SEAT Workshop Service and Repair Manuals

Removal: –  Remove engine cover → Booklet101. –  Remove the air filter housing, the air hose and the air conduit hoses → Rep. gr.24. –  Remove battery → Rep. gr.27.

–  Extract the bolts -arrows- and extract battery bracket. –  Remove relay lever → Chapter

–  Remove the circlip -arrow 1- and after unscrewing the nut, remove the selector rod.

–  Remove cable support bracket from gearbox -arrows- and place to one side.

–  Unscrew the earth cable -1-. –  Detach wires -2- and -3- from starter motor. –  Release the cables from the connections on the starter motor.

–  To remove, the release the safety fastener -2- with a screwdriver then unscrew and disconnect the air bleeder valve -4- from the slave cylinder -1-.

–  Seal off the pressure conduits of the clutch circuit using the clutch circuit seal (male) -SAT 1211- on the side of the clutch slave cylinder, and using the clutch circuit seal (female) -SAT 1210- on the side of the clutch master cylinder.   WARNING Do not depress clutch pedal after removing slave cylinder.

–  Take the active carbon filter out by pulling upwards with all hoses connected -arrow-   Note In order to avoid damage to the condenser or the pipes/hoses of the refrigerant, avoid pulling, bending or twisting excessively.

–  Unscrew the bolts -2- and -3- from the supports for the refrigerant tubes.   Note Do not observe -item 1-.   WARNING The air conditioning refrigerant circuit must not be opened. –  Raise the vehicle. –  Remove the front wheels → Running gear, axles, steering; Rep. gr.44. –  Remove centre sound insulation → Bodywork, exterior installation work; Rep. gr.50.

–  Remove the front left vehicle level sender -G78--arrows-. –  Remove noise insulation → Rep. gr.66.

–  Remove the supercharger air hoses -arrows-.

–  Disconnect the electrical connection from the Supercharge pressure sender -G31--1-. –  Bring lock carrier into service position, with mechanical components → Bodywork, exterior fitting work; Rep. gr.50.   WARNING None of the coolant hoses should be detached from the radiator.

–  Unscrew the bolts and clamps -arrows- and remove the supercharger air hose by pulling downwards.

–  Unscrew the bolts -arrows- from the engine / gearbox flange.   Note In order to support the engine correctly with the support -U-30025E- this must be centred as much as possible with the axis of the engine assembly.

–  Fit the support -U-30025E-. l  Ensure at all times that when the gearbox is being positioned for removal that the supports of the engine/gearbox support tool -U-30025E- are correctly seated –  Secure the spindle hooks on the engine rings. –  Take up weight of engine evenly with both spindles; do not lift. –  Raise the vehicle.

–  Disconnect electrical connection -2- for the reversing light switch. –  Unscrew the nut -1- and take out bracket with electrical connections pin. –  Move the bracket along with the cables to one side. –  Unscrew the securing bolts of the starter, and remove the starter. –  Unscrew left and right half shafts from the gearbox → Running gear, axles, steering; Rep. gr.40.

–  Unbolt the exhaust system bracket -arrows-.

–  Remove front crosspiece from vehicle underbody -arrows-. –  Remove the front section of the cardan shaft → Final drive 0AV; Rep. gr.39.

–  Remove the bolts from the right hand drive shaft heat shield -arrows-, depending on the version and remove the plate.

–  Unscrew the bolts holding the gearbox to the engine and the pair of bevelled gears -arrows 1 and 2-.   Note The gearbox mount is removed after separating the gearbox from the engine.

–  Remove the protection plate -A- behind the bevelled gears -arrow-.

–  Remove assembly mounting bolts -arrows- at gearbox.

–  Adjust the support spindles to lower the gearbox to a distance -a -. l  Dimension -a- = 70 mm

–  Unscrew and remove the bolts -arrows- of the gearbox console and remove the console.

–  Unscrew the bolts for fixing the engine to the gearbox from underneath -1- and -2- (as seen from the engine side).   Note Loosen the bolt -3- and leave screwed in hand tight.

–  Attach the support tool -T20138C- on the base -T20145-, and move these onto the engine and gearbox jack -SAT 1040- using the adapter for the hydraulic engine and gearbox jack -SAT 1001/1-. –  Unscrew the bottom securing bolts on the gearbox and remove the gearbox from the dowel sleeves. –  Regulate counterhold -T20138C- so that gearbox moves without force on the rigid drive shaft, at the same time separating gearbox from engine.

–  Remove the gearbox support -A-. –  Carefully lower gearbox.