SEAT Workshop Service and Repair Manuals

Detaching –  The vehicle should be checked if a coded radio is fitted in the vehicle. If necessary obtain radio anti-theft code first. –  With ignition switched off, disconnect battery earth strap. → Electrical system; Rep. gr.27. Then the engine bracket