SEAT Workshop Service and Repair Manuals

Installing   Note! Refer to procedure “Removing gearbox” for required special tools → Chapter. –  All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid using a thread chaser. –  Always renew self-locking bolts and nuts. –  Clean input shaft splines and lightly coat with grease -G 000 100-. The clutch plate must be able to slide easily to and fro on the input shaft. –  Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gear, clutch problems and possible rattling of gears which are not engaged could occur. –  Ensure that intermediate plate is correctly seated on engine.

Gearbox with threaded hole in gearbox housing -arrow- To install gearbox “02N”, set up gearbox support -3282- with adjustment plate -3282/33-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A - and -C- (pin -3282/34-) on adjustment plate as shown. –  Align adjustment plate and gearbox parallel to one another. –  Then screw pin -3282/34- into hole on gearbox for securing bolt of pendulum support (⇒, figure N34-1410 → Anchor).

–  Secure adapter-VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. –  Secure gearbox to gearbox support -3282- using bolt -A-. Gearbox without threaded hole in gearbox housing -arrow- → Fig. To install gearbox “02N”, set up gearbox support -3282- with adjustment plate -3282/58-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A- and -C- (pin -3282/34-) on adjustment plate as shown. –  Align adjustment plate and gearbox parallel to one another. –  Screw pin -3282/34- into hole in gearbox for securing bolt of pendulum support ( → Anchor, figure N34-1334).

–  Secure the two safety supports -3282/59- as shown in figure.

–  Take special care in attaching the safety support -3282/59- on left of gearbox -arrow-.

–  Position gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. Continuation for all –  Tilt gearbox to left via spindles of gearbox support -3282- and turn upwards in vicinity of bevel box.

–  Then carefully raise gearbox further, observing the following: I -  Guide bevel box -1- past sump -2- as illustrated -arrow A-.  -  II - At the same time, guide gearbox past subframe -arrows B-.

–  Carefully loosen tensioning strap -T10038-. –  Remove tensioning strap -T10038- from front towing eye and bolt -1-. –  Remove bolt -1-. –  Align gearbox to engine and join. –  Screw in new front engine/gearbox connecting bolt -M12- and tighten to specified torque. → Chapter –  After gearbox has been bolted to engine, remove engine and gearbox jack -V.A.G 1383 A- from gearbox. –  Insert new lower engine/gearbox securing bolts and tighten to specified torque → Chapter.

–  Raise engine about 50 mm using left spindle -1- of support bracket -10 - 222 A-. –  Lower adapter -10 - 222 A /16- until engine contacts engine mounting.   Note! t  Use step ladder -VAS 5085-. t  If left bracket has been removed from left subframe, it must now be reinstalled.

–  Position engine and gearbox jack -V.A.G 1383/A- with universal support -V.A.G 1359/2 - under gearbox and exert slight counter pressure. A -  Wooden block –  Align engine and gearbox in installation position.

–  Install left bracket -1- on gearbox using new hexagon bolt -arrows A- and -arrows B- and tighten to specified torque → Chapter. Hexagon bolt -arrow B- is not visible in figure.

–  Screw new hexagon bolts -arrows A- for left assembly mounting -2- into bracket -1- and tighten to specified torque → Chapter. –  Screw new hexagon nut -arrow B- onto stud of bracket and tighten to specified torque → Chapter.   Caution Do not remove support bracket -10 - 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque.

–  Install nuts for right engine mounting -arrows- and tighten to specified torque → Repair group 10; Removing and installing engine; Assembly mounting. –  Insert new upper engine/gearbox securing bolts and tighten to specified torque → Chapter. –  Install front exhaust pipe. → Rep. Gr.26

–  Bolt propshaft to bevel box flange -arrows- and tighten bolts to specified torque → Item, → Item.

–  Install pendulum support using new hexagon bolts -1- and tighten to specified torque → Running gear, axles, steering - front and four-wheel drive; Repair group 40; Repairing front suspension –  Insert hexagon bolt -3- and nut -2- and tighten to specified torque → Running gear, axles, steering - front and four-wheel drive; Repair group 40; Repairing front suspension

–  Join threaded connection between left wheel bearing housing and lower suspension link -arrow-. → Running gear, axles, steering front and four-wheel drive; Rep. Gr.40.

–  Attach left coupling rod to anti-roll bar -arrow-. → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40.

–  Install new bolt above bevel box -arrow- and tighten to specified torque → Chapter.

–  Bolt bevel box carrier to engine and bevel box with new bolts -A- and -B- → Anchor. –  Attach drive shafts to gearbox → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40. –  Install cowl with fans → 6-cylinder injection engine, mechanics; Rep. Gr.19.

–  Screw in new engine/gearbox connecting bolt -arrow A- and tighten to specified torque → Chapter. –  Bolt bracket -3- for secondary air pump to engine -arrows- → Rep. Gr.26. –  Then attach motor for secondary air pump -V101--2- and push on connector -1- → Rep. Gr.26.

–  Then insert starter -3- and tighten lower bolt → Electrical system; Rep. Gr.27. –  Push on reversing light connector -2-. –  Attach bracket -1- to starter -arrow A- and to retaining clip for secondary air pump air filter -arrow B- → Rep. Gr.26.

–  If fitted, attach connector to speedometer sender -arrow-. –  Secure heat shield -2- with nut -1-.

–  Push pipe/hose line in direction of arrow and press down clamp -arrow-.

–  Press pipe/hose line -A- into retainer on gearbox bracket. –  Remove hose clamp -3094-. –  Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque → Item, → Item. –  Then install upper securing bolt on starter. → Electrical system; Rep. Gr.27

–  Assemble gear selector lever -B--arrow 2-. –  Tighten hexagon nut -arrow 2- to specified torque → Item. –  Insert relay lever -A- and secure with securing clip -arrow 1-. –  Connect gear selector cable and gate selector cable to respective cable end-pieces. –  Adjust selector mechanism → Chapter. –  Install air filter → Rep. Gr.24. –  Install wheel → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.44. –  Install battery and battery holder → Electrical system; Rep. Gr.27.

–  Install battery trim -2-. –  Install air duct trim -1--arrows-. –  Bolt on coolant expansion tank. –  Push connector onto coolant expansion tank. –  Connect earth strap to battery.   Note! Note radio code for vehicles with coded radio. –  Bleed clutch system → Chapter. –  Check oil in gearbox with bevel box → Chapter. –  Install engine cover. –  Install noise insulation tray.