F25
0.5 * *
sw/ge 0.5 0.5 1
sw/ge sw/ge sw/ge
1 ws = white
sw = black
N79 57 63 53 ro = red
br = brown
Q6
2
0.5
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with gn = green
br bl = blue
gr = grey
110
110
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98 or = orange
97--43448
rs = pink
Edition 02.2003
Fuel gauge sender, fuel gauge, fuel pump (pre-supply pump),
speedometer sender, coolant shortage indicator sender
G Fuel gauge sender
G32 Coolant shortage indicator sender
a T10a 10-pin connector, red, connector point
b T10c 10-pin connector, black, connector point
c T14b 14-pin connector, on engine

J 362
T10x/3

0.35 0.35 0.5 0.5
li/sw br/ws bl/ro sw
A38
132
0.5 0.35
sw/gr ws/bl 131 Earth connection -2-, in engine compartment wiring harness
T10/2 T10c/3
221 Earth connection (engine earth), in engine wiring harness
0.5 0.5
sw ws/bl
A38 Positive (+) connection -2- (15a), in dash panel wiring harness
36
T14b/ T14b/9
8
B109 Earth connection, in interior wiring harness, rear left
4 0.5 0.5
ro/ge sw ws/bl
1 2 1 1 2
V/5 Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
G6 G G32 G22 1 correctness of information in this document. Copyright by SEAT S.A.
respect to the
br
4 3 2 3 86
131
1.5 0.5 0.5 0.5 0.5 2.5
br br/ws br/ws br/ws br br
42
82 ws = white
B109 T10a/1 T14b/10 sw = black
ro = red
2.5 1 1 1 1.5 6
br br br br br br br = brown
221 gn = green
bl = blue
gr = grey
61 12
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112 or = orange
97--43449
rs = pink
Edition 02.2003
Control unit with display in dash panel insert, fuel gauge,
coolant temperature gauge, oil pressure switch
F1 Oil pressure switch
G1 Fuel gauge
J285 Control unit with display in dash panel insert
a K28 Coolant temperature warning lamp/coolant shortage warning lamp
b K29 Glow period warning lamp
c K105 Reserve fuel warning lamp
40 T10a 10-pin connector, red, connector point
T10c 10-pin connector, black, connector point
0.5 0.5 T14b 14-pin connector, on engine
bl/ro ge/ro
T10c/2 T10/3 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
0.35 0.35 0.35 0.35 0.35
bl/sw ro/bl br/ws li/sw ge/ro
T32/10 T32/22 T32/7 T32/5 T32/8
G1 G3
T10a/6 K3
J285
0.5
br/ws
T14b/3 K105 K28

K29 K2
T32/13 T32/12
0.5 0.35 0.35

ge ro/ge bl
1 T10a/3
F1 41 0.5
bl ws = white
sw = black
13 ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42314
rs = pink
Edition 02.2003
Control unit with warning lamps on the dash panel insert, rev.
counter, speedometer
G5 Rev. counter
G21 Speedometer

16a

SB 16
5A
59
16b
0.5 0.5 0.5
br/ro br/ro gn/ws
108
108 39 A27 Connection (speed signal), instrument panel wiring harness
B158 7 A27
0.35 0.35 0.35 0.35 A121 Connection (High-Bus), instrument panel wiring harness
br/ro ws/bl gn/ws sw
T32/30 T32/28 T32/3 T32/11 A122 Connection (Low-Bus), instrument panel wiring harness
J285
G21 G5
T32a/20 T32a/19 T32/9 T32/24
CAN--L CAN--H
0.35 0.35 0.35 0.35

or/br or/sw br br
A122 A121 249
ws = white
0.5 0.5 0.5 0.5 2.5 sw = black
or/br or/br or/swby copyright.
Protected or/sw br
Copying for private or commercial purposes, in part or in whole, is not ro = red
gn = green
J 362 68 65 J362 bl = blue
T10x/1 T10x/2 2.5
br gr = grey
76 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--45770
rs = pink
Edition 02.2003
1.7 l - Diesel injection engine/44 kW, engine code letters AKU

From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
3 - Fuel shut-off control unit (405)

Warning:
♦ The brackets after the names of the relays refers to the control number on the housing.
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 09.2002
31 30
A Battery (00532)
7 J59 B Starter
X 75x C Alternator
16 93
E1 E19 Parking light switch
T17/15
0.5 1 6 2.5 2.5 1.5 6 SA1 Fuse -1- on battery fuse holder
br sw/ge sw/ge ro ro ro ro SA2 Fuse -2- on battery fuse holder
A61 SA3 Fuse -3- on battery fuse holder
A32 A40
4 6 4 T2b 2-pin connector, black, near the alternator
ro ro ro
T10 10-pin connector, green, in interconnection station
502 501
D 30 1 Earth strap, battery body
TV2
X 50 15 S
P
500
2.5 2.5 4 1 0.5
sw/ge ro/sw sw gr br/ro 500 Screw connection -1- (30), on relay plate
E 1
E19 123
123 128
128 33
T17/1 T7a/5 501 Screw connection -2- (30), on relay plate
A2
* 502 Screw connection -1- (30a), on relay plate
2.5 10 0.5 0.35
sw ro bl ro/sw
A2 Positive (+) connection (15), in dash panel wiring harness
21 97 60
T10/1
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with T2b/1 T2b/2 A32 Positive connection (30), in dash panel wiring harness
2.5 6 4
*
25 16 0.5 0.5
ro/sw sw ro ro sw bl gn
50 30 + 3 4 2 1 B+ D+ W
A61 Positive connection (X), in instrument panel wiring harness

SA 3 SA 4 SA 2 SA 1 G C ws = white
B 50A 50A 80 A 110 A
sw = black
C1 ro = red B102 Earth connection, in front left interior wiring harness
M
br = brown
-- A gn = green * Only vehicles with additional heater
25 25 bl = blue
sw sw
gr = grey
B102 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--41776
rs = pink
Edition 09.2002
Diesel direct injection system control unit, intake air
temperature sender, fuel shut- off control unit (crash),
30 31 DA exhaust gas recirculation valve
J491 3
* G42 Intake air temperature sender
CRASH 15 15DA J234 Airbag control unit
T9c/3 T9c/6 T9c/5 T9c/2 T9c/4 T9c/8 J491 Fuel shut-off control unit (Crash)
J 362 N18 Exhaust gas recirculation valve
0.5 0.5 0.5 0.5 1
** 1 1 T10x/7 SB15 Fuse -15- in fuse box
br ro gr/ge sw sw sw sw
A125 0.5 T10a 10-pin connector, red, connector point
32b ws/ge T10b 10-pin connector, blue, connector point
2.5 1 0.5
ro ro gr/ge SB 32 T10b/10 T10a/7 10 Earth point, in plenum chamber
10A
15a
7 32a
J 234 *** 76 Earth point, near selector mechanism
SB 15 T75/72 1 0.35 0.35
10A sw sw ws/ge
15b A104 W 81 Earth connection -1-, in dash panel wiring harness

T121/37 J248 T121/16
1 2.5
ro/ge sw
A2 T121/61 T121/ T121/ T121/ T121/
54 73 4 5
78
4 A52 Positive (+) connection -2- (30), in dash panel wiring harness
sw
5 0.35 0.35 0.35 2.5 2.5 A104 Positive (+) connection -2- (15), in dash panel wiring harness
br/ws br/bl gr/bl br br

2 2
N18 G42 * Only models with airbag

** Only models without airbag
1 1 *** Wire W for self-diagnosis
81
1
sw/ge
90
2.5 ws or =
Protected by copyright. Copying for private white purposes, in part or in whole, is not
commercial
br permitted unless authorised by SEAT S.A.sw SEAT = S.Ablack
ro
respect to the correctness of information =in this
reddocument. Copyright by SEAT S.A.
br = brown
gn = green
bl = blue
gr = grey
76 10 10
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--45816
rs = pink
Edition 09.2002
Diesel direct injection system control unit, engine speed
sender, needle lift sender
G28 Engine speed sender
G80 Needle lift sender
124
124 116
116
0.35 0.35
gn ro/ge
T10a/8 T10/6
0.35 0.35
156 Earth connection, in diesel direct injection wiring harness
gn ro/ge
* Only models with additional heater
J248by copyright.T121/27
Protected T121/40
** Only models without additional heater
T121/86 T121/ T121/101 T121/ T121/102 T121/38
109 110
** *
0.35 0.35 0.35 0.35 0.35 0.35 0.35
br/ro ws br bl gr br ro/sw
14
T2e/1 T2e/2 T3/2 T3/1
V/5
G80 G28
1
br
T3/3 131 ws = white

sw = black
0.35 0.35 2.5 ro = red
sw sw br br = brown
gn = green
6
156 82 br bl = blue
gr = grey
12
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--45817
rs = pink
Edition 09.2002
Diesel direct injection system control unit, fuel temperature
sender, modulating piston movement sender, fuel shut-off
valve, metering adjuster
G81 Fuel temperature sender
G149 Modulating piston movement sender
N109 Fuel shut-off valve
N146 Metering adjuster
T10p 10-pin connector, black, near injection pump
F26 Connection -2-, in diesel direct injection system wiring harness
J248
T121/ T121/ T121/ T121/ T121/ T121/ T121/ T121/1 T121/2 T121/120
103 111 108 106 99 121 116
0.35 0.35 0.35 0.35 0.35 1 1 1.5 1.5 1

br/bl ge/sw li/sw gr/ro ws/gn br/ge br/ge sw/ws sw/ws ws/sw
F26
F28
1 2.5
br/ge sw/ws
T10a/4 T10p/8 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1.5
T10p/ T10p/ T10p/ T10p/ T10p/6 sw/ws
7 1 2 3
37b
1
SB 37 N109 ws = white
15A
sw = black
G81 G149 N146 37a ro = red
br = brown
1 1.5
T10p/4 T10p/5 sw/ws sw/ge gn = green
bl = blue
gr = grey
93 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--42316
rs = pink
Edition 09.2002
Diesel direct injection system control unit, low heat output
relay, high heat output relay, kick-down switch, idling switch,
accelerator pedal position sender, coolant heating elements
F8 Kick-down switch
F60 Idling switch
J
104 131
131 129
129 J104 J248 Diesel direct injection system control unit
T25/11 T25/10 J359 Low heat output relay
0.5 0.5
134
134 T10b 10-pin connector, blue, connector point
T10n/4 T10n/5 T10n 10-pin connector, grey, connector point
0.5 0.35 0.35 0.35 0.35 T24a 24-pin connector, on cylinder head, left
gn/ws or/sw or/sw or/br or/br
D78
T10b/9
D159 D160 harness
0.35 0.35 0.35

ws or/sw or/br D98 Connection (glow plugs), in engine compartment wiring harness
CAN--H CAN--L
T121/20 J248 T121/7 T121/6
D159
harness
Positive (+) connection (low bus), in engine compartment wiring

T121/21 T121/22 T121/ T121/ T121/ T121/ T121/ T121/ D160
51 63 70 50 12 69 harness
D78
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
sw/bl 4 4 * 4 sw/br br/bl gn/ws gr/bl gr/ro ge/gn ws/bl
ro ro ro
30a 30a
T9f/6 T9f/2 T6c/1 T6c/4
* 7 *
J359 J360
T9f/4 T9f/8 T6c/2 T6c/3
87a GK RV 87a
0.5 4 0.5
sw/ge sw sw/ge 6 1 5 3 2 4
D98 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
88 90 respect to the correctness of information in this document. Copyright by SEAT S.A.
2.5 2.5 2.5
sw/ws sw sw
F60 F8 G79
T24a/18 T24a/ T24a/15 ws = white
14
2.5 2.5 2.5 sw = black
sw sw sw
ro = red
br = brown
* gn = green
Q7 bl = blue
gr = grey
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70 or = orange
97--45818
rs = pink
Edition 09.2002
Diesel direct injection control unit, brake light switch,
clutch pedal switch, cruise control brake pedal switch/
diesel direct injection system, coolant temperature
sender, engine temperature sender
F36 Clutch pedal switch (00650)
F47 Cruise control brake pedal switch/diesel direct injection
system (00629)
G27 Engine temperature sender (01204)
J248 Diesel direct injection control unit
M25 High brake light bulb
T24a 24-pin connector, in the cylinder head, on the left
0.35
ge/bl B131 Connection (54), in interior wiring harness
T121/42 J248 Positive connection (54), in engine compartment wiring

D73
harness
T121/66 T121/65 T121/32 T121/112 T121/ * Only vehicles without ABS
104 ** Only vehicles with ABS
B131
* ** permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
0.35 1 1 0.35 0.35 0.35 0.35

ws/ro sw/ro sw/ro sw/ro sw/ro bl/br br/bl
D73
T10d/7 T24a/4 T24a/7
0.35 1 * 1 ** 0.5 0.5
sw/ge ws/sw sw/ro bl/br br/bl
2 1 M9/ 2 3 G62 G2 1
F36 F47 M10/

M25 F
1 2 1 4 2
1 1 1 0.5 1
sw/ge ws/ge ro/ge ge/ro br/ws
ws = white
sw = black
T10/8 T10d/6 T24a/3 ro = red
107
107 br = brown
0.5 1 0.5 gn = green
ws/ge ro/ge ge/ro bl = blue
gr = grey
90 17 121
121 li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84 or = orange
97--42318
rs = pink
Edition 09.2002
Diesel direct injection control unit, terminal 30 voltage supply
relay, glow plugs relay, commencement of injection valve,
throttle valve, glow plugs (engine)
J52 Glow plugs relay (01266-4111)
J317 Terminal 30 voltage supply relay (01054)
J248 Diesel direct injection control unit
N108 Commencement of injection valve (01269-4114)
N211 Throttle valve (01693)
Q6 Glow plugs (engine)
T10a/5 SB23 Fuse -23- in fuse box
2.5 2.5
ro ro
J317 2/30a T10p 10-pin connector, black, close to the injection pump
8 T24a 24-pin connector, in the cylinder head, on the left
52 74 8 F25 Connection -1-, in the diesel direct injection system wiring harness
9/85 6/87
0.35 2.5 1.5 0.35 6

sw/li sw/ge sw/ge ge/bl ro Connection (engine glow plugs), in the diesel direct injection system
F31
wiring harness
Protected byT copyright. Copying
30afor private or commercial purposes, in part or in whole, is not
J248 T121/18 T6e/5 T6e/1
*
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability Only
with vehicles with additional heater
J52
T10/5
T121/62 T121/114 T6e/3 T6e/2
87a G
0.35 1 0.5 1
ro/bl br/sw sw/ge sw/ge 1 6
sw ro
T24a/22 T10p/9 24a 23a

0.5 1
ro/bl br SB 24 SB 23
5A 52 5A
2 1
24b 23b
N211 N108 0.5 F31
1 2 ws/ge
0.5 1 1 2.5 2.5

sw/ge sw 72 sw/ge ro ro
23
T24a/21 T10p/10 T10/4 T24a/ T24a/8
16
1 1 1 1 2.5 2.5
sw/ge sw/ge sw/ge sw/ge sw sw
ws = white
F25 sw = black
* * ro = red
0.5 0.5 br = brown
sw/ge sw/ge Q6 gn = green
bl = blue
57 62 gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98 or = orange
97--42319
rs = pink
Edition 09.2002
Fuel gauge sender, speedometer sender, coolant
shortage sender, oil pressure switch
a T10a 10-pin connector, red, in the interconnection station
b T10c 10-pin connector, black, in the interconnection station
c T24a 24-pin connector, in the cylinder head, on the left
d
15 Earthing point, in the cylinder head
A38 Positive connection -2- (15a), in dash panel wiring harness

J362
T10x/3
0.5 0.35 0.5 0.35 0.35

sw li bl/ro br/ws bl/sw
136
136 84
A38
0.5 0.35 1 1
sw/gr ws/bl br/ws
G32
2
T10/2 T10c/3 T24a/13 T10a/6
0.5 0.5 0.5 1 0.5
sw ws/bl br/ws br/ws ge
T24a/ T24a/5 T24a/10

9
T10a/1
0.5 0.5 0.5
sw ws/bl ge
1 2 1 1 document. Copyright by SEAT S.A.
respect to the correctness of information in this
G22 G F1
3 2 ws = white
1 0.5 sw = black
br/ws br/ws ro = red
br = brown
gn = green
bl = blue
gr = grey
15 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112 or = orange
97--45819
rs = pink
Edition 09.2002
Control unit with warning display on dash panel insert,
fuel gauge, coolant temperature indicator, rev. counter,
oil pressure warning lamp, temperature/coolant
shortage warning lamp
G1 Fuel gauge (00664)
G3 Coolant temperature indicator
G5 Rev. counter (00662)
J285 Control unit with warning display on dash panel insert
a
b
(01317)
c
K3 Oil pressure warning lamp (00755)
d K28 Temperature/coolant shortage warning lamp
82 K29 Pre-heating period warning lamp (00626)
K105 Fuel gauge warning lamp (01082)
0.5 0.5 T10 10-pin connector, green, in the interconnection station
bl/ro ge/ro T10c 10-pin connector, black, in the interconnection station
34
T10c/2 T10/3
0.35 0.35 0.35 0.35 0.35 0.35 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
bl/sw br/ws ro/bl li ge/ro gn
T32/10 T32/7 T32/22 T32/5 T32/8 T32/11
G1 G3
K3
J285
K29 K105 K28

G5
T32/13
0.35
ro/ge
36
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--45814
rs = pink
Edition 09.2002
Control unit with warning lamps on the dash panel insert,
speedometer, alternator warning lamp
G21 Speedometer
...... b
16a 76 Earth point, near gearbox control
SB 16
5A
13 59
16b
0.5 0.5 0.5 0.5 249 Earth connection -2-, interior wiring harness
br/ro br/ro bl gn/ws
101
101
B158 7 T10a/3 A27 A27 Connection (speed signal), in the instrument panel wiring harness
0.35 0.35 0.35 0.35

br/ro bl gn/ws ws/bl A121 Connection (High-Bus), instrument panel wiring harness
T32/30 T32/12 T32/3 T32/28
K2 B158 Connection (S), interior wiring harness

J285
G21
T32a/20 T32a/19 T32/9 T32/24
CAN--L CAN--H
0.5 0.5 0.35 0.35

or/br or/sw br br
A122 A121 249
ws = white
0.5 0.35 0.35permitted
0.5 unless authorised by SEAT S.A. SEAT S.A 2.5does not guarantee or accept any sw
liability with
= black
or/br or/br or/sw or/sw br document. Copyright by SEAT S.A.
respect to the correctness of information in this
ro = red
br = brown
238
gn = green
J 362 67 65 J362
bl = blue
T10x/1 T10x/2 2.5
br gr = grey
76 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--45815
rs = pink
Edition 09.2002
Air conditioner
⇒ 1.0 l/37 kW Motronic, engine codes AUC
⇒ 1.4 l/44 kW Motronic, engine codes ANW and AUD
From July 2000
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 02.2003
Fuse in fuse box/battery:
SA5
SA6
10A 20A 30A 30A

1 2 3 4
SA7
SA8
SA1 SA2 SA3 SA4
E97-0056
SA4 - Fuse -4- air conditioning system control unit (30 A)

SA7 - Fuse -7- radiator fan (20 A)
Edition 02.2003
Fresh air blower switch, air conditioner switch, fresh air/air
recirculating flap switch, fresh air blower, fresh/recirculating air
flap control motor
E1 Light switch
E9 Fresh air blower switch
E35 Air conditioner switch
E159 Fresh air/air recirculating flap switch
E1/17 26a 49a K84 Air conditioning system warning lamp
K114 Fresh air/air recirculation warning lamp
1 1.5
SB 26 2.5
SB 49 L16 Fresh air control light bulb
gr/bl sw sw/ge 25A
5A N24 Fresh air blower with overheating fuse series resistor
B145 A2 26b A61 49b V2 Fresh air blower
V154 Fresh air/recirculating air flap control motor
0.5 4 0.5 6 2.5
gr/bl sw sw sw sw/ro
45 Earth point, behind dash panel
T4j/3 D/15 T4j/4 J59 T4j/1 a
T6h/2
0.5 0.5 162 Earth connection, in blower motor wiring harness
gr/bl gn/ro
D52
0.5 0.5 0.5 2.5 0.5
sw gn/ws gn/ro sw/ro br/ge
T10q/3 T10q/4 T10q/1 T10q/2 A61 Positive (+) connection (X), in dash panel wiring harness
0.5 30 0.5 39 2.5 0.5
gr/bl sw/bl sw/bl bl/ro
58b Xa B145 Positive (+) connection (58b), in interior wiring harness
T8m/3 K114 T8m/5 E159 E9 T6t/2 K84 T8m/1
L16 E35 D52 Positive (+) connection (15a), in engine compartment wiring harness
T8m/4 T8m/7 T8m/8 T6t/1 T6t/3 T6t/4 T6t/5 T8m/2

31 L45 Connection, in air conditioner controls wiring harness
0.5 0.5 0.5 2.5 2.5 2.5 2.5 0.5
br bl/ge ws/ro ge gn ws bl ws/sw
L66 L45
2.5 2.5 2.5

ge ge ws/sw
2 1
1 4 1 3 2
ws = white
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ro = red
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee2 or accept any liability with
3
respect to the correctness of information in this document. Copyright by SEAT S.A. br = brown
0.5 2.5 gn = green
br 162 br bl = blue
2.5
br gr = grey
45
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--45842
rs = pink
Edition 02.2003
Radiator fan control unit, ambient temperature switch, air
conditioning system magnetic coupling, radiator fan,
coolant fan, right
F38 Ambient temperature switch
J293 Radiator fan control unit (00831)
N25 Air conditioning system magnetic coupling (01270-4121)
V7 Radiator fan (01018-3433)
V35 Coolant fan, right
F38 1
a
Connection (1st fan speed), in engine - headlight wiring
2 D135
harness
0.5 0.5 0.5
br/ge gr/bl bl Connection (radiator fan run-on), in engine compartment
D161
wiring harness
* Only ANW vehicles with automatic gearbox
T14c/8 J293 T14c/5 T14c/14
T14c/6 T14c/3 T14c/10 T4g/4 T4g/2
0.5 0.5 1 4 2.5

br gn/bl gn/sw ro/bl ro/ws
D161 *
T5s/4
Protected by copyright. Copying forTprivate
3b/1 or commercial purposes, in part or in whole, is not
0.5 1
V V
bl sw
35 7
2
J 220 N25
T80/42
1
1
br/ws T3b/3 T3b/2 ws = white
T5s/5 sw = black
ro = red
1 4 2.5 br = brown
br br ro/ws
gn = green
1.5 D135 c bl = blue
br gr = grey
201 82 201 108
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--41787
rs = pink
Edition 02.2003
Radiator fan control unit, radiator fan thermo-switch, high
pressure sender
A Battery (00532)
F18 Radiator fan thermo-switch
G65 High pressure sender (00819)
J293 Radiator fan control unit (00831)
D135 Connection (1st fan speed), in engine - headlight wiring harness

J220
T80/17
K20 Positive connection -1-, in evaporator housing unit wiring harness
0.5
ro/ws
4
L5
6 L5 Connection -1-, in evaporator housing unit wiring harness
0.5 0.5 0.5 0.5
sw ro/ws ro/ws gn/ro
T14c/9 T14c/2 T3j/2 T3j/3
J293 G65
T14c/7 T4g/3 T14c/ T4g/1 T3j/1
4
0.5 2.5 1 4 0.5

ro/sw ro/ge ro ro br
K20
2.5 2.5
ro/ge ro/ge
3 2
II I T4a/3 T4a/4 4
F18
1 SA
20 A
7 SA
10A
8 SA
30 A
4
ws = white
2.5 sw = black
ro/ws
ro = red
br = brown
A/+ gn = green
c D135 bl = blue
gr = grey
201
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--41788
rs = pink
Edition 02.2003
Air conditioner
⇒ 1.4 l/74 kW Marelli - 4LV, engine codes AUB
From July 2000
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7.5 A - brown permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 A - beige
3 A - purple
Edition 02.2003
SA5
SA6
10A 20A 30A 30A

1 2 3 4
SA7
SA8
SA1 SA2 SA3 SA4
E97-0056

Edition 02.2003
flap control motor
E1 Light switch
1 1.5
SB 26 2.5
gr/bl sw sw/ge 25A
0.5 4 0.5 6 2.5
gr/bl sw sw sw sw/ro a
T4j/3 D/15 T4j/4 J59 T4j/1
T6h/2
gr/bl gn/ro
D52
0.5 0.5 0.5 2.5 0.5
sw gn/ws gn/ro sw/ro bl
0.5 30 0.5 39 2.5 0.5
T8m/3 K114 T8m/5 E159 E9 T6t/2 K84 T8m/1

0.5 0.5 0.5 2.5 2.5 2.5 2.5 0.5
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with L66 Connection, in heater blower wiring harness
L66 Copyright by SEAT S.A.
respect to the correctness of information in this document. L45
2.5 2.5 2.5

ge ge ws/sw
2 1
1 4 1 3 2
ws = white
ro = red
2
3 br = brown
0.5 2.5 gn = green
br 162 br bl = blue
2.5
br gr = grey
45
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--45843
rs = pink
Edition 02.2003
Coolant fan control unit, coolant fan pressure switch,
external temperature switch, right coolant fan, coolant
fan
A Battery (00532)
F18 Coolant fan pressure switch
F38 External temperature switch
J293 Coolant fan control unit (00831)
V7 Coolant fan (01018-3433)
V35 Right coolant fan
J537
T121/40
a
1
0.5 0.35 108 Earthing point -2-, in the front left wiring harness
bl bl F38
D157 2 Connection (fan speed I), in engine wiring harness-
D135
headlights
0.5 0.5 0.5
bl gr/bl bl Connection (air conditioner ON), in engine compartment
D157
wiring harness
T14c/8 J293 T14c/5 T14c/14

K20 Positive connection -1- (30), in coolant fan wiring harness
T4g/4 T4g/2 T14c/7 T4g/3 T14c/ T4g/1

4
4 2.5 0.5 2.5 1 4

ro/bl ro/ws ro/sw ro/ge ro ro
K20
2.5 2.5
T3b/1 ro/ge ro/ge
V35 V7
3 2 T4a/3 T4a/4 4
II I
F18 SA 7 SA 8 SA 4
20A 10A 30A
1
T3b/3 T3b/2 ws = white

4 2.5 2.5 sw = black
ro/ws
br ro/ws ro = red
A/+Copying for private or commercial
Protected by copyright. br =purposes,
brownin part or in whole, is not
gn = green
6 D135 bl = blue
br gr = grey
12
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42061
rs = pink
Edition 02.2003
Coolant fan control unit, high pressure sender, magnetic
coupling for air conditioner
G65 High pressure sender (00819)
J293 Coolant fan control unit (00831)
N25 Magnetic coupling for air conditioner (01270-4121)
82 Earthing connection -1-, in the front left wiring harness
201 Earthing connection -5-, in engine compartmentwiring harness

J537
T121/61
L5 Connection -1-, in air conditioner wiring harness
0.35
4 ro/ws 6
L5
0.5 0.5 0.5 0.5
sw ro/ws ro/ws gn/rorespect to the correctness of information in this document. Copyright by SEAT S.A.
T14c/9 J293 T14c/2 2 3
G65
T14c/3 T14c/6 T14c/10 1
0.35 0.5 1
gn/bl br gn/sw 0.5
br
T5s/4
J 537
T121/41 1
sw
2
N25
1
1
br/ws
ws = white
T5s/5 sw = black
82 ro = red
br = brown
1 1.5 4 gn = green
br br br
bl = blue
gr = grey
201 12
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42321
rs = pink
Edition 02.2003
Air conditioner
⇒ 1.4 l/55 kW diesel injection engine, engine codes AMF
From July 2000
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
25 A - white permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 02.2003
SA5
SA6
30A 10A 20A 30A 30A

1 2 3 4
SA7
SA8
SA9
SA1 SA2 SA3 SA4
E97-0053

Edition 02.2003
flap control motor
E1 Light switch
1 1.5
SB 26 2.5
gr/bl sw sw/ge 25A
0.5 4 0.5 6 2.5
gr/bl sw sw sw sw/ro a
T4j/3 D/15 T4j/4 J59 T4j/1
T6h/2
gr/bl gn/ro
D52
0.5 0.5 0.5 2.5 0.5
sw gn/ws gn/ro sw/ro bl
0.5 34 0.5 24 2.5 0.5
T8m/3 K114 T8m/5 E159 E9 T6t/2 K84 T8m/1

0.5 0.5 0.5 2.5 2.5 2.5 2.5 0.5
L66 L45
2.5 2.5 2.5

ge ge ws/sw
2 1
1 4 1 3 2
ws = white
16
ro is=notred
Protected by copyright. Copying for private or commercial purposes, in part or in whole,
3 permitted unless2authorised by SEAT S.A. SEAT S.A does not guarantee or accept any brliability
= with
brown
0.5 0.5 respect2.5 gn = green
br br br
bl = blue
162 2.5
br gr = grey
45
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--45844
rs = pink
Edition 02.2003
Radiator fan control unit, ambient temperature switch, air
conditioner magnetic coupling, high pressure sender, radiator
fan
F38 Ambient temperature switch
G65 High pressure sender
N25 Air conditioner magnetic coupling
T4j 4-pin connector, behind dash panel
T10q 10-pin connector, behind dash panel
T14b 14-pin connector, on engine
V7 Radiator fan
J248
T121/34
a
0.5 0.35
bl bl 1 82 Earth connection -1-, in front left wiring harness
J248
T121/15 D157
F38
2
0.35 0.5 0.5 0.5

bl gr/bl bl
ws/ge D135 Connection (1st fan speed), in engine - headlight wiring harness
T14c/8 J293 T14c/5 T14c/14
D157
harness
T10a/9
T14c/10 T14c/6 T14c/2
0.35 1 0.5 0.5

ws/gn gn/sw br ro/ws
6
T4j/2 T14b/6
0.5 1 0.5
ws/gn sw/gn gn/ro
2 2 3
T10q/6
N25 G65 V7
0.5
li 1
1
2
1
br
T2k/1 T2k/2
Protected ws = white
F268 T14b/7
4
br
2.5
ro/ws
sw authorised
permitted unless = blackby SEAT S.A. SEAT S.A does not guarantee or accept any liability with
D135 ro = red
1
82 br = brown
b gn = green
0.5 1 0.5 1.5 6
br br br br br bl = blue
gr = grey
6 201 12
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42718
rs = pink
Edition 02.2003
Radiator fan control unit, radiator fan thermo-switch
A Battery
SA9 Convertible -9- in fuse box/battery
D135 Connection (1st fan speed), in engine - headlight wiring harness
K20 Positive (+) connection -1- (30), in radiator fan wiring harness
0.5
sw
T14c/9 J293
T4g/2 T4g/1 T4g/3 T4g/4 T14c/4 T14c/3
4 4 4 4 1 0.35
ro/ge ro/ge ro/ge ro/ge ro gn/bl
K20
J248
4 4 T121/29
ro/ge ro/ge
T3d/2 T5f/3 T5f/5

I
F18 SA 7 SA 9
20A 30A
T3d/1
ws = white
2.5 sw = black
ro/ws ro permitted
= redunless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
A/+ br = brown
b D135 gn = green
bl = blue
gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--43451
rs = pink
Edition 02.2003
30
75x
30
75x Motronic control device, pinking sensor, injection valves
G61 Pinking sensor I
J220 Motronic control device, on centre of water tank
J362 Immobiliser control device, steering column side
N30 Injection valve cylinder 1
T2c 2-contact connector on the engine
T4d 4-contact connector on the engine
T6b 6-contact connector on the engine
T10 10-contact connector, pillar A connection station, on the left
T10a 10-contact connector, pillar A connection station, on the left
T10b 10-contact connector, pillar A connection station, on the left
T10e 10-contact connector, in the engine
J 362 T14 14-contact connector, in the engine
T6b/2 T45 45-contact connector
92
12 Point to earth, in the engine compartment, left

0,35
gn/ws
Earth connection -1-, in the cabling harness of the engine
85
compartment
T10b/9 T10a/7
0,5 0,5
Connection (injection valve), in the cabling harness of the engine
gn/ws ws/ge D95
J 220 compartment
T45/ Protected by copyright. Copying for private or commercial purposes, inT45/
36 29
T45/ T45/ T45/ T45/ T45/ T45/ T45/ T45/
0,519 0,539 0,545 1,51 1,07 1,06 1,028 1,04
bl gr sw br gr/sw gr/gn gr/ro gr/bl
58
T14/7 T14/6 T14/8 T10e/2 T10e/5 T10e/6 T10e/9
1,0 1,0 1,0 1,0 1,5
gn gr/gn gr/ro gr/bl ro/ge
T2c/2 T2c/1 T10/5
2 2 2 2
N30 N31 N32 N33 T4d/1

G61 1 1 1 1 ws = white
1,0 1,0 1,0 1,0 1,5 sw = black
ro ro ro ro ro
ro = red
D95 br = brown
gn = green
2,5 bl = blue
br
12 85
gr = grey
li = purple
43 44 45 46 47 48 49 50 51 52 53 54 55 56 ge = yellow
or = orange
97--14468
rs = pink
Edition 02.2003
30
75x
30
75x Motronic control device, lambda probe, speedometer
transmitter
G22 Transmitter for speedometer
4/30 4/85
G39 Lambda probe
4 J 17 H1 Horn
6/87 1/86
J17 Fuel pump relay
J220 Motronic control device, on centre of water tank
J362 Immobiliser control device, steering column side
T23/16 T23/23 T23/20 b
N80 Electromagnetic valve 1 for active carbon tank installation
S8 Fuse in its fuseholder
4,0 0,5 0,5
ro/sw ro/ge sw S11 Fuse in its fuseholder
B146
B135
1,5 1,5 0,5 T4c 4-contact connector in the transmission
ro/sw sw br/ro T6b 6-contact connector on the engine
8 11 26
T10a 10-contact connector, pillar A connection station, on the left
S8 20
S11 S226 T10c 10-contact connector, pillar A connection station, on the left
15A 15A 5A
8A 11A 26A T10d 10-contact connector, pillar A connection station, on the left
T14 14-contact connector, in the engine
1,5 1,5 1,5 0,5 0,35 0,5 0,35 T23 23-contact connector
Protected by copyright. ro/gefor private or commercial purposes, insw/ge
ro/geCopying part or in whole, issw
not sw sw/gr ws/bl
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with T45 45-contact connector
75 55 59
T10a/9
respect to the correctness of information in this H1by SEAT S.A.J 362
document. Copyright
94
T10/2 T10c/3
0,5 T6b/1 15 Point to earth, in the cylinder head
ro/ge
J 220 T45/25
Earth connection -2-, in the cabling harness of the engine
131
compartment
T45/38 T45/15 T45/3
0,5 0,5 1,0 0,5 Earth connection -4-, in the cabling harness of the engine
167
sw ws gn/ge ws/bl compartment
59 24
B135 Connection (15a), in the inside cabling harness

