2010 SEAT LEON MK2 Service and Repair Manual
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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.
Workshop Manual
Altea 2004 ➤ , Altea 2009 ➤ ,
Altea XL 2007 ➤ , Altea XL 2009 ➤ ,
Altea XL Freetrack 2008 ➤ ,
Altea XL Freetrack 2009 ➤ ,
León 2006 ➤ , León 2009 ➤ ,
Toledo 2005 ➤ , Toledo 2009 ➤
4-cylinder petrol engine (2.0 l, direct injection, 4V,
turbo, mechanics)
Engine ID
BWA BWJ
CDL
D
CDL
A
Edition 07.2016
Service
Service Department. Technical Information
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.
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information 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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2016 Seat S.A D4B802A2C04
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.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Removing and positioning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Engine: dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Attaching engine to repair stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Engine: fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.1 Poly V-belt, bracket for ancillary mechanical units: component overview . . . . . . . . . . . . . . 25
1.2 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.5 Sealing flanges: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.6 Crankshaft oil seal- pulley side: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.7 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 Sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Rear sealing flange and dual-mass flywheel - exploded view . . . . . . . . . . . . . . . . . . . . . . 42
2.2 Crankshaft sealing flange, flywheel side: removing and fitting . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4 Drive plate: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1 Crankshaft: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2 Sender wheel: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.3 Needle bearing: extracting and inserting into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.5 Measure axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.6 Measure radial play for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.7 Oil pump chain sprocket: removing and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1 Piston and conrod: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2 Fitted position in the half bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3 Pistons, piston rings and cylinder bore: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.2 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Cylinder head: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3 Valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
4-cylinder petrol engine (2.0 l, direct injection, 4V, turbo, mechanics) - Edition 07.2016
Contents i
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.
3.1 Valve gear: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.3 Valve guides: verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.4 Replacing valve shaft seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.5 Exhaust camshaft oil seal: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.6 Variator: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.7 Valve 1 for variable distribution N205 : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . 98
3.8 Camshaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1 Cooling system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.2 Lubrication system components: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3 Oil filter housing:draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.4 Removing and replacing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.5 Oil pump with rotational balancing unit: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . 116
1.6 Oil radiator: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.7 Oil filter bracket: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.8 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.9 Check the oil pressure and oil pressure switch (oil pressure switch with 1 contact) . . . . . . 124
1.10 Check the oil pressure and oil pressure switch (oil pressure switch with 2 contacts) . . . . 126
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Engine cooling system components: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Coolant pump V50 : assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.3 Cooling system components, bodywork side: assembly overview . . . . . . . . . . . . . . . . . . . . 132
1.4 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.7 Coolant pipes: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.8 Coolant distribution box with thermostat: removing and fitting . . . . . . . . . . . . . . . . . . . . . . 141
1.9 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 141
1.10 Radiator: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.11 Check the cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2 Fuel pressure reduction in the high-pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.2 Fuel tank: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.3 Fuel tank: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.4 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3 Repairs to the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.5 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4 Electronic regulation of engine output, electronic accelerator . . . . . . . . . . . . . . . . . . . . . . 176
4.1 Operation of electronic throttle system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.2 Accelerator pedal module: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.3 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
4-cylinder petrol engine (2.0 l, direct injection, 4V, turbo, mechanics) - Edition 07.2016
ii Contents
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.
