SEAT Workshop Service and Repair Manuals

Removal –  With the ignition switched off disconnect battery earth strap.   Note! For vehicles fitted with a coded radio, first check the anti-theft code. –  Disassembling the engine casing.

–  Remove the intake hose -1- that goes from the air filter to the exhaust gas turbocompressor, the air mass meter connector -2- and the breather hose -3-. –  Remove the air filter casing, removing screws -4- and -5-. –  Remove the connecting pipes that go between the intercooler and the intake manifold pressure hose: → 4 cyl. diesel engine, mechanical; Rep. Gr.21.

–  Unhook hose -A- of the cable counterhold. –  Remove the gearbox counterhold -arrows-.

–  Remove the selection cable -A- with the return lever. To do so the safety washer must be removed -arrow-. –  Remove the connection cable -B- with the selection rod. To do so unscrew bolt -arrow-. –  Hold the connection cable up with the selection rod and the selection cable with the return lever.

–  Remove the clutch coil, place it on one side and secure it with a wire.   Note! t  Do not depress the clutch pedal. t  Do not open the brake pressure system.

–  Disconnect connector -arrow 1- for starter. –  Separate the reversing light connector -arrow 2-. –  Remove cable support -A- from the starter motor. –  Remove the upper bolt from the starter motor.

–  Remove the speedometer sender connector -arrow-. –  Remove the earth cable from the upper connection bolt engine/gearbox. –  Remove the upper bolts that secure the engine to the gearbox. –  Remove any hoses and cables that might be in the area of the engine where the lifting eyes for support of the drive train unit go.

–  Fit the support cross member -U-30025B- and tool -U-40068- over the engine bay. –  Attach the support cross member retainers -U-30025B- to the engine. –  Attach tool -U-40068- over the gearbox. –  Pretension the drive train group with the spindles of tools -U-30025B- and -U-40068-. –  Remove the insulation tray: → General body repairs-assembly work; Rep. Gr.50. –  Remove the intercooler and the input and output pipes: → 4 cyl. diesel engine, mechanical; Rep. Gr.21.

–  Removing the counterweight -A-from the sub-frame. Mark fitting position. –  Remove protective cover for right-hand inner constant velocity joint. –  Turn the wheels left. –  Disattach the right hand drive shafts from the articulation flange with the 8 mm spanner on tool -U-40020- and tighten it as much as possible. –  Remove left-hand driveshaft: → Running gear, axles, steering; Rep. Gr.40.

–  Remove the flywheel small protective cover -A-, located behind the right-hand articulation flange -arrows- (if fitted). –  Remove lower flywheel protector plate (if fitted). –  Remove support for power steering that secures it to the gearbox.   Note! t  To keep the connections out of the way tie them to the bodywork or some other element with a piece of string or wire. t  The connections must be pulled aside without twisting or stretching them, so that they are out of the way when removing and fitting the gearbox. –  Removing the starter motor: → Electrical system; Rep. Gr.27.

–  Remove the centre front console of the drive train group -arrows-.

–  Remove the rear gearbox console -arrows-.

–  Remove the central bolt -arrow- from the rear right console, from the engine. –  Tilt the engine slightly by turning the -U-30025B- support tool left-hand spindle.

–  Move the drive train group forwards with tool -T20111-. –  Remove the lower bolts from the engine/gearbox joint. –  Remove gearbox from centralising bushes and lower it using spindle of tool -U-40068-. –  Reserve the part of the differential from the sub-frame and lower it to the ground.   Note! On lowering the gearbox be careful with the PAS pipe.