1,5 1,0
ro/ge sw/ge
B146 Positive connection -1- (87), in the inside cabling harness
T10a/4 T4c/4 T4c/3 T10d/8 T14/
14 T14/13
14
1,0 1,0 1,0 1,0
ws/ro sw sw ws/bl
G39 1 1 2
T4c/1 N80 G22

2 3
ws = white
1,0 1,0 1,0 1,0 0,5
sw = black
ws ws gr sw/ge br/ws ro = red
br = brown
T4c/2 gn = green
bl = blue
2,5 1,0
br br gr = grey
167 131 15
li = purple
57 58 59 60 61 62 63 64 65 66 67 68 69 70 ge = yellow
or = orange
97--14896
rs = pink
Edition 02.2003
30
75x
30
75x Fan for coolant, fuel supply, transmitter for coolant-required
warning, oil pressure switch
F18 Heat switch of the coolant fan
F22 Oil pressure switch (0.3 bar)
G Transmitter for available fuel indicator
G6 Fuel pump
G32 Transmitter for coolant-required warning
T3a 3-contact connector in the radiator
b b
T4d 4-contact connector in the engine
c
T10a 10-contact connector, pillar A connection station, left
d
e
T14 14-contact connector on the engine
10 57
f V7 Coolant fan
2,5 1,5 0,5 0,35 0,35
ro/ge sw/ro bl/ro br/ws bl/sw 12 Point to earth, in the engine compartment, left
T10a/6 15 Point to earth, in the cylinder head
32 1 57 Point to earth, rear pillar, on the left

2
F18 S232 G32 36
15A Earth connection -4-, in the cabling harness of the engine
167
3 1 32A 2 compartment
2,5 2,5 0,5 0,5 0,5
ro/bl ro/ws br/ws br/ws br/sw
221 Earth connection (engine earth), in the engine cabling harness
B109 Earth connection in inside cabling harness, rear left
221
1,0 1,0
br/ws br/ws
T3a/1 T3a/2 T10a/1 T14/9

1,5 0,35
ro/ge li/sw
1 3
M V7 G6 M G T4d/2 F22
4 2 ws = white
1,5 0,5 1,5 sw = black
br br/ws br/ws
ro = red
T3a/3 br = brown
gn = green
2,5 6,0 1,5 bl = blue
167
br br
12 B109
br
57 15
gr = grey
li = purple
71 72 73 74 75 76 77 78 79 80 81 82 83 84 ge = yellow
or = orange
97--14897
rs = pink
Edition 02.2003
30
75x
30
75x Control panel, available fuel indicator, coolant-required
warning and coolant temperature indicator, speedometer
G1 Fuel indicator
G21 Speedometer
J285 Control device with indication unit on control panel
K3 Oil pressure control lamp
K28 Temperature coolant control lamp/ coolant-required warning
b
T10c 10-contact connector, pillar A connection station, on the left
c 27
T14 14-contact connector on the engine
d
e
T32 32-contact connector
Y4 Travel indicator
f
T14/4
0,5
ge/ro
T10c/2 44 67 T10/3
0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35

bl/sw br/ws bl/ro li/sw ws/bl gn/ws sw ge/ro unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
T32/10 T32/7 T32/22 T32/5 T32/28 T32/3 T32/1 T32/8
G1 G3
J 285
K3 K 28
Y4 G21
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
85 86 87 88 89 90 91 92 93 94 95 96 97 98 ge = yellow
or = orange
97--45845
rs = pink
Edition 02.2003
Radiator fan
⇒ 1.4 l - Marelli 4LV/74 kW, engine codes AUB
From July 2000
Fuse in fuse box/attery:
SA5
SA6
10A 20A 30A 30A
1 2 3 4
SA7
SA8
SA1 SA2 SA3 SA4 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
E97-0056
SA7 - Radiator fan (20 A)
Edition 09.2002
Radiator fan thermo-switch, radiator fan
A Battery
V7 Radiator fan
A/+
SA
20A
7
T4a/3
2.5
ro/ge
II I
F18
3 1
2.5 2.5
ro/bl ro/ws
T3a/1 T3a/2
V7
T3a/3
ws = white
2.5
sw = black
br ro = red
br = brown
108 gn = green
6 bl = blue
br gr = grey
12 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
or = orange
97--43452
rs = pink
Edition 09.2002
Radiator fan
⇒ 1.7 l/44 kW diesel injection engine, engine codes AKU
From July 2000
SA5
SA6
10A 20A 30A 30A

1 2 3 4
SA7
SA8
SA1 SA2 SA3 SA4
E97-0056
SA7 - Radiator fan (20 A) respect to the correctness of information in this document. Copyright by SEAT S.A.
Edition 09.2002
A Battery
V7 Radiator fan
A/+
SA
20A
7
T4a/3
2.5 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ro/ge respect to the correctness of information in this document. Copyright by SEAT S.A.
2/30a
II I
F18
3 1
2.5 2.5
ro/bl ro/ws
T3a/1 T3a/2
V7
T3a/3
ws = white
4 sw = black
br ro = red
br = brown
82
gn = green
6 bl = blue
br gr = grey
12
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
or = orange
97--43453
rs = pink
Edition 09.2002
Radiator fan
From July 2000
Fuse in fuse box/attery
SA5
SA6
30A 10A 20A 30A 30A

1 2 3 4
SA7
SA8
SA9
SA1 SA2 by copyright.
Protected SA3 SA4 for private or commercial purposes, in part or in whole, is not
Copying
E97-0053
Edition 09.2002
A Battery
V7 Radiator fan
A/+
SA
20A
7
T5f/3
4
ro/ge
2/30a
I
F18
1
2.5
ro/ws
T2k/2
V7
ws = white permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
sw = black respect to the correctness of information in this document. Copyright by SEAT S.A.
ro = red
T2k/1 br = brown
gn = green
4 6 bl = blue
br br
gr = grey
82 12 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
or = orange
97--43454
rs = pink
Edition 09.2002
Fuel cut-off control

⇒ only petrol vehicles with airbag
From July 2000
Different fuse and relay placement, multiple connectors see chapter "Positioning".
11 10 9 8 7
6 5 4 3 2 1
97-40408

Warning!
♦ The brackets after the part name refers to the casing control number.
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 05.2001
Fuel pump relay, fuel pump (pre-supply pump)
J17 G6 Fuel pump (pre-supply pump)
2 J... Engine control units
J234 Airbag control unit (01321)
6/31 9/TK 7/50 1/T 3/CRASH 2/30 4/15 8/87F W Front inside illumination
0.5 2.5 0.5 0.5 0.5 4 61 Earth point, C strut left

br/ws ro/sw ro/ge gr/ge sw ro

B154 A41 T10a/9 A125 A104 A32
0.5 2.5 0.5 0.5 0.5 4 4 81 Earth connection -1-, instrument panel wiring harness
br/ws ro/sw ro/ge gr/ge sw ro ro/sw
A2 A2 Positive connection (15), instrument panel wiring harness

W/TK D/50 J... J234 D/30
T75/72
4 A32 Positive connection (30), in the instrument panel wiring harness
sw
A99
1.5 A41 Positive connection (50), in the instrument panel wiring harness
D/15 ro/bl
0.5
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 40a A99 Connection -1- (87), in the instrument panel wiring harness
br permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
SB 40
15A A104 Positive connection -2- (15), instrument panel wiring harness
40b
A125 Connection (impact signal), instrument panel wiring harness

1.5
ro/ge

1
G6 B154 Connection -1- (door contact), in interior wiring harness

4
1.5
ws = white
br sw = black
ro = red
br = brown
81 B109
gn = green
2.5 2.5 bl = blue
br br gr = grey
76 61
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--45695
rs = pink
Edition 05.2001
Automatic gearbox
⇒ 1.4 l - Motronic/44 kW, engine code ANW and AUD
From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
1 - Starter blocking relay (53)

Warning!
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A unless
permitted - brownauthorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 A - beige
3 A - purple
Edition 05.2001
Starter blocking relay, automatic gearbox control unit, multi-
50 30 function switch
P/N 50 D Ignition and starter switch
F125 Multi-function switch (00293-1314)
J207 Starter blocking relay
T9a/4 T9a/6 T9a/8 T9a/2 J285 Control unit with warning lamps on the instrument panel (01317)
M17 Right-hand reversing light
2.5 0.5 2.5 2.5 T5s 5-way connector, in the transmission
ro/sw br/ge ro/sw ro
J 285 T10 10-way connector, green, in the wiring harness interconnection
T10k/1 T10/1 T32a/32 T10a 10-way connector, red, in the wiring harness interconnection
A32 T10k 10-way connector, brown, in the wiring harness interconnection
D/50 T28 28-way connector, black, in the gearbox
0.5 2.5 4 2.5 0.35
br/ge ro/sw ro ro ws
14 Gearbox earthing point
T5s/1 T10k/9
11 29
2.5 D/30 0.5 A32 Positive connection (30), in the instrument panel wiring harness
ro/sw ro/ge
B/50 J217 T68/31 U27 Connection (RF), in the gearbox switch wiring harness
T68/40 T68/42 T68/41 T68/44 T68/43 T68/19 T68/18
1 0.5 0.5 0.5 0.5 0.5 0.5
sw/bl ro/ge gn/ge gn/sw gn/ro gn/gr gn/li
U27
0.5 1
sw/bl sw/bl
T10a/2 T28/17 T28/ T28/ T28/ T28/ T28/ T28/16

10 12 13 14 15
1 0.5
sw/bl sw/bl
5/R 4/P 6/N 7/0 8/1 9/2 10/3
M17
3
F125 2 1/31
1 0.5
sw/ws br/ge ws = white
sw = black
T28/8 T28/18 ro = red
br = brown
0.5 0.5 0.5
ro/sw br/ge gn
gn = green
bl = blue
47 3 gr = grey
14
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42070
rs = pink
Edition 05.2001
Automatic gearbox control unit, gearbox oil temperature
sender, solenoid valve 1, solenoid valve 2, solenoid
valve 3, solenoid valve 4, solenoid valve 5, solenoid
valve 6
G93 Gearbox oil temperature sender (00300-1333)
J285 Control unit with display in dash panel insert (01317)
J 220
F/4 T80/23 N88 Solenoid valve 1 (00258-1113)
A76 N89 Solenoid valve 2 (00260-1121)
N90 Solenoid valve 3 (00262-1123)
1 1 0.35 0.5 0.5 N91 Solenoid valve 4 (00264-1131)
sw/ro sw/ro gr gr/ws gr/ws
D73 T16/7 T10k/5 T10a 10-pin connector, red, in the interconnection station
J285
T10k 10-pin connector, brown, in the interconnection station
T32/25
1 0.5
sw/ro gr/ws T16 16-pin connector, black
T28 28-pin connector, black, in the gearbox
K for private or commercial purposes, in part or in whole, is not
Protected by copyright. Copying
T68/21 J217 114
T68/5S.A. SEAT S.A does not guarantee or accept any liability
permitted unless authorised by SEAT with Earth connection, in automatic gearbox wiring harness
A76 Connection (diagnosis wire K), in dash panel wiring harness

T68/13 T68/48 T68/49 T68/26 T68/25 T68/50 T68/66 T68/33 T68/34 T68/64
T
28/6
D73
harness
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1 0.5
gn/bl gr/ro gr gr/sw gr/bl gn/br gr/gn ro/ws br li
T10a/8 T28/1 T28/2 T28/3 T28/5 T28/26 T28/4 T28/7 T28/22
0.35 0.5 0.5

gn gn/br ws/ro
T8f/1 T8f/2 T8f/3 T8f/5 T8f/8 T8f/4 T8f/6 T8f/7

J285
T32/11
ws = white
N88 N89 N90 N91 N92 N93 G93 sw = black
ro = red
br = brown
0.5 gn = green
li bl = blue
gr = grey
114
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--41807
rs = pink
Edition 05.2001
Automatic gearbox control unit, road speed sender,
gearbox speed sender
G38 Gearbox speed sender (00297-1324)
G68 Road speed sender (inductive sender, 2 connections)
(00281-1231)
J 220 J293 J 285 J
220 J 104 J 285 J
220 J104 J285 Control unit with display in dash panel insert (01317)
T80/42 T14c/3 T32a/19 T80/31 T25/11 T32a/20 T80/32 T25/10 J293 Radiator fan control unit (00831)
T10n 10-pin connector, grey, in the interconnection station
0.5 0.5 0.35 0.35 0.35 0.35 0.35 0.35
T28 28-pin connector, black, in the gearbox
bl gn/bl or/sw or/sw or/sw or/br or/br or/br
Connection (high bus), in engine compartment wiring
D159
harness
* T10n/4 T10n/5
0.35 0.35
or/sw or/br
D160 Connection (low bus), in engine compartment wiring harness
D161 D159 D160
Connection (radiator fan run-on), in engine compartment
1 0.35 0.35 D161
sw/ro or/sw or/br wiring harness
CAN--H CAN--L * Only vehicles with air conditioning
T68/30 J217 T68/15 T68/16
T68/35 T68/36 T68/9 T68/10
0.5 0.5 0.5 0.5

ws sw br sw
T28/23 T28/24 T28/19 T28/20
2 2
G68 G38
1 1 ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--41808
rs = pink
Edition 05.2001
Automatic gearbox control unit, selector lever lock solenoid
L79 Selector lever illumination
N110 Selector lever lock solenoid (01236-4314)
D/15 T4f 4-pin connector, black, near gearbox
T10k 10-pin connector, brown, in the interconnection station
4
8 sw
A2
2.5 2.5
ro sw
57 Earth point, left rear pillar
A52 A104 SB26
0.5 1 0.5
ro sw sw
21a 33a 25a A2 Positive (+) connection (15), in dash panel wiring harness
J217
SB 21 SB 33 SB 25
5A 10A 7.5A
T68/1 T68/24 T68/6 T68/68 T68/45 T68/22 21b 33b 25b
2.5 1 1 1 1 0.5 0.5 A104 Positive connection -2- (15), in dash panel wiring harness
0.5
br br gr/ge sw/br sw/br ro ro sw/ws

U8
T10k/2 T10k/3 T4f/4
U8 Positive connection (15a), in automatic gearbox wiring harness
1 0.5 1 1 1 0.5
gr/ge ro/sw sw/br sw/br sw sw/ws
T4f/1 7 T10k/4 T4f/2

2
1
L79
Protected byNcopyright.
110 Copying for private or commercial purposes, in part or in whole, is not 1
permitted unless
2 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. 0.5
br ws = white
sw = black
T4f/3 ro = red
br = brown
4 2.5 0.5 gn = green
br br br
bl = blue
gr = grey
167 167 10 57 B102
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--41809
rs = pink
Edition 05.2001
Radio
From July 2000
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
Radio, aerial, aerial booster, treble loudspeaker, front left, bass
loudspeaker, front left, treble loudspeaker, front right, bass
loudspeaker, front right
R Radio
R11 Aerial
R20 Treble loudspeaker, front left
R21 Bass loudspeaker, front left
R22 Treble loudspeaker, front right
R23 Bass loudspeaker, front right
R24 Aerial booster
T1c Single connector
R11 R24 T1d Single connector
T5 5-pin connector
T10f 10-pin connector, black, A-pillar, lower front passenger's side
T10g 10-pin connector, black, A-pillar, lower driver's side
B189 Connection (positive, FR loudspeaker), in interior wiring harness

T1d/1 T1c/1
HF 1
sw B190 Connection (negative, FR loudspeaker), in interior wiring harness
T5/4
B191 Connection (positive, FL loudspeaker), in interior wiring harness
1
sw *
30a
A T8/5 B192 Connection (negative, FL loudspeaker), in interior wiring harness
* Only models with provision for radio

T8q/6 T8q/5 R T8q/4 T8q/3
1 1 1 1
br/bl bl br/ro ro
B191 B189
1 1
bl ro
T10g/7 T10f/7
1 1 1 1
bl bl ro ro
+ + + +
R20 R21 R22 R23

-- -- -- --
ws = white
1 1 1 1
br/bl br/bl br/ro br/ro sw = black
ro = red
T10g/6 T10f/6 br = brown
gn = green
1 1
br/bl br/ro bl = blue
B190
B192 gr = grey
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
or = orange
97--45696
rs = pink
Edition 09.2002
Radio
E1 Lighting switch
R Radio (01304)
D/S T16 16-pin connector, black
A40
** 238 Earth connection -1-, in interior wiring harness
4 1.5 0.5
ro ro br/ro
42a 16a A27 Connection (speed signal), in dash panel wiring harness
TV2 SB 42 SB 16 E 1 J285
5A 5A T17/17 T32/3
T16/7 A40 Positive connection -1- (30), in dash panel wiring harness
42b 16b K
0.5 1 0.35 0.5

br/ro gr/bl gn/ws gr/ws A76 Connection (diagnosis wire K), in dash panel wiring harness
B158 B145 A27 A76

B145 Positive connection (58b), in interior wiring harness
2.5 0.5 0.5 0.5 0.5
ro br/ro gr/bl gn/ws gr/ws
30a S 58b SGV K B158 Connection (S), in interior wiring harness
T8/7 T8/4 T8/6 T8/1 T8/3
** Only vehicles without central lock
R T8/8
ws = whitepermitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
sw = black
ro = red
br = brown
2.5 gn = green
br
bl = blue
gr = grey
238 li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
or = orange
97--45697
rs = pink
Edition 09.2002
Thermal ejectors
From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
Color of fuses
30 A - green
25 A - white
20 AProtected
- yellow by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 07.2000
Heater element, left washer jet, heater element, right washer jet
T2j 2-pin connector, black, near the plenum chamber, left
Z20 Heater element, left washer jet
Z21 Heater element, right washer jet
A2 A2 Positive (+) connection (15), in dash panel wiring harness
4 1.5
sw sw
29a
D/15 SB 29
5A
29b
1
sw
T10d/4 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1
sw
T2j/1
0.5 0.5
sw sw
2 2
Z20 Z21
1 1
0.5 0.5
br br
ws = white
T2j/2 sw = black
ro = red
br = brown
1 gn = green
br
bl = blue
gr = grey
131
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--41803
rs = pink
Edition 07.2000
Sliding sunroof
From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
Color of fuses permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 07.2000
Sliding sunroof control unit, sliding sunroof adjustment regulator,
sliding sunroof motor
E139 Sliding sunroof adjustment regulator
J245 Sliding sunroof adjustment control unit
J379 Central locking and anti-theft alarm system control unit
J379 J379 T1b Single connector
T23/8 TV2 D/15 T23/4 T2f 2-pin connector
* * T5 5-pin connector
0.5 4 4 0.5 TV2 Terminal 30 junction box
gr/ge ro sw bl/ws V1 Sliding sunroof motor
Q49 A40 A2 Q9
163 Earth connection -2-, in interior light wiring harness
* 4 1.5
ro sw
* A2 Positive (+) connection (15), in dash panel wiring harness
35a 26a
SB 35 SB 26 A40 Positive connection -1- (30), in dash panel wiring harness

5A 5A
35b 26b
0.5 4 0.5 0.5
gr/ge ro sw bl/ws
B169 ** B102 Earth connection, in front left interior wiring harness
4
ro/ge B169 Positive connection -1- (30), in interior wiring harness
T2f/1 T1b/1 E139

T5/5 Q9 Connection in electric window wiring harness
4
ro/ge
A104 T6y/4 T6y/5 T6y/1 T6y/3 T6y/2 Q49 Connection (closed), in interior wiring harness
0.5 2.5 0.5
gr/ge ro/ge bl/ws * Only vehicles with central lock
** Only vehicles without central lock
30a
T6g/3 T6g/4 T6g/2 T6z/4 T6z/5 T6z/1 T6z/3 T6z/2
ws = white
V1 T6g/1
31 J245 sw = black
T2f/2 ro = red
2.5 4 4
br = brown
br br br gn = green
bl = blue
gr = grey
163 B102
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--41804
rs = pink
Edition 07.2000
Fabric sunroof
From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 07.2000
Switch to open folding sliding sunroof, switch to close folding sliding
sunroof, folding fabric sunroof motor
E1 Lighting switch
E268 Switch to open folding sliding sunroof
E269 Switch to close folding sliding sunroof
S83 Sliding sunroof thermo-fuse
T1 Single connector
T1a Single connector
V86 Folding fabric sunroof motor
44 Earth point, A-pillar left, bottom
A77 238 Earth connection -1-, in interior wiring harness
2.5 A61 Positive connection (X), in instrument panel wiring harness

E1 sw/ge
T17/17
2 A77 Connection (folding sliding sunroof), in dash panel wiring harness

1
gr/bl S83
20A B145 Positive connection (58b), in interior wiring harness
B145 1
1 2.5 B238 Positive connection -2- (58b), in interior wiring harness

gr/bl sw/ge
B238 A61
2.5 0.5 0.5 2.5 6

sw/ge gr/bl gr/bl sw/ge sw/ge
75x 58b 58b 75x Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
T6k/6 T6k/3 T6n/3 T6n/6
10 10
J59
E268 E269
T6h/2
T6k/2 T6k/4 T6k/1 T6n/1 T6n/4 T6n/2

31 31 AUF ZU 31 31
2.5 2.5 4 4 2.5 2.5
br br sw/ro ro br br
T1/1 T1a/1
4 4 ws = white
bl/gn ro
2
sw = black
ro = red
V86 br = brown
gn = green
1 2.5
br
bl = blue
gr = grey
238 238 238 238 44
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--41805
rs = pink
Edition 07.2000
Day-time lights
From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
7 - Contact discharge relay X (100)

Warning!
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 A - beige
3 A - purple
Edition 05.2001
Battery, starter motor, ignition and starter switch, discharge relay
for contact X, control unit with warning lamps on the instrument
31 30 panel, headlight warning lamp, cable distributor terminal 30
7 J59 A Battery (00532)
X 75x B Starter motor
J59 Discharge relay for contact X
T6h/4 T6h/3 T6h/2 T6h/1
J285 Control unit with warning lamps on the instrument panel (01317)
K1 Headlight warning lamp
1 1 6 6
br sw/ge sw ro
SA1 Fuse -1- in the fuseholder/battery
a
SA2 Fuse -2- in the fuseholder/battery
A61 b SB16 Fuse -16- in fuseholder
501
4 TV2 T10 10-way connector, green, in the wiring harness interconnection
sw/ro TV2 Cable distributor terminal 30
A80
1 Earth strap, battery - bodywork
1.5 502 500
sw/ge
24
6 4 0.35 0.35 2 Earth strap, gearbox - bodywork
ro ro gr/ro gr/ge
A32
T32/26 T32/27 61 Earth point, C strut left
4 15
ro
D 30 500 Bolted joint -1- (30), on the relay plate
J285
X 50 15 P S 501 Bolted joint -2- (30), on the relay plate
2.5 2.5 4 1 0.5

502 Bolted joint -1- (30a), on the relay plate
T10/1 10
21 57 ro K1
A2 Positive connection (15), instrument panel wiring harness
2.5
ro/sw A2
SB16
T32/17 T32/20
B/30 A32 Positive connection (30), in the instrument panel wiring harness
B/50
25 0.35 0.35
sw ws gr/bl
A61 Positive connection (X), in the instrument panel wiring harness
+ 1 2
B102 52 28
A80 Connection -1- (X), in the instrument panel wiring harness
SA 1 SA 2 ws = white
A 110A 80A
sw = black
ro = B102 Copying
red Protected by copyright. Earth connection, interior wiring
for private or commercial harness,
purposes, in partfront left is not
or in whole,
br = brown
-- respect to the correctness of information in this document. Copyright by SEAT S.A.
gn = green
2.5 25 25 bl = blue
br sw sw gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42077
rs = pink
Edition 05.2001
Electric and heated rear-view mirrors

From July 2000
11 10 9 8 7
6 5 4 3 2 1
97-40408
Fuse colours
30 A - green permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 05.2001
Outside rear-view mirror regulator switch, mirror regulating motor
(driver's side), thermal outside mirror, driver's side
E15 Rear window heating switch (00973)
E43 External mirror regulating switch (01706)
T4j 4-way connector , behind instrument panel
E43 T5b 5-way connector, brown, in strut C, left-hand side
T10e 10-way connector, black, in the rear-view mirror, driver's side
a
b T10g 10-way connector, black, in strut A, lower driver's side
c
T10z 10-way connector, blue, in strut A, lower driver's side
V17 Mirror regulating motor (driver's side)
d
17 e Z1 Rear heated window (00975)
f
Z4 Heated external mirror, drive's side (00943)
T10l/5 T10l/9 T10l/6
15a
1 0.35 0.35 0.35 Z1 61 Earth point, C strut left
sw/ro sw li gr/li
g
A20 A2 Positive connection (15), instrument panel wiring harness
1 B162 h
sw
18b 26b 0.5 0.5 1 A20 Connection (15a), instrument panel wiring harness
sw gr sw/ro
SB 18 SB 26
5A 5A T4j/4 T10z/ T10z/ T10z/ T10g/5
7 1 6 B102 Earth connection, interior wiring harness, front left
E15/6 18a 26a
0.5 0.5 0.5 0.5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
li gr/li gr ws
E159
2.5 1 1.5 B162 Connection
respect to (75a),
the correctness in the interior
of information wiring harness
sw sw/gn sw T8m/5
T10e/ T10e/ T10e/ T10e/5
Z5 7 8 6
A2 0.5 0.5 0.5 0.5 Z1 Connection -1-, in the wiring harness/mirror heating
li gr/li gr ws
2.5 4
3 1 2 5
sw sw
Z5 Connection, in the wiring harness of the window heating
Z4
T5b/1 * Only vehicles without central locking
D/15 V17
4
2.5 0.5
sw br
T10e/4
Z1/+ 0.5
br * ws = white
sw = black
ro = red
T10g/1
br = brown
2.5 gn = green
br
2.5 bl = blue
br B102 gr = grey
61
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42082
rs = pink
Edition 05.2001
Airbag
From July 2000
Different location for relays and fuses, provision of multiple connectors, see "Positioning Points" chapter.
11 10 9 8 7
6 5 4 3 2 1
97-40408
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2000
Airbag control unit, coil spring for airbag, return spring with slip
ring, airbag igniter - driver side, airbag igniter 1 - passenger side,
side airbag igniter, driver side, side airbag igniter, passenger
side
F138 Coil spring for airbag, return spring with slip ring
J379 Central locking/anti-theft alarm control unit
J491 Fuel shut-off control unit (crash)
N95 Airbag igniter - driver side (00588)
N131 Airbag igniter 1 - passenger side (00589)
N199 Side airbag igniter, driver side (01217)
N200 Side airbag igniter, passenger side (01218)
J 379 J 17 J491 T3g 3-pin connector, in driver seat
T24/21 T9b/3 T9c/5
T3h 3-pin connector, in front passenger seat
24 25
*** ** * T3i 3-pin connector
0.35 0.35 0.5 0.5 0.5
T4k 4-pin connector
or/sw or/br gr/ge gr/ge gr/ge
A121 Connection (High-Bus), in dash panel wiring harness
A121 A122 A125
*** A122 Connection (Low-Bus), in dash panel wiring harness

0.35 0.35 0.5
or/sw or/br gr/ge
CAN--H CAN--L A125 Connection (crash signal), in dash panel wiring harness
T75/74 T75/75 J234 T75/72
* Diesel vehicles only
** Petrol vehicles only
T75/33 T75/34 T75/31 T75/32 T75/30 T75/29 T75/27 T75/28 *** Vehicles with central locking only
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

ge ws ws gr ws gn ws bl
T4k/1 T4k/2 T3i/2 T3i/1 T3g/2 T3g/1 T3h/2 T3h/1 respect to the correctness of information in this document. Copyright by SEAT S.A.
0.5 0.5 0.5 0.5 0.5 0.5

bl br bl sw bl sw
1 1 1
F138 N131 N199 N200

2 2 2
ws = white
sw = black
ro = red
N95 br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42084
rs = pink
Edition 09.2000
Airbag control unit, side airbag crash sensor, driver side, side
airbag crash sensor, passenger side, control unit with display in
dash panel insert, airbag warning lamp
D Ignition/startup switch
G179 Side airbag crash sensor, driver side (01221)
G180 Side airbag crash sensor, passenger side (01222)
K75 Airbag warning lamp
T16/7
T3g 3-pin connector, in driver seat
0.5 T3h 3-pin connector, in front passenger seat
D/15 gr/ws T3i 3-pin connector
T16 16-pin connector, in the dash panel, centre. Self-diagnosis connection
4 A76
sw
34 Earth point, under driver seat
0.35
A2 gr 35 Earth point, under passenger seat
2.5
sw T32/6 T32/25
A104
0.5 0.5 0.35
sw gr/ws ge/ws K75 109 Earth connection, in the airbag wiring harness
T75/26 J234
K
T75/54 T75/64
J285
T75/70 T75/71 T75/51 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. 249 Earth
Copyright connection
by SEAT S.A. -2-, in interior wiring harness
0.5 0.5 0.5 0.5

ge ws br br
A2 Positive connection (15), in dash panel wiring harness
1 1
* ** T32a/
19
T32a/20 T32/9
G179 G180 A76 Connection (diagnosis wire K), in dash panel wiring harness
* 2 * 2 0.35 0.35 0.35
or/sw or/br br
0.5 0.5 A104 Positive connection -2- (15), in dash panel wiring harness
br br
109
4 6 * Vehicles with side airbag only
249
** Vehicles without side airbag only
* * *
0.5 0.5 0.5 2.5 ws = white
br br br br
sw = black
ro = red
T3g/3 T3h/3 T3i/3 238 br = brown
gn = green
0.5 0.5 0.5 2.5 bl = blue
br br sw br
gr = grey
34 35 35 76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42085
rs = pink
Edition 09.2000
Central locking and electric window lifter

⇒ Remote control
⇒ Alarm system
From July 2000
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
Central locking and anti-theft alarm system control unit, central
locking lock unit (driver's side), central locking warning lamp -
SAFE-
F220 Central locking lock unit, driver's side
K133 Central locking warning lamp -SAFE-
T10e pin connector, black, exterior mirror, driver's door
T10i 10-pin connector, black, connector point, left A pillar
Z4 Heated exterior mirror, driver's side
205 Earth connection, in door wiring harness - driver's side

J379
B133 Connection (central locking open), in interior wiring harness
T23/11 T24/8 T24/6 T24/12 T24/15 T23/13 T23/6 T24/7 * Only models with electrically adjustable exterior mirrors
0.5 0.5 0.5 0.5 0.5 1 1 0.5

ws/gn gr/ge bl/li ro/bl bl/gr ws ro/sw bl/br Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
B133
0.5 0.35
bl/br bl/br
T10i/3 T10i/ T10i/ T10i/ T10i/ T10g/ T10g/ T10g/4

10 9 6 7 2 3 J285
T32/21
0.5 0.5 0.5 0.5 0.5 1 1 0.5
ws/gn gr/ge bl/li ro/bl bl/gr ro/sw ws bl/br
2 4/zu 6/auf 3/Safe 5 1 2 8
K133 M
F220
Z4/4
1
7/31
0.5
br B102 ws = white
2.5 sw = black
br
T10e/4 75 60 58 62 67 ro = red
T10g/1 br = brown
0.5
* gn = green
0.5 2.5 2.5 0.5 0.5 0.35 0.35 2.5 2.5
br br br br br br br br br br bl = blue
gr = grey
205 61
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--45699
rs = pink
Edition 09.2002
Central locking and anti-theft alarm system control unit,
central locking lock unit (front passenger's side)
F221 Central locking lock unit, front passenger's side
T10h 10-pin connector, red, A-pillar, lower front passenger's side
T10e pin connector, black, exterior mirror, front passenger's side
J 234 Z5 Heated exterior mirror, front passenger's side
T75/72

*
0.5
gr/ge
A125
* 206 Earth connection, in door wiring harness - front passenger's side

0.5
gr/ge
J379 T24/21

T24/9 Protected
T24/1 byT24/13
copyright. Copying
T24/18 for private
T23/14 T23/3or commercial purposes, in partT23/22
T24/5 or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with * Only models with airbag
respect to the correctness of information in this document. Copyright by SEAT S.A. ** Only models with electrically adjustable exterior mirrors
0.5 0.5 0.5 0.5 1 1 0.5 1.5
gn/br ro/bl ws/gn gn/ge gr/bl br/ge bl/sw br
T10h/ T10h/ T10h/ T10h/ T10f/ T10f/3 T10f/4

10 9 6 7 2
0.5 0.5 0.5 0.5 1 1 0.5

gr/ge bl/li ro/bl bl/gr ro/sw ws bl/br
4/zu 6/auf 3/Safe 5 1 2 8
Z5/4
M
F221
7/31
0.5 81
br 238 ws = white
2.5 sw = black
br
T10j/4 83 105
105 107
107 ro = red
T10f/1 br = brown
0.5
** gn = green
0.5 2.5 0.5 0.5 2.5 2.5 2.5
br br br br br br br br bl = blue
gr = grey
206 76 76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--45700
rs = pink
Edition 09.2002
Central locking control unit and anti- theft alarm, switches and
engines for central locking - tailgate/boot lid
F218 Tailgate/boot lid central locking switch
R47 Central locking and anti-theft alarm system
T5g 5-pin connector, black, left C-pillar
T5j 5-pin connector, black, in luggage compartment
T16 16-pin connector, in dash panel centre, self-diagnosis connection
V53 Central locking motor, tailgate/boot lid

R47
98 Earth connection, in tailgate/boot lid wiring harness
HF
T15/7 T15/10 J379