5 Active carbon filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.1 functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.2 Active carbon filter system: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1 Exhaust gas turbocharger (engine code BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.1 Assembly of hose connections with couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.3 Exhaust turbocharger: assembly overview (engine codes BWA) . . . . . . . . . . . . . . . . . . . . 186
1.4 Remove and install the exhaust gas turbocharger (engine code BWA) . . . . . . . . . . . . . . . . 189
1.5 Check the pressure capsule for the exhaust gas turbocharger (engine code BWA) . . . . . . 196
1.6 Remove and install the pressure capsule for the exhaust gas turbocharger (engine code
BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.7 Adjust the pressure capsule for the exhaust gas turbocharger (engine code BWA) . . . . . . 199
1.8 Charged air system (engine code BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.9 Charge air cooling: assembly overview (engine codes BWA) . . . . . . . . . . . . . . . . . . . . . . 203
1.10 General diagram of the exhaust gas turbocharger supercharger air system (engine code
BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.11 Remove and install the supercharger air system (engine code BWA) . . . . . . . . . . . . . . . . 205
1.12 Check the supercharger air system for leaks (engine code BWA) . . . . . . . . . . . . . . . . . . . . 206
2 Exhaust gas turbocharger (engine codes BWJ, CDLD, CDLA) . . . . . . . . . . . . . . . . . . . . . . 209
2.1 Assembly of hose connections with couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.3 Exhaust turbocharger: assembly overview (engine codes BWJ, CDLA, CDLD) . . . . . . . . 210
2.4 Removing and installing the exhaust gas turbocharger (engine codes BWJ, CDLA, CDLD)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.5 Charge air system (engine codes BWJ, CDLA, CDLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.6 Charge air cooling: assembly overview (engine codes BWJ, CDLA, CDLD) . . . . . . . . . . . . 223
2.7 Structure-borne sound of the engine (Soundaktor) (engine codes BWJ, CDLA, CDLD) . . 224
2.8 General diagram of the exhaust gas turbocharger supercharger air system (engine codes
BWJ, CDLA, CDLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.9 Removing and installing the charge air cooler (engine codes BWJ, CDLA, CDLD) . . . . . . 226
2.10 Supercharger air system tightness (engine codes BWJ, CDLA, CDLD) . . . . . . . . . . . . . . 227
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.5 Fitting location overview, vehicles with engine identification letters BWA . . . . . . . . . . . . . . 234
1.6 Fitting location overview, vehicles with engine identification codes BWJ, CDLD, CDLA . . 238
1.7 Engine cover / air filter: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.8 Removing and installing engine cover / air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.9 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.10 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.11 Intake manifold: installation survey (engine codes BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.12 Intake manifold: assembly overview, vehicles with engine codes BWJ, CDLD, CDLA . . . . 255
1.13 Intake manifold: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.14 Fuel distributor: assembly overview (Version I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.15 Fuel distributor: assembly overview (Version II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
1.16 Fuel rail: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.17 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
1.18 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
1.19 Removing and installing intake manifold flap motor V157 with intake manifold flap
potentiometer G336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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Contents iii
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.
1.20 High-pressure pump: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1.21 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.22 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.23 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1.24 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1.25 Teflon seal in the injector: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.26 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.1 Checking dual non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3.2 Engine control unit with antitheft protection: removing and fitting . . . . . . . . . . . . . . . . . . . . 285
3.3 Reading out and erasing the engine control unit event memory . . . . . . . . . . . . . . . . . . . . 288
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1 Parts of exhaust system: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.1 Exhaust system: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
1.3 Catalytic converter with main exhaust pipe: removing and installing . . . . . . . . . . . . . . . . . . 293
1.4 Exhaust system: install without stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
1.5 Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
1.6 Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1
heater after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.1 General information about the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.3 Ignition system: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.4 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.5 Spark plug test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2 Conversion table by relevance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
2.1 Graphic information on SEAT equivalent tools and equipment . . . . . . . . . . . . . . . . . . . . . . 306
2.2 Graphical information of equivalent tools and equipment at SEAT . . . . . . . . . . . . . . . . . . 319
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iv Contents
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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.
00 – Technical data
1 Technical data
(ERL003144; Edition 07.2016)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine data”, page 1
⇒ “1.3 Safety precautions”, page 2
⇒ “1.4 General repair instructions”, page 3
1.1 Engine number
The engine number (“Engine code” and “Serial number”) can be
found on the left side of the join between engine and gearbox.
