SEAT Workshop Service and Repair Manuals

Removing gearbox –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  With ignition switched off, disconnect battery earth strap. –  Remove cover from engine.

–  Remove air duct trim -1--arrows-. –  Remove battery trim -2-. –  Pull connector off coolant expansion tank. –  Unbolt coolant expansion tank and place to side. Do not open cooling system. –  Remove battery and battery tray. → Electrical system; Rep. Gr.27. –  Remove air cleaner housing and intake hose. → Rep. Gr.24

–  Pull locking mechanisms on gate selector cable and gear selector cable forward to stop -direction of arrow 1- and then turn to left to lock -direction of arrow 2-.

–  Pull securing clip -arrow 1- off relay lever -A- and remove relay lever. –  Remove gearbox selector lever -B- by removing nut -arrow 2-. If necessary, use puller e.g. -Kukko 20-10-.

–  Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094-. –  Pull pipe/hose line out of retainer on gearbox bracket. –  Remove cable support bracket from gearbox -arrows-. –  Then tie up selector cable and gate cable.

–  Remove nut -1- for heat shield -2-. –  Pull connector off speedometer sender -arrow-.

–  Lever out clip -arrow- for pipe/hose line to stop with a screwdriver. –  Pull out pipe/hose line in -direction of arrow-.   Note! Do not depress clutch pedal. –  Remove upper engine/gearbox connecting bolts. –  Then remove upper securing bolt on starter. –  If there are hose and cable connections in area of engine support eye for support bracket -10 - 222 A-, remove these now. –  Pull connecting hose for crankcase breather off cylinder head near right engine lifting eye.

–  Assemble support bracket -10 - 222 A- in conjunction with adapters -10 - 222 A /14- and -10 - 222 A /15-. –  Secure adapter -10 - 222 A /14- in threaded holes for battery carrier -arrows-.

–  Hook adapter -10 - 222 A /16- in right engine lifting eye -arrow-.

–  Remove nuts for right engine mounting -arrows-. –  Take up weight of engine/gearbox assembly on spindles. –  Remove front left wheel bolts. –  Raise vehicle. –  Remove left wheel. –  Remove noise insulation tray.

–  Remove bracket -1- from starter -arrow A- and from retaining clip for secondary air pump air filter -arrow B-. –  Pull off reversing light connector -2-. –  Remove starter -3- → Electrical system; Rep. Gr.27.

–  Pull connector -1- off motor for secondary air pump -V101--2-. –  Remove motor for secondary air pump -V101- from bracket -3-. –  Unbolt bracket for secondary air pump from engine -arrows- → Rep. Gr.26. –  Remove engine/gearbox connecting bolt -arrow A-. –  Then remove cowl with fans → 6-cylinder injection engine, mechanics; Rep. Gr.19. –  Disconnect drive shafts from gearbox flange shafts. –  Raise right drive shaft and secure.

–  Separate -arrow- left coupling rod from anti-roll bar.

–  Separate threaded connection between left wheel bearing housing and lower swivel joint -arrow-. –  Swing wheel bearing housing outwards. –  Remove left drive shaft between subframe and gearbox. –  Lift drive shaft and secure to suspension strut with wire.

–  Unbolt bevel box carrier from engine and bevel box (bolts -A- and -B-). –  Separate exhaust system behind front exhaust pipe and remove front exhaust pipe → Rep. Gr.26.

–  Remove bolt above bevel box -arrow-. –  Remove lower rear engine/gearbox connecting bolt. –  Mark position of propshaft relative to bevel box flange.

–  Unbolt propshaft from bevel box flange -arrows-.

–  Remove pendulum support, removing bolts -1-, nut -2- and bolt -3-.

–  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

–  Unbolt hexagon bolts -arrows A- of left engine/gearbox mounting -2- from left bracket -1-. –  Loosen hexagon nut -arrow B-.   Note! Use step ladder -VAS 5085- to remove securing bolts. The left bracket does not need to be removed from left subframe in order to remove gearbox. –  Remove left bracket -1- from gearbox -arrows A- and -arrow B-.

Bolt -arrow B- is not visible in figure. –  Remove engine and gearbox jack -V.A.G 1383/A- with universal support -V.A.G 1359/2 - from beneath gearbox. –  Carefully press engine and gearbox forwards. –  Carefully tilt engine with gearbox until left bracket can be moved freely. –  Remove lower engine/gearbox connecting bolts except for one bolt near the front.

Gearbox with threaded hole in clutch housing -arrow- To remove 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.

–  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox. –  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Secure gearbox to gearbox support -3282- using bolt -A-. –  Then screw pin -3282/34- into hole on gearbox for securing bolt of pendulum support. Gearbox without threaded hole in clutch housing -arrow- → Fig. To remove 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.

–  Position gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox.

–  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-. Continuation for all –  Remove last engine/gearbox connecting bolt. –  Push gearbox off dowel sleeves and carefully swing to subframe while at the same time guiding gearbox input shaft completely out of clutch pressure plate.

–  Take load off engine support by raising engine slightly using adapter -10 - 222 A /16-. –  Carefully tilt engine and gearbox. To do this, lower left spindle -1- of support bracket -10 - 222 A- approx. 50 mm.   Note! Use step ladder -VAS 5085- to lower engine.

–  Insert bolt -1- M10 with large washer -2- and hexagon nut -3- in bolting eye of engine sump. –  Tighten bolt with nut -arrow-, counterholding on hexagon nut -3-. –  Secure tensioning strap -T10038- on front towing eye and bolt -1-. –  Pull engine forward carefully. Observe tight clearance between alternator and refrigerant line in vehicles with air conditioning. –  Turn gearbox upwards near bevel box using spindles of gearbox support -3282-. –  Lower gearbox slightly and incline to left via the spindles of gearbox support -3282-.

–  Then carefully lower 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-.