T24/23 T24/2 T24/3 T23/2 T23/18

K
0.5
0.5 0.5 1 1
gr/ws sw/ro sw/bl gr gn
A76
T5g/3 T5g/2 T5g/4 T5g/1
0.35 0.5 0.5 1 1
gr gr/ws sw/bl gr gn
T16/7
T5j/2 T5j/4 T5j/1
J285
T32/25 0.5 1 1
sw/bl gr gn
T3d/3 1
F218 218 V53

T3d/2 1.5 2 ws = white
br sw = black
ro = red
T5a/1 br = brown
0.5 1.5 2.5 gn = green
br br br bl = blue
gr = grey
98 61
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42322
rs = pink
Edition 09.2002
Central locking and anti-theft alarm system control unit, anti-
theft alarm/rodent repellent system contact switch, anti-theft
alarm system horn
F120 Anti-theft alarm/rodent repellent system contact switch
H8 Anti-theft alarm system horn
T10b 10-pin connector, blue, connector point
W/TK T10n 10-pin connector, grey, connector point
0.5 10 Earth point, in plenum chamber

br/ws
B154 12 Earth point, in engine compartment, left

0.5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
br/ws 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. 82 Earth connection -1-, in front left wiring harness
T23/19 J379
Positive (+) connection (right turn signal), in dash panel wiring
A5
harness
T15/1 T15/11 T15/14 T15/13 T23/21 Positive (+) connection (left turn signal), in dash panel wiring
A6
harness
0.5 1.5 0.5 0.5 0.5 A27 Connection (speed signal), in dash panel wiring harness
ge/br ro/bl sw/ws sw/gn gn/ws
B154 Connection -1- (TK (door contact)), in interior wiring harness

T10n/9 T10n/8 A6 A5 A27
* Only models with engine codes AMF
0.5 1.5 0.35 0.35 0.35 0.5

ge/br ro/ws sw/ws sw/gn gn/ws gn/ws
1 1
F120 T10b/9
H8
2
2
J
285 J285 J285 J...
* T32/18 T32/2 T32/3
ws = white
0.5 0.5 1.5 sw = black
br br br ro = red
br = brown
82 4 gn = green
br bl = blue
gr = grey
10 12
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--43458
rs = pink
Edition 09.2002
Central locking control unit and anti-theft alarm, front left
window lifter switch, window lifter switch, front right (in driver's
door), interior locking
E40 Front left window lifter switch
E81 Window lifter switch, front right, (driver's door)
E150 Interior locking switch, driver's side
L53 Window lifter switch light bulb
L99 Interior lock switch illumination
T10z 10-pin connector, blue, A-pillar, lower driver's side
Positive (+) connection -1- (30), in door wiring harness - driver's
R10
side
R51 Connection (58b), in door wiring harness - driver's side
J379
T24/11 T24/24
0.5 0.5
sw/gn ge/bl
T10i/ T10z/8
2 107
107
R10
1 a
gr/bl
R51
0.5 authorised
permitted unless 0.5 0.5SEAT S.A. SEAT
by 0.35 0.35
S.A does not guarantee 0.35with
or accept any liability 0.35
sw/gn to the
respect ws/bl gr/bl of information
correctness gr/bl bl/ge
in this document. Copyright by SEAT S.A. gr/bl bl/ge
2 1 3 2 5 2 5
E150 L53 E81 L53 E40

5 4 6 1 4 6 1 4
L99
0.35 0.35 ws = white
0.5 0.5 0.35 sw/ge ge 0.35 0.35 0.35 sw = black
br br br br gn/ge gn
ro = red
T10z/ T10z/5 br = brown
4 b
8 7 9 0.5 0.5 10 gn = green
c
gn/ge sw/gn bl = blue
gr = grey
81 80
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70 or = orange
97--42092
rs = pink
Edition 09.2002
electric window control unit, left, electric window control
unit, right, left electric window motor, right electric
window motor
J295 Electric window control unit, left
J296 Electric window control unit, right
T10h 10-pin connector, red, in A pillar, lower passenger's side
T10i 10-pin connector, brown, in A pillar, lower driver's side
T10y 10-pin connector, blue, in A pillar, lower passenger's side
T10z 10-pin connector, blue, in A pillar, lower driver's side
V14 Left electric window motor
V15 Right electric window motor
Q9 Connection in the electric window wiring harness
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Q48 Connection (open), in interior wiring harness
J379 respect to the correctness of information in this document. Copyright by SEAT S.A.
Q49 Connection (closed), in interior wiring harness
T23/4 T23/8 T23/7 R10 Positive connection -1- (30), in driver's door wiring harness
0.5 0.5 0.5
102
102 bl/ws gr/ge bl/li
Q9
Q49
2.5
bl/ge Q48
0.5 0.5 0.5 0.5 0.5 0.5

a R10 bl/ws gr/ge bl/li bl/li gr/ge bl/ws
106
106 104
104
T10z/ T10z/ T10z/10 T10y/ T10y/ T10y/

2 3 10 3 2
2.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 2.5
bl/ge bl/ws gr/ge bl/li bl/li gr/ge bl/ws ge bl/ge
T12/10 T12/6 T12/9 T12/2 T12a/2 T12a/9 T12a/6 T12a/3 T12a/10
V14 J296 V15

J295 T12/1 T12/4 T12/5 T12/7 T12a/
7
T12a/
1
T12a/4 T12a/5
0.35 0.35 2.5 1 1 0.5 0.5 2.5

gn gn/ge br sw sw sw/gn gn/ge br ws = white
sw = black
T10i/4 T10h/ T10y/ T10y/4 ro = red
4 5
b br = brown
c 5 0.5 0.5 0.5 0.5 19 gn = green
sw sw sw/gn gn/ge
bl = blue
gr = grey
92 90 64 63
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84 or = orange
97--42323
rs = pink
Edition 09.2002
Central locking and anti-theft alarm system control unit
E3 Hazard warning lights switch
R Radio (01304)
d
6
ro 502 Screwed union -1- (30a), on relay plate
A32 D/S D/15
2.5 4
ro sw
A52 A2
A20 Connection (15a), in dash panel wiring harness
1.5 2.5 1 0.5 1.5
ro ro ro br/ro sw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
J379 41a 42a 14a 16a 26a A32 Positive
respect to the correctness connection
of information (30), in Copyright
in this document. dash panel wiring
by SEAT harness
S.A.
SB 41 SB 42 SB 14 SB 16 SB 26
15A 20A 10A 5A 5A
T24/20 T23/10 T15/15 T15/12 T23/23
S 41b 42b 14b 16b 26b

0.5 0.5 1 1.5 1.5 2.5 1 0.5 1
sw br/ro ro/ge ro/ws ro/ws ro ro/ge br/ro sw
R E3/7
T8/7
B158
A20
0.5 0.5
sw sw
79 76 ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98 or = orange
97--45701
rs = pink
Edition 09.2002
Heated seats
From July 2000
Different location for relays and fuses, provision of multiple connectors, see "Positioning Points" chapter.
11 10 9 8 7
6 5 4 3 2 1
97-40408
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2000
Heated driver seat control unit, heated driver seat adjustment,
heat sensor - driver seat, heated seat switch light bulb, heated
driver seat
E1 Lights switch
E94 Heated driver seat adjustment (01175)
G59 Heat sensor - driver seat (01172)
J31 Automatic intermittent wiper-washer relay
J 59 J131 Heated driver seat control unit
T6h/2
L44 Heated seat switch light bulb
6
sw SB51 Fuse -51- in fuse box
Z6 Heated driver seat (00825)
A80
2.5 1.5 61 Earth point, left C pillar
sw/ge sw
E1/17
50a 51a 76 Earth point, near selector mechanism
1
SB 50 SB 51 gr/bl
15A 15A 21 25 Protected by copyright. Copying for private or commercial purposes, in 238
part or inEarth
whole,connection
is not -1-, in interior wiring harness
B145 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
50b 51b
1.5 1.5 1.5 1.5 1.5 249 Earth connection -2-, in interior wiring harness
sw/gr sw sw sw gr/bl B238
A36 O11 a
1.5 1.5 1.5 0.5

sw/gr sw sw gr/bl A80 Connection -1- (X), in dash panel wiring harness
5 4 J131 1 L44
J 31
B109 Earth connection, in interior wiring harness, behind to the left
T9/8
E94
3 2 6
B145 Positive connection (58b), in interior wiring harness
0.5 1.5 1.5
sw/ws sw/ge br
B238 Positive connection -2- (58b), in interior wiring harness
T6l/2 T6l/4 249
O11 Positive connection (Xa), heated seat wiring harness

G59 Z6 2.5
br
1.5
br
ws = white
sw = black
T6l/1 T6l/3 238 ro = red
25
br = brown
1.5 1.5 2.5 gn = green
br br br
bl = blue
2.5
br gr = grey
61 B109 76
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42096
rs = pink
Edition 09.2000
Heated front passenger seat control unit, heated front
passenger seat adjustment, heat sensor - front passenger seat,
heated seat switch light bulb, heated front passenger seat
E95 Heated front passenger seat adjustment
G60 Heat sensor - front passenger seat (01171)
J132 Heated front passenger seat control unit
L44 Heated seat switch light bulb
Z8 Heated front passenger seat (00826)
61 Earth point, left C pillar
B102 Earth connection, in interior wiring harness, front left
B238 Positive connection -2- (58b), in interior wiring harness
B238 6 7
0.5 1.5 1.5

gr/bl sw sw
1 4 J132 5 L44
E95
3 2 6
0.5 1.5 1.5

bl/ws ws/ge br
T6m/2 T6m/4
12
G60 Z8 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ws =bywhite
sw = black
ro = red
T6m/1 T6m/3
br = brown
1.5 1.5
gn = green
br br bl = blue
2.5
br gr = grey
61 B102
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42097
rs = pink
Edition 09.2000
1.4 l - Marelli 4LV/74 kW, engine code letters AUB

From November 2000
Different relay, fuse and multi-way connector allocation: see section on "Fitting locations".
11 10 9 8 7
6 5 4 3 2 1
97-40408

7 - X-contact relief relay (100)
Note:
♦ in brackets, afterProtected
the component designation,
by copyright. Copying appear the
for private or commercial production
purposes, control
in part or in whole, is notnumbers on the housing.
Color of fuses
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2001
starter switch, terminal 30 junction box, X-contact relief relay
31 30
A Battery (00532)
X 75x C Alternator
T6h/4 T6h/3 T6h/2 T6h/1 E1 Lights switch
1 1 6 6 J59 X-contact relief relay
br sw/ge sw ro
29 99 E1/15 SA2 Fuse -2- in fuse box/battery
A61
2.5 4 2.5
ro ro/bl ro TV2 Terminal 30 junction box
A32 A40 1 Earthing strap, battery - bodywork

4
permitted unless authorised 6 by SEAT4 S.A. SEAT S.A does not guarantee or accept any liability with
respect to ro ro
the correctness ofroinformation in this document. Copyright by SEAT S.A.
2 Earthing strap, gearbox - bodywork
D 30 502 501
TV2 61 Earthing point, C pillar, left

X 50 15 P S
500
2.5 2.5 4 1 0.5 500 Screwed union -1- (30), on the relay plate
501 Screwed union -2- (30), on the relay plate

E1/1 25 E 19 140
140
T7a/5
T10/1 152
152 27
502 Screwed union -1- (30a), on the relay plate
2.5 10 0.5 0.35
ro/sw ro bl sw/ge

T5s/1 T5s/2 T5s/3
2.5 25 16 0.5 0.5 A40 Postive connection -1- (30), in dash panel wiring harness
ro/sw sw sw bl gn
50 30 + 2 1 B+ D+ W
A61 Positive connection (X), in dash panel wiring harness
B102 SA 2 SA 1 G C
B A 80A 110A
B102 Earthing connection, in interior wiring harness, front left
ws = white
M
C1 sw = black
-- ro = red
br = brown
2.5 25 25 gn = green
br sw sw bl = blue
gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42026
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), coolant
temperature sender, ignition transformer, spark plug
connector, spark plugs
P Spark plug connector
A2 Q Spark plugs
2.5 1.5 0.5 1.5 4
sw sw sw sw sw SB30 Fuse -30- in fuse box
A104 34a 24a 36a SB36 Fuse -36- in fuse box
5 T5l 5-pin connector, in the engine
0.5
sw SB 34 SB 24 SB 36 T10 10-pin connector, green, in the interconnection station
10A 5A 15A
T10d 10-pin connector, white in the interconnection station
Protected by copyright. Copying for private or commercial purposes,T10n
in part or10-pin connector,
in whole, is not grey in the interconnection station
30a 34b 24b 36b
1.5 0.5 1.5 T14 14-pin
connector, in the engine
sw ws/ge sw
SB 30 T14a 14-pin connector, brown, in the engine
5A
30b
T10/4 T10n/10 T10/8 14
10 Earthing point, in the plenum chamber
0.5 1.5 1 1.5 0.35
Earthing connection -1-, in the engine compartment wiring
85
harness
T10d/8 103
103 T121/4 J537 T121/28
A2 Positive connection (15), in the dash panel wiring harness
1 0.5
sw/ge sw/ge
T121/ T121/103 121
121 T121/93
102 A104 Positive connection -2- (15), in dash panel wiring harness
0.35 0.35 1 0.35
35 100
100 gn/br gn/ge br/ws bl/gr
T5l/4 T14a/ T14a/12 T5l/2 T14/3

11
1 0.5 0.5 1 0.5
sw gn/gr gn/ge br/ws bl/gr
2 N152 1 3
2 3
G62 G2
1 4
4
2.5 0.5 0.5 ws = white
ro = red
P
Q gn = green
2.5 0.5 bl = blue
br ge/ro
a
gr = grey
10 85
131
131 li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42324
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), hall sender,
potentiometer for exhaust gas recirculation, exhaust gas
recirculation valve
G40 Hall sender (00515-2113)
G212 Potentiometer for exhaust gas recirculation (00556)
J293 Control unit for coolant fan (00831)
N18 Exhaust gas recirculation valve (01265-4312)
2.5 0.5 1 1.5 T10a 10-pin connector, red, in the interconnection station
ro ro ro ro
T10d 10-pin connector, white in the interconnection station
15a 37a T14 14-pin connector, in the engine
7 149
149
SB 15 SB 37 J293 J293 J293 85 Earthing connection -1-, in the engine compartment wiring harness
10A 15A
T14c/8 T14c/2 T14c/3
15b 37b
* * * 220 Earthing connection (sender earth), in engine wiring harness
0.5 0.5
1 1.5 bl ro/ws Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ro/ge ro permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
D157 L5 respect to the correctness of information in this document.A52 Positive
Copyright by SEATconnection
S.A. -2- (30), in dash panel wiring harness
T10d/ T10a/5
6
1 1.5 0.35 0.35 0.35
ro/ge ro bl ro/ws gn/bl D101 Connection -1-, in engine compartment wiring harness
105
105 * *
J537 T121/3 T121/40 T121/61 T121/41 Connection (air conditioner ON), in engine compartment wiring
D157
harness
T121/86 T121/98 T121/ T121/100 L5 Connection -1-, in air conditioner wiring harness
114
0.35 0.35 1 0.35
gn/br ge li gn/br * Only vehicles with air conditioning
T14/1
0.5 0.5
gn/br br/sw
2 5 6 4
G40 N18
3 1 1
G212 2
0.5 1 0.5
ro/ws sw/ge gn/li
49 47 123
123 ws = white
16 ro = red
0.5 0.5 0.35 0.5 1 1 0.5
br = brown
bl = blue
a b
gr = grey
85 220
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42028
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), engine
speed sender, intake air temperature sender, intake
accelerator pedal position sender -2-
G28 Engine speed sender (00513-2111)
G42 Intake air temperature sender (00523-2322)
G71 Intake manifold pressure sender (00519-2222)
G79 Accelerator position sender (00777-3131)
G185 Accelerator pedal position sender -2-
220 Earthing connection, (sender earth), in engine wiring harness
149
149 150
150
0.35 0.35
ws/gn ws/bl
T121/47 J537 T121/30
T121/ T121/ T121/108 T121/109 T121/85 T121/ T121/ T121/ T121/ T121/ T121/
87 82 72 34 33 36 35 73
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
T3/1 T3/2 T14/10 T14/12

0.5 0.5
ge/sw ws/br
4 2 1 6 5 3 4 2
G28 G71 G42

3 1
0.5 0.5 G185 G79
gn/li br/ws
ws = white
sw = black
T3/3 T14/11 ro = red
0.35 by copyright.
0.35
br = brown
Copying 0.5
Protected
br/sw br/bl
gn/li gn = green
respect to the correctness of information in this document. Copyright by SEAT S.A. bl = blue
b
34 29 gr = grey
220
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--45702
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), throttle
valve control unit, throttle control (electric accelerator
control), throttle valve angle sender -1- (electric
accelerator control)
G186 Throttle control (electric accelerator control)
G187 Throttle valve angle sender -1- (electric accelerator control)
G188 Throttle valve angle sender -2- (electric accelerator control)
J338 Throttle valve control unit (01165)
J 104 J 104 T10n 10-pin connector, grey, in interconnection station
T25/10 143
143 T25/11 145
145
T14a 14-pin connector, brown, in the engine
0.35 0.35 10 Earthing point, in the plenum chamber

or/br or/sw
Connection (High-Bus), in engine compartment wiring

T10n/5 T10n/4 D159
harness
0.35 0.35 0.35 0.35
or/br or/br or/sw or/sw Connection (Low-Bus), in engine compartment wiring
D160 in part or in whole, is not
Protected by copyright. Copying for private or commercial purposes,
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee harness
D160
D159
0.35 0.35
or/br or/sw
CAN--L CAN--H
T121/58 J537 T121/60
T121/1 T121/2 T121/91 T121/ T121/ T121/ T121/117 T121/118

92 83 84
2.5 2.5 0.35 0.35 0.35 0.35 1 1

T14a/7 T14a/ T14a/ T14a/ T14a/8 T14a/1

10 4 3
0.5 1 1 0.5 0.5 0.5
1 2 4 3
J338 G186
6 5
G187 G188
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
10 10
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42030
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), knock
sensor I, cylinder 1 injector, cylinder 3 injector, cylinder
4 injector
G61 Knock senor I (00524-2142)
T5l 5-way connector, in the engine
T10 10-way connector, green, in the wiring harness
interconnection
J362 T10b 10-way connector, blue, in the wiring harness
136
136 142
142 128
128 T10x/7
interconnection
T10n 10-way connector, grey, in the wiring harness
0.5 0.35 0.35 0.5
interconnection
T10b/9 T10n/7 T10a/7
* 200 Earth connection (screened), engine bay wiring harness
0.35 0.35 0.35
gn/ws ge/gr ws/ge
W D95 Connection (injectors) wiring harness engine bay

T121/54 T121/48 J537 T121/43
* W auto-diagnosis line
T121/ T121/106 T121/96 T121/97 T121/88 T121/89

99
0.35 0.35 0.35 0.35 0.35 0.35

200
102
102
T14a/2 T14a/5 T14a/6 T14a/9
0.35 0.35 0.5 0.5 0.5 0.5 1
T14/8 T14/7 T14/6 T10/5

N30 2 N31 2 N32 2 N33 2
0.5 0.5 0.5 1
sw bl gr ro/ge
1 1 1 1 ws = white
T5l/1
sw = black
0.5 0.5 0.5 0.5 1 ro = red
gn = green
D95 bl = blue
G61 gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42325
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), Lambda probe,
Lambda probe after catalytic converter, Lambda probe
heating, heating for Lambda probe 1, after catalytic converter
G130 Lambda probe after catalytic converter (00699)
147
147
0.35
gn
T10a/8
0.35
gn/bl
T121/37 J537
T121/ T121/69 T121/63 T121/ T121/5 T121/ T121/ T121/ T121/51

68 81 70 71 52
0.35 0.35 0.35 0.35 1 0.35 0.35 0.35 0.35

gn sw br ws/gr br/ro
Protected by gr/roCopying
copyright. sw for private
gn or gr/ws

1 1 1
gr sw ws
Z29 Z19 G39

103
103
G130 ws = white
1 1
ws ro/ge sw = black
ro = red
gn = green
1.5 1.5 1.5 1.5 bl = blue
gr = grey
E30
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
or = orange
97--42308
rs = pink
Edition 09.2001
Control unit for Marelli 4LV (injection system), fuel pump
30 15 relay, brake light switch, brake pedal switch,
speedometer sender, activated charcoal filter solenoid
J17
2 valve 1
87F T F Brake light switch (00526-2131)
F63 Brake pedal switch
T6i/1 T6i/2 T6i/5 T6i/3
4 4 0.5 0.5 J537 Control unit for Marelli 4LV (injection system)
A99 A2 M25 High brake light bulb
8
1.5 1 1 0.5 1
N80 Activated charcoal filter solenoid valve 1 (01247-4343)
ro/bl ro/sw ro/sw sw sw (frequency)
3a 1a 27a 28a
116
116
SB 3 SB 1 SB 27 SB 28 SB27 Fuse -27- in fuse box
10A 10A T10a/9 5A 7.5A SB28 Fuse -28- in fuse box
3b 1b 27b 28b
1 1 0.35 0.35 1 T14 14-pin connector, in the engine
ro/ge ro/ge ro/ge sw sw
144
A38
83 91 139
139
J537 T121/65 0.5 0.35 12 Earthing point in the engine compartment, on the left
sw/gr ws/bl
T10/2 T10c/3 82 Earthing connection -1-, in the front left wiring harness
T121/64 T121/55 T121/56
0.35 0.35 0.35 0.5 0.5

gn/ge li/gn sw/ro sw/gr ws/bl A2 Positive connection (15), in the dash panel wiring harness
D73 T14/14 T14/13 A38 Positive connection -2- (15a), in dash panel wiring harness
1 1 0.5 0.5
sw/ro sw/ro sw/gr
Protected ws/bl for private or commercial purposes, in part or in whole, is not
by copyright. Copying
permitted unless authorised by SEAT
A99 Connection
-1- (87), in dash panel wiring harness
2 1 2 1 2
N80 F63 F T10d/7 G22 D73
harness
1 2 1 3
0.5 1 1 1 1 Positive connection -2- (15a), in engine compartment wiring
sw/ge sw ro/ge sw/ro br ws = white D136
harness
sw = black
17 D136 32 M9 T14a/14 ro = red
M10 br = brown
sw sw 4
br
br
bl = blue
gr = grey
113
113 21 82 12
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--42033
rs = pink
Edition 09.2001
Fuel gauge sender, fuel pump (pre-supply pump), coolant
shortage sender, oil pressure switch 0.3 bar, intake manifold
preheating heater element
F22 Oil pressure switch 0.3 bar (00772-3114)
N51 Intake manifold preheating heater element
b SB40 Fuse -40- in fuse box
c
T5l 5-pin connector, in the engine
d
e
102
102 101
101
1 1.5 0.35 0.35

sw ro/bl ro/bl bl/sw 61 Earthing point, C pillar, left
40a
108 Earthing connection -2-, in the front wiring harness, left
T5l/3 SB 40 T10c/2 T10a/6
15A
131 Earthing connection -2-, in the engine compartment wiring harness
1 40b
sw/ge
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not B109 Earthing connection, in interior wiring harness,rear left
* respect to the correctness of information in this document. Copyright by SEAT S.A. * Only vehicles in Scandinavian countries
N51
2
1 1.5 0.35 0.35 0.5 0.5

br ro/ge li/sw br/ws bl/ro bl/sw
T14/9
1
br 1 2 1 1
G6 G T10a/1 G32 F22

131
4 3 2
ws = white
2.5 1.5 0.5 1 0.5 sw = black
ro = red
108 B109
br = brown
gn = green
26 42 bl = blue
6 2.5
br br gr = grey
12 61
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42326
rs = pink
Edition 09.2001
lamp
G1 Fuel gauge
G21 Speedometer
b
c
16a
5A
26 73
16b
T10/3 A27 B158

0.35 0.35 0.35 0.35 0.35 0.35 0.35
T32/10 T32/22 T32/7 T32/8 T32/5 T32/3 T32/30
G3 G1
K3
J285
K28 K105
G21
T32/13 T32/1
0.35 0.35
ge/gr sw
78 107
107
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42035
rs = pink
Edition 09.2001
Control unit with warning lamps in the dash panel insert, revolution
G5 Rev. counter
ro
11a 13
SB 11 0.5
5A bl
11b
77 111
111 91
T10a/3
0.35 0.35 0.35 0.35 0.35 249 Earth connection -2-, interior wiring harness
ge/gr ws/bl gn ro bl

K132 K2
J285
K83
G5
T32a/20 T32a/19 T32/ T32a/10 T32/9 T32/24
CAN--L CAN--H 32
0.35
Protected 0.35Copying for private or commercial
by copyright. 0.35 0.35 in part or in whole,
purposes, 0.35 is not 0.35
or/br unless authorised
permitted or/sw by SEAT S.A. SEAT S.A doesws/gn ws/bl or accept anybr
not guarantee br
liability with
A122 A121 249
3
0.5 0.5 0.5 0.5 0.35 0.35 2.5 sw = black
br = brown
238
gn = green
J362 62 67 J362 47 52
bl = blue
T10x/1 T10x/2 2.5
br gr = grey
76 li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 152 153
or = orange
97--42713
rs = pink
Edition 09.2001
Fuel shut-off
⇒ Only models with petrol engine and airbags
From May 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

4 - Fuel shut- off control unit (405) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note:
Edition 09.2002
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055 respect to the correctness of information in this document. Copyright by SEAT S.A.
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
Fuel shut- off control unit (crash)
CRASH 31 30
J491 J... Engine control units
4 J234 Airbag control unit
J491 Fuel shut-off control unit (Crash)
T 15 T
T9b/3 T9b/5 T9b/8 T9b/2 T9b/4 T9b/6 76 Earth point, near selector mechanism
0.5 0.5 0.5 0.5 0.5

gr/ge ro/sw sw ro/ge ro

A125 T10a/9 A104 D/30
24
0.5 0.5 2.5 4 A32 Positive (+) connection (30), in dash panel wiring harness
gr/ge ro/ge sw ro
A32
A2 a A104 Positive (+) connection -2- (15), in dash panel wiring harness
b
J234 J...
T75/72
4
sw
D/15
0.5
br
ws = white
sw = black
ro = red
br = brown
gn = green
2.5 bl = blue
81 br gr = grey
76
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--43459
rs = pink
Edition 09.2002
Fuel pump relay, fuel pump (pre-supply pump)
87F T
J17 J17 Fuel pump relay (pre-supply pump)
2 N30 Injector, cylinder 1
N31 Injector, cylinder 2
30 15
T6i/1 T6i/3 T6i/5 T6i/2 SB3 Fuse -3- in fuse box
4 0.5 0.5 4
ro/bl sw ro/ge ro/sw 61 Earth point, left C-pillar
9
A32 A32 Positive (+) connection (30), in dash panel wiring harness
a
b
A99 Connection -1- (87), in dash panel wiring harness
A2
A99
1.5 1
ro/bl ro/sw
40a 3a
SB 40 SB 3
15A 10A
40b 3b
1.5 1
ro/ge ro/ge
T10/5
1
G6 1
ro/ge
4
N30 ws = white
1.5 N31
br
N32 sw = black
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not N33 ro = red
respect to the correctness of information in this document. Copyright by SEAT S.A. gn = green
2.5 bl = blue
br
B109 gr = grey
61
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
or = orange
97--43460
rs = pink
Edition 09.2002
Radio with CD
From May 2001
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Edition 09.2002
Radio, aerial, treble loudspeaker, rear right, bass loudspeaker,
rear right and rear left, treble loudspeaker, front right and front left,
bass loudspeaker, front right and front left
R Radio
R11 Aerial
R14 Treble loudspeaker, rear left
R15 Bass loudspeaker, rear left
R16 Treble loudspeaker, rear right
R17 Bass loudspeaker, rear right
R20 Treble loudspeaker, front left
R21 Bass loudspeaker, front left
R11 R22 Treble loudspeaker, front right
R23 Bass loudspeaker, front right
T1d Single connector
T1d/1 B189 Connection (positive, FR loudspeaker), in interior wiring harness
HF
permitted unless authorised B191
by SEATConnection
S.A. SEAT S.A(positive, FL loudspeaker),
does not guarantee or accept anyinliability
interior
withwiring harness
B193 Connection (positive (+), RR loudspeaker), in interior wiring harness

R A
B194 Connection (negative, RR loudspeaker), in interior wiring harness
T8q/6 T8q/5 T8q/4 T8q/3

1 1 1 1 B195 Connection (positive (+), RL loudspeaker), in interior wiring harness
br/sw B196 B191 bl/sw br/ge B194 B189 ro/ge
B196 Connection (negative, RL loudspeaker), in interior wiring harness

1 1
bl ro
T10g/7 T10f/7
1 1 1 1 1 1 1 1
br/bl br/bl bl bl br/ro br/ro ro ro
R14 2 T4i/3 R20 + + R16 2 T4l/3 R22 + +
R15 R21 R17 R23

1 T4i/2 -- -- 1 T4l/2 -- -- ws = white
sw = black
1 1 1 1 1 1 1 1
bl bl br/bl br/bl ro ro br/ro br/ro ro = red
br = brown
T10g/6 T10f/6 gn = green
1 1 bl = blue
B195 B193
br/bl br/ro gr = grey
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
or = orange
97--43461
rs = pink
Edition 09.2002
Radio, CD changer
E1 Light switch
R Radio (01304)
R41 CD changer (00857)
D/S T16 16-way connector, in the instrument panel, in the auto-diagnostic
connection centre
A40 * TV2 Cable distributor terminal 30
4 1.5 0.5
ro ro br/ro
42a 16a
TV2 SB 42 SB 16 J285 238 Earth connection -1-, interior wiring harness

20A 5A T32/3
T16/7
E1/17
42b 16b
0.5 0.35 0.5 1
br/ro gn/ws gr/ws gr/bl
B158 A27 A76 B145 A40 Positive connection -1- (30), in the instrument wiring harness
2.5 0.5 0.35 0.5 1

ro br/ro gn/ws gr/ws gr/bl A76 Connection (diagnosis cable K), instrument panel wiring harness
30a S K 58b
T8/7 T8/4 R T8/1 T8/3 T8/6
T8/8
31

gr/bl permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
T2g/2
ws = white
R41 T2g/1
sw = black
ro = red
br = brown
2.5 2.5 1 gn = green
br br br
bl = blue
gr = grey
76 238
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28
or = orange
97--42484
rs = pink
Edition 09.2002
Sun roof
From May 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5A - brown
5 A - beige
3 A - purple
Edition 05.2001
Sun roof regulating control unit, sun roof regulator, sun roof motor
E139 Sun roof regulator
J245 Sun roof regulating control unit
J379 Control unit for central locking and alarm system
T1b 1-way connector
T2f 2-way connector
J379 J 379
T23/8 TV2 D/15 T23/12 T5 5-way connector
TV2 Cable distributor terminal 30
* * V1 Sun roof motor
0.5 4 4 0.5
gr/ge ro sw bl/ws
Q49 A40 A2 Q9
2.5 1.5
* ro sw * 163 Earth connection -2-, interior lighting wiring harness
35a 26a

SB 35 SB 26
25A 5A
35b 26b
A40 Positive connection -1- (30), in the instrument wiring harness
0.5 4 0.5
** 0.5
gr/ge ro/bl sw bl/ws
T5/5 T2f/1 T1b/1

E139 B156 Positive connection (30a), interior wiring harness
4
ro/ge
B156 Q9 Connection in the electric window wiring harness

4 5 1 3 2
0.5 2.5 0.5
gr/ge ro/ge bl/ws
30a
Q49 Connection (closed), in the interior wiring harness
T6g/3 T6g/4 T6g/2 T6z/4 T6z/5 T6z/1 T6z/3 T6z/2
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or *acceptOnly vehicles
any liability with with central locking
**by SEAT
respect to the correctness of information in this document. Copyright OnlyS.A.
vehicles without central locking
V1 T6g/1
31 J245
2.5
br
163
4 ws = white
br sw = black
ro = red
T2f/2 br = brown
4 gn = green
br bl = blue
2.5
br gr = grey
B102
61 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42485
rs = pink
Edition 05.2001
Airbag
From May 2001
Different fuse and relay placement, multiple connectors see chapter"Positioning".
11 10 9 8 7
6 5 4 3 2 1
97-40408
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2001
Airbag control unit, airbag spring/recoil ring with contact ring, airbag
trigger - driver's side, airbag trigger 1 - passenger's side, side airbag
trigger, driver's side, side airbag trigger, passenger's side
F138 Airbag spring/recoil ring with contact ring
J379 Control unit for central locking and anti-theft alarm system
J491 Fuel shut-off control unit (collision)
N95 Airbag trigger - driver's side
N131 Airbag trigger 1 - passenger's side
N199 Side airbag trigger, driver's side
N200 Side airbag trigger, passenger's side
T3g 3-way connector, in the driver's seat
T3h 3-way connector, in the passenger's seat
J379 J491/5 J491 T3i 3-way connector
T23/19 T9c/5
T4k 4-way connector
24 25
*** ** *
0.35 0.35 0.5 0.5 0.5
or/sw or/br gr/ge gr/ge gr/ge

A121 A122 A125
0.35 0.35 0.5 or commercial purposes, in part or in whole, is not A125 Connection (impact signal), instrument panel wiring harness
Protected by copyright. Copying for private
or/sw or/br permitted unless authorised by SEAT S.A. gr/ge
CAN--H CAN--L respect to the correctness of information in this document. Copyright by SEAT S.A. * Only diesel vehicles
T75/74 T75/75 J234 T75/72 ** Only petrol vehicles
*** Only vehicles with central locking
T75/33 T75/34 T75/31 T75/32 T75/30 T75/29 T75/27 T75/28
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

ge ws ws gr ws gn ws bl
T4k/1 T4k/2 T3i/2 T3i/1 T3g/2 T3g/1 T3h/2 T3h/1
0.5 0.5 0.5 0.5 0.5 0.5

bl br bl sw bl sw
1 1 1
F138 N131 N199 N200

2 2 2
ws = white
sw = black
ro = red
N95 br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42722
rs = pink
Edition 09.2001
Airbag control unit, side airbag impact sensor, driver's side, side
airbag impact sensor, passenger's side, control unit with warning
lamps in the instrument panel, airbag warning lamp
G179 Side airbag impact sensor, driver's side (01221)
G180 Side airbag impact sensor, passenger's side (01222)
T16/7
T3g 3-way connector, in the driver's seat
0.5 T3h 3-way connector, in the passenger's seat
D/15 gr/ws T3i 3-way connector
T16 16-way connector, in the instrument panel, in the auto-diagnostic
connection centre
4 A76
sw
34 Earth point, under the driver's seat
0.35
A2 gr
2.5
35 Earth point, passenger's side
sw T32/6 T32/25
A104 76 Earth point, near gearbox control