The engine code is also stamped on the cylinder head.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (3 identification letters max.) makes up the
“engine code”; and the second part (6 characters) the “serial
number”. If more than 999,999 engines with the same engine
identification letters are produced, the first of the six characters is
replaced with a letter.
In addition, a label with the “engine code” and the“serial number”
has been attached to the toothed belt protector.
As well, the engine code appears in the vehicle documents.
Vehicles with four-digit engine codes
Four-digit engine codes are now being used, starting with the let‐
ter "C". The first 3 positions describe the mechanical structure of
the engine and are, as they have been done to date, engraved on
the engine. The fourth position digit describes the engine power
and torque and depends on the engine control unit. The four-digit
engine codes are given on the model plate, the vehicle data plate
and the engine control unit.
1.2 Engine data
Engine code BWA1 BWA BWA BWJ BWJ CDLD CDLA
Exhaust emission
limits as per
EU4
Standard
EU4
Standard,
EU4/Mex
EU2
Standard
USA TIER
1, EU4/
Mex
Standard
EU4
Standard
EU5
Standard
EU5
Standard
Capacity
cm
3
1984 1984 1984 1984 1984 1984 1984
Output kW at
1/min
136/5100-
6000
147/5700 147/5700 177/6000 177/6000 177/6300 195/6000
Torque Nm/
min
270/1800-
4500
280/2000 280/2000 300/2200–
5500
300/2200–
5500
300/2200–
5500
350/2500–
5000
Bore: ∅ in
mm
82,5 82,5 82,5 82,5 82,5 82,5 82,5
Stroke mm 92,8 92,8 92,8 92,8 92,8 92,8 92,8
Compression: 10,5 - 0,3 10,3 10,3 9,8 9,8 9,8 9,8
Valves per cylin‐
der
4 4 4 4 4 4 4
RON 98 lead-
free
1)
98 lead-
free
1)
95 lead-
free
2)
98 lead-
free
1)
98 lead-
free
1)
98 lead-
free
1)
98 lead-
free
1)
Injection, ignition Motronic
MED 9.1
Motronic
MED 9.1
Motronic
MED 9.1
Motronic
MED 9.1
Motronic
MED 9.1
Motronic
MED 9.1
Motronic
MED 9.1
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1. Technical data 1
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Engine code BWA1 BWA BWA BWJ BWJ CDLD CDLA
Mixing system homoge‐
neous
homoge‐
neous
homoge‐
neous
homoge‐
neous
homoge‐
neous
homoge‐
neous
homoge‐
neous
Knock control Yes Yes Yes Yes Yes Yes Yes
Lambda control 2 Probes 2 Probes 2 Probes 2 Probes 2 Probes 2 Probes 2 Probes
3-way catalytic
converter
Yes Yes Yes Yes Yes Yes Yes
Variable valve tim‐
ing
Yes Yes Yes Yes Yes Yes Yes
Electronic power
control
Yes Yes Yes Yes Yes Yes Yes
1)
95 octane petrol may also be used, but will result in a slight loss
of power
2)
91 octane petrol may also be used, but will result in a slight loss
of power
1.3 Safety precautions
When working on the fuel systems take note of the following:
WARNING
♦ Fuel system is under pressure! Before opening the system
place a cloth around the connection. Then release pres‐
sure by carefully loosening the connection.
♦ Wear protection gloves.
♦ Wear eye protection.
Observe the following to avoid injuries to persons and/or damage
to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Certain tests may lead to a fault being detected by the engine
control unit and stored in the memory. Therefore, after com‐
pleting all checks and repairs, read-out the event memory and
erase if necessary. After deleting the event memory, generate
the readiness code in the engine control unit in the “guided
functions” mode ⇒ Vehicle diagnostic tester.
♦ Always switch off the ignition before cleaning the engine.
Caution
♦ Follow steps required when disconnecting battery ⇒ Rep.
gr. 27 .
♦ Only disconnect and connect the battery with the ignition
switched off, otherwise the engine control unit may be
damaged.
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2 Rep. gr.00 - Technical data
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.
