SEAT Workshop Service and Repair Manuals

Removing –  Disconnect the battery earth strap.   Note Observe the safety measures to be adopted when disconnecting the battery → Electrical system; Rep. gr. 27 –  Remove engine cover → Booklet101. –  Remove the air filter body, breather hose and air duct hoses → Rep. gr.24 and → Rep. gr.23 .

–  Remove the battery → Electrical system; Rep. gr.27 . –  Remove battery tray -arrows- and remove from vehicle.

–  Disassemble the connectors -1- of the starter motor, and the reverse gear light switch -4-. –  Remove the cable -2- and the earth cable -3- of starter motor. –  Expose the wiring. –  Unscrew top securing bolt on starter motor.

–  Remove the safety washer -arrow 1- that secures the connector cable to selector rod -A-. –  Pull gear selector cable off pin. Metal idler rod –  Remove the safety washer -arrow 2- that secures the connector cable to idler lever-B-. –  Remove the selector cable from the pivot. –  Remove the safety washer -arrow 3- from the idler rod -B- and remove the lever. Plastic idler rod:

–  Detach the fastening element from the selector cable → Fig. –  Press the tab down-arrow 1- as far as it goes and remove the idler rod together with the cable fastener. Continued for all vehicles –  Remove the gear selection rod -A-. To do so the nut -arrow 4- must be unscrewed (⇒ highlighted illustration).

–  Remove retaining bracket from gearbox. For this purpose, unscrew the screw -arrow- and tie up to the side together with the connector cable –  Loosen the bolts -arrows-, and remove the support for the gear selector and connection cables from the gearbox, and secure it to one side above, together with the cables.

–  Remove the support from the gearbox -arrows A-. –  Remove the slave cylinder -arrows B-, and secure to one side. Do not open the hydraulic system of the clutch.   Note Do not press on the clutch pedal following the removal of the slave cylinder. –  Remove upper engine/gearbox connecting bolts.

–  Place support -U-30025E- on body profile. l  When using the holder -U-30025E- pay attention so that the supporting feet remain firmly attached to the profile of the wing and the tool rod. Look in the middle of the gear without damaging the body. –  Place eyes onto spindle hooks. –  Pre-tension engine with both spindles uniformly and without raising it. –  Remove front left-hand wheel. –  Turn steering to the left.

–  Remove bolts -1- and - 2- and remove central soundproofing panel. –  Remove the left wheelhouse liner → Bodywork, exterior installation work; Rep. gr.66.

–  Unscrew nut -arrow- and remove support for cables from threaded bolt. –  Remove the starter motor by extracting the lower bolt.

–  Unbolt heat shield for right hand side wheel drive shaft -arrows-. –  Unbolt left and right drive shafts from the gearbox flange → Running gear, shafts, steering; Rep. gr.42. –  Secure drive shafts above.   Note The left drive shaft must be placed as far forward as possible.

–  Unscrew bolts -2 and 3- and remove reinforcement -A-.

–  Unbolt the exhaust system bracket -arrows-.

–  Remove the exhaust by the surrounding hose -1-.   Note The connecting elements of the front exhaust pipes must not be bent more than 10°, otherwise they could be damaged. –  Secure high up front exhaust pipe to vehicle underbody.

–  Remove left hand side air hose -arrows-.

–  Extract the bolts -1 ... 3- unscrew and remove the pendulum support.

–  Unscrew bolts -arrows- of gearbox suspension mounting.

–  Lower gearbox by adjusting spindle hooks in support -U-30025E- until obtaining the dimension -a-. l  Distance a = 50 mm

–  Unbolt gearbox console -A- from its location in gearbox -arrows-.

–  Unscrew the securing screws of the right flange shaft -arrow-. To do so, screw two screws into the flange and lock the shaft with a lever. –  Remove flanged shaft together with compression spring.

–  Unscrew bolt -1- with gearbox installed. –  Remove protection plate -2- upwards.   Note The removed gearbox is shown in the figure.

–  Take out the thermal protection plate and secure the tool -T20185-. –  Insert the counterhold -T20111- between the counterhold -T20185- and the engine. Operate the nut on the engine tool -T20111- and separate the drive train from the subframe. –  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-. –  Fix the gearbox support -T20138C- to gearbox -arrows- –  Remove gearbox securing bolts by lower part, disengage gearbox from guide sleeves. –  Adjust the base -T20145- so that gearbox moves easily on the rigid drive shaft, at the same time separating gearbox from engine. –  Swing gearbox forwards on adjustment spindle.

–  Move gearbox a little forwards and position it as shown in illustration. –  Lower gearbox. When lowering, ensure that sleeve passes -1- through pressure plate side, but without damaging it -arrow-.

–  Re-install flanged shaft and tighten conical bolt -arrow- to 25 Nm.