0.5 0.5 0.35
sw gr/ws ge/ws K75
109 Earth connection in the airbag wiring harness
T75/26 J234
K
T75/54 T75/64
J285
T75/70 T75/71 T75/51
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 249 Earth connection -2-, interior wiring harness
permitted0.5
unless authorised0.5
by SEAT S.A. SEAT0.5 S.A does
0.5 not guarantee or accept any liability with
ge ws br br
1 1
* ** T32a/ T32a/20 T32/9 A2 Positive connection (15), instrument panel wiring harness
19
G179 G180
* 2 * 2 0.35 0.35 0.35 A76 Connection (diagnosis cable K), instrument panel wiring harness
or/sw or/br br
0.5 0.5
br br A104 Positive connection -2- (15), instrument panel wiring harness
4 6
109 249
* Only vehicles with side airbag
* * * ** Only vehicles without side airbag
0.5 0.5 0.5 2.5 ws = white
br br br br
sw = black
ro = red
T3g/3 T3h/3 T3i/3 238 br = brown
gn = green
0.5 0.5 0.5 2.5 bl = blue
br br sw br
gr = grey
34 35 35 76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42487
rs = pink
Edition 09.2001
Central locking and electric window lifter

⇒ Remote control
⇒ Alarm system
From May 2001
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 02.2003
Central locking and anti-theft alarm system control unit, central
locking lock unit (driver's side), central locking warning lamp -
SAFE-
F220 Central locking lock unit, driver's side
K133 Central locking warning lamp -SAFE-
T10e pin connector, black, exterior mirror, driver's door
T10i 10-pin connector, brown, A-pillar, lower driver's side
Z4 Heated exterior mirror, driver's side
205 Earth connection, in door wiring harness - driver's side

J379
B133 Connection (central locking open), in interior wiring harness
T24/21 T24/2 T24/5 T24/11 T24/10 T24/19 T24/12 T24/7 * Only models with electrically adjustable exterior mirrors
0.5 0.5 0.5 0.5 0.5 1 1 0.5

ws/gn gr/ge bl/li ro/bl bl/gr ws ro/sw bl/br
B133
0.5 0.35
bl/br bl/br
T10i/3 T10i/ T10i/ T10i/ T10i/ T10g/ T10g/ T10g/4

10 9 6 7 2 3
J285
0.5 0.5 0.5 0.5 0.5 1 1 0.5 T32/21
ws/gn gr/ge bl/li ro/bl bl/gr ro/sw ws bl/br
2 4/zu 6/auf 3/Safe 5 1 2 8
K133 M
F220
Z4/4
1
7/31
0.5
br B102 wsCopying
Protected by copyright. = white
sw = black
br
T10e/4 75 60 58 62 67
ro = red
T10g/1 br = brown
0.5
* gn = green
0.5 2.5 0.5 0.5 0.5 0.35 0.35 2.5 2.5
br br br br br br br br br br bl = blue
gr = grey
205 61
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--45703
rs = pink
Edition 02.2003
central locking lock unit (front passenger's side)
F221 Central locking lock unit, front passenger's side
T10h 10-pin connector, red, A-pillar, lower front passenger's side
T10j 10-pin connector, black, exterior mirror, front passenger's side
J 234 Z5 Heated exterior mirror, front passenger's side
T75/72

*
0.5
gr/ge
A125
* 206 Earth connection, in door wiring harness - front passenger's side

0.5
gr/ge
J379 T23/19

T24/9 T24/6 T24/18 T24/13 T24/22 T24/3 T24/4 T23/23
* Only models with airbag
** Only models with electrically adjustable exterior mirrors
0.5 0.5 0.5 0.5 1 1 0.5 1.5
gn/br ro/bl ws/gn gn/ge gr/bl br/ge bl/sw br
T10h/ T10h/ T10h/ T10h/ T10f/ T10f/3 T10f/4

10 9 6 7 2
0.5 0.5 0.5 0.5 1 1 0.5

gr/ge bl/li ro/bl bl/gr ro/sw ws bl/br
4/zu 6/auf 3/Safe 5 1 2 8
Z5/4 M
F221 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7/31
0.5 81
br 238 ws = white
2.5 sw = black
br
T10j/4 83 105
105 107
107 ro = red
T10f/1 br = brown
0.5
** gn = green
0.5 2.5 0.5 0.5 2.5 2.5 2.5
br br br br br br br br bl = blue
gr = grey
206 76 76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--45704
rs = pink
Edition 02.2003
Central locking control unit and anti-theft alarm, switches and
engines for central locking - tailgate/boot lid
F218 Tailgate/boot lid central locking switch
R47 Central locking and anti-theft alarm system
T5g 5-pin connector, black, left C-pillar
T5j 5-pin connector, black, in luggage compartment
V53 Central locking motor, tailgate/boot lid

R47
HF
J379of information in this document. Copyright by SEAT S.A.

T15/7 T15/10
T23/11 T23/10 T23/18 T23/3

K
0.5 0.5 1 1
gr/ws sw/bl gr gn
A76 T5g/2 T5g/4 T5g/1
0.35 0.5 0.5 1 1

gr gr/ws sw/bl gr gn
T16/7
T5j/2 T5j/4 T5j/1
J285
T32/25 0.5 1 1
sw/bl gr gn
T3d/3 1
F218 218 V53

T3d/2 1.5 2 ws = white
br sw = black
ro = red
T5a/1 br = brown
0.5 1.5 2.5 gn = green
br br br bl = blue
gr = grey
98 61
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42490
rs = pink
Edition 02.2003
Central locking and anti-theft alarm system control unit, anti-
theft alarm/rodent repellent system contact switch, anti-theft
alarm system horn
F120 Anti-theft alarm/rodent repellent system contact switch
H8 Anti-theft alarm system horn
T10n 10-pin connector, grey, connector point
W/TK
0.5
br/ws
T23/21 J379
Positive (+) connection (right turn signal), in dash panel wiring
A5
harness
T15/5 T15/11 T15/15 T15/14 T23/15 Positive (+) connection (left turn signal), in dash panel wiring
A6
harness
0.5 1.5 0.5 0.5 0.5
ge/br ro/bl sw/ws sw/gn gn/ws
A27 Connection (speed signal), in dash panel wiring harness
* Only models with engine codes AMF

A6 A5 A27
T10n/9 T10n/8
0.5 1.5 0.35 0.35 0.35 0.5

ge/br ro/ws sw/ws sw/gn gn/ws gn/ws
1 1
F120 T10b/9
H8
2
2
J
285 J285 J285 J...
T32/18 T32/2 T32/3
* ws = white
0.5 0.5 1.5 sw = black
br br br ro = red
br = brown
82 gn = green
4 bl = blue
br gr = grey
10 12 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--43464
rs = pink
Edition 02.2003
Central locking control unit and anti-theft alarm, front left
window lifter switch, window lifter switch, front right (in driver's
door), interior locking
E40 Front left window lifter switch
E81 Window lifter switch, front right, (driver's door)
E150 Interior locking switch, driver's side
L53 Window lifter switch light bulb
L99 Interior lock switch illumination
T10z 10-pin connector, blue, A-pillar, lower driver's side
Positive (+) connection -1- (30), in door wiring harness - driver's
R10
side
R51 Connection (58b), in door wiring harness - driver's side
J379
T23/16 T23/14 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
0.5 0.5
sw/gn ge/bl
T10i/ T10z/8
2 107
107
R10
1 a
gr/bl
R51
0.5 0.5 0.5 0.35 0.35 0.35 0.35

sw/gn ws/bl gr/bl gr/bl bl/ge gr/bl bl/ge
2 1 3 2 5 2 5
E150 L53 E81 L53 E40

5 4 6 1 4 6 1 4
L99
0.35 0.35 ws = white
0.5 0.5 0.35 sw/ge ge 0.35 0.35 0.35 sw = black
br br br br gn/ge gn
ro = red
T10z/ T10z/5 br = brown
4 b
8 7 9 0.5 0.5 10 gn = green
c
gn/ge sw/gn bl = blue
gr = grey
81 80
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70 or = orange
97--42492
rs = pink
Edition 02.2003
Control unit for central locking and alarm system, control
unit for front left electric window, control unit for front right
electric window, left window motor, right window motor
J295 Control unit for front left electric window
J296 Control unit for front right electric window
T10h 10-way connector, red, in strut A, lower passanger's side
T10i 10-way connector, brown, in strut A, lower driver's side
T10y 10-way connector, blue, in strut A, lower passanger's side
V14 Left-hand electric window motor
V15 Right-hand electric window motor
Q9 Connection in the electric window wiring harness
Q48 Connection (open), in the interior wiring harness

J379
respect to the correctness of information in this document. Copyright by SEAT S.A. Q49 Connection (closed), in the interior wiring harness
R10 Positive connection -1- (30), driver's side door wiring harness
T23/12 T23/8 T23/1
0.5 0.5 0.5

102
102 bl/ws gr/ge bl/li
Q9
Q49
2.5
bl/ge Q48
0.5 0.5 0.5 0.5 0.5 0.5

a R10 bl/ws gr/ge bl/li bl/li gr/ge bl/ws
106
106 104
104
T10z/ T10z/ T10z/10 T10y/ T10y/ T10y/

2 3 10 3 2
2.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 2.5
bl/ge bl/ws gr/ge bl/li bl/li gr/ge bl/ws ge bl/ge
T12/10 T12/6 T12/9 T12/2 T12a/2 T12a/9 T12a/6 T12a/3 T12a/10
V14 J296 V15

J295 T12/1 T12/4 T12/5 T12/7 T12a/
7
T12a/
1
T12a/4 T12a/5
0.35 0.35 2.5 1 1 0.5 0.5 2.5

gn gn/ge br sw sw sw/gn gn/ge br ws = white
sw = black
T10i/4 T10h/ T10y/ T10y/4 ro = red
4 5
b br = brown
c 5 0.5 0.5 0.5 0.5 19 gn = green
sw sw sw/gn gn/ge
bl = blue
gr = grey
92 90 64 63
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84 or = orange
97--42493
rs = pink
Edition 02.2003
Control unit for central locking and alarm system
R Radio (01304)
502 SB41 Fuse -41- in fuseholder
T16 16-way connector, in the instrument panel, in the auto-diagnostic
4 6
ro ro A32 connection centre
W Front inside illumination
102
102
2.5 502 Bolted joint -1- (30a), on the relay plate
ro
A52
A20 Connection (15a), instrument panel wiring harness
0.5 0.5 0.5 1 1.5 2.5
ro ro ro ro ro ro
10a 11a 14a 41a 42a

J379 T23/20 A32 Positive connection (30), in the instrument panel wiring harness
SB 10S.A does notSB
permitted unless authorised by SEAT S.A. SEAT 11 SB
guarantee or14 SB 41with
accept any liability SB 42
7.5A 5A 10A 15A 20A
respect to the correctness of information in this document. Copyright by SEAT S.A. A52 Positive connection -2- (30), instrument panel wiring harness
T23/5 T23/17 T15/12 T23/22 T15/13
S 10b 11b 14b 41b 42b
0.5 0.5 1.5 1.5 1 0.5 0.5 0.35 1 2.5 B158 Connection (S), interior wiring harness
sw br/ro ro/ws ro/ws ro/ge ro ro ro ro/ge ro
W/2 T16/16 J 285 E3/7 R

T32/23 T8/7
B158
A20 e
f
0.5 0.5
sw sw
79 76 ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98 or = orange
97--42494
rs = pink
Edition 02.2003
Front left-hand electric window switch, illumination lamp/electric
window switch
E1 Light switch
E41 Front right-hand electric window switch
L53 Illumination lamp/electric window switch
T10h 10-way connector, red, in strut A, lower passanger's side
D/S D/15 93 T10i 10-way connector, brown, in strut A, lower driver's side
T10y 10-way connector, blue, in strut A, lower passanger's side
4
4 ro
sw
A2 A40
0.5 1.5 2.5 2.5
br/ro sw ro ro A20 Connection (15a), instrument panel wiring harness
16a 26a 38a 39a
62
E1/17
SB 16 SB 26 SB 38 SB 39
5A 5A 25A 25A
1 1
gr/bl gr/bl
16b 26b 38b 39b B145 Positive connection (58b), interior wiring harness
2.5 2.5
0.5 1 ro/gn ro/gn T10z/9 B145
br/ro sw B158 Connection (S), interior wiring harness
1 1.5
T10i/1 T10h/1 gr/bl gr/bl
B238 Positive connection -2- (58b), interior wiring harness
2.5 83 B238
bl/ge
2.5 2.5 1 R16 Positive connection -1- (30), passenger's side door wiring harness
72 bl/ge bl/ge gr/bl
B158 R16 T10y/9 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
e respect to the correctness of information in this document. Copyright by SEAT S.A.
f A20
0.5 0.5
bl/ge gr/bl
1/30 3/58b
E41 L53
ws = white
5/31 4 2/31
sw = black
ro = red
0.5 0.5 0.5
br ge br br = brown
gn = green
bl = blue
20 82 21
gr = grey
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112 or = orange
97--42495
rs = pink
Edition 02.2003
Basic equipment
⇒ 1,0 l - Motronic/37 kW, engine codes AUC, (with air conditioner and/or with ABS)
⇒ 1.4 l - Motronic/44 kW, engine codes ANW and AUD , (with air conditioner and/or with ABS and/or with automatic gearbox)
⇒ 1.4 l - Marelli 4LV/74 kW, engine codes AUB, 1.4 l/55 kW diesel injection engine, engine codes AMF
From January 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

Note:
Edition 09.2002
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
junction box
31 30
A Battery
7 J59 B Starter
X 75x
C Alternator
T6h/4 T6h/3 T6h/2 T6h/1 SA1 Fuse -1- in fuse box/battery
203
203
1 1 6 2.5
ro
br sw/ge sw ro SA4 Fuse -4- fuse box/battery
A32 71
150
4 6 4 SA9 Convertible -9- in fuse box/battery
ro ro ro
D 30 502 501
TV2
X 50 15 P S
500 2 Earth strap, gearbox - body
2.5 2.5 4 1 0.5
16a 500 Screw connection -1- (30), on relay plate

66 77 186
186 113
113
T10/1 SB 16
5A
41
501 is not
Protected by copyright. Copying for private or commercial purposes, in part or in whole, Screw connection -2- (30), on relay plate
ro/sw 16b respect to the correctness of information in this document. Copyright by SEAT S.A.
0.5 0.35 10 502 Screw connection -1- (30a), on relay plate

B/30 B/50 br/ro br/ro C/B+ ro
B158 A32 Positive (+) connection (30), in dash panel wiring harness
25 16
sw sw
+
* T5f/1 T5f/2 T5f/3 T5f/4 T5f/5 1 2 3 4 * For all models, does not apply to AMF, 4-pin connector, T4a
30A 30A 20A 10A 30A 110 A 80A 50A 50A
ws = white
-- sw = black
ro = red
br = brown
gn = green
25 25 bl = blue
sw sw
gr = grey
1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--43465
rs = pink
Edition 09.2002
A38 Positive connection-2- (15a), in instrument panel wiring harness
J 234 J 234
J... 0.35 0.35
34 32
* T10n/4 T10n/5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
206
206 0.5 0.35 0.35 0.5 0.5 0.35 0.35 A122
permitted unless Connection
authorised (Low-Bus),
by SEAT S.A. SEAT S.Ainstrument panelorwiring
does not guarantee acceptharness
any liability with
ws/ge or/sw or/sw or/sw or/br or/br or/br respect to the correctness of information in this document. Copyright by SEAT S.A.
* W self-diagnosis line
A122
T10a/7 A121
1 0.5 0.5 0.5

30 W CAN--H CAN--L
T10x/10 T10x/7 J362 T10x/2 T10x/1
T3/1 T3/2 T3/3 T10x/9 T10x/3 T10x/8

31 15a K
0.5
sw
A38
1 0.5
sw gr/ws
28b
SB 28
7.5A
28a
ws = white
D2 1
sw = black
1
br sw ro = red
br = brown
gn = green
185
185
b
bl = blue
A76
gr = grey
76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42706
rs = pink
Edition 09.2002
triangle symbol
T10b/9
0.5
gn/ws
26 20 202
202 9
A27
*
0.35 0.35 0.35 0.35 0.35
CAN--L CAN--H
T32a/20 T32a/19 T32/3 T32/21 T32/30
K63 J533 J285
T32/25 T32a/28 T32a/27 T32/23 T32/1

CAN--L CAN--H 199
199
0.35 0.35 0.35 0.35 0.5 0.35

gr gn sw ro ro sw
11b 10b
T16/14 T16/6
192
192
SB 11 permittedSB
unless
10 authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5A wsthis document.
7.5A to the correctness of information in
respect = white Copyright by SEAT S.A.
T16/7 T16/4 T16/16
11a 10a
sw = black
K 31
ro = red
0.5 0.5 0.5 0.5 0.5 br = brown
gr/ws br ro ro ro
gn = green
b A76
* bl = blue
84 205
205 gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--45707
rs = pink
Edition 09.2002
Control unit with warning lamps in the dash panel insert ,
buzzer/gong, headlights warning lamp, alternator warning
lamp, left flasher warning lamp, airbag warning lamp, right
flasher warning lamp, digital clock, odometer
C Alternator
H3 Buzzer/gong
J285 Control unit with warning lamps in the dash panel insert
K1 Headlights warning lamp
K65 Left flasher warning lamp
C/D+ K75 Airbag warning lamp
K94 Right flasher warning lamp
bl Y2 Digital clock
108
108 Y4 Odometer
T10a/3 249 Earth connection -2-, interior wiring harness
0.35 or commercial purposes, in part or in whole, is not

Protected by copyright. Copying for private 0.35 * Only vehicles without airbag
permitted unless authorised by SEAT S.A. bl ws
** Only vehicles without central locking
T32/12 T32/17
K2 K1
Y2 H3
J285
K94 K65 K75

Y4
T32/2 T32/18 T32/24 T32/9 T32/6
0.35 0.35
gn/sw sw/ws
122
122 115
115 206
206 200
200 131
131 136
136
ws = white
** * sw = black
ro = red
2.5 0.5 0.5 0.5 0.35 0.35 0.35
br br br br br br br br = brown
gn = green
249 bl = blue
gr = grey
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
or = orange
97--45708
rs = pink
Edition 09.2002
Control unit with warning lamps in the dash panel,
handbrake control switch, brake fluid level switch, sidelight
warning lamp, ABS warning lamp, brake system control
warning lamp, digital display illumination
F9 Handbrake control switch
K4 Sidelight warning lamp
c K19 Warning lamp for the seat belt warning system
d K47 Antiblocking system (ABS) warning lamp
e K118 Brake system warning lamp
142
142 131
131 83 135
135 L75 Digital display illumination
0.5 1 1 0.5 0.35 0.35 0.35 T10c 10-way connector, black, in the wiring harness interconnection
B145 B160
0.35 0.35 0.5 0.5
gr/bl br/bl br/ge br/ge
T32/20 T32/14 T32/26 T32/27 T32/29

B160 Connection (brake system monitoring), interior wiring harness

L75 K4 K118 T10c/6
* Only petrol vehicles without ABS
J285 ** Only diesel vehicles without ABS
0.5 *** Only vehicles without central locking
bl/br
1 Copyright by SEAT
1 S.A.
K47 K19
F9 F34
T32/19 2 2
0.35
ge
204
204 198
198 181
181 1
***
0.5 0.5 1 1 0.5 0.5
T10/10 br br br br br br/sw
ws = white
sw = black
167
167
ro = red
B102
0.5 0.5 br = brown
ge br
2.5 gn = green
* ** br bl = blue
gr = grey
61
157
157 156
156 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42724
rs = pink
Edition 09.2002
Light switch, anti-fog light switch, light switch illumination
E1 Light switch
E7 Anti-fog light switch
L9 Light switch illumination
81 Earth connection -1-, dash panel insert wiring harness

c
d
A3 Positive connection (58), dash panel insert wiring harness
e
156
156 f
g
0.35 0.5 0.5

gr/gn gr/gn gr/gn
A3
99 111
111 107
107 106
106 124
124 59 156
156
0.35
Protected0.5 0.35 Copying
by copyright. 0.5 for 1.5 2.5 purposes,
private or commercial 2.5 in part or in1.5
whole, is1.5
not 1 0.5
gr/ge
permitted gr/ge authorised
unless gr/ro gr/ro
by SEAT gr/gn
S.A. SEAT S.A doessw/ws ge
not guarantee or acceptws/ge gr/ws
any liability with gr/bl gr/bl
13/58L 14/58R 16/58 6/B 4/56 7/56b 3/TFL 8/NL 9/NSL 17/58b
E1 15/30 1/Xz
E7 2/Xf
L9 10/31
2.5 2.5 1.5 1

ro sw/ge gr/ws br
3 139
139 180
180 157
157 32
A40
4 1.5 1.5 0.5 0.5 ws = white

ro ro br br br
sw = black
ro = red
81
11 109
109 br = brown
2.5 gn = green
br bl = blue
gr = grey
76
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42005
rs = pink
Edition 09.2002
Rear right-hand light bulb, rear left-hand light bulb, rear left-
hand flasher bulb, left-hand brake light bulb, right-hand brake
light bulb, right-hand reversing light bulb, high brake light bulb,
rear anti-fog light bulb, number plate light
M2 Rear light bulb, right
M4 Rear light bulb, left
M6 Rear left flasher bulb
M8 Rear right flasher bulb
f M17 Right reversing light bulb
g M25 High brake light bulb
F/2 L20 Rear anti-fog light bulb
1 0.5
sw/ro gr/gn T10a 10-way connector, red, in the wiring harness interconnection
D73 2a
1 SB 2 61 Earth point, C strut left
sw/ro 5A
2b
T10d/7
1 0.5
sw/ro gr/gn
B131
114
114 99 190
190 112
112 121
121 B131 Connection (54), interior wiring harness
B132
1 1 B132 Connection (number plate light), in the interior wiring harness

sw/ro sw/bl
T5b/2 T10a/2 D73 Positive connection (54), engine bay wiring harness
1.5 0.5 0.5 1 1 1 1 0.5 0.5 0.5 0.5

gr/ws sw/ws gr/sw sw/ro sw/ro sw/ro sw/bl gr/ro sw/gn gr/gn gr/gn
1/NSL 2/BLL 6/58L 5/54 2 1/54 6/RFL 2/58R 5/BLR 1
X Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
L20 M6 M4 M9 M25 M10 M17 M2 M8 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ws = white
3/31 4/31 1 3/31 4/31 2 2 sw = black
ro = red
1.5 1.5 1 1.5 1.5 0.5 0.5
2.5 gn = green
br 137
137 bl = blue
B109
61 gr = grey
li = purple
85 86 87 88 89 90 91 92 93 94 95 96 97 98 ge = yellow
97--42006 or = orange
rs = pink
Edition 09.2002
Dip beam and headlamp flasher switch, twin-filament bulb,
left headlamp/Left sealed beam unit, twin-filament bulb,
right headlamp/Right sealed beam unit, left sidelight bulb,
right sidelight bulb, left front flasher light bulb
E4 Dip beam and headlamp flasher switch
L1 Twin filament bulb/sealed beam unit, left
L2 Twin filament bulb/sealed beam unit, right
77 72 M1 Sidelight bulb, left
M3 Sidelight bulb, right
2.5 1.5 M5 Flasher bulb, front left
sw/ws ro
M7 Flasher bulb, front right
56 30
T5d/3 T5d/5 SB4 Fuse -4- in the fusebox
E4 SB12 Fuse -12- in the fusebox
T5d/2 T5d/4 SB44 Fuse -44- in the fusebox
78 56b
56a
T10b 10-way connector, blue, in the wiring harness interconnection
2.5 2.5 1.5 1.5 T10c 10-way connector, black, in the wiring harness interconnection
72 113
113 110
110 ge ge ws ws 74 114
114
A9 A9 Positive connection (56b) in the dash panel wiring harness

0.5 0.5 1.5 1.5 2.5 102
102 0.5 0.5
gr/ge gr/ge ws ge ge gr/ro gr/ro
A95 Connection -1- (56a), in the dash panel wiring harness
4a 13a 44a 45a 12a 5a
SB 4 SB 13 SB 44 SB 45 SB 12 SB 5 B167 Connection (56b), interior wiring harness

5A 10A 15A 15A 10A 5A
4b 13b 44b 45b 12b 5b

Protected by copyright. Copying for private or 1.5
commercial purposes, in part or in whole, is 0.5
not B247 Connection -2- (56b), in interior wiring harness
0.5 0.5 1.5 1.5 1.5 0.5
gr/sw gr/sw permitted
ws/sw unless authorised
ge/sw by159SEAT S.A. SEAT ge S.A does not guarantee
ws or accept any
gr/roliability with
gr/ro
159 163
163
A95
T10b/6 T10b/4 T10b/5 T10c/5 T10b/
87 7
2.5 1 1 2.5 0.35 1.5 94
116
116 ge/sw ge/sw ge ge ws ws
119
119
T10c/4
1 0.5 1.5 1.5 B247 B167 1.5 53
sw/ws gr/sw ws/sw ge/sw ge 1.5 0.5 1
ws gr/ro sw/gn
BLL 58 56a 56b 56b 56a 58 BLR
T8d/3 T8d/4 T8d/8 T8d/6 T8e/6 T8e/8 T8e/4 T8e/3
ws = white
ro = red
T8d/2 T8e/2 br = brown
31 31 gn = green
2.5 2.5 bl = blue
br br
gr = grey
123
123 165
165 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--45709
rs = pink
Edition 09.2002
Flasher switch, parking light switch, left anti-fog light lamp, right
anti-fog light lamp, left side flasher lamp, right side flasher lamp
E2 Flasher switch
L22 Left anti-fog light lamp
L23 Right anti-fog light lamp
M18 Left side flasher lamp
6 M19 Right side flasher lamp
h T10b 10-way connector, blue, in the wiring harness interconnection
1 0.5 T10c 10-way connector, black, in the wiring harness interconnection
ge sw/ge
P 49a 12 Earth point in engine bay, on the left
T7a/5 T7a/2
E19 108 Earth connection -2-, front left wiring harness
T7a/4
PL
T7a/6
PR E2 T7a/3
L
T7a/7
R A5
Positive connection (right hand flasher) instrument panel wiring
harness
0.5 0.5 1 1
gr/ge gr/ro sw/ws sw/gn Positive connection (left hand flasher) instrument panel wiring
A6
harness
100
100 112
112 permitted unless authorised by SEAT S.A.D57SEAT S.AConnection (flashers,
does not guarantee right),
or accept engine
any bay
liability with wiring harness
A6 A5 D58 Connection (flashers, left), engine bay wiring harness

80
0.5 0.5 0.35 0.5 0.5 0.5 0.5 0.35 1.5

sw/ws sw/ws sw/ws sw/ws sw/gn sw/gn sw/gn gn/sw ws/ge D59 Connection (anti-fog lamps), in the engine bay wiring harness
* Only petrol vehicles

127
127 86 45 T10b/8 T10c/1 128
128 95 43 T10c/8
0.5 0.5 1.5
sw/ws sw/gn ws/ge
D58 D57 D59
0.5 1 0.5 1 1.5 1.5

2 99 2 112
112 1 1
M18 M19 L22 L23 ws = white

155
155 104
104
sw = black
1 1
* 2 2 ro = red
0.5 0.5 2.5 2.5 1.5 1.5 br = brown
br br br br br br
6 gn = green
br
bl = blue
166
166 164
164
108 gr = grey
12 li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42008
rs = pink
Edition 09.2002
Emergency flasher switch, rear window heating switch,
flasher relay, emergency flasher warning lamp, rear window
heating warning lamp, heated window switch illumination
lamp, heated windscreen
E15 Rear window heating switch
J1 Flasher relay
i K6 Emergency lights warning lamp
h
204
204 K10 Heated rear window warning lamp
A80 L39 Heated window switch illumination lamp
0.5 1 1 2.5 1.5
sw/ge ro sw/ge sw/ge sw/ge SB43 Fuse -43- in the fusebox
14a 7a 48a 43a Z1 Heated rear window
SB 14 SB 7 SBby
permitted unless authorised SB S.A.
48 SEAT 61 with
43 SEAT S.A does not guarantee or accept any liability Earth point, C strut left
10A 7.5A 20A 15A
14b 7b 48b 43b
58 60 209
1 0.5 1 0.5 0.5 2.5 1.5

1/49a E3 7/30a 6/75a 4/58b 8 J1 80

1/58b K10 5/75a
L39 E15
2/31 6/+
2.5
*
3/L 2/R 5/31
K6 sw
T5b/1
0.5 0.5 0.5 0.5 2.5
+
113
113 120
120 49 50
Z1
-- ws = white
184
184 90 sw = black
ro = red
br = brown
2.5 1.5 1 2.5 gn = green
gr = grey
61 218
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42009
rs = pink
Edition 09.2002
Fresh air fan switch, warning lamp for fresh air and circulating
air functions, additional resistance for fresh air fan with thermal
overload fuse, fresh air blower, servo-motor for fresh/
circulating air flap
E9 Fresh air fan switch
1 2.5 0.5 4 N24 Fresh air fan with overheating fuse additional resistance
sw/ge sw/ge ge/bl sw/ro SB6 Fuse -6- in the fusebox
6a 50a 9a A61 SB49 Fuse -49- in fusebox
SB 6 SB 50 SB 9 6 2.5 T4j 4-way connector, behind dash panel insert
15A 15A 5A sw sw/ge V2 Fresh air blower
6b 50b 9b V154 Servo-motor for fresh/circulating air flap
4 49a
1 1.5 0.5 45 Earth point, behind the instrument panel
sw/ge sw/gr ge/bl SB 49
25A
57
186
186 171
171 160
160 49b 162 Earth connection, fan motor wiring harness
0.5 2.5
gr/bl sw/ro
188
188
A61 Positive connection (X), instrument panel wiring harness
T4j/3 T4j/1
0.5 0.5 2.5 A80 Connection -1- (X), in the instrument panel wiring harness
gr/bl sw/bl sw/bl
58b Xa
T8m/3 K114 T8m/5 E159 E9 T6t/2
L66 Connection, heater blower wiring harness
L16
T8m/4 T8m/7 T8m/8 T6t/1 T6t/3 T6t/4 T6t/5
0.5 0.5 0.5 2.5 2.5 2.5 2.5

L66
2.5 2.5
ge ge
2 1
1 4 1 3 2
ws = white
2
ro = red
3 br = brown
0.5
Protected by copyright. Copying for private2.5 2.5
gn = green
br
permitted unless authorised by SEAT S.A. SEAT br S.A does not guarantee
br or accept any liability with bl = blue
respect to the correctness of information in this document. Copyright by SEAT S.A. gr = grey
162 45
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
or = orange
97--42010
rs = pink
Edition 09.2002
Light dimmer - switches and instruments, light range adjuster,
left light range regulator engine, right light range regulator
engine
E20 Lighting dimmer - switches and instruments
E102 Headlight range adjuster
V48 Headlight range adjuster motor, left
V49 Headlight range adjuster motor, right
131 Earth connection-2-, in the engine compartment wiring harness
* Only petrol vehicles without ABS

** Only diesel vehicles without ABS
*** Only petrol vehicles
76 148
148
0.5 0.5
gr/gn ge/bl
58 56b
T6e/3 T6e/4
E20 E102
T6e/5 T6e/1 T6e/2
58b 31 G
0.5 0.5 0.5

gr/bl br ro/bl
84 82 105
105 T10b/1 106
106
1 0.5 0.5 1
+ G G +
T8d/5 T8d/1 T8e/1 T8e/5
V48 V49
T8d/7 T8e/7
31 31 ws = white
sw = black
122
122 59 58 118
118 107
107 115
115 69
ro = red
*** ** * br = brown
gn = green
2.5 0.5 0.5 0.5 0.5 0.5 2.5 0.5 0.5 bl = blue
br br ge br/bl br/bl br br br br/sw
131 gr = grey
j li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
or = orange
97--42725
rs = pink
Edition 09.2002
Automatic intermittent wash-wiper relay, intermittent
windscreen wiper switch, rear window wiper switch,
windscreen wiper motor, windscreen and rear window washer
J31 8
pump
53M 75a 53s J T 31
E22 Intermittent windscreen wiper switch
E34 Rear window wiper switch
T9/4
T9/2 T9/8 T9/5 T9/1 T9/6
1 1.5 1 0.5 1 1 1
gn sw/gr gn br/sw gn gn br V Windscreen wiper motor
V59 Windscreen and rear window washer pump
T10c/10 131 Earth connection -2-, in the engine compartment wiring harness
1
gn 65
A36 Connection (75a), in the instrument panel wiring harness
1
V59
2 k
1 l
A36 gn/sw
T10c/9
1.5 1 1.5 1.5 1 1 1 1
sw/gr sw/gr sw/gr sw/gr sw/gr gn/sw gn/sw bl
53c
75a 53s J T
T5c/2 T5c/3 T5c/5 T4b/2 T4b/1 T5e/5
146
146 181
181 W E34
21 O
T5c/4 E22 T5c/1T
T4b/4 T4b/3 T5e/1
H
53e 53b 75a 31
O
gn/ge J
1 1 1.5 1.5
gn/sw br sw/gr
T10d/3 T10d/10 T10d/9 T10d/2