When working on the coolant system take note of the following:
WARNING
Hot coolant and vapours can cause burns!
♦ When the engine is hot the cooling system is under pres‐
sure.
♦ To reduce the system charge pressure, cover the expan‐
sion tank plug with a rag and open carefully.
When working on the exhaust system, take note of the following:
Caution
Risk of damage to the engine.
♦ Do not bend flexible connection more than 10°.
♦ Do not load the release element by pulling on it.
♦ Do not damage the cable of the release element.
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
♦ Always attach the testers and measuring instruments to
the rear seat and have them operated from there by a
second person.
♦ If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci‐
dent, there is a possibility that the person sitting in this seat
may receive serious injuries when the airbag is triggered.
1.4 General repair instructions
♦ Cleaning rules for working on the turbocharger, injection and
fuel supply systems ⇒ page 3 .
♦ Placement and fitting of the tubing ⇒ page 4 .
♦ Check fuel system for leaks ⇒ page 4 .
♦ Contact corrosion ⇒ page 4 .
♦ Vacuum system: checking ⇒ page 4 .
♦ Installation of the radiator, condensers and charge air coolers
⇒ page 5 .
1.4.1 Cleaning rules for working on the turbo‐
charger, injection and fuel supply sys‐
tems
A little dirt may also cause faults. For this reason, when working
on the fuel system and the fuel injection system or the turbo‐
charger, meticulously respect the following cleaning rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
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1. Technical data 3
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.
♦ Seal off open lines and connections immediately with suitable
protective caps.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Only fit clean parts: Only remove replacement parts from
packaging immediately before assembly. Do not use parts that
have been stored loose (e.g. in tool boxes etc.).
♦ When the system is open, do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect the unplugged connectors against dirt and humidity.
They should be dry before plugging them.
1.4.2 Fitting and securing of the conductions
To avoid the risk of errors and guarantee the original mounting
location, mark the electrical, charge pressure or hydraulic con‐
duits before dismounting them. If necessary, draw diagrams or
take photos.
1.4.3 Checking fuel system for leaks
– Allow engine to run for a few minutes at medium speed.
– Switch ignition OFF.
– Check the entire fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, renew the relevant component.
– Road-test vehicle and accelerate with full throttle at least once.
– Then check the high pressure area again for leakage.
1.4.4 Contact corrosion
Contact corrosion can occur if unsuitable connecting elements
(bolts, nuts, washers...) are used.
For this reason, joint elements are mounted only with surfaces
treated with a special cover.
Also, the rubber or plastic parts and the glues are composed of
nonconductive materials.
Always fit new components if you are not sure that the old com‐
ponents are suitable ⇒ Electronic parts catalogue .
Take into account:
♦ It is recommended to only use genuine spare parts; they have
already been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion are excluded from the
guarantee.
1.4.5 Vacuum system: checking
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 303
Special tools and workshop equipment required
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4 Rep. gr.00 - Technical data
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The 2010 SEAT LEON MK2 Service and Repair Manual is the ultimate guide for anyone looking to service or repair their SEAT LEON MK2. This comprehensive manual covers all aspects of maintenance, troubleshooting, and repair for this specific model.
- SEAT LEON MK2 2010 Base Model
- SEAT LEON MK2 2010 S Model
- SEAT LEON MK2 2010 SE Model
- SEAT LEON MK2 2010 FR Model
- SEAT LEON MK2 2010 Cupra R Model
Whether you are a professional mechanic or a DIY enthusiast, this manual provides detailed step-by-step instructions, diagrams, and illustrations to help you accurately diagnose and fix any issues with your SEAT LEON MK2. From routine maintenance tasks like oil changes and fluid checks to more complex repairs, this manual has got you covered.
With this service and repair manual, you can save time and money by avoiding costly trips to the mechanic. It empowers you to take control of your SEAT LEON MK2's maintenance and repair needs. Stay ahead of potential problems and keep your vehicle running smoothly with the help of this comprehensive manual.
