SEAT Workshop Service and Repair Manuals

Installation Installation is carried out in the reverse sequence; note the following:   Note t  Always replace self-locking nuts and bolts during assembly. t  Replace bolts that are submitted to goniometric tightening, along with seals and gaskets. t  Secure hose unions with hose clamps the same as those of the series → Current Spare parts catalogue. t  All cable clamps that become loose or cut when removing must be re-installed in the same place when installing. t  Clean the cogs of the input shaft and, if the clutch plates are worn, also the hub cogs; eliminate corrosion and apply a very fine layer of lubricating grease to the cogs → Spare parts catalogue. Then move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. It is essential to remove excess grease. –  Check whether there are adjusting sleeves in the engine for centring the engine/gearbox assembly and fit if necessary. –  Ensure that intermediate plate is connected to the sealing flange and housed in the dowel sleeves. –  Check that clutch plate is centred. –  Check clutch release collar for wear and replace if necessary. –  Lubricate the contact points between the clutch release lever and the spherical pivot with grease → Spare parts catalogue. –  Then raise gearbox.   Note When lifting the gearbox, care should be taken not to damage any cables and pipes. –  Swing gearbox forwards on adjustment spindle.

–  During this operation, pass the gearbox carefully next to the flywheel -arrow 2- and the support bridge for the mechanics -arrow 1-.

–  Turn gearbox upwards in vicinity of 6th gear cover as shown -arrow 1-. –  Next, turn the gearbox downwards in the region of the differential thus placing it in the assembly position. –  Make sure that the bolts joining the engine to the gearbox -arrows 2- are in contact with the exhaust system. l  Line up the gearbox so that it is parallel to the engine. –  Fit the gearbox, threading on the bolts -arrows 2- and tightening them to the corresponding torque → Chapter.

–  Thread on the bolt joining the engine to the gearbox-arrow- and tighten to the corresponding torque → Chapter..

–  Fit the bolt securing the engine to the gearbox -A- and tighten to the corresponding torque → Chapter. –  After bolting the gearbox to the engine, separate assembly gearbox support -T20138C -, base -T20145- and hydraulic jack - SAT 1040- from the gearbox.

–  Mount the clutch slave cylinder -1- and tighten the bolts to a torque of 20 Nm. –  Fit the pipe and hose assembly -A- on the gearbox support -B-. –  Fasten the left fastening -2- of the engine mount using new hexagonal bolts -arrows- and tighten to the corresponding torque → Chapter. –  Check that adjustment of subframe has been done without tensioning and re-adjust if necessary → Mechanical components and injection; Rep. gr.10 . –  Remove the support - U-30025E -.   Note Before removing the support - U-30025E- the bolts of the mechanical assemblies mounting must have been tightened to corresponding torque. –  Fit the upper bolts securing the engine to the gearbox and tighten to the corresponding torque → Chapter.

–  Fit the pendulum arm support . To do so the screws -arrows A, B- and -C- must be screwed in the prescribed tightening moment must be achieved → running gear, shaft, steering; Rep. gr.40 . –  Bolt pliers to flanged shafts → Running gear, shafts, steering; Rep. gr.40 . –  Install exhaust system and align without tensioning → Mechanical components and injection; Rep. gr. 26 . –  Install starter motor → Electrical system; Rep. gr.27

–  Fix battery earth strap -3- to connecting bolt of upper part of engine/gearbox assembly. –  Attach connector -arrow 4- for reversing lights.

–  Depending on the version, connect the connector -1- of the oil level and oil temperature sender -G266 -. For vehicles with start stop system

–  Connect the connector -arrow- of the gearbox neutral position sender -G701 -. Continuation for all vehicles

–  Mount the counter supports for the control cables on the gearbox and tighten the bolts -arrows- to a torque of 25 Nm.

–  Install gearbox selector lever -A- → Fig.. –  Tighten hexagonal nut -arrow 4- to a torque of 25 Nm. –  Apply a little grease on the gear selection lever pivot -A- and on the idler rod pivot -B-. –  Mount the idler rod together with the cable fastener → Chapter –  Fasten the gear selection lever connection cable with a new safety washer -arrow 1- .   Note Disregard: Item -2 & 3- –  Adjust selector mechanism → Chapter. –  Check gear oil → Chapter. –  Install left wheel housing moulding → Bodywork, exterior work; Rep. gr.66 –  Fit the front left hand side wheel. –  Install battery → Electrical system; Rep. gr.27 .