1 1 1 1 81 173
173
gn sw/gr gn/sw gn/ge
ws = white
4/53 1/75a 3/53e 2/53b sw = black
Vpermitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ro = red
respect to the correctness of information in this document. Copyright by SEAT S.A. br = brown
5/31 gn = green
1 bl = blue
br
gr = grey
131
j li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
or = orange
97--45706
rs = pink
Edition 09.2002
Reversing light switch, horn actioning, two-tone horn, rear
window washer motor
H Horn actioning
H1 Two-tone horn
T4j 4-way connector, behind dash panel insert
A2 T5a 5-way connector, brown, in the tailgate
1 4 1.5 1.5 0.5 2.5
sw sw sw sw sw sw T10d 10-way connector, white, in the wiring harness interconnection
V12 Windscreen washer motor
26a 29a 27a A104
24 5 A2 Positive connection (15), instrument panel wiring harness
1.5
SB 26 SB 29 SB 27 sw
5A 5A 5A
19a A104 Positive connection -2- (15), dash panel insert wiring harness
26b 29b 27b
k
144
144
SB 19 * Only vehicles without central locking
l 15A
* 19b
1 1 1 0.5 1 0.35 1.5

bl gn/sw sw/ge sw sw sw sw/ge
T5b/5 T5b/3 T5b/4 T4j/4 T10d/4 41 T10d/5

1 1 1 0.5 1
bl gn/sw sw/ge sw/bl sw 1.5
sw/ge
1
T5a/5 T5a/3 T5a/4 146
146 1
1
bl
1
gn/sw
1
sw/ge
F4 H1
2
2 3 4 2
1 1.5
V12 sw/bl br/sw
1 93 T10d/1
1 1.5 ws = white
br br/sw
sw = black
T7a/1 ro = red
T5a/1 br Copying
Protected by copyright. = brown for private or commercial purposes, in part or in whole, is not
1.5
H permitted unless authorised
gn = bygreen
br bl = blue
gr = grey
136
136 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
or = orange
97--42015
rs = pink
Edition 09.2002
Inside front illumination, driver's side door switch, passenger's side
door switch, cigarette lighter illumination, cigarette lighter
F2 Door switch, driver's side
F3 Door switch, passenger's side
L28 Cigarette lighter illumination
T5 5-way connector
39
T10f 10-way connector, black, in strut A, lower passenger's side
0.5
T10g 10-way connector, black, in strut A, lower driver's side
ro U1 Cigarette lighter
A52 W Front interior illumination
T5/1
0.5 2.5 1 0.5 1 1.5
ro ro ro ro ro ro
2/30a 46a
7 129
129 37 16
W SB 46
15A
1/31 3/TK 46b
0.5 0.5
ro br/ws
B154 Connection -1- (door contact), in interior wiring harness
136
136
T5/3 T5/2 * Only vehicles without central locking
** Only vehicles with central locking
0.5 0.5 1.5 0.5
br/ws br/ws B154 ro gr/bl
** *
T4d/2 T4d/3
J379 * * *
0.5 0.5 0.35 0.5
T23/21
U1 L28
64 T10f/9 39 T10g/9 47 T4d/1
0.5 0.5 2.5 1.5

br/ge br/ge br br
2 2
F3 F2
238
1 1
0.5 0.5 2.5
br br br
ws = white
sw = black
T10f/10 T10g/10 ro = red
Protected by copyright. Copying for private or commercialbrpurposes,
= brown
0.5 0.5 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
br br gn = green
* * bl = blue
48 63 gr = grey
76
li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
or = orange
97--42726
rs = pink
Edition 09.2002
Basic equipment
⇒ 1.0 l - Motronic/37 kW, engine codes AUC (without air conditioner and/or without ABS)
⇒ 1.4 l - Motronic/44 kW, engine codes ANW and AUD (without air conditioner and/or without ABS and/or without automatic gearbox)
From May 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

Note:
Edition 02.2003
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 02.2003
junction box
31 30
A Battery
7 J59 B Starter
T6h/4 T6h/3 T6h/2 T6h/1 T10 10-pin connector, green, connector point
203
203
6
1 1 6 2.5 ro
br sw/ge sw ro 1 Earth strap, battery - body
150
150 A32 71 2 Earth strap, gearbox - body
4 6 4
ro ro ro 500 Screw connection -1- (30), on relay plate
D 30 502 501
501 Screw connection -2- (30), on relay plate
TV2
X 50 15 P S 502 Screw connection -1- (30a), on relay plate
500
2.5 2.5 4 1 0.5
16a
66 77 186
186 113
113
SB 16 B158 Connection (S), in interior wiring harness

T10/1 5A
41
16b
2.5 0.5 0.35 10

ro/sw br/ro br/ro ro B/30
B158
B/50 25
sw
A
ws = white
-- sw = black
ro = red
Protected by copyright. Copying for private or commercial purposes, inbrpart or
= inbrown
whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guaranteegn = any
or accept green
liability with
25 of information
25 in this document. Copyright by SEAT S.A.
sw sw
bl = blue
gr = grey
1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42727
rs = pink
Edition 02.2003
J 234 J 234
J... 0.35 0.35
34 32
* T10n/4 T10n/5
206
206 0.5 0.35 0.35 0.5 0.5 0.35 0.35 A122 Connection (Low-Bus), instrument panel wiring harness
A122
T10a/7 A121
1 0.5 0.5 0.5

30 W CAN--H CAN--L
T10x/10 T10x/7 J362 T10x/2 T10x/1
T3/1 T3/2 T3/3 T10x/9 T10x/3 T10x/8

31 15a K
0.5
sw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A38 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1 0.5
sw gr/ws
28b
SB 28
7.5A
28a
ws = white
D2 1
sw = black
1
br sw ro = red
br = brown
gn = green
185
185
b
bl = blue
A76
gr = grey
76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42706
rs = pink
Edition 02.2003
triangle symbol
T10b/9
0.5
gn/ws
26 20 202
202 9
A27
*
0.35 0.35 0.35 0.35 0.35
CAN--L CAN--H
T32a/20 T32a/19 T32/3 T32/21 T32/30
K63 J533 J285

T32/25 T32a/28 T32a/27 T32/23 T32/1

CAN--L CAN--H 199
199
0.35 0.35 0.35 0.35 0.5 0.35

gr gn sw ro ro sw
11b 10b
T16/14 T16/6
192
192
SB 11 SB 10
5A 7.5A ws = white
T16/7 T16/4 T16/16
11a 10a
sw = black
K 31
ro = red
0.5 0.5 0.5 0.5 0.5 br = brown
gr/ws br ro ro ro
gn = green
b A76
* bl = blue
84 205
205 gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--45713
rs = pink
Edition 02.2003
Control unit with display in dash panel insert, main beam
warning lamp, alternator warning lamp, airbag warning lamp,
digital clock
C Alternator
H3 Buzzer/gong
K1 Main beam warning lamp
K65 Left turn signal warning lamp
C/D+ K94 Right turn signal warning lamp
T10a 10-pin connector, red, coupling station
Y2 Digital clock
0.5
bl Y4 Odometer display
108
108
T10a/3
* Only models without airbag
0.35 0.35 ** Only models without central locking
bl ws
T32/12 T32/17
K2 K1
Y2 H3
J285
K94by copyright. Copying

Protected K65 for private or commercial purposes, in part or in whole, is not K75
permitted unless authorised by SEAT S.A. SEATYS.A 4 does not guarantee or accept any liability with
T32/2 T32/18 T32/24 T32/9 T32/6
0.35 0.35
gn/sw sw/ws
122
122 115
115 206
206 200
200 131
131 136
136
ws = white
** * sw = black
ro = red
2.5 0.5 0.5 0.5 0.35 0.35 0.35
gn = green
249 bl = blue
gr = grey
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
or = orange
97--45714
rs = pink
Edition 02.2003
Control unit with display in dash panel insert, handbrake
warning switch, brake fluid level warning contact, side light
warning lamp
F9 Handbrake warning switch
K4 Side light warning lamp
K19 Seat belt warning system warning lamp
K47 ABS warning lamp
c
K118 Brake system warning lamp
d
e
L75 Digital display illumination
142
142 131
131 83 135
135 T10 10-pin connector, green, coupling station
T10c 10-pin connector, black, coupling station
0.5 1 1 0.5 0.35 0.35 0.35
B145 B160 B102
permitted Earth
unless connection,
authorised in front
by SEAT S.A. SEATleft
S.Ainterior
does notwiring harness
0.35 0.35 0.5 0.5

gr/bl br/bl br/ge br/ge B145 Positive (+) connection (58b), in interior wiring harness
T32/20 T32/14 T32/26 T32/27 T32/29
B160 Connection (brake system monitoring), in interior wiring harness
L75 K4 K118 T10c/6 * Only models without central locking
J285
0.5
bl/br
1 1
K47 K19
F9 F34
T32/19 2 2
0.35
ge
204
204 198
198 181
181 1
*
0.5 0.5 1 1 0.5 0.5
ws = white
sw = black
167
167
ro = red
B102
0.5 br = brown
ge
2.5 gn = green
br bl = blue
gr = grey
61
157
157 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--45715
rs = pink
Edition 02.2003
Light switch, anti-fog light switch, light switch illumination
E1 Light switch
E7 Anti-fog light switch
L9 Light switch illumination
81 Earth connection -1-, dash panel insert wiring harness

c
d
A3 Positive connection (58), dash panel insert wiring harness
e
156
156 f
g
0.35 0.5 0.5

gr/gn gr/gn gr/gn
A3
99 111
111 107
107 106
106 124
124 59 156
156
0.35 0.5 0.35 0.5 1.5 2.5 2.5 1.5 1.5 1 0.5
gr/ge gr/ge gr/ro gr/ro gr/gn sw/ws ge ws/ge gr/ws gr/bl gr/bl
13/58L 14/58R 16/58 6/B 4/56 7/56b 3/TFL 8/NL 9/NSL 17/58b
E1 15/30 1/Xz
E7 2/Xf
L9 10/31
2.5 2.5 1.5 1

ro sw/ge gr/ws br
3 139
139 180
180 157
157 32
A40
4 1.5 1.5 0.5 0.5 ws = white

ro ro br br br
sw = black
ro = red
81
11 109
109 br = brown
2.5 gn = green
br bl = blue
gr = grey
76
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42005
rs = pink
Edition 02.2003
Rear right-hand light bulb, rear left-hand light bulb, rear left-
hand flasher bulb, left-hand brake light bulb, right-hand brake
light bulb, right-hand reversing light bulb, high brake light bulb,
rear anti-fog light bulb, number plate light
M2 Rear light bulb, right
M4 Rear light bulb, left
M6 Rear left flasher bulb
M8 Rear right flasher bulb
f M17 Right reversing light bulb
g M25 High brake light bulb
F/2 L20 Rear anti-fog light bulb
1 0.5
sw/ro gr/gn T10a 10-way connector, red, in the wiring harness interconnection
D73 2a
1 SB 2 61 Earth point, C strut left
sw/ro 5A
2b
T10d/7
1 0.5
sw/ro gr/gn
B131
114
114 99 190
190 112
112 121
121 B131 Connection (54), interior wiring harness
B132
1
permitted unless authorised by SEAT S.A. SEAT S.A does not1 guarantee or accept any liability with B132 Connection (number plate light), in the interior wiring harness
sw/ro sw/bl
T5b/2 T10a/2 D73 Positive connection (54), engine bay wiring harness
1.5 0.5 0.5 1 1 1 1 0.5 0.5 0.5 0.5

1/NSL 2/BLL 6/58L 5/54 2 1/54 6/RFL 2/58R 5/BLR 1
X
L20 M6 M4 M9 M25 M10 M17 M2 M8
ws = white
3/31 4/31 1 3/31 4/31 2 2 sw = black
ro = red
1.5 1.5 1 1.5 1.5 0.5 0.5
2.5 gn = green
br 137
137 bl = blue
B109
61 gr = grey
li = purple
85 86 87 88 89 90 91 92 93 94 95 96 97 98 ge = yellow
97--42006 or = orange
rs = pink
Edition 02.2003
Headlight dipper/flasher switch, twin filament bulb for
headlight, left and right, side light bulb, left and right, turn
signal bulb front left and right
77 72
sw/ws ro SB4 Fuse -4- in fuse box
56 30 SB5 Fuse -5- in fuse box
T5d/3 T5d/5
E4 SB13 Fuse -13- in fuse box
T5d/2 T5d/4
56b
T10b 10-pin connector, blue, coupling station
78 56a
2.5 2.5 1.5 1.5 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ge ge ws ws A9 Positive (+) connection (56b),
72 113
113 110
110 74 114
114 respect to the correctness of information in this document. Copyright by SEATinS.A.
dash panel wiring harness
A9
0.5 0.5 1.5 1.5 2.5 102
102 0.5 0.5
gr/ge gr/ge ws ge ge gr/ro gr/ro A95 Connection -1- (56a), in dash panel wiring harness
4a 13a 44a 45a 12a 5a

B167 Connection (56b), in interior wiring harness
SB 4 SB 13 SB 44 SB 45 SB 12 SB 5
5A 10A 15A 15A 10A 5A
4b 13b 44b 45b 12b 5b B247 Connection -2- (56b), in interior wiring harness
0.5 0.5 1.5 1.5 1.5 1.5 0.5 0.5

159 163
163 ge ws gr/ro gr/ro
A95
T10b/6 T10b/4 T10b/5 T10c/5 T10b/
87 7
2.5 1 1 2.5 0.35 1.5 94
116
119
119
T10c/4
1 0.5 1.5 1.5 B247 B167 1.5 53
ws gr/ro sw/gn
BLL 58 56a 56b 56b 56a 58 BLR
ws = white
ro = red
31 31 gn = green
2.5 2.5 bl = blue
br br
gr = grey
123
123 165
165 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--45716
rs = pink
Edition 02.2003
Turn signal switch, parking light switch, fog light bulb, left and
right, side turn signal bulb, left and right
E2 Turn signal switch
M18 Side turn signal bulb, left
6 M19 Side turn signal bulb, right
h T10b 10-pin connector, blue, coupling station
1 0.5
ge sw/ge
P 49a 12 Earth point, left in engine compartment
T7a/5 T7a/2
E19 108 Earth connection -2-, in front left wiring harness
T7a/4 T7a/6
E2 T7a/3 T7a/7 Positive (+) connection (right turn signal), in dash panel wiring
PL PR L R A5
harness
0.5 0.5 1 1
gr/ge gr/ro sw/ws sw/gn Positive (+) connection (left turn signal), in dash panel wiring
A6
harness
112 Connection (right turn signal), in engine compartment wiring

100
100 112 D57
harness
A6 A5 D58 Connection (left turn signal), in engine compartment wiring harness

80
0.5 0.5 0.35 0.5 0.5 0.5 0.5 0.35 1.5

sw/ws sw/ws sw/ws sw/ws sw/gn sw/gn sw/gn gn/sw ws/ge D59 Connection (fog light), in engine compartment wiring harness
127
127 86 45 T10b/8 T10c/1 128
128 95 43 T10c/8
0.5 0.5 1.5
sw/ws sw/gn ws/ge
D58 D57 D59
0.5 1 0.5 1 1.5 1.5

2 99 2 112
112 1 1
M18 M19 L22 L23

156
156 104
104 ws = white
sw = black
1 1 2 2 ro = red
0.5
Protected by copyright. 0.5
Copying for private or commercial purposes, in part or in2.5
whole, is2.5
not 1.5 1.5 br = brown
br br br br br br
6
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with gn = green
br
respect to the correctness of information in this document. Copyright by SEAT S.A. bl = blue
166
166 164
164
108 gr = grey
12 li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--45710
rs = pink
Edition 02.2003
Emergency flasher switch, rear window heating switch,
flasher relay, emergency flasher warning lamp, rear window
heating warning lamp, heated window switch illumination
lamp, heated windscreen
E15 Rear window heating switch
J1 Flasher relay
i K6 Emergency lights warning lamp
h
204
A80 L39 Heated rear window switch illumination lamp
0.5 1 1 2.5 1.5
sw/ge ro sw/ge sw/ge sw/ge SB43 Fuse -43- in the fusebox
SB 14 SB 7 SB 48 SB 43 61 Earth point, C strut left

10A 7.5A 20A 15A
14b 7b 48b 43b

58 60 209
1 0.5 1 0.5 0.5 2.5 1.5

1/49a E3 7/30a 6/75a 4/58b 8 J1 80

1/58b K10 5/75a
L39 EProtected
15 by copyright. Copying for private or commercial purposes, in part or in whole, is not
2/31 6/+ respect to the correctness of information in this document. Copyright by SEAT S.A.
2.5
*
3/L 2/R 5/31
K6 sw
T5b/1
0.5 0.5 0.5 0.5 2.5
+
113
113 120
120 49 50
Z1
-- ws = white
184
184 90 sw = black
ro = red
br = brown
2.5 1.5 1 2.5 gn = green
gr = grey
61 218
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42009
rs = pink
Edition 02.2003
Fresh air fan switch, warning lamp for fresh air and circulating
air functions, additional resistance for fresh air fan with thermal
overload fuse, fresh air blower, servo-motor for fresh/
circulating air flap
E9 Fresh air fan switch
1 2.5 0.5 4 N24 Fresh air fan with overheating fuse additional resistance
sw/ge sw/ge ge/bl sw/ro SB6 Fuse -6- in the fusebox
6a 50a 9a A61 SB49 Fuse -49- in fusebox
SB 6 SB 50 SB 9 6 2.5 T4j 4-way connector, behind dash panel insert
15A 15A 5A sw sw/ge V2 Fresh air blower
6b 50b 9b V154 Servo-motor for fresh/circulating air flap
4 49a
1 1.5 0.5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
sw/ge sw/gr ge/bl SB 49 permitted unless 45 Earth
authorised point,S.A.
by SEAT behind
SEAT the instrument
S.A does panelor accept any liability with
not guarantee
25A respect to the correctness of information in this document. Copyright by SEAT S.A.
57
186
186 171
171 160
160 49b 162 Earth connection, fan motor wiring harness
0.5 2.5
gr/bl sw/ro
188
188
T4j/3 T4j/1
0.5 0.5 2.5 A80 Connection -1- (X), in the instrument panel wiring harness
gr/bl sw/bl sw/bl
58b Xa
T8m/3 K114 T8m/5 E159 E9 T6t/2
L66 Connection, heater blower wiring harness
L16
T8m/4 T8m/7 T8m/8 T6t/1 T6t/3 T6t/4 T6t/5
0.5 0.5 0.5 2.5 2.5 2.5 2.5

L66
2.5 2.5
ge ge
2 1
1 4 1 3 2
ws = white
2
ro = red
3 br = brown
0.5 2.5 2.5
gn = green
br br br bl = blue
gr = grey
162 45
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
or = orange
97--42010
rs = pink
Edition 02.2003
Switches and instruments - lighting control, headlight range
control adjuster, headlight range control motor - left, headlight
range control motor, right
E20 Lighting regulator - switches and instruments
V49 Headlight range control motor, right
76 148
148
0.5 0.5
gr/gn ge/bl
58 56b
T6e/3 T6e/4
E20 E102
T6e/5 T6e/1 T6e/2
58b 31 G
0.5 0.5 0.5

gr/bl br ro/bl
84 82 105
105 T10b/1 106
106
1 0.5 0.5 1
+ G G +
T8d/5 T8d/1 T8e/1 T8e/5
V48 V49
T8d/7 T8e/7
31 31 ws = white
sw = black
122
122 58 118
118 107
107 115
115 69
ro = red
br = brown
gn = green
2.5 0.5 0.5 0.5 0.5 2.5 0.5 0.5 bl = blue
br ge br/bl br/bl br br br br/sw
131 gr = grey
j li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
or = orange
97--45711
rs = pink
Edition 02.2003
Automatic intermittent wash/wipe relay, intermittent wiper
switch, rear wiper switch, windscreen wiper motor,
windscreen and rear window washer pump
J31 8
53M 75a 53s J T 31
T9/2 T9/8 T9/5 T9/1 T9/6 T9/4
T10d 10-pin connector, white, coupling station
1 1.5 1 0.5 1 1 1
gn sw/gr gn br/sw gn gn br

T10c/10
1
gn 65
V59
2 k
1 l
A36 gn/sw
T10c/9
1.5 1 1.5 1.5 1 1 1 1
sw/gr sw/gr sw/gr sw/gr sw/gr gn/sw gn/sw bl
53c
75a 53s J T
T5c/2 T5c/3 T5c/5 T4b/2 T4b/1 T5e/5
146
146 181
181 W E34
21 O
T5c/4 E22 53bT T5c/1 T4b/4 T4b/3 T5e/1
H
53e 75a 31
O
gn/ge J
1 1 1.5 1.5
gn/sw br sw/gr
Trespect T10d/10 of information in T
10d/3 to the correctness 10d/9
this T10d/2 by SEAT S.A.
document. Copyright
1 1 1 1 81 173
173
ws = white
4/53 1/75a 3/53e 2/53b sw = black
V ro = red
br = brown
5/31 gn = green
1 bl = blue
br
gr = grey
131
j li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
or = orange
97--45712
rs = pink
Edition 02.2003
Reversing light switch, horn actioning, two-tone horn, rear
window washer motor
H Horn actioning
H1 Two-tone horn
T4j 4-way connector, behind dash panel insert
A2 T5a 5-way connector, brown, in the tailgate
1 4 1.5 1.5 0.5 2.5
sw sw sw sw sw sw T10d 10-way connector, white, in the wiring harness interconnection
V12 Windscreen washer motor
26a 29a 27a A104
24 5 A2 Positive connection (15), instrument panel wiring harness
1.5
5A 5A 5A
19a A104 Positive connection -2- (15), dash panel insert wiring harness
26b 29b 27b
k
144
144
SB 19 * Only vehicles without central locking
l 15A
* 19b
1 1 1 0.5 1 0.35 1.5

T5b/5 T5b/3 T5b/4 T4j/4 T10d/4 41 T10d/5

1 1 1 0.5 1
sw/ge
1
T5a/5 T5a/3 T5a/4 146
146 1 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1
bl
1
gn/sw
1
sw/ge
F4 H1
2
2 3 4 2
1 1.5
V12 sw/bl br/sw
1 93 T10d/1
1 1.5 ws = white
br br/sw
sw = black
T7a/1 ro = red
T5a/1 br = brown
1.5
H gn = green
br bl = blue
gr = grey
136
136 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
or = orange
97--42015
rs = pink
Edition 02.2003
Inside front illumination, driver's side door switch, passenger's side
door switch, cigarette lighter illumination, cigarette lighter
F2 Door switch, driver's side
F3 Door switch, passenger's side
L28 Cigarette lighter illumination
T5 5-way connector
39
T10f 10-way connector, black, in strut A, lower passenger's side
0.5
T10g 10-way connector, black, in strut A, lower driver's side
ro U1 Cigarette lighter
A52 W Front interior illumination
T5/1
0.5 2.5 1 0.5 1 1.5
ro ro ro ro ro ro
2/30a 46a
7 129
129 37 16
W SB 46
15A
1/31 3/TK 46b
0.5 0.5
ro br/ws
B154 Connection -1- (door contact), in interior wiring harness
136
136
T5/3 T5/2 * Only vehicles without central locking
** Only vehicles with central locking
0.5 0.5 1.5 0.5
** *
T4d/2 T4d/3
J379 * * * by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
0.5 0.5 0.35 0.5
T23/21 permitted
br/ws unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctnessU
of1information in thisLdocument.
br br/ws bl/br
64 T10f/9 39 T10g/9 47 T4d/1
0.5 0.5 2.5 1.5

br/ge br/ge br br
2 2
F3 F2
238
1 1
0.5 0.5 2.5
br br br
ws = white
sw = black
T10f/10 T10g/10 ro = red
0.5 0.5
br = brown
br br gn = green
* * bl = blue
48 63 gr = grey
76
li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
or = orange
97--42726
rs = pink
Edition 02.2003
1,0 l - Motronic/37 kW, engine code AUC 1.4 l - Motronic/44 kW, engine code ANW and AUD
From may 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

Warning!
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2001
start switch, cable distributor for terminal 30, contact X discharge
31 30 relay
7 J59 A Battery
C Alternator
T6h/4 T6h/3 T6h/2 T6h/1
1 1 6 6 E1 Headlight switch
br sw/ge sw
E1/15 ro E19 Parking light switch
29 99
A61
T5s 5-way connector, in the transmission
2.5 4 2.5 T10 10-way connector, green, in the interconnection station
ro ro/bl ro
TV2 Terminal 30 cable distributor
A32 A40
4 6 4
ro ro ro
2 Earth strap, gearbox - bodywork

D 30 502 501
TV2 61 Earth point, C strut left

X S 15 P 50
500
2.5 0.5 4 1 2.5 10 500 Bolted joint -1- (30), on the relay plate
sw/ge br/ro sw ge ro/sw ro
E1/1 140
140 25 E 19 T10/1 501 Bolted joint -2- (30), on the relay plate
T7a/5
2.5
ro/sw 502 Bolted joint -1- (30a), on the relay plate
134
134 27
T5s/1
0.5 1 A32 Positive connection (30), instrument panel wiring harness
bl sw/ge
2.5
ro/sw
Protected by copyright.TCopying
5s/2 Tfor private or commercial purposes, in part or in whole, is not
5s/3 A40 Positive connection -1- (30), in the instrument wiring harness
0.5 0.5 16 25
bl gn sw sw A61 Postive connection (X), in the instrument panel wiring harness
D+ W B+ 30 50 +
B102
C G
ws = white
B A
sw = black
C1 M ro = red
-- br = brown
2.5 gn = green
br 25 25 bl = blue
sw sw gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42728
rs = pink
Edition 09.2001
temperature sender, spark plug cap, spark plugs
P Spark plug cap
Q Spark plugs
A2 SB24 Fuse -24- in the fusebox
sw sw sw sw sw
A104 34a 24a 36a
T10 10-way connector, green, in the interconnection station
7
T10d 10-way connector, white, in the interconnection station
0.5
sw SB 34 SB 24 SB 36 T10n 10-way connector, grey, in the interconnection station
10A 5A 15A
10 Earth point, in the plenum chamber
30a 34b 24b 36b
1.5 0.5 1.5
sw ws/ge sw
SB 30 220 Earth connection, (sender earth), in the engine cable harness
5A
30b
T10/4 T10n/10 T10/8 5

sw/ge sw sw sw/ge
Positive connection -2- (15), in the instrument panel wiring

T10d/8 103
103 T80/27 J220 T80/11
A104
harness
1 0.5 * Only ANW and AUD vehicles with automatic gearbox
sw/ge sw/ge ** Only on vehicles without automatic gearbox
T80/57 T80/71 T80/74 T80/54
38 101
101 130
130
1.5 0.5 0.5 0.5 0.5

2 N152 1 3
2 3
G62 G2 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 4 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 respect to the correctness of information in this document. Copyright by SEAT S.A.
1 1 1 ws = white
br br ro = red
P
* ** br = brown
59
Q 121
121 gn = green
bl = blue
a
gr = grey
10 220
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42729
rs = pink
Edition 09.2001
Motronic control unit, servodirection/manual switch, engine
RPM sender, Hall sender, exhaust recirculation potentiometer,
exhaust recirculation valve
F88 Servodirection/manual switch
G28 Engine revolution number sender
G40 Hall Sender
G212 Exhaust recirculation potentiometer
A52 J293 Coolant fan control unit
ro ro ro ro
T10c 10-way connector, black, in the interconnection station
15a 31a T10d 10-way connector, white, in the interconnection station
9 149
149 85 T14 14-way connector, in the engine
SB 15 SB 31 0.5 J293 J293 J293 J217 T14a 14-way connector, brown, in the engine
10A 10A
ws T14c/2 T14c/3 T14c/3 T68/30
15b 31b 220 Earth connection, (sender earth), in the engine cable harness
2 * *
1 1 0.5 0.5 0.5 1
L5 D161
T10d/ T10c/7 1
**
6
1 1 0.5 0.5 0.5
ro/ge ro ws/sw ro/ws bl D101 Connection -1-, in the vane motor wiring harness
105
105 * Connection (post function radiator fan), in the vane motor wiring
J220 T80/15 T80/49 T80/17 T80/42 D161
harness
T80/60
L5 authorised
permitted unless Connection -1-, S.A.
by SEAT in the airS.A
SEAT conditioning wiring or
does not guarantee harness
T80/62 T80/53 T80/67 T80/78 T80/69
0.5 0.5 0.5 0.5 1 0.5 * Only vehicles with air conditioning
ge/sw ge ws sw li gn/br ** Only ANW and AUD vehicles with automatic gearbox
*** Only ANW and AUD vehicles without automatic gearbox
T14a/ T14a/ T14/5
13 14
1 0.5 0.5
2 5 6 4
G40 G28 N18 ***

3 1 1
G212 2
1 0.5
T3/1 sw/ge gn/li
123
123 46 44
ws = white
T14a/12 T14/11 sw = black
ro = red
0.5 0.5 0.5 0.5 0.5 0.5 1 0.5 1
br/ws br/ws br/sw gn/li gn/li ge sw/ge gn/li br/sw br = brown
D101 gn = green
16 bl = blue
a
gr = grey
220
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42730
rs = pink
Edition 09.2001
Motronic control unit, air intake temperature sender, intake
collector pressure sender, accelerator position sender,
sender -2- for the accelerator pedal
G42 Intake air temperature sender
G71 Intake manifold pressure sender
G79 Accelerator position sender
150
150 151
151
0.5 0.5
ws/gn ws/bl
T80/16 J220 T80/12
T80/70 T80/56 T80/6 T80/45 T80/19 T80/7 T80/33 T80/8
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

T14/10 T14/12
0.5 0.5
ge/sw ws/br
4 2 1 6 5 3 4 2
G71 G42 G185 G79

3 1
0.5 0.5
gn/li br/ws
ws = white
ro = red
0.5 0.5 br = brown
gn/li br/ws
gn = green
bl = blue
34 30
gr = grey
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--42018
rs = pink
Edition 09.2001
(accelerator electric control), yaw sender -1- for the throttle
valve (accelerator electric control)
G186 Throttle valve (accelerator electric control)
G187 Yaw sender -1- for the throttle valve (electric accelerator control)
G188 Yaw sender -2- for the throttle valve (electric accelerator control)
J 217 J 104 J 104 J 217 T10n 10-way connector, grey, in the interconnection station
T68/16 T25/10 143
143 T25/11 T68/15 145
145 T14 14-way connector, in the engine
0.5 0.5
or/br or/sw 10 Earth point, in the plenum chamber
T10n/5 T10n/4
167 Earth connection -4-, in the engine compartment wiring harness
0.35 0.35 0.35 0.35 0.35 0.35
or/br or/br or/br or/sw or/sw or/sw
D159 Connection (High-Bus), in the vane motor wiring harness
D160 D159
0.35 0.35 D160 Connection (Low-Bus), in the vane motor wiring harness
or/br or/sw
CAN--L CAN--H
T80/32 J220 T80/31 * Only ANW and AUD vehicles with automatic gearbox
T80/2 T80/28 T80/61 T80/68 T80/55 T80/75 T80/80 T80/66
0.5 0.5 0.5 0.5 1 1

T14a/7 T14a/ T14a/ T14/8 T14a/ T14/6

10 4 8
0.5 0.5 0.5 0.5 1 1
1 2 4 3
18
J338 G186 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
G187 G188
** * * * ** ws = white
sw = black
2.5 2.5 2.5 2.5 2.5
br = brown
gn = green
bl = blue
167
gr = grey
10 10 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42709
rs = pink
Edition 09.2001
Control unit for Motronic, knock sensor I, injector cylinder 1,
injector cylinder 2, injector cylinder 3, injector cylinder 4
G61 Knock sensor I
N30 Injector cylinder 1
T10a 10-way connector, red, in the interconnection station
T10b 10-way connector, blue, in the interconnection station
T10n 10-way connector, grey, in the interconnection station
J362 T14 14-way connector, in the engine
136
136 142
142 128
128 T10x/7 T14a 14-way connector, brown, in the engine
Earth connection (screened), in the engine compartment wiring
0.5 0.35 0.35 0.5 200
gn/ws ge/gr ge/gr ws/ge harness
D95 Connection (injectors) in the vane motor wiring harness

T10b/9 T10n/7 T10a/7 respect to the correctness of information in this document. Copyright by SEAT S.A.
* Self-diagnostic line W
0.5 0.35 0.5
*
gn/ws ge/gr ws/ge
W
T80/5 T80/30 J220 T80/29
T80/63 T80/77 T80/79 T80/59 T80/73 T80/65
0.5 0.5 1 1 1 1
T14/7 T14a/5 T14a/6 T14a/9 102

102
0.5 0.5 1 1 1 1 1
T14a/ T14a/ T14a/1 T10/5

3 2
N30 2 N31 2 N32 2 N33 2
0.5 0.5 0.5 1
sw bl gr ro/ge
1 1 1 1 ws = white
T14a/11
sw = black
1 1 1 1 1 ro = red
gn = green
D95 bl = blue
G61 gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42303
rs = pink
Edition 09.2001
catalytic converter, lambda probe heating, lambda probe 1
heating, after the catalytic converter
G39 Lambda probe
G130 Lambda probe after catalytic converter
D102 Connection -2-, in the vane motor wiring harness

147
147
0.35
gn
T10a/8
0.5
gn/bl
T80/41 J220
T80/21 T80/47 T80/13 T80/46 T80/20 T80/1 T80/34 T80/35

1 0.5 1 0.5 0.35 1.5 0.5 0.35
0.5 0.5
ws ws

35
1 1 1 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
gr sw ws respect to the correctness of information in this document. Copyright by SEAT S.A.
Z29 G39
103
103
ws = white
G130 Z19 sw = black
1 1
ws ro/ge ro = red
br = brown
1 1 1.5 bl = blue
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
or = orange
97--42304
rs = pink
Edition 09.2001
J17
J17 Fuel pump relay
T6i/1 T6i/2 T6i/5 T6i/3
4 4 0.5 0.5
A99 A2
N80 Electrovalve 1 for the active charcoal filter system (activated in
8 cadence)
1.5 1 1 0.5 1
ro/bl ro/sw ro/sw sw sw T10 10-way connector, green, in the interconnection station
3a 1a 27a 28a
T10c 10-way connector, black, in the interconnection station
116
116 T10d 10-way connector, white, in the interconnection station
SB 3 SB 1 SB 27 SB 28 T14 14-way connector, in the engine
10A 10A T10a/9 5A 7.5A
3b 1b 27b 28b 12 Earth point in engine bay, on the left

0.35 1
1 1 0.5 sw sw
ro/ge ro/ge ro/ge
144
144 82 Earth connection -1-, in the front left wiring harness
A38
83 91 137
137
0.5 0.35
J220 T80/26 sw/gr ws/bl A2 Positive connection (15), instrument panel wiring harness
T80/14 T80/51 T80/23

T10/2 T10c/3 A38 Positive connection-2- (15a), instrument panel wiring harness
0.5 1 1 0.5 0.5
gn/ge li/gn sw/ro sw/gr ws/bl
A99 Connection -1- (87), in the instrument panel wiring harness
D73 T14/2 T14/1
1 1
permitted unless authorised by0.5
SEAT S.A. SEAT0.5 S.A does not guarantee or accept any liability with D73 Positive connection (54), in the vane motor cable harness
sw/ro sw/ro respect to the correctness
sw/gr of information
ws/bl
2 1 2 1 2
N80 F63 F T10d/7 G22

1 2 1 3
0.5 1 1 1 1
ws = white
sw = black
17 21 32 M9 T14/3 ro = red
M10 br = brown
M25 gn = green
4 1 bl = blue
br br
gr = grey
12 82
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--42710
rs = pink
Edition 09.2001
Fuel level indicator sender, fuel pump (prefeed pump), coolant
lack indicator sender, oil pressure switch 0,3 bar
G Fuel level indicator sender
G32 Coolant lack indicator sender
b T10c 10-way connector, black, in the interconnection station
c
e

101
101
1.5 0.35 0.35

ro/bl ro/bl bl/sw
40a
SB 40 T10c/2 T10a/6
15A
40b
1.5 0.35 0.35 0.5 0.5

ro/ge li/sw br/ws bl/ro bl/sw
1 2 T10a/1 1 1
G6 G G32 F22 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
4 3 2 ws = white
sw = black
1.5 0.5 1 0.5
br = brown
gn = green
2.5 bl = blue
br 26 29
B109 gr = grey
61
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42023
rs = pink
Edition 09.2001
Control unit with warning lamps in the dash panel, fuel level
indicator, coolant temperature indicator, speedometer, oil
pressure warning lamp,coolant lack indicator/temperature
warning lamp
G1 Fuel level indicator
G21 Speedometer
b
c
K2 Alternator indicator lamp
16a
e K28 Temperature indicator/coolant lack indicator lamp
5A
26 4 73
16b
0.5 0.5 0.5 0.5 0.5 T10a 10-way connector, red, in the interconnection station

T10/3 T10a/3 A27 B158 6
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

bl/sw ro/bl br/ws ge/ro li/sw bl gn/ws br/ro 238 Earth connection -1-, interior wiring harness
T32/10 T32/22 T32/7 T32/8 T32/5 T32/12 T32/3 T32/30

249 Earth connection -2-, in the interior wiring harness
G3 G1
J285
K28 K105
G21
T32/13 T32/1 T32/9 T32/24
0.35 0.35 0.35 0.35

ge/gr sw br br
78 107
107
249 ws = white
2.5 sw = black
br ro = red
br = brown
238
gn = green
2.5 bl = blue
br gr = grey
76 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--45717
rs = pink
Edition 09.2001
Control unit with warning lamps in the dash panel, tachometer,
exhaust warning lamp (EOBD), accelerator electrical control
warning lamp (EPC)
G5 tachometer
K83 Exhaust warning lamp (EOBD)
K132 Accelerator electric control warning lamp (EPC)
T10n 10-way connector, grey, in the interconnection station
30

0.5
ro
11a
SB 11
5A
77 111
111 91
11b
0.35 0.35 0.35 0.35

ge/gr ws/bl gn ro
T32a/15 T32/28 T32/11 T32/23
K132
J285 purposes, in part or in whole, is not
Protected by copyright. Copying for private or commercial
K83
G5
T32a/20 T32a/19 T32/ T32a/10
CAN--L CAN--H 32
0.35 0.35 0.35 0.35

or/br or/sw ws/gn ws/bl
A122 A121
3
0.5 0.5 0.5 0.5 0.5 0.5 sw = black
br = brown
gn = green
J 362
62 67 J362
47 52
bl = blue
T10x/1 T10x/2
gr = grey
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 152 153
or = orange
97--45718
rs = pink
Edition 09.2001
1.4 l - Marelli 4LV/74 kW, engine code AUB

From october 2001
11 10 9 8 7
6 5 4 3 2 1 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
97-40408

Warning!
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
Battery, starter motor, alternator, voltage regulator, ignition/starter
switch, cable distributor for terminal 30, discharge relay for contact
31 30
X
7 J59 A Battery
C Alternator
T6h/4 T6h/3 T6h/2 T6h/1
1 1 6 6 E1 Light switch
br sw/ge sw ro E19 Parking light switch
E1/15 J59 Discharge relay for contact X
29 99
A61 T5s 5-way connector, transmission
TV2 Cable distributor for terminal 30
2.5 4 2.5
ro ro/bl ro T10 10-way connector, green, in the wiring harness interconnection
A32 A40 1 Earth strap, battery - bodywork

4 6 4
ro ro ro
D 30 502 501
TV2 61 Earth point, C strut left

X 50 15 P S
500
2.5 2.5 4 1 0.5 500 Bolted joint -1- (30), on the relay plate
501 Bolted joint -2- (30), on the relay plate

E1/1 25 E 19 140
140
T7a/5
T10/1 152
152 27
502 Bolted joint -1- (30a), on the relay plate

2.5 10 0.5 0.35
ro/sw ro bl sw/ge

T5s/1 T5s/2 T5s/3
2.5 25 16 0.5 0.5
ro/sw sw sw bl gn A40 Positive connection -1- (30), in the instrument wiring harness
50 30 + 2 1 B+ D+ W
B102 SA 2 SA 1 G C
B A 80A 110A
ws = white
M
C1 sw = black B102 Earth connection, interior wiring harness, front left
ro = red
--
br
Protected= bybrown
gn respect
= green
2.5 25 25 to the correctness of information in this document. Copyright by SEAT S.A.
br sw sw bl = blue
gr = grey
61 1 2 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42026
rs = pink
Edition 09.2002
Marelli 4LV control unit (injection system), coolant
temperature sender, ignition transformer, spark plug cap,
spark plugs
P Plug cap
A2 Q Spark plugs
2.5 1.5 0.5 1.5 4
sw sw sw sw sw SB30 Fuse -30- in the fusebox
A104 34a 24a 36a SB36 Fuse -36- in the fusebox
0.5
sw SB 34 SB 24 SB 36 T10 10-way connector, green, in the wiring harness interconnection
10A 5A 15A
30a 34b 24b 36b T10n 10-way connector, grey, in the wiring harness interconnection
1.5 0.5 1.5 T14 14-way connector, engine
sw ws/ge sw
SB 30 T14a 14-way connector, brown, engine
5A
30b
T10/4 T10n/10 T10/8 14
0.5 1.5 1 1.5 0.35
85 Earth connection -1-, engine bay wiring harness
T10d/8 103
103 T121/4 J537 T121/28
1 0.5
sw/ge sw/ge
T121/ T121/103 121
121 T121/93
102 A104 Positive connection -2- (15), dash panel insert wiring harness
0.35 0.35 1 0.35
35 100
100 gn/br gn/ge br/ws
bl/gr
T5l/4 T14a/ T14a/12 T5l/2 T14/3
11
1 0.5 0.5 1 0.5
sw gn/gr gn/ge br/ws bl/gr
2 N152 1 3
2 3
G62 G2
1 4
4
2.5 0.5 0.5 ws = white
ro = red
P
Q gn = green
2.5 0.5 bl = blue
br ge/ro
a
gr = grey
10 85
131
131 li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42324
rs = pink
Edition 09.2002
Marelli 4LV control unit (injection system), Hall sender,
exhaust gas recirculation potentiometer, exhaust gas
recirculation valve
G40 Hall sender
N18 Exhaust gas recirculation valve
2.5 0.5 1 1.5 T10a 10-way connector, red, in the wiring harness interconnection
ro ro ro ro
15a 37a T14 14-way connector, engine
7 149
149
SB 15 SB 37 J293 J293 J293 85 Earth connection -1-, engine bay wiring harness
10A 15A
T14c/8 T14c/2 T14c/3
15b 37b
0.5
* 0.5
* * 220 Earth connection (sender earth), engine wiring harness
1 1.5 bl ro/ws
ro/ge ro
D157 L5 A52 Positive connection -2- (30), instrument panel wiring harness
T10d/ T10a/5
6
1 1.5 0.35 0.35 0.35
ro/ge ro bl ro/ws gn/bl D101 Connection -1-, engine bay wiring harness
105
105 * *
J537 T121/3 T121/40 T121/61 T121/41
D157 Connection (air conditioning ON), engine bay wiring harness
T121/86 T121/98 T121/ T121/100

L5 Connection -1-, air conditioning wiring harness
Protected by114
0.35 0.35 1 authorised
permitted unless 0.35 by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
gn/br ge li to the
respect gn/br
correctness of information in this document. Copyright by SEAT S.A. * Only vehicles with air conditioning
T14/1
0.5 0.5
gn/br br/sw
2 5 6 4
G40 N18
3 1 1
G212 2
0.5 1 0.5
ro/ws sw/ge gn/li
49 47 123
123
ws = white
16 ro = red
0.5 0.5 0.35 0.5 1 1 0.5
br = brown
bl = blue
a b
gr = grey
85 220
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42028
rs = pink
Edition 09.2002
Marelli 4LV control unit (injection system), engine revolution
sender, inlet air temperature sender, inlet manifold pressure
sender, accelerator position sender, sender -2- for the
accelerator pedal position
220 Earth connection (sender earth), engine wiring harness
149
149 150
150
0.35 0.35
ws/gn ws/bl
T121/47 J537 T121/30
T121/ T121/ T121/108 T121/109 T121/85 T121/ T121/ T121/ T121/ T121/ T121/
87 82 respect to the correctness of information in this
72 document.
34 Copyright
33 by36SEAT S.A.
35 73
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
T3/1 T3/2 T14/10 T14/12

0.5 0.5
ge/sw ws/br
4 2 1 6 5 3 4 2
G28 G71 G42

3 1
0.5 0.5 G185 G79
gn/li br/ws
ws = white
sw = black
T3/3 T14/11 ro = red
0.35 0.35 0.5
br = brown
br/sw br/bl gn/li gn = green
bl = blue
b
34 29 gr = grey
220
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--45719
rs = pink
Edition 09.2002
Marelli 4LV (injection system) control unit, throttle valve control
unit, throttle valve control (electric accelerator control), angle
sender -1- for throttle valve (electric accelerator control)
control)
control)
J 104 J 104 J537 Control unit for Marelli 4LV (injection system)
T25/10 143
143 T25/11 145
145 T10n 10-way connector, grey, in the wiring harness interconnection
0.5 0.5
or/br or/sw 10 Plenum chamber earthing point
T10n/5 T10n/4
0.35 0.35 0.35 0.35
or/br or/br or/sw or/sw
D160 Connection (Low-Bus), engine bay wiring harness

D160 D159
0.35 0.35
or/br or/sw
CAN--L CAN--H
T121/58 J537 T121/60
T121/1 T121/2 T121/91 T121/ T121/ T121/ T121/117 T121/118

92 83 84
2.5 2.5 0.35 0.35 0.35 0.35 1 1

T14a/7 T14a/ T14a/ T14a/ T14a/8 T14a/1

10 4 3
0.5 1 1 0.5 0.5 0.5
1 2 4 3 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
J338 G186 respect to the correctness of information in this document. Copyright by SEAT S.A.
6 5
G187 G188
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
10 10
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42712
rs = pink
Edition 09.2002
4LV control unit (injection system), knock sensor I, injector,
cylinder 1, injector, cylinder 2, injector, cylinder 3, injector,
cylinder 4
G61 Knock sensor I
J537 4LV control unit (injection system)
T5l 5-pin connector, on engine
J362 T10n 10-pin connector, grey, connector point
136
136 142
142 128
128 T10x/7
T14 14-pin connector, on engine
T14a 14-pin connector, brown, on engine
0.5 0.35 0.35 0.5
gn/ws ge/gr ge/gr ws/ge Earth connection (screening), in engine compartment wiring
200
harness
T10b/9 T10n/7 T10a/7
D95 Connection (injectors), in engine compartment wiring harness
0.35 0.35 0.35 *
gn/ws ge/gr ws/ge
* Wire W for self-diagnosis
W
T121/54 T121/48 J537 T121/43
T121/ T121/106 T121/96 T121/97 T121/88 T121/89

99
0.35 0.35 0.35 0.35 0.35 0.35

200
102
102
T14a/2 T14a/5 T14a/6 T14a/9
0.35 0.35 1 1 1 1 1
T14/8 T14/7 T14/6 Copying for private or commercial purposes, in part or in whole, is not T10/5
Nby30SEAT2 S.A. SEAT
N31S.A does not N N33
Protected by copyright.
permitted unless authorised 2 32 2 or accept
guarantee 2
any liability with
0.5 0.5 0.5 1
sw blrespect gr
to the correctness of information in this document. Copyright by SEAT S.A. ro/ge
1 1 1 1 ws = white
T5l/1
sw = black
1 1 1 1 1 ro = red
gn = green
D95 bl = blue
G61 gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--43466
rs = pink
Edition 09.2002
4LV control unit Marelli (injection system), lambda probe,
lambda probe after catalyst, lambda probe heater, lambda
probe 1 heater, after catalyst
G39 Lambda probe
G130 Lambda probe after catalyst
J537 4LV control unit Marelli (injection system)
T14a 14-pin connector, brown, on engine
Z29 Lambda probe 1 heater, downstream of catalytic converter
E30 Connection (87a), in engine wiring harness
147
147
0.35
gn
T10a/8
0.35
gn/bl
T121/37 J537 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
T121/ T121/69 T121/63 T121/ T121/5 T121/ T121/ T121/ T121/51

68 81 70 71 52
0.35 0.35 0.35 0.35 1 0.35 0.35 0.35 0.35

gn sw br ws/gr br/ro gr/ro sw gn gr/ws

1 1 1
gr sw ws
Z29 Z19 G39

103
103
G130 ws = white
1 1
ws ro/ge sw = black
ro = red
gn = green
1.5 1.5 1.5 1.5 bl = blue
gr = grey
E30
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
or = orange
97--42308
rs = pink
Edition 09.2002
Marelli 4LV (injection system) control unit, fuel pump relay,
30 15 brake light switch, brake pedal switch, speedometer sender,
activated charcoal filter system solenoid valve 1
J17
2 F Brake light switch)
J17 Fuel pump relay
T6i/1 T6i/2 T6i/5 T6i/3
4 4 0.5 0.5 M10 Right brake light bulb
ro/bl ro/sw ro/ge sw M25 High brake light bulb
A99 A2
8 T10a 10-way connector, red, in the wiring harness interconnection
1.5 1 1 0.5 1
ro/bl ro/sw ro/sw sw sw T10c 10-way connector, black, in the wiring harness interconnection
3a 1a 27a 28a
116
116 T10d 10-way connector, white, in the wiring harness interconnection
SB 3 SB 1 SB 27 SB 28
10A 10A T10a/9 5A 7.5A
3b 1b 27b 28b
1 1 0.35 0.35 1
ro/ge ro/ge ro/ge sw sw 82 Earth connection -1-, front left wiring harness
144
144
A38
83 91 139
139 A2 Positive connection (15), instrument panel wiring harness
J537 T121/65 0.5
sw/gr
0.35
ws/bl

T121/64 T121/55 T121/56
T10/2 T10c/3
0.35 0.35 0.35 0.5 0.5 A99 Connection -1- (87), in the instrument panel wiring harness
gn/ge li/gn sw/ro sw/gr ws/bl
D73 Positive connection (54), engine bay wiring harness

D73 T14/14 T14/13
1 1 0.5 0.5
sw/ro sw/ro sw/gr ws/bl D136 Positive connection -2- (15a), engine bay wiring harness
2 3
F 4 1 2
N80 F63 T10d/7 G22

1 2 1 3
0.5 1 1 1 1
permitted unless authorised by SEAT S.A. sw
sw/ge SEAT S.A does not guarantee
ro/ge sw/ro or accept any liability with
br ws = white
sw = black
17 D136 32 M9 T14a/14 ro = red
M10 br = brown
sw sw 4
br
br
bl = blue
gr = grey
113
113 21 82 12
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--42733
rs = pink
Edition 09.2002
Fuel level indicator sender, fuel pump (pre-supply pump),
coolant level indicator sender, oil pressure switch 0,3 bar,
thermal resistance for pre-heating the inlet manifold
G Fuel level sender
N51 thermal resistance for pre-heating the inlet manifold
b SB40 Fuse -40- in the fusebox
c
d
e
102
102 101
101
1 1.5 0.35 0.35

sw ro/bl ro/bl bl/sw 61 Earth point, C strut left
40a
108 Earth connection -2-, front left wiring harness
T5l/3 SB 40 T10c/2 T10a/6
15A
131 Earth connection-2-, in the engine compartment wiring harness
1 40b
sw/ge
1
* * Only for nordic countries vehicles
N51
2
1 1.5 0.35 0.35

Protected by0.5
copyright. Copying
0.5 for private or commercial purposes, in part or in whole, is not
br ro/ge li/sw br/wspermitted unless bl/sw S.A. SEAT S.A does not guarantee or accept any liability with
bl/roauthorised by SEAT
T14/9
1
br 1 2 1 1
G6 G T10a/1 G32 F22

131
4 3 2
ws = white
2.5 1.5 0.5 1 0.5 sw = black
ro = red
br = brown
108 B109
gn = green
26 42 bl = blue
6 2.5
br br gr = grey
12 61
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42326
rs = pink
Edition 09.2002
lamp
G1 Fuel gauge
G21 Speedometer
b
c
16a
5A
26 73
16b
T10/3 A27 B158

0.35 0.35 0.35 0.35 0.35 0.35 0.35
T32/10 T32/22 T32/7 T32/8 T32/5 T32/3 T32/30
G3 G1
K3
J285
K28 K105
G21
T32/13 T32/1
0.35 0.35
ge/gr sw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
78 107
107
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42035
rs = pink
Edition 09.2002
Control unit with warning lamps in the dash panel insert, revolution
G5 Rev. counter
ro
11a 13
SB 11 0.5
5A bl
11b
77 111
111 91
T10a/3
0.35 0.35 0.35
respect to the
0.35 0.35 249 Earth connection -2-, interior wiring harness
ge/gr ws/bl gn correctness of ro
information in this document.
bl Copyright by SEAT S.A.

K132 K2
J285
K83
G5
T32a/20 T32a/19 T32/ T32a/10 T32/9 T32/24
CAN--L CAN--H 32
0.35 0.35 0.35 0.35 0.35 0.35

or/br or/sw ws/gn ws/bl br br
A122 A121 249

3
0.5 0.5 0.5 0.5 0.35 0.35 2.5 sw = black
br = brown
238
gn = green
J362 62 67 J362 47 52
bl = blue
T10x/1 T10x/2 2.5
br gr = grey
76 li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 152 153
or = orange
97--42713
rs = pink
Edition 09.2002
1.4 l/55 kW diesel injection engine, engine codes AMF

From October 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

3 - Fuel shut- off control unit (405)
Note:
Edition 02.2003
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
20 A - yellow respect to the correctness of information in this document. Copyright by SEAT S.A.
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 02.2003
31 30
A Battery
7 J59 B Starter
X 75x C Alternator
1
br
1
sw/ge
6
sw 16 93 E1/15 34
6
ro
2.5 2.5 2.5 1.5 T14b 14-pin connector, on engine
A61 ro ro ro ro TV2 Terminal 30 junction box
A32 A40 1 Earth strap, battery - body

4 6 4
ro ro ro
D 30 502 501
TV2 61 Earth point, left C-pillar

X 50 15 P S
500
2.5 2.5 4 1 0.5 10
sw/ge ro/sw sw ge br/ro ro
E1/1 21 E19 130
130
T7a/5
A61 Positive (+) connection (X), in dash panel wiring harness
120
120 45
0.5 0.35 B102 Earth connection, in front left interior wiring harness
bl br/ro
60 97 * Only models with additional heater

T10/1 T14b/ T14b/4 ** Only models without additional heater
5
* * **
2.5by copyright. Copying
Protected 25 for private 10 6
or commercial purposes, in25part or in
16whole, is not 0.5 0.5
permittedro/sw
unless authorisedsw
by SEAT S.A. SEAT ro S.A does
ro not guaranteeswor acceptswany liability with bl br/ro
B102
50 30 + 4 3 2 1 B+ D+ W
SA 4 SA 3 SA 2 SA 1 G C
B 80A 50A 80A 150A
* ws = white
110A ** sw = black
M
C1 ro = red
-- br = brown
2.5 A gn = green
br 25 25 bl = blue
sw sw gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--43444
rs = pink
Edition 02.2003
Direct diesel injection control unit, fuel shut-off control unit
(collision), engine revolution sender, fuel temperature
30 31 DA sender
J491 3
* G28 Engine revolution sender
CRASH 15 15DA G81 Fuel temperature sender
J248 Direct diesel injection control unit
T9c/3 T9c/6 T9c/5 T9c/2 T9c/4 T9c/8
J 362 J491 Fuel shut-off control unit (collision)
0.5 0.5 0.5 0.5 1
** 1 1 T10x/7 SB15 Fuse -15- in the fusebox
A125 0.5 T10a 10-way connector, red, in the wiring harness interconnection
32b ws/ge T10b 10-way connector, blue, in the wiring harness interconnection
2.5 1 0.5
ro ro gr/ge SB 32 T10b/10 T10a/7 76 Earth point, near gearbox control
10A
15a
7 32a
J 234 *** 81 Earth connection -1-, dash panel insert wiring harness
SB 15 T75/72 1 0.35 0.35
10A sw sw ws/ge
15b A104 W A2 Positive connection (15), instrument panel wiring harness

T121/37 J248 T121/16
1 2.5
ro/ge sw
A2 T121/ T121/110 T121/ T121/
102 103 111
78
4 0.35 0.35 A104 Positive connection -2- (15), dash panel insert wiring harness
sw br/sw ws
5
F27
A125 Connection (impact signal), instrument panel wiring harness
0.35 0.35 0.35 0.35 Connection (screened), in the direct diesel injection wiring
sw br sw/ge li F27
harness
* Only vehicles with airbag
T3/3 T3/2 T3/1 ** Only vehicles without airbag
*** W self-diagnosis line
81 1
G28 G81authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless
2
ws = white
2.5 sw = black
br ro = red
br = brown
gn = green
bl = blue
gr = grey
76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--45721
rs = pink
Edition 02.2003
Direct diesel injection control unit, fuel pump relay, coolant
85 87 temperature sender, inlet manifold pressure sender, air intake
J17 temperature sender,solenoid valve to limit supercharging
2 pressure
86 30a
T6j/5 T6j/3 T6j/1 T6j/2 G71 Inlet manifold pressure sender
G72 Air intake temperature sender
0.5 0.5 4 4
gn sw/ge ro/bl ro/ge J17 Fuel pump relay
138
138 117
117 J248 Direct diesel injection control unit
24a 40b N18 Exhaust gas recirculation valve
0.35 0.35
gn ro/ge N75 Solenoid valve to limit supercharging pressure
SB 24 SB 40 SB24 Fuse -24- in fusebox
5A 15A
T10a/10 T10a/8 T10/6 SB40 Fuse -40- in the fusebox
24b 40a T10 10-way connector, green, in the wiring harness interconnection
0.35 0.5 0.5 1.5 0.35 0.35 T10a 10-way connector, red, in the wiring harness interconnection
gn sw/ge ws/ge ro gn ro/ge T14b 14-way connector, engine
91 72 10 100
100
T121/80 J248 T121/27 T121/40
T121/ T121/73 T121/ T121/71 T121/61 T121/62 T121/112 T121/

52 31 104
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

br/bl bl/ge li/ro sw/ge br/ws Protected by copyright. bl/br
ro/bl Copying for private
br/blor commercial purposes, in part or in whole, is not
T14b/13 T14b/11
0.5 0.5
ge/ro br/bl
2 G72 G71 3 2 2 3 G62 G2 1
N18 N75
1 4 1 1 4 2
0.5 0.5 0.5 0.5

sw/ge sw/ge ws/gr br/ws ws = white
sw = black
90 91 T14b/14 T14b/12 ro = red
br = brown
0.5
ge/ro
1
br
gn = green
bl = blue
124
124 109
109 gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42311
rs = pink
Edition 02.2003
Diesel direct injection system control unit, air mass meter,
unit injector solenoid valve, cylinder 1, unit injector solenoid
valve, No. 2 cyl., unit injector solenoid valve, No. 3 cyl.
G70 Air mass meter
T8b 8-pin connector
1 T10a 10-pin connector, red, coupling station
sw/ge
2
14
G70 D95 Connection (injectors), in engine compartment wiring harness
4 3 5
0.35 0.35 0.35 0.35

br/ro ro/gn br/bl br/ro F26 Connection -2-, in diesel direct injection system wiring harness
T121/38 J248 T121/30 T121/49 T121/68
T121/116 T121/118 T121/121 T121/114 T121/1 T121/2 T121/ T121/

4 5
2.5 2.5 2.5 2.5 1.5 1.5

br/ge br/gn br/ws br/ro sw/ws sw/ws 2.5 2.5
br br
F26
T8b/3 respect to T8b/5
the correctness of T8b/2
information in this T8b/6
2.5
sw/ws
T10a/4
1.5 1.5 1.5 1.5 1.5
ro ge ws br sw/ws
37b
2 2 2
N240 N241 N242 SB 37

15A ws = white
1 1 1
37a
sw = black
ro = red
1.5 1.5 1.5 1.5 br = brown
br br br sw/ge gn = green
D95 bl = blue
93
gr = grey
10 10
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--45722
rs = pink
Edition 02.2003
Diesel direct injection system control unit, high and low heat
output relay, idling switch, accelerator pedal position sender,
coolant heating elements
F8 Kick-down switch
F60 Idling switch
J104 130
130 J
104 128
128
J359 Low heat output relay
T25/11 T25/10
0.5 0.5
134
134
S109 Coolant heater element fuse
T10n/4 T10n/5 S143 Coolant heater element fuse 2
0.5 S265 Coolant heater elements fuse 3
gn/ws 0.35 0.35 0.35 0.35 T10b 10-pin connector, blue, coupling station
or/sw or/sw or/br or/br
T10b/9 D159 D160
D78
0.35 0.35 0.35 harness
ws or/sw or/br
CAN--H CAN--L
T121/20 J248 T121/7 T121/6 D98 Connection (glow plugs), in engine compartment wiring harness

D159
T121/22 T121/21 T121/ T121/ T121/ T121/ T121/ T121/ harness
51 63 70 50 12 69
0.35 0.35 Positive (+) connection (low bus), in engine compartment wiring
sw/br * D78 sw/bl Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not D160
6 6 harness
ro 10 ro
permitted unless0.35
0.35 0.35by SEAT
authorised 0.35S.A. SEAT
0.35 S.A0.35
ro br/bl ws/bl
respect to gn/ws
the correctness gr/ro ge/gn in this
of information gr/bldocument. Copyright by SEAT S.A. * Only models with additional heater
30a 30a
T6b/4 T6b/1 T6c/1 T6c/4
*
J359 6 *
J360
T6b/3 T6b/2 T6c/2 T6c/3
87a GK RV 87a
0.5 6 0.5
sw/ge sw/ro sw/ge
D98
88 6 6 6 90
sw ro/ws ro
1 1 1 6 1 5 3 2 4
* * *
S109 S143 S265
40A 40A 40A
ws = white
2 2 2
F60 F8 G79 sw = black
4 4 4 ro = red
sw ws ro br = brown
gn = green
Q7 bl = blue
gr = grey
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70 or = orange
97--45723
rs = pink
Edition 02.2003
Diesel direct injection system control unit, brake light switch,
clutch pedal switch, cruise control system brake pedal
switch/diesel direct inj. system
F47 Cruise control system brake pedal switch (diesel direct injection
system)
J293 J293 M9 Brake light bulb, left
T14c/8 T14c/3
* * M25 High level brake light bulb
0.5 0.35 T4j 4-pin connector, behind dash panel
bl gn/bl T10 10-pin connector, green, connector point
95
D157
*
0.35 0.35
ge/bl bl 45 Earth point, behind dash panel
T121/42 J248 T121/34 T121/29

162 Earth connection, in blower motor wiring harness
T121/66 T121/65 T121/32 T121/15

*** **
B131 Positive (+) connection (54), in engine compartment wiring
D73
harness
0.35 0.35 1 1 0.35 0.35 0.35
ws/ro sw/ge sw/ro sw/ro sw/ro sw/ro ws/ge
D157
harness
T10d/7 D73 T10a/9
* Only models with air conditioner
M9 1 *** 1 ** 0.35 ** Only models with ABS
M10 ws/sw sw/ro ws/gn
*** Only models without ABS
M25
2 3 4
T4j/2
F36
0.5
1 2
F47 F 1 li
0.5 0.5 1 2
br/bl ws/ge ro/ge
F268 in part or in ws
Protected by copyright. Copying for private or commercial purposes, whole,=is not
white
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any
1
sw liability
= blackwith
T10/8 T10d/6
ro = red
0.5 1 0.5
br = brown
ws/ge ro/ge br gn = green
2.5 bl = blue
32 17 br 162 gr = grey
45 li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84 or = orange
97--43468
rs = pink
Edition 02.2003
Diesel direct injection system control unit, terminal 30 voltage
supply relay, glow plugs relay, Hall sender, glow plugs -
engine
G40 Hall sender
J52 Glow plugs relay
J317 Terminal 30 voltage supply relay
N79 Heater element (crankcase breather)
N239 Intake manifold flap change-over valve
T10a/5 Q6 Glow plugs - (engine)
2.5 2.5
ro ro
J317 2/30a
8 F25 Connection -1-, in diesel direct injection system wiring harness
9/85 6/87
52 73 7 * Only models with additional heater
0.35 2.5 1.5 0.35 6

sw/li sw/ge sw/ge ge/bl ro
T 30a
J248 T121/18 T6e/5 T6e/1
T10/5
J52
T121/ T121/109 T121/81 1 T6e/3 T6e/2
101 sw/ge 87a G
0.35 0.35 0.35 23a

br/sw gn/li ro/bl
1 6
0.5
sw/ge SB 23 sw/ge ro
T3k/3 T3k/2 5A
2 23b
G40 N239 31 1
sw/ge
1
35 37
T3k/1 T10/4
0.5 0.5 0.5 0.5 1
sw/ge sw/ge sw/ge sw/ge sw/ge
F25
0.5 * *
sw/ge 0.5 0.5 1
sw/ge sw/ge sw/ge
1 ws = white
sw = black
* 57 63 by copyright. Copying for private or commercial purposes, in part or in whole, is ro
53 = red
N79 Protected not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability brwith = brown
2 Q6 S.A. gn
respect to the correctness of information in this document. Copyright by SEAT = green
0.5
br bl = blue
gr = grey
110
110
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98 or = orange
97--43469
rs = pink
Edition 02.2003
Fuel gauge sender, fuel pump (pre-supply pump),
speedometer sender, coolant shortage indicator sender
G Fuel gauge sender
G32 Coolant shortage indicator sender
a T10a 10-pin connector, red, connector point
b T10c 10-pin connector, black, connector point
c T14b 14-pin connector, on engine

J 362
T10x/3

0.35 0.35 0.5 0.5
li/sw br/ws bl/ro sw
A38
132
0.5 0.35
sw/gr ws/bl 131 Earth connection -2-, in engine compartment wiring harness
T10/2 T10c/3
221 Earth connection (engine earth), in engine wiring harness
0.5 0.5
sw ws/bl
36
T14b/ T14b/9
8
4 0.5 0.5
ro/ge sw ws/bl
1 2 1 1 2
V/5
G6 G G32 G22 1
br
4 3 2 3 86
131
1.5 0.5 0.5 0.5 0.5 2.5
br br/ws br/ws br/ws br br
permitted unless authorised by SEAT S.A. SEAT S.A does 42 not guarantee or accept any liability with
82 S.A. ws = white
B109 T10a/1 T14b/10
respect to the correctness of information in this document. Copyright by SEAT
sw = black
ro = red
2.5 1 1 1 1.5 6
br br br br br br br = brown
221 gn = green
bl = blue
gr = grey
61 12
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112 or = orange
97--43449
rs = pink
Edition 02.2003
Control unit with display in dash panel insert, fuel gauge,
coolant temperature gauge, oil pressure switch
G1 Fuel gauge
a K28 Coolant temperature warning lamp/coolant shortage warning lamp
b K29 Glow period warning lamp
c K105 Reserve fuel warning lamp
40 T10a 10-pin connector, red, connector point
0.5 0.5 T14b 14-pin connector, on engine
bl/ro ge/ro
T10c/2 T10/3
0.35 0.35 0.35 0.35 0.35

bl/sw ro/bl br/ws li/sw ge/ro
T32/10 T32/22 T32/7 T32/5 T32/8
G1 G3
T10a/6 K3
J285
0.5
br/ws
T14b/3 K105 K28

K29 K2
T32/13 T32/12
0.5 0.35 0.35 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ge ro/ge bl respect to the correctness of information in this document. Copyright by SEAT S.A.
1 T10a/3
F1 41 0.5
bl ws = white
sw = black
13 ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42314
rs = pink
Edition 02.2003
Control unit with warning lamps on the dash panel insert, rev.
counter, speedometer
G5 Rev. counter
G21 Speedometer

16a
238 Earth connection-1-, interior wiring harness

SB 16
5A
59
16b
0.5 0.5 0.5
br/ro br/ro gn/ws
108
108 39 A27 Connection (speed signal), instrument panel wiring harness
B158 7 A27
0.35 0.35 0.35 0.35 A121 Connection (High-Bus), instrument panel wiring harness
br/ro ws/bl gn/ws sw
T32/30 T32/28 T32/3 T32/11 A122 Connection (Low-Bus), instrument panel wiring harness
J285
G21 G5
T32a/20 T32a/19 T32/9 T32/24
CAN--L CAN--H
0.35 0.35 0.35 0.35

or/br or/sw br br
A122 A121 249
ws = white
0.5 0.5 0.5 0.5 2.5 sw = black Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
or/br or/br or/sw or/sw br ro = red permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
br = brown respect to the correctness of information in this document. Copyright by SEAT S.A.
238
gn = green
J362 68 65 J362 bl = blue
T10x/1 T10x/2 2.5
br gr = grey
76 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--45720
rs = pink
Edition 02.2003
1.7 l - Diesel injection engine/44 kW, engine code AKU

From october 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408
3 - Fuel cut-off control unit (405)

Warning!
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 A - red permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
31 30 X
7 J59 A Battery
C Alternator
T6h/4 T6h/3 T6h/2 T6h/1
E1 Light switch
1
br
1
sw/ge
6
sw 16 93 E1/15 6
ro
A61
2.5 2.5 2.5 T2b 2-way connector, engine
ro ro ro
A32 A40
4 6 4 1 Earth strap, battery - bodywork
ro ro ro
D 30 502 501 2 Earth strap, gearbox - bodywork
TV2
X 50 15 P S
500
2.5 2.5 4 1 0.5
E1/1 21 E 19 130
130
T7a/5
132
132 40 502 Bolted joint -1- (30a), on the relay plate
10 0.5 0.35
*
ro bl ro/sw
60 97
T10/1 T2b/1 T2b/2
* A40 Positive connection -1- (30), in the instrument wiring harness
2.5 25 4 6 16 0.5 0.5
ro/sw sw ro ro sw bl gn
50 30 + 4 3 2 1 B+ D+ W permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
B102 respect to the correctness of information in this document. Copyright by SEAT S.A.
C B102 Earth connection, interior wiring harness, front left
SA 4 SA 3 SA 2 SA 1 G
ws = white
B 50A 50A 80A 110A
sw = black * Only vehicles with additional heating
M
C1 ro = red
-- br = brown
2.5 A gn = green
br 25 25 bl = blue
sw sw gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42047
rs = pink
Edition 09.2002
Diesel direct injection system control unit, intake air
temperature sender, fuel shut- off control unit (crash),
30 31 DA exhaust gas recirculation valve
J491 3
* G42 Intake air temperature sender
CRASH 15 15DA J234 Airbag control unit
T9c/3 T9c/6 T9c/5 T9c/2 T9c/4 T9c/8 J491 Fuel shut-off control unit (Crash)
J 362 N18 Exhaust gas recirculation valve
0.5 0.5 0.5 0.5 1
** 1 1 T10x/7 SB15 Fuse -15- in fuse box
A125 0.5 T10a 10-pin connector, red, connector point
32b ws/ge T10b 10-pin connector, blue, connector point
2.5 1 0.5
ro ro gr/ge SB 32 T10b/10 T10a/7 10 Earth point, in plenum chamber
10A
15a
7 32a
J 234 *** 76 Earth point, near selector mechanism
SB 15 T75/72 1 0.35 0.35
10A
Protected by copyright. Copying for private or sw sw in part or in whole, is not
commercial purposes, ws/ge
15b A104 W 81 Earth connection -1-, in dash panel wiring harness
T121/37 by SEAT J
respect to the correctness of information in this document. Copyright S.A.
248 T121/16
1 2.5
ro/ge sw
A2 T121/61 T121/ T121/ T121/ T121/
54 73 4 5
78
4 A52 Positive (+) connection -2- (30), in dash panel wiring harness
sw
5 0.35 0.35 0.35 2.5 2.5 A104 Positive (+) connection -2- (15), in dash panel wiring harness
br/ws br/bl gr/bl br br

2 2
N18 G42 * Only models with airbag

** Only models without airbag
1 1 *** Wire W for self-diagnosis
81
1
sw/ge
90
2.5 ws = white
br sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
76 10 10
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--45726
rs = pink
Edition 09.2002
Diesel direct injection system control unit, engine speed
sender, needle lift sender
G28 Engine speed sender
G80 Needle lift sender
124
124 116
116
0.35 0.35
gn ro/ge
T10a/8 T10/6
0.35 0.35
156 Earth connection, in diesel direct injection wiring harness
gn ro/ge
J248 T121/27 T121/40 ** Only models without additional heater
T121/86 T121/ T121/101 T121/ T121/102 T121/38

109 110
** *
0.35 0.35 0.35 0.35 0.35 0.35 0.35
br/ro ws br bl gr br ro/sw
14
T2e/1 T2e/2 T3/2 T3/1
V/5
G80 G28
1
br
T3/3 131 ws = white

sw = black
0.35 0.35 2.5 ro = red
sw sw br br = brown
gn = green
6
156 82 br bl = blue
gr = grey
12
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--45727
rs = pink
Edition 09.2002
Diesel direct injection system control unit, fuel temperature
sender, modulating piston movement sender, fuel shut-off
valve, metering adjuster
G81 Fuel temperature sender
G149 Modulating piston movement sender
N109 Fuel shut-off valve
N146 Metering adjuster
T10p 10-pin connector, black, near injection pump
J248 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
T121/ T121/ T121/ T121/ T121/ T121/ T121/ T121/1 T121/2 T121/120
103 111 108 106 99 121 116
0.35 0.35 0.35 0.35 0.35 1 1 1.5 1.5 1

br/bl ge/sw li/sw gr/ro ws/gn br/ge br/ge sw/ws sw/ws ws/sw
F26
F28
1 2.5
br/ge sw/ws
T10a/4 T10p/8
1.5
T10p/ T10p/ T10p/ T10p/ T10p/6 sw/ws
7 1 2 3
37b
1
SB 37 N109 ws = white
15A
sw = black
G81 G149 N146 37a ro = red
br = brown
1 1.5
T10p/4 T10p/5 sw/ws sw/ge gn = green
bl = blue
gr = grey
93 li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--42316
rs = pink
Edition 09.2002
Diesel direct injection system control unit, low heat output
relay, high heat output relay, kick-down switch, idling switch,
accelerator pedal position sender, coolant heating elements
F8 Kick-down switch
F60 Idling switch
J
104 131
131 129
129 J104 J248 Diesel direct injection system control unit
T25/11 T25/10 J359 Low heat output relay
0.5 0.5
134
134 T10b 10-pin connector, blue, connector point
T10n/4 T10n/5 T10n 10-pin connector, grey, connector point
0.5 0.35 0.35 0.35 0.35 T24a 24-pin connector, on cylinder head, left
gn/ws or/sw or/sw or/br or/br
D78
T10b/9
D159 D160 harness
0.35 0.35 0.35

ws or/sw or/br D98 Connection (glow plugs), in engine compartment wiring harness
CAN--H CAN--L
T121/20 J248 T121/7 T121/6
D159
harness
Positive (+) connection (low bus), in engine compartment wiring

T121/21 T121/22 T121/ T121/ T121/ T121/ T121/ T121/ D160 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
51 63 70 50 12 69 harness
D78 respect to the correctness of information in this document. Copyright by SEAT S.A.
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
sw/bl 4 4 * 4 sw/br br/bl gn/ws gr/bl gr/ro ge/gn ws/bl
ro ro ro
30a 30a
T9f/6 T9f/2 T6c/1 T6c/4
* 7 *
J359 J360
T9f/4 T9f/8 T6c/2 T6c/3
87a GK RV 87a
0.5 4 0.5
sw/ge sw sw/ge 6 1 5 3 2 4
D98
88 90
2.5 2.5 2.5
sw/ws sw sw
F60 F8 G79
T24a/18 T24a/ T24a/15 ws = white
14
2.5 2.5 2.5 sw = black
sw sw sw
ro = red
br = brown
* gn = green
Q7 bl = blue
gr = grey
li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70 or = orange
97--45728
rs = pink
Edition 09.2002
Direct injection diesel control unit, brake light switch, clutch
pedal switch, direct injection diesel system/GRA brake
pedal switch, coolant temperature sender, coolant
temperature sender
F47 Brake pedal switch of the GRA/direct diesel injection system
T10d 10-way connector, white, in the interconnection station
95 T24a 24 way connector, in the cylinder head, to the left
0.35
B131 Conection (54), interior wiring harness
ge/bl
T121/42 J248 D73 Positive connection (54), in the vane motor cable harness
* Only vehicles without ABS
T121/66 respectT121/65 T121/32
to the correctness of information in this document. Copyright by SEAT T121/112
S.A. T121/ ** Only vehicles with ABS
104
B131
* **
0.35 1 1 0.35 0.35 0.35 0.35

ws/ro sw/ro sw/ro sw/ro sw/ro bl/br br/bl
D73
T10d/7 T24a/4 T24a/7
0.35 M9/ 1 * 1 ** 0.5 0.5
sw/ge ws/sw sw/ro bl/br br/bl
M10/
M25
2 3 4 3 G62 G2 1
F36
1 2
F47 F 1 4 2
1 1 1 0.5 1
sw/ge ws/ge ro/ge ge/ro br/ws
ws = white
sw = black
T10/8 T10d/6 T24a/3 ro = red
107
107 br = brown
0.5 1 0.5 gn = green
ws/ge ro/ge ge/ro bl = blue
gr = grey
90 17 121
121 li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84 or = orange
97--42737
rs = pink
Edition 09.2002
Direct injection diesel control unit, terminal 30 voltage supply
relay, incandescent spark plugs relay, injection start valve,
throttle valve, warmup spark plugs (engine)
J52 I ncandescent spark plugs relay
J317 Relay to supply voltage to terminal 30
N108 Injection start valve
N211 Throttle valve
Q6 Pre-heating spark plugs (engine)
T10a/5 SB23 Fuse -23- in fusebox
2.5 2.5
ro ro
J317 2/30a T10p 10 way connector, black, near the injection pump
8 T24a 24 way connector, in the cylinder head, to the left
52 Connection -1-, in the direct injection diesel equipment wiring
9/85 6/87 74 8 F25
harness
0.35 2.5 1.5 0.35 6
sw/li sw/ge sw/ge ge/bl ro Connection (warmup spark plugs, engine), in the direct injection
F31
T 30a diesel system wiring harness
J248 T121/18 T6e/5 T6e/1
* Only vehicles with additional heating
T10/5 J52
T121/62 T121/114 T6e/3 T6e/2
87a G
0.35 1 0.5 1
ro/bl br/sw sw/ge sw/ge 1 6
sw ro
T24a/22 T10p/9 24a 23a

0.5 1
ro/bl br SB 24 SB 23by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
5A 52 permitted
5A unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
24b 23b
N211 N108 0.5 F31
1 2 ws/ge
0.5 1 1 2.5 2.5

sw/ge sw 72 sw/ge ro ro
23
T24a/21 T10p/10 T10/4 T24a/ T24a/8
16
1 1 1 1 2.5 2.5
sw/ge sw/ge sw/ge sw/ge sw sw
ws = white
F25 sw = black
* * ro = red
0.5 0.5 br = brown
sw/ge sw/ge Q6 gn = green
bl = blue
57 62 gr = grey
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98 or = orange
97--42319
rs = pink
Edition 09.2002
Fuel level indicator sender, speedometer sender, coolant
lack indication sender, oil pressure switch
G Fuel level indicator sender
G32 Coolant lack indicator sender
a T10a 10-way connector, red, in the interconnection station
b T10c 10-way connector, black, in the interconnection station
c
T24a 24 way connector, in the cylinder head, to the left
d
15 Earth point, in the cylinder head
A38 Positive connection -2- (15a), instrument panel wiring harness

J362
T10x/3
0.5 0.35 0.5 0.35 0.35

sw li bl/ro br/ws bl/sw
136
136 84
A38
0.5 0.35 1 1
sw/gr ws/bl br/ws
G32
2
T10/2 T10c/3 T24a/13 T10a/6
0.5 0.5 0.5 1 0.5
sw ws/bl br/ws br/ws ge
T24a/ T24a/5 T24a/10

9
T10a/1 in this document. Copyright by SEAT S.A.
respect to the correctness of information
0.5 0.5 0.5
sw ws/bl ge
1 2 1 1
G22 G F1
3 2 ws = white
1 0.5 sw = black
br/ws br/ws ro = red
br = brown
gn = green
bl = blue
gr = grey
15 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112 or = orange
97--45729
rs = pink
Edition 09.2002
gauge, coolant temperature gauge, revolution counter, oil
lamp
G1 Fuel gauge
G5 Rev. counter
a
b
c K28 Coolant temperature/level warning lamp
d K29 Pre-heating period warning lamp
82 K105 Fuel level indicator lamp
0.5 0.5 T10c 10-way connector, black, in the wiring harness interconnection
bl/ro ge/ro
34
T10c/2 T10/3
0.35 0.35 0.35 0.35 0.35 0.35

bl/sw br/ws ro/bl li ge/ro gn
T32/10 T32/7 T32/22 T32/5 T32/8 T32/11
G1 G3
K3
J285
K29 K105 K28

G5
T32/13 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
0.35
ro/ge
36
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--45724
rs = pink
Edition 09.2002
Control unit with warning lamps on the dash panel insert,
speedometer, alternator warning lamp
G21 Speedometer
SB16 Fuse -16- in fuse holder
16a 76 Earth point, near gearbox control
SB 16
5A
13 59
16b
0.5 0.5 0.5 0.5 249 Earth connection -2-, interior wiring harness
br/ro br/ro bl gn/ws
101
101
B158 7 T10a/3 A27 A27 Connection (speed signal), in the instrument panel wiring harness
0.35 0.35 0.35 0.35

br/ro bl gn/ws ws/bl A121 Connection (High-Bus), instrument panel wiring harness
T32/30 T32/12 Protected T32/3
T32/28
respect to the correctness of information in this document. Copyright by SEAT S.A. A122 Connection (Low-Bus), instrument panel wiring harness
K2 B158 Connection (S), interior wiring harness

J285
G21
T32a/20 T32a/19 T32/9 T32/24
CAN--L CAN--H
0.35 0.35 0.35 0.35

or/br or/sw br br
A122 A121 249
ws = white
0.5 0.5 0.5 0.5 2.5 sw = black
or/br or/br or/sw or/sw br
ro = red
br = brown
238
gn = green
J362 67 65 J362 bl = blue
T10x/1 T10x/2 2.5
br gr = grey
76 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--45725
rs = pink
Edition 09.2002
Radiator fan
From May 2001
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 A - red permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
Fuse in fuse box/attery
SA5
SA6
10A 20A 30A 30A

1 2 3 4
SA7
SA8
SA1 SA2 SA3 SA4
E97-0056
Edition 09.2002
A Battery
V7 Radiator fan

A32

6
ro
2.5
ro *
47a
A/+ A32 Positive (+) connection (30), in dash panel wiring harness
TV2 SB 47
20A * Only models without ABS
** Only models with ABS
47b
2.5
ro/ge SA
20A
7
**
T10n/1 T4a/3
2.5 * 2.5 ** Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ro/ge ro/ge
2
II I
F18
3 1
2.5 2.5
ro/bl ro/ws
T3a/1 T3a/2
V7
T3a/3
ws = white
2.5
sw = black
br ro = red
br = brown
108 gn = green
6 bl = blue
br gr = grey
12 li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
or = orange
97--43470
rs = pink
Edition 09.2002
CAN bus wires

From July 2000
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 02.2003
Control unit with display in dash panel insert
A121 Connection (high bus), in dash panel wiring harness
A122 Connection (low bus), in dash panel wiring harness
D159 Connection (high bus), in dash panel wiring harness
J285 D160 Connection (low bus), in dash panel wiring harness
* Only models with engine codes AUC, ANW and AUD

** Only models with engine codes AUB
J537 J537
T121/60 T121/58
J248 J248
T121/7 T121/6
T32a/20 T32a/19
J220 ** J220 ** CAN--L CAN--H
T121/60 T121/58
J 104 J 104 J220 * J220 * J 217 J 217
T25/11 T25/10 T80/31 T80/32 T68/15 T68/16
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

or/sw or/br or/sw or/br or/sw or/br or/br or/sw
D160
D159
0.35 0.35
or/sw or/br
J234 J 234 J362 J362

T75/74 T75/75 T10x/2 T10x/1
T10n/4 T10n/5 ws = white
sw = black
0.35 0.35 0.5 0.5 0.5 0.5
or/sw or/br or/sw or/br or/sw or/br ro = red
br = brown Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
gn = green respect to the correctness of information in this document. Copyright by SEAT S.A.
bl = blue
A122
gr = grey
A121
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97-42739
rs = pink
Edition 02.2003
R Radio
T10k 10-way connector, brown, in the wiring harness interconnection
T16 16-way connector, in the instrument panel, in the center. Auto-diagnostic
connection centre
TV2 TV2 Cable distributor for terminal 30
6 76 Earth point, near gearbox control

ro
A32
81 Earth connection -1-, instrument panel wiring harness
2.5
J285 ro
A52
0.5
ro A52 Positive connection -2- (30), instrument panel wiring harness
11a

SB 11
T32/25 T32a/28 T32a/27 5A
K CAN--L CAN--H
11b
0.35 0.35 0.35 0.5

gr or/br or/sw ro
CAN--L CAN--H 30a
respect to the correctness of information in this document.T16/14
T16/6 T16/16
J104 J217
T25/7 T68/5 T16/7 T16/4
K 31
0.5 0.5
gr/ws gr/ws R J 362 J 234 J 379
0.5
br ws = white
T8/3 T10x/8 T75/54 T24/23
sw = black
T10b/2 T10k/5 81 ro = red
br = brown
0.5 0.5 0.5 0.5 0.5 0.5 0.5 2.5 gn = green
gr/ws gr/ws gr/ws gr/ws gr/ws gr/ws gr/ws br
bl = blue
gr = grey
A76 76
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97-42740
rs = pink
Edition 02.2003
CAN bus wires

From May 2001
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green respect to the correctness of information in this document. Copyright by SEAT S.A.
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 02.2003
A121 Connection (high bus), in dash panel wiring harness
A122 Connection (low bus), in dash panel wiring harness
D159 Connection (high bus), in dash panel wiring harness
J285 D160 Connection (low bus), in dash panel wiring harness
* Only models with engine codes AUC, ANW and AUD

** Only models with engine codes AUB
J537 J537
T121/60 T121/58
J248 J248
T121/7 T121/6
T32a/20 T32a/19
J220 ** J220 ** CAN--L CAN--H
T121/60 T121/58
J 104 J 104 J220 * J220 * J 217 J217
T25/11 T25/10 T80/31 T80/32 T68/15 T68/16
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

or/sw or/br or/sw or/br or/sw or/br or/br or/sw
D160 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
D159
0.35 0.35
or/sw or/br
J234 J 234 J362 J362

T75/74 T75/75 T10x/2 T10x/1
T10n/4 T10n/5 ws = white
sw = black
0.35 0.35 0.5 0.5 0.5 0.5
or/sw or/br or/sw or/br or/sw or/br ro = red
br = brown
gn = green
bl = blue
A122
gr = grey
A121
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97-42739
rs = pink
Edition 02.2003
R Radio
T10k 10-way connector, brown, in the wiring harness interconnection
T16 16-way connector, in the instrument panel, in the center. Auto-diagnostic
connection centre
TV2 TV2 Cable distributor for terminal 30
6 76 Earth point, near gearbox control

ro
A32
81 Earth connection -1-, instrument panel wiring harness
2.5
J285 ro
A52
0.5
ro A52 Positive connection -2- (30), instrument panel wiring harness
11a

SB 11
T32/25 T32a/28 T32a/27 5A
K CAN--L CAN--H
11b
0.35 0.35 0.35 0.5

gr or/br or/sw ro
CAN--L CAN--H 30a

T16/14 T16/6 T16/16
JProtected
104 J217
T25/7
permitted T68/5 authorised by SEAT S.A. SEAT S.A does not
unless T16/7 T16/4 any liability with
guarantee or accept
K
respect to the correctness of information in this document. Copyright 31
by SEAT S.A.
0.5 0.5
gr/ws gr/ws R J 362 J 234 J 379
0.5
br ws = white
T8/3 T10x/8 T75/54 T23/11
sw = black
T10b/2 T10k/5 81 ro = red
br = brown
0.5 0.5 0.5 0.5 0.5 0.5 0.5 2.5 gn = green
gr/ws gr/ws gr/ws gr/ws gr/ws gr/ws gr/ws br
bl = blue
gr = grey
A76 76
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97-42741
rs = pink
Edition 02.2003
1.0 l - Motronic/37 kW, engine code AUC 1.4 l - Motronic/44 kW, engine code ANW and AUD
From october 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

Warning!
Fuse colours
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2001
31 30 X
7 J59 A Battery
C Alternator
T6h/4 T6h/3 T6h/2 T6h/1
1 1 6 6 E1 Light switch
br sw/ge sw
E1/15 ro E19 Parking light switch
29 99
A61
T5s 5-way connector, transmission
2.5 4 2.5 T10 10-way connector, green, in the wiring harness interconnection
ro ro/bl ro
A32 A40
4 6 4
ro ro ro

D
Protected by copyright. Copying for private or commercial purposes, in part502
30
or in whole, is not501
TV2
X S 15 P 50
500
2.5 0.5 4 1 2.5 10 500 Bolted joint -1- (30), on the relay plate
sw/ge br/ro sw ge ro/sw ro
E1/1 140
140 25 E 19 T10/1 501 Bolted joint -2- (30), on the relay plate
T7a/5
2.5
ro/sw 502 Bolted joint -1- (30a), on the relay plate
134
134 27
T5s/1
0.5 1 A32 Positive connection (30), instrument panel wiring harness
bl sw/ge
2.5
ro/sw
T5s/2 T5s/3 A40 Positive connection -1- (30), in the instrument wiring harness
0.5 0.5 16 25
bl gn sw sw A61 Positive connection (X), instrument panel wiring harness
D+ W B+ 30 50 +
B102
C G
ws = white
B A
sw = black
C1 M ro = red
-- br = brown
2.5 gn = green
br 25 25 bl = blue
sw sw gr = grey
61 1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42728
rs = pink
Edition 09.2001
temperature sender, plug cap, spark plugs
P Plug cap
Q Spark plugs
A2 SB24 Fuse -24- in fusebox
sw sw sw sw sw
A104 34a 24a 36a
7
0.5
sw SB 34 SB 24 SB 36 T10n 10-way connector, grey, in the wiring harness interconnection
10A 5A 15A
30a 34b 24b 36b
1.5 0.5 1.5
sw ws/ge sw
SB 30 220 Earth connection (sender earth), engine wiring harness
5A
30b
T10/4 T10n/10 T10/8 5

sw/ge sw sw sw/ge
T10d/8 103
103 T80/27 J220 T80/11
A104 Positive connection -2- (15), dash panel insert wiring harness
1 0.5 * Only on ANW and AUD vehicles with automatic gearbox

sw/ge sw/ge
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not T80/74
T80/57 T80/71 T80/54
38 101
101 130
130
1.5 0.5 0.5 0.5 0.5

2 N152 1 3
2 3
G62 G2
1 4
4
1 1 1 ws = white
br br ro = red
P
* ** br = brown
59
Q 121
121 gn = green
bl = blue
a
gr = grey
10 220
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42729
rs = pink
Edition 09.2001
Motronic control unit, PAS pressure switch, engine revolution
sender, Hall sender, exhaust gas recirculation potentiometer,
exhaust gas recirculation valve
F88 PAS pressure switch
G40 Hall sender
A52 J293 Radiator fan control unit
ro ro ro ro
15a 31a T10d 10-way connector, white, in the wiring harness interconnection
9 149
149 85 T14 14-way connector, engine
SB 15 SB 31 0.5 J293 J293 J293 J217 T14a 14-way connector, brown, engine
10A 10A
ws T14c/2 T14c/3 T14c/3 T68/30
15b 31b 220 Earth connection (sender earth), engine wiring harness
2 * *
1 1 0.5 0.5 0.5 1
L5 D161
T10d/ T10c/7 1
**
6
1 1 0.5 0.5 0.5
ro/ge ro ws/sw ro/ws bl D101 Connection -1-, engine bay wiring harness
105
105 * Connection (radiator fan run-on cycle), in the engine bay wiring
J220 T80/15 T80/49 T80/17 T80/42 D161
harness
T80/60
L5 Connection -1-, air conditioning wiring harness
T80/62 T80/53 T80/67 T80/78 T80/69
0.5 0.5 0.5 0.5 1 0.5 * Only vehicles with air conditioning
ge/sw ge ws sw li gn/br ** Only on ANW and AUD vehicles with automatic gearbox
*** Only on ANW and AUD vehicles without automatic gearbox
T14a/ T14a/ T14/5
13 14
1 0.5 0.5
2 5 6 4
G40 G28 N18 ***

3 1 1
G212 2
1 0.5
T3/1
Protected by copyright. Copying for private or commercial purposes, sw/geis not
in part or in whole, gn/li
123 unless
permitted
123 46authorised by SEAT S.A. SEAT S.A 44does not guarantee or accept any liability with
ws = white
respect to the correctness of information in this document. Copyright by SEAT S.A. T14a/12 T14/11 sw = black
ro = red
0.5 0.5 0.5 0.5 0.5 0.5 1 0.5 1
br/ws br/ws br/sw gn/li gn/li ge sw/ge gn/li br/sw br = brown
D101 gn = green
16 bl = blue
a
gr = grey
220
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--42730
rs = pink
Edition 09.2001
Motronic control unit, inlet air temperature sender, inlet
sender -2- for the accelerator pedal position
150
150 151
151
0.5 0.5 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ws/gn ws/bl
T80/16 J220 T80/12
T80/70 T80/56 T80/6 T80/45 T80/19 T80/7 T80/33 T80/8
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

T14/10 T14/12
0.5 0.5
ge/sw ws/br
4 2 1 6 5 3 4 2
G71 G42 G185 G79

3 1
0.5 0.5
gn/li br/ws
ws = white
ro = red
0.5 0.5 br = brown
gn/li br/ws
gn = green
bl = blue
34 30
gr = grey
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56 or = orange
97--42018
rs = pink
Edition 09.2001
control (electric accelerator control), angle sender -1- for
throttle valve (electric accelerator control)
control)
control)
J 217 J 104 J 104 J 217 J220 Motronic control unit
T68/16 T25/10 143
143 T25/11 T68/15 145
145 J338 Throttle valve control unit
0.5 0.5 T14 14-way connector, engine
or/br or/sw T14a 14-way connector, brown, engine
T10n/5 T10n/4 10 Plenum chamber earthing point
0.35 0.35 0.35 0.35 0.35 0.35

or/br or/br or/br or/sw or/sw or/sw 167 Earth connection -4-, engine bay wiring harness
D160 D159
0.35 0.35
or/br or/sw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
CAN--L CAN--H
T80/32 J220 T80/31 D160Copyright
respect to the correctness of information in this document. Connection
by SEAT(Low-Bus),
S.A. engine bay wiring harness
* Only on ANW and AUD vehicles with automatic gearbox

T80/2 T80/28 T80/61 T80/68 T80/55 T80/75 T80/80 T80/66
0.5 0.5 0.5 0.5 1 1

T14a/7 T14a/ T14a/ T14/8 T14a/ T14/6

10 4 8
0.5 0.5 0.5 0.5 1 1
1 2 4 3
18
J338 G186
6 5
G187 G188
** * * * ** ws = white
sw = black
2.5 2.5 2.5 2.5 2.5
br = brown
gn = green
bl = blue
167
gr = grey
10 10 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42709
rs = pink
Edition 09.2001
Motronic control unit, knock sensor I, injector cylinder 1,
injector cylinder 2, injector cylinder 3, injector cylinder 4
G61 Knock sensor I
N30 Cylinder 1 injector
J362 T14 14-way connector, engine
136
136 142
142 128
128 T10x/7 T14a 14-way connector, brown, engine
0.5 0.35 0.35 0.5 200 Earth connection (screened), engine bay wiring harness
D95 Connection (injectors) in engine bay wiring harness

T10b/9 T10n/7 T10a/7
0.5 0.35 0.5
*
gn/ws ge/gr ws/ge
W
T80/5 T80/30 J220 T80/29
T80/63 T80/77 T80/79 T80/59 T80/73 T80/65
0.5 0.5 1 1 1 1
T14/7 T14a/5 T14a/6 T14a/9 102

102
0.5 0.5 1 1 1 1 1
T14a/ T14a/ T14a/1 T10/5

3 2
N30 2 N31 2 N32 2 N33 2
0.5 0.5 0.5 1 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
sw bl gr ro/ge permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1 1 1 1 ws = white
T14a/11
sw = black
1 1 1 1 1 ro = red
gn = green
D95 bl = blue
G61 gr = grey
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42303
rs = pink
Edition 09.2001
catalytic converter, lambda probe heating, lambda probe 1
heating, after the catalytic converter
G39 Lambda probe
G130 Lambda probe after catalytic converter
Z19 Lambda probe heating
Z29 Lambda probe 1 heating, after catalytic converter
D102 Connection -2-, engine bay wiring harness
E30 Connection (87a), engine wiring harness

147
147
0.35
gn
T10a/8 respect to the correctness of information in this document. Copyright by SEAT S.A.
0.5
gn/bl
T80/41 J220
T80/21 T80/47 T80/13 T80/46 T80/20 T80/1 T80/34 T80/35

1 0.5 1 0.5 0.35 1.5 0.5 0.35
0.5 0.5
ws ws

35
1 1 1
gr sw ws
Z29 G39
103
103
ws = white
G130 Z19 sw = black
1 1
ws ro/ge ro = red
br = brown
1 1 1.5 bl = blue
li = purple
ge = yellow
85 86 87 88 89 90 91 92 93 94 95 96 97 98
or = orange
97--42304
rs = pink
Edition 09.2001
J17
J17 Fuel pump relay
T6i/1 T6i/2 T6i/5 T6i/3
4 4 0.5 0.5
M25 High brake light bulb
A99 A2
8 T10 10-way connector, green, in the wiring harness interconnection
1.5 1 1 0.5 1
ro/bl ro/sw ro/sw sw sw T10a 10-way connector, red, in the wiring harness interconnection
3a 1a 27a 28a
116
SB 3 SB 1 SB 27 SB 28
10A 10A T10a/9 5A 7.5A
3b 1b 27b 28b
0.35 1
1 1 0.5 sw sw
ro/ge ro/ge ro/ge 82 Earth connection -1-, front left wiring harness
144
144
A38
83 91 137
137
0.5 0.35 A2 Positive connection (15), instrument panel wiring harness
J220 T80/26 sw/gr ws/bl

T80/14 T80/51 T80/23
T10/2 T10c/3
0.5 1 1 0.5 0.5
gn/ge li/gn sw/ro sw/gr ws/bl A99 Connection -1- (87), in the instrument panel wiring harness
D73 T14/2 T14/1 D73 Positive connection (54), engine bay wiring harness
1 1 0.5 0.5
sw/ro sw/ro sw/gr ws/bl
2 3
F 4 1 2
N80 F63 T10d/7 G22

1 2 1 3
0.5 1 1 1 1
ws = white
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not sw = black
17 by SEAT21S.A. SEAT S.A does M9
32 not guarantee T14/3
or accept any liability with ro = red
M10Copyright by SEAT S.A.
br = brown
M25 gn = green
4 1 bl = blue
br br
gr = grey
12 82
li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--42731
rs = pink
Edition 09.2001
Fuel level sender, fuel pump (pre-supply pump), coolant level
sender, oil pressure switch 0,3 bar
G Fuel level sender
b T10c 10-way connector, black, in the wiring harness interconnection
c
e

101
101
1.5 0.35 0.35

ro/bl ro/bl bl/sw
40a
SB 40 T10c/2 T10a/6
15A
40b
1.5 0.35 0.35 0.5 0.5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ro/ge li/sw br/ws bl/ro bl/sw permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1 2 T10a/1 1 1
G6 G G32 F22
4 3 2 ws = white
sw = black
1.5 0.5 1 0.5
br = brown
gn = green
2.5 bl = blue
br 26 29
B109 gr = grey
61
li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42023
rs = pink
Edition 09.2001
lamp
G1 Fuel gauge
G21 Speedometer
b
c
16a
e K28 Coolant temperature/level warning lamp
5A
26 4 73
16b
0.5 0.5 0.5 0.5 0.5 T10a 10-way connector, red, in the wiring harness interconnection

T10/3 T10a/3 A27 B158 6
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35

bl/sw ro/bl br/ws ge/ro li/sw bl gn/ws br/ro 238 Earth connection -1-, interior wiring harness
T32/10 T32/22 T32/7 T32/8 T32/5 T32/12 T32/3 T32/30

G3 G1
J285
K28 K105
G21
T32/13 T32/1 T32/9 T32/24
0.35 0.35 0.35 0.35

ge/gr sw br br Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
78 107
107
249 ws = white
2.5 sw = black
br ro = red
br = brown
238
gn = green
2.5 bl = blue
br gr = grey
76 li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--45730
rs = pink
Edition 09.2001
counter, exhaust gas warning lamp (EOBD), electronic accelerator
control warning lamp (EPC)
G5 Rev. counter
K132 Electric accelerator control warning lamp (EPC)
30

0.5
ro
11a
SB 11
5A
77 111
111 91
11b
0.35 0.35 0.35 0.35

ge/gr ws/bl gn ro
T32a/15 T32/28 T32/11 T32/23
K132
J285
K83
G5
T32a/20 T32a/19 T32/ T32a/10
CAN--L CAN--H 32
0.35 0.35 0.35 by0.35
or/br or/sw respect to thews/gn ws/blof information in this document. Copyright by SEAT S.A.
correctness
A122 A121
3
0.5 0.5 0.5 0.5 0.5 0.5 sw = black
br = brown
gn = green
J 362
62 67 J362
47 52
bl = blue
T10x/1 T10x/2
gr = grey
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 152 153
or = orange
97--45731
rs = pink
Edition 09.2001
Basic equipment
⇒ 1.0 l - Motronic/37 kW, engine codes AUC (with air conditioner and/or with ABS)
⇒ 1.4 l - Motronic/44 kW, engine codes ANW and AUD (with air conditioner and/or with ABS and/or with automatic gearbox)
⇒ 1.4 l - Marelli 4LV/74 kW, engine codes AUB
From October 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

Note:
Edition 09.2002
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - verde
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple
Edition 09.2002
SA5
SA6
10A 20A 30A 30A

1 2 3 4
SA7
SA8
SA1 SA2 SA3 SA4
E97-0056
SA1 - Fuse -1- alternator (110 A)

SA2 - Fuse -2- interior wiring harness (80 A)
SA5
permitted
SA6 unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
30A 10A 20A 30A 30A
1 2 3 4
SA7
SA8
SA9
SA1 SA2 SA3 SA4
E97-0053
SA1 - Fuse -1- alternator (110 A) (without additional heater)

- Fuse - 1 - alternator (150 A) (with additional heater)
Edition 09.2002
SA2 - Fuse -2- interior wiring harness (80 A)
Edition 09.2002
junction box
31 30
A Battery
7 J59 B Starter
X 75x C Alternator
T6h/4 T6h/3 T6h/2 T6h/1 SA1 Fuse -1- in fuse box/battery
203
203
1 1 6 2.5
ro
br sw/ge sw ro T10 10-pin connector, green, connector point
71
150
150 A32 1 Earth strap, battery - body
4 6 4
ro ro ro
D 30 502 501
500 Screw connection -1- (30), on relay plate
TV2
X 50 15 P S 501 Screw
Protected by copyright. connection
Copying for private or-2- (30), onpurposes,
commercial relay plate
2.5 2.5 4 1 0.5 respect to the correctness of information in this document. Copyright by SEAT S.A.
502 Screw connection -1- (30a), on relay plate
16a
66 77 186
186 113
113
T10/1 SB 16 A32 Positive (+) connection (30), in dash panel wiring harness
5A
41
2.5
ro/sw 16b
0.5 0.35 10
B/30 B/50 br/ro br/ro C/B+ ro
* For all models, does not apply to AMF, 4-pin connector, T4a
B158
25 16
sw sw
+
* T5f/1 T5f/2 T5f/3 T5f/4 T5f/5 1 2 3 4
30A 30A 20A 10A 30A 110 A 80A 50A 50A
ws = white
-- sw = black
ro = red
br = brown
gn = green
25 25 bl = blue
sw sw
gr = grey
1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--43465
rs = pink
Edition 09.2002
Immobilizer control unit, immobilizer reading coil
D2 Immobilizer reading coil
J 234 J 234
T75/74 J... J... T75/75 A76 Connection (diagnosis wire K), in dash panel wiring harness
J... 0.35 0.35
or/sw or/br
34 Protected by copyright.
32 Copying for private or commercial purposes, in part or inA121
whole, isConnection
not (high bus), in dash panel wiring harness
* T10n/4 T10n/5
206
206 0.5 0.35 0.35 0.5 0.5 0.35 0.35 A122 Connection (low bus), in dash panel wiring harness
A122
T10a/7 A121
1 0.5 0.5 0.5

30 W CAN--H CAN--L
T10x/10 T10x/7 J362 T10x/2 T10x/1
T3/1 T3/2 T3/3 T10x/9 T10x/3 T10x/8

31 15a K
0.5
sw
A38
1 0.5
sw gr/ws
28b
SB 28
7.5A
28a
ws = white
D2 1
sw = black
1
br sw ro = red
br = brown
gn = green
185
185
b
bl = blue
A76
gr = grey
76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42706
rs = pink
Edition 09.2002
Control unit with display in dash panel insert, data bus
diagnostic interface, warning lamp for symbol Yellow triangle
J533 Data bus diagnostic interface
K63 Warning lamp for symbol 'Yellow triangle'
J...
T10b/9
0.5 A76 Connection (diagnosis wire K), in dash panel wiring harness
gn/ws
26 20 202
202 9
* Only models without central locking
A27
*
0.35 0.35 0.35 0.35 0.35
CAN--L CAN--H
T32a/20 T32a/19 T32/3 T32/21 T32/30
K63 J533 J285
T32/25 T32a/28 T32a/27 T32/23 T32/1

CAN--L CAN--H 199
199
0.35 0.35 0.35 0.35 0.5 0.35

gr gn sw ro ro sw
11b 10b
T16/14 T16/6
192
192
SBProtected
11 SB 10 Copying
5A by copyright.
7.5A ws = white
to the correctness of information in thissw = black
T16/7 T16/4 T16/16
K 31 11a respect 10a document. Copyright by SEAT S.A.
ro = red
0.5 0.5 0.5 0.5 0.5 br = brown
gr/ws br ro ro ro
gn = green
b A76
* bl = blue
84 205
205 gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--45736
rs = pink
Edition 09.2002
warning lamp, alternator, airbag and turn signal left and right,
digital clock, odometer display
C Alternator
H3 Buzzer/gong
Y2 Digital clock
0.5
108
108
T10a/3
bl ws
T32/12 T32/17
K2 K1
Y2 H3
J285
K94 K65 K75 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Y4 respect to the correctness of information in this document. Copyright by SEAT S.A.
T32/2 T32/18 T32/24 T32/9 T32/6
0.35 0.35
gn/sw sw/ws
122
122 115
115 206
206 200
200 131
131 136
136
ws = white
** * sw = black
ro = red
2.5 0.5 0.5 0.5 0.35 0.35 0.35
gn = green
249 bl = blue
gr = grey
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
or = orange
97--45737
rs = pink
Edition 09.2002
Dash panel insert, handbrake warning switch and brake fluid
level, side light warning lamp, anti-lock brake system and
brake system
F34 Brake fluid level warning contact
c K47 ABS warning lamp
d K118 Brake system warning lamp
e L75 Digital display illumination
142
142 131
131 83 135
135 T10 10-pin connector, green, connector point
0.5 1 1 0.5 0.35 0.35 0.35
gr/bl gr/bl gr/bl gr/bl gr/gn gr/ro gr/ge 61 Earth point, left C-pillar
B145 B160 B102 Earth connection, in front left interior wiring harness
0.35 0.35 0.5 0.5

T32/20 T32/14 T32/26 T32/27 T32/29
B160 Connection (brake system monitoring), in interior wiring harness
L75 K4 K118 T10c/6

permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee * or accept
Only any
models
liabilitywith
with petrol engine without ABS
**
respect to the correctness of information in this document. Copyright Only models
by SEAT S.A. with diesel engine without ABS
J285 *** Only models without central locking
0.5
bl/br
1 1
K47 K19
F9 F34
T32/19 2 2
0.35
ge
204
204 198
198 181
181 1
***
0.5 0.5 1 1 0.5 0.5
T10/10 br br br br br br/sw ws = white
sw = black
167
167 ro = red
B102
0.5 0.5 br = brown
ge br gn = green
2.5
* ** br bl = blue
gr = grey
61
157
157 156
156 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--42724
rs = pink
Edition 09.2002
Lighting switch, fog light switch, lighting switch light bulb
E1 Lighting switch
E7 Fog light switch

c
d
e
156
156 f
g
0.35 0.5 0.5

gr/gn gr/gn gr/gn
A3
99 111
111 107
107 106
106 124
124 59 156
156
0.35 0.5 0.35 0.5 1.5 2.5 2.5 1.5 1.5 1 0.5
13/58L 14/58R 16/58 6/B 4/56 7/56b 3/TFL 8/NL 9/NSL 17/58b
E1 15/30 1/Xz
E7 L9
2/Xf respect to the correctness
10/31 of information in this document. Copyright by SEAT S.A.
2.5 2.5 1.5 1

ro sw/ge gr/ws br
3 139
139 180
180 157
157 32
A40
4 1.5 1.5 0.5 0.5 ws = white

ro ro br br br
sw = black
ro = red
81
11 109
109 br = brown
2.5 gn = green
br bl = blue
gr = grey
76
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42005
rs = pink
Edition 09.2002
Tail light bulb, left and right, turn signal bulb, rear left and right,
brake light, left, right and upper, reversing light bulb, rear fog
light bulb
M8 Turn signal bulb, rear right
f M25 High level brake light bulb
g L20 Rear fog light bulb
F/4
T5b 5-pin connector, brown, left C-pillar
1 0.5
sw/ro gr/gn
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not X Number plate light
D73 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee
2a or accept any liability with
1 SB 2
sw/ro 5A
T10d/7 2b B109 Earth connection, in interior wiring harness, rear left
1 0.5
sw/ro gr/gn B131 Connection (54), in interior wiring harness
B131
114
114 99 190
190 112
112 121
121
B132
B132 Connection (number plate light), in interior wiring harness
1 1
sw/ro sw/bl
D73 Positive (+) connection (54), in engine compartment wiring harness
T5b/2 T10a/2
1.5 0.5 0.5 1 1 1 1 0.5 0.5 0.5 0.5

1/NSL 2/BLL 6/58L 5/54 2 1/54 6/RFL 2/58R 5/BLR 1
X
L20 M6 M4 M9 M25 M10 M17 M2 M8
ws = white
3/31 4/31 1 3/31 4/31 2 2 sw = black
ro = red
1.5 1.5 1 1.5 1.5 0.5 0.5
2.5
gn = green
br 137
137 bl = blue
B109
61 gr = grey
li = purple
85 86 87 88 89 90 91 92 93 94 95 96 97 98 ge = yellow
97--43471 or = orange
rs = pink
Edition 09.2002
77 72
T5d/3 T5d/5
T5d/2 T5d/4
56b
78 56a
2.5 2.5 1.5 1.5
72 113
113 110
110 ge ge ws ws 74 114
114 A9 Positive (+) connection (56b), in dash panel wiring harness
A9
0.5 0.5 1.5 1.5 2.5 102
102 0.5 0.5
4a 13a 44a 45a 12a 5a

SB 4 SB 13 SB 44 SB 45 SB 12 SB 5
5A 10A 15A 15A 10A 5A
0.5 0.5 1.5 1.5 1.5 1.5 0.5 0.5

159 163
163 ge ws gr/ro gr/ro
A95
T10b/6 T10b/4 T10b/5 T10c/5 T10b/
87 respect7 to the correctness of information in this document. Copyright by SEAT S.A.
2.5 1 1 2.5 0.35 1.5 94
116
119
119
T10c/4
1 0.5 1.5 1.5 B247 B167 1.5 53
ws gr/ro sw/gn
BLL 58 56a 56b 56b 56a 58 BLR
ws = white
ro = red
31 31 gn = green
2.5 2.5 bl = blue
br br
gr = grey
123
123 165
165 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--45734
rs = pink
Edition 09.2002
h T10b 10-pin connector, blue, connector point
1 0.5
ge sw/ge
P 49a 12 Earth point, in engine compartment, left
T7a/5 T7a/2
T7a/4 T7a/6
PL PR L R A5
harness
0.5 0.5 1 1
Protected
gr/ge by copyright. Copying
gr/ro sw/wsfor private orsw/gn
commercial purposes, in part or in whole, is not Positive (+) connection (left turn signal), in dash panel wiring
A6
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with harness

100
100 112 D57
harness

80
0.5 0.5 0.35 0.5 0.5 0.5 0.5 0.35 1.5

* Only models with petrol engine

127
127 86 45 T10b/8 T10c/1 128
128 95 43 T10c/8
0.5 0.5 1.5
sw/ws sw/gn ws/ge
D58 D57 D59
0.5 1 0.5 1 1.5 1.5

2 99 2 112
112 1 1
M18 M19 L22 L23

155
155 104
104 ws = white
sw = black
1 1
* 2 2 ro = red
0.5 0.5 2.5 2.5 1.5 1.5 br = brown
br br br br br br
6 gn = green
br
bl = blue
166
166 164
164
108 gr = grey
12 li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--42008
rs = pink
Edition 09.2002
Hazard warning light switch, heated rear window switch,
hazard warning light relay, hazard warning light system
warning lamp, heated rear window switch bulb, heated rear
window
E3 Hazard warning light switch
E15 Heated rear window switch
J1 Turn signal relay
i K6 Hazard warning light system warning lamp
h
204
A80 L39 Heated rear window switch bulb
0.5 1 1 2.5 1.5
sw/ge ro sw/ge sw/ge sw/ge SB43 Fuse -43- in fuse box
SB 14 SB 7 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee
SB 48 or SBaccept
43 any liability with 61 Earth point, left C-pillar
10A 7.5A 20A
respect to the correctness of information in this document. 15A by SEAT S.A.
Copyright
14b 7b 48b 43b

58 60 209
209 218 Earth connection, in tailgate/boot lid wiring harness
1 0.5 1 0.5 0.5 2.5 1.5

ro/ge sw/gr gr/bl gr/bl gr/bl bl gr/ws A80 Connection -1- (X), in dash panel wiring harness
1/49a E3 7/30a 6/75a 4/58b 8 J1 80

* Only models without electrically adjustable exterior mirrors
1/58b K10 5/75a
L39 E15
2/31 6/+
2.5
*
3/L 2/R 5/31
K6 sw
T5b/1
0.5 0.5 0.5 0.5 2.5
+
113
113 120
120 49 50
Z1
-- ws = white
184
184 90 sw = black
ro = red
br = brown
2.5 1.5 1 2.5 gn = green
gr = grey
61 218
li = purple
ge = yellow
127 128 129 130 131 132 133 134 135 136 137 138 139 140
or = orange
97--42009
rs = pink
Edition 09.2002
Fresh air blower switch, fresh air blower with overheating fuse
series resistor, fresh air blower, fresh/recirculating air flap
control motor
L16 Fresh air control light bulb
i A80
N24 Fresh air blower with overheating fuse series resistor
1 2.5 0.5 4
sw/ge sw/ge ge/bl sw/ro
A61
6a 50a 9a
V2 Fresh air blower
SB 6 SB 50 SB 9 6 2.5
15A 15A 5A sw sw/ge V154 Fresh/recirculating air flap control motor
6b 50b 9b
4 49a 45 Earth point, behind dash panel
1 1.5 0.5
sw/ge sw/gr ge/bl SB 49
57
25A 162 Earth connection, in blower motor wiring harness
186
186 171
171 160
160 49b
0.5 2.5
gr/bl sw/ro A61 Positive (+) connection (X), in dash panel wiring harness
188
188
T4j/3 T4j/1 A80 Connection -1- (X), in dash panel wiring harness
0.5 0.5 2.5
gr/bl sw/bl sw/bl
58b Xa
T8m/3 K114 T8m/5 E159 E9 T6t/2
L16
T8m/4 T8m/7 T8m/8 T6t/1 T6t/3 T6t/4 T6t/5
0.5 0.5 0.5 2.5 2.5 2.5 2.5

L66
2.5 2.5
ge ge Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 1
1 4 1 3 2permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to thews = white
2 ro = red
3 br = brown
0.5 2.5 2.5 gn = green
br br br bl = blue
gr = grey
162 45
li = purple
ge = yellow
141 142 143 144 145 146 147 148 149 150 151 152 153 154
or = orange
97--42010
rs = pink
Edition 09.2002
Switches and instruments - lighting control, headlight range
control adjuster, headlight range control motor, left, headlight
range control motor, right
E20 Lighting regulator - switches and instruments
V49 Headlight range control motor, right
* Only models with petrol engine without ABS

** Only models with diesel engine without ABS
*** Only models with petrol engine
76 148
148
0.5 0.5
gr/gn ge/bl
58 56b Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
T6e/3 T6e/4 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
E20 E102
T6e/5 T6e/1 T6e/2
58b 31 G
0.5 0.5 0.5

gr/bl br ro/bl
84 82 105
105 T10b/1 106
106
1 0.5 0.5 1
+ G G +
T8d/5 T8d/1 T8e/1 T8e/5
V48 V49
T8d/7 T8e/7
31 31 ws = white
sw = black
122
122 59 58 118
118 107
107 115
115 69
ro = red
*** ** * br = brown
gn = green
2.5 0.5 0.5 0.5 0.5 0.5 2.5 0.5 0.5 bl = blue
br br ge br/bl br/bl br br br br/sw
131 gr = grey
j li = purple
ge = yellow
155 156 157 158 159 160 161 162 163 164 165 166 167 168
or = orange
97--42725
rs = pink
Edition 09.2002
Automatic intermittent wash/wipe relay, intermittent wiper
switch, rear wiper switch, windscreen wiper motor,
windscreen and rear window washer pump
J31 8
53M 75a 53s J T 31
T9/2 T9/8 T9/5 T9/1 T9/6 T9/4
1 1.5 1 0.5 1 1 1
gn sw/gr gn br/sw gn gn br

T10c/10
1
gn 65
V59
2 k
1 l
A36 gn/sw
T10c/9
1.5 1 1.5 1.5 1 1 1 1
sw/gr sw/gr sw/gr sw/gr sw/gr gn/sw gn/sw bl Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
53c
75a 53s J T respect to the correctness of information in this document. Copyright by SEAT S.A.
T5c/2 T5c/3 T5c/5 T4b/2 T4b/1 T5e/5
146
146 181
181 W E34
21 O
T5c/4 E22 T5c/1T
T4b/4 T4b/3 T5e/1
H
53e 53b 75a 31
O
gn/ge J
1 1 1.5 1.5
gn/sw br sw/gr
T10d/3 T10d/10 T10d/9 T10d/2

1 1 1 1 81 173
173
ws = white
4/53 1/75a 3/53e 2/53b sw = black
V ro = red
br = brown
5/31 gn = green
1 bl = blue
br
gr = grey
131
j li = purple
ge = yellow
169 170 171 172 173 174 175 176 177 178 179 180 181 182
or = orange
97--45735
rs = pink
Edition 09.2002
Reversing light switch, horn plate, dual tone horn, rear
window wiper motor
H Horn plate
H1 Horn
A2 T5a 5-pin connector, brown, in tailgate/boot lid
1 4 1.5 1.5 0.5 2.5
sw sw sw sw sw sw T10d 10-pin connector, white, connector point
V12 Rear window wiper motor
26a 29a 27a A104
24 5 A2 Positive (+) connection (15), in dash panel wiring harness
1.5
5A 5A 5A
19a A104 Positive (+) connection -2- (15), in dash panel wiring harness
26b 29b 27b
k
144
144
SB 19 * Only models without central locking
l 15A
* 19b
1 1 1 0.5 1 0.35 1.5

T5b/5 T5b/3 T5b/4 T4j/4 T10d/4 41 T10d/5

1 1 1 0.5 1
sw/ge
1
T5a/5 T5a/3 T5a/4 146
146 1
1
bl
1
gn/sw
1
sw/ge
F4 H1
2
2 3 4 2
1 1.5
V12Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
sw/bl br/sw
1 93
respect to the correctness T10d/1
1 1.5 ws = white
br br/sw
sw = black
T7a/1 ro = red
T5a/1 br = brown
1.5
H gn = green
br bl = blue
gr = grey
136
136 li = purple
ge = yellow
183 184 185 186 187 188 189 190 191 192 193 194 195 196
or = orange
97--42015
rs = pink
Edition 09.2002
Front interior light, door contact switch driver's side, door contact
switch on front passenger's side, cigarette lighter light bulb,
cigarette lighter
F2 Door contact switch, driver's side
F3 Door contact switch, front passenger's side
L28 Cigarette lighter light bulb
39
T5 5-pin connector
0.5 T10f 10-pin connector, black, A-pillar, lower front passenger's side
ro T10g 10-pin connector, black, A-pillar, lower driver's side
A52
U1 Cigarette lighter
T5/1 W Interior light, front
0.5 2.5 1 0.5 1 1.5
ro ro ro ro ro ro 76 Earth point, near selector mechanism
2/30a 46a
7 129
129 37 16
W SB 46
15A
1/31 3/TK 46b

0.5 0.5
br br/ws
136
136 B154 Connection -1- (TK (door contact)), in interior wiring harness
T5/3 T5/2
0.5 0.5 1.5 0.5 ** Only models with central locking
** *
T4d/2 T4d/3
J379 * * *
0.5 0.5 0.35 0.5
T23/21
U1 L28
64 T10f/9 39 T10g/9 47 T4d/1
0.5 0.5 2.5 1.5

br/ge br/ge br br
2 2
F3 F2 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
0.5 0.5 2.5
br br br
ws = white
sw = black
T10f/10 T10g/10 ro = red
0.5 0.5
br = brown
br br gn = green
* * bl = blue
48 63
76
gr = grey
li = purple
ge = yellow
197 198 199 200 201 202 203 204 205 206 207 208 209 210
or = orange
97--43472
rs = pink
Edition 09.2002
Basic equipment
⇒ 1.0 l/37 kW Motronic, engine codes AUC (without air conditioner and/or without ABS)
⇒ 1,4 l/44 kW Motronic, engine codes ANW and AUD (without air conditioner and/or without ABS and without automatic gerbox)
From October 2001
11 10 9 8 7
6 5 4 3 2 1
97-40408

Note:
Edition 02.2003
SB11
SB10
SB12
SB13
SB14
SB15
SB16
SB17
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB18
SB19
SB21
SB23
SB24
SB25
SB26
SB27
SB31
SB20
SB22
SB28
SB29
SB30
SB32
SB33
SB34
SB35
SB36
SB42
SB43
SB44
SB48
SB37
SB38
SB39
SB40
SB41
SB45
SB46
SB47
SB49
SB50
SB51
E97-0055
30 A - green
25 A - white
20 A - yellow
15 A - blue
10 A - red
7.5 A - brown
5 A - beige
3 A - purple Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Edition 02.2003
junction box
31 30
A Battery
7 J59 B Starter
T6h/4 T6h/3 T6h/2 T6h/1 T10 10-pin connector, green, connector point
203
203
6
1 1 6 2.5 ro
br sw/ge sw ro 1 Earth strap, battery - body
150
150 A32 71 2 Earth strap, gearbox - body
4 6 4
ro ro ro 500 Screw connection -1- (30), on relay plate
D 30 502 501
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 501 Screw connection -2- (30), on relay plate
TV2
X 50 15 P S 502 Screw connection -1- (30a), on relay plate
500
2.5 2.5 4 1 0.5
16a
66 77 186
186 113
113
SB 16 B158 Connection (S), in interior wiring harness

T10/1 5A
41
16b
2.5 0.5 0.35 10

ro/sw br/ro br/ro ro B/30
B158
B/50 25
sw
A
ws = white
-- sw = black
ro = red
br = brown
gn = green
25 25 bl = blue
sw sw
gr = grey
1 2
li = purple
ge = yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 or = orange
97--42727
rs = pink
Edition 02.2003
Immobilizer control unit, immobilizer reading coil
D2 Immobilizer reading coil
J 234 J 234
T75/74 J... J... T75/75 A76 Connection (diagnosis wire K), in dash panel wiring harness
J... 0.35 0.35
or/sw or/br A121 Connection (high bus), in dash panel wiring harness
34 32
* T10n/4 T10n/5
206
206 0.5 0.35 0.35 0.5 0.5 0.35 0.35 A122 Connection (low bus), in dash panel wiring harness
A122
T10a/7 A121
1 0.5 0.5 0.5

30 W CAN--H CAN--L
T10x/10 T10x/7 J362 T10x/2 T10x/1
T3/1 T3/2 T3/3 T10x/9 T10x/3 T10x/8

31 15a K
0.5
sw
A38
1 0.5
sw gr/ws
28b
SB 28
7.5A
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability28awith
ws = white
D2 in this1 document. Copyright by SEAT S.A.
respect to the correctness of information sw = black
1
br sw ro = red
br = brown
gn = green
185
185
b
bl = blue
A76
gr = grey
76
li = purple
ge = yellow
15 16 17 18 19 20 21 22 23 24 25 26 27 28 or = orange
97--42706
rs = pink
Edition 02.2003
Control unit with display in dash panel insert, data bus
diagnostic interface, warning lamp for symbol Yellow triangle
J533 Data bus diagnostic interface
K63 Warning lamp for symbol 'Yellow triangle'
J...
T10b/9
0.5 A76 Connection (diagnosis wire K), in dash panel wiring harness
gn/ws
26 20 202
202 9
A27
*
0.35 0.35 0.35 0.35 0.35
CAN--L CAN--H
T32a/20 T32a/19 T32/3 T32/21 T32/30
K63 J533 J285

T32/25 T32a/28 T32a/27 T32/23 T32/1

CAN--L CAN--H 199
199
0.35 0.35 0.35 0.35 0.5 0.35

gr gn sw ro ro sw
11b 10b
T16/14 T16/6
192
192
SB 11 SB 10
5A 7.5A ws = white
T16/7 T16/4 T16/16
11a 10a
sw = black
K 31 30A
ro = red
0.5 0.5 0.5 0.5 0.5 br = brown
gr/ws br ro ro ro
gn = green
b A76
* bl = blue
84 205
205 gr = grey
li = purple
ge = yellow
29 30 31 32 33 34 35 36 37 38 39 40 41 42 or = orange
97--45741
rs = pink
Edition 02.2003
warning lamp, alternator, airbag and turn signal left and right,
digital clock, odometer display
C Alternator
H3 Buzzer/gong
T10a 10-pin connector, red, coupling station
Y2 Digital clock
0.5
108
108
T10a/3
bl ws
T32/12 T32/17
K2 K1
Ypermitted
2
unless authorised by SEAT S.A. J SEAT S.A does not guarantee or accept any liability with H3
285
K94 K65 K75

Y4
T32/2 T32/18 T32/24 T32/9 T32/6
0.35 0.35
gn/sw sw/ws
122
122 115
115 206
206 200
200 131
131 136
136
ws = white
** * sw = black
ro = red
2.5 0.5 0.5 0.5 0.35 0.35 0.35
gn = green
249 bl = blue
gr = grey
li = purple
ge = yellow
43 44 45 46 47 48 49 50 51 52 53 54 55 56
or = orange
97--45742
rs = pink
Edition 02.2003
Dash panel insert, handbrake warning switch and brake fluid
level, side light warning lamp, anti-lock brake system and
brake system
K47 ABS warning lamp
c
K118 Brake system warning lamp
d
e
L75 Digital display illumination
142
142 131
131 83 135
135 T10 10-pin connector, green, coupling station
0.5 1 1 0.5 0.35 0.35 0.35
B145 B160 B102 Earth connection, in front left interior wiring harness
0.35 0.35 0.5 0.5

T32/20by SEAT S.A. SEAT T32/14
permitted unless authorised S.A doesT32/26 T32/27or T32/29
not guarantee accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A. B160 Connection (brake system monitoring), in interior wiring harness
L75 K4 K118 T10c/6 * Only models without central locking
J285
0.5
bl/br
1 1
K47 K19
F9 F34
T32/19 2 2
0.35
ge
204
204 198
198 181
181 1
*
0.5 0.5 1 1 0.5 0.5
ws = white
sw = black
167
167
ro = red
B102
0.5 br = brown
ge
2.5 gn = green
br bl = blue
gr = grey
61
157
157 li = purple
ge = yellow
57 58 59 60 61 62 63 64 65 66 67 68 69 70
or = orange
97--45743
rs = pink
Edition 02.2003
Lighting switch, fog light switch, lighting switch light bulb
E1 Lighting switch
E7 Fog light switch

c
d
e
156
156 f
g
0.35 0.5 0.5

gr/gn gr/gn gr/gn
A3
99 111
111 107
107 106
106 124
124 59 156
156
0.35 0.5 0.35 0.5 1.5 2.5 2.5 1.5 1.5 1 0.5
13/58L 14/58R 16/58 6/B 4/56 7/56b 3/TFL 8/NL 9/NSL 17/58b
E1 E7 L9
15/30 respect to the correctness of1/Xz 2/Xf Copyright by SEAT S.A.
information in this document. 10/31
2.5 2.5 1.5 1

ro sw/ge gr/ws br
3 139
139 180
180 157
157 32
A40
4 1.5 1.5 0.5 0.5 ws = white

ro ro br br br
sw = black
ro = red
81
11 109
109 br = brown
2.5 gn = green
br bl = blue
gr = grey
76
li = purple
ge = yellow
71 72 73 74 75 76 77 78 79 80 81 82 83 84
or = orange
97--42005
rs = pink
Edition 02.2003
Tail light bulb, left and right, turn signal bulb, rear left and right,
brake light, left, right and upper, reversing light bulb, rear fog
light bulb
M8 Turn signal bulb, rear right
f M25 High level brake light bulb
g L20 Rear fog light bulb
F/4
1 0.5
sw/ro gr/gn
D73 2a
1 SB 2
sw/ro 5A
T10d/7 2b B109 Earth connection, in interior wiring harness, rear left
1 0.5
sw/ro gr/gn B131 Connection (54), in interior wiring harness
B131
114
114 99 190
190 112
112 121
121
B132
B132 Connection (number plate light), in interior wiring harness
1 1
sw/ro sw/bl
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with D73 Positive (+) connection (54), in engine compartment wiring harness
T5b/2
respect to the correctness of information in T
10a/2
1.5 0.5 0.5 1 1 1 1 0.5 0.5 0.5 0.5

1/NSL 2/BLL 6/58L 5/54 2 1/54 6/RFL 2/58R 5/BLR 1
X
L20 M6 M4 M9 M25 M10 M17 M2 M8
ws = white
3/31 4/31 1 3/31 4/31 2 2 sw = black
ro = red
1.5 1.5 1 1.5 1.5 0.5 0.5
2.5
gn = green
br 137
137 bl = blue
B109
61 gr = grey
li = purple
85 86 87 88 89 90 91 92 93 94 95 96 97 98 ge = yellow
97--43471 or = orange
rs = pink
Edition 02.2003
77 72
T5d/3 T5d/5
T5d/2 T5d/4
56b
78 56a
2.5 2.5 1.5 1.5
72 113
113 110
110 ge ge ws ws 74 114
114 A9 Positive (+) connection (56b), in dash panel wiring harness
A9
0.5 0.5 1.5 1.5 2.5 102
102 0.5 0.5
4a 13a 44a 45a 12a 5a

SB 4 SB 13 SB 44 SB 45 SB 12 SB 5
5A 10A 15A 15A 10A 5A
0.5 0.5 1.5 1.5 1.5 1.5 0.5 0.5

159 163 ge ws gr/ro gr/ro
Protected by copyright. Copying for private or163
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept A95
any liability with
T10b/6 respectTto10b/4
the correctnessTof
10b/5 T10c/5 Copyright by SEAT S.A. T10b/
information in this document.
87 7
2.5 1 1 2.5 0.35 1.5 94
116
119
119
T10c/4
1 0.5 1.5 1.5 B247 B167 1.5 53
ws gr/ro sw/gn
BLL 58 56a 56b 56b 56a 58 BLR
ws = white
ro = red
31 31 gn = green
2.5 2.5 bl = blue
br br
gr = grey
123
123 165
165 li = purple
ge = yellow
99 100 101 102 103 104 105 106 107 108 109 110 111 112
or = orange
97--45744
rs = pink
Edition 02.2003
h T10b 10-pin connector, blue, coupling station
1 0.5
ge sw/ge
P 49a 12 Earth point, left in engine compartment
T7a/5 T7a/2
T7a/4 T7a/6
PL PR L R A5
harness
0.5 0.5 1 1
gr/ge gr/ro sw/ws sw/gn Positive (+) connection (left turn signal), in dash panel wiring
A6
harness

100
100 112 D57
harness

80
0.5 0.5 0.35 0.5 0.5 0.5 0.5 0.35 1.5

127
127 86 45 T10b/8 T10c/1 128
128 95 43 T10c/8
0.5 0.5 1.5
sw/ws sw/gn ws/ge
D58 D57 D59
0.5 1 0.5 1 1.5 1.5

2 99 2 112
112 1
Protected by copyright. Copying for private or 1
M18 M19 L22 L23
156
156 104
104 ws = white
sw = black
1 1 2 2 ro = red
0.5 0.5 2.5 2.5 1.5 1.5 br = brown
br br br br br br
6 gn = green
br
bl = blue
166
166 164
164
108 gr = grey
12 li = purple
ge = yellow
113 114 115 116 117 118 119 120 121 122 123 124 125 126
or = orange
97--45738
rs = pink
Edition 02.2003
Hazard warning light switch, heated rear window switch,
hazard warning light relay, hazard warning light system
warning lamp, heated rear window switch bulb, heated rear
window
E3 Hazard warning light switch

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Service

Service Department. Technical Information

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Copyright © 2015 Seat S.A S01B0018620

38 - Gears, Hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2 Free sprocket: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

39 - Final drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

2 Notes on “Automatic gearbox 001”

2 Rep. Gr. 00 - Technical data

3 Code letters, group numbers, ratios, equipment

Gear change Codes CMJ DPP

Automatic gearbox 001

3. Code letters, group numbers, ratios, equipment 3

Automatic gearbox 001

Gear change Codes EAS EHD

Gear change Codes FMA

4 Rep. Gr. 00 - Technical data

Gear change Codes FMA

3. Code letters, group numbers, ratios, equipment 5

6 Rep. Gr. 00 - Technical data

5 General instructions for gearbox re‐

5. General instructions for gearbox repairs 7

8 Rep. Gr. 00 - Technical data

The legs of bridge /1 have different-sized cut-outs -arrows- to fa‐

– Adjust the threaded legs of the bridge /1 so that the bridge is

♦ Clutches K1, K2 and K3 should be dismantled for cleaning;

5. General instructions for gearbox repairs 9

10 Rep. Gr. 00 - Technical data

1.1 Identifying the torque converter

Torque converter code

1.2 Torque converter: empty

If dirt and abrasive particles are present in the ATF or if a general

1.3 Torque converter seal: removing and in‐

– Using extractor -T20143- , disengage the torque converter

12 Rep. Gr. 32 - Torque converter

– Using plunger -U-40002- , assemble the torque converter

1.4 Torque converter: removing and instal‐

The ATF pump is activated via the torque converter -arrows- .

The converter has been correctly fitted when the measurement

14 Rep. Gr. 32 - Torque converter

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

♦ During the test drive, testing and measuring instruments

1. Connect fault reader V.A.G 5051 and select the functions 15

Connecting -VAS 5051-

The display zones in the functions “04 - Basic setting” or “08 -

– Continue with the self-diagnosis of the vehicle system which

16 Rep. Gr. 37 - Controls, Housing

2 Electrical/electronic components and

2.1 Vehicle components

1 - Automatic gearbox control

2. Electrical/electronic components and their location 17

❑ Dismantling and fitting ⇒ page 20

Removal and assembly of the automatic gearbox control unit -

– Partially remove windscreen wiper

– Release the multiple connector and disengage from the con‐

18 Rep. Gr. 37 - Controls, Housing

– Carry out basic adjustment: ⇒ VAS 5051; Vehicle self-diag‐

Diagnosis connection in vehicles up to 06.00

Diagnosis connection in vehicles from 07.00 onwards

2. Electrical/electronic components and their location 19

Kick-down switch -F8-

2.1.3 Removal and installation of the kick-

2.2 Gearbox electrical/electronic components

20 Rep. Gr. 37 - Controls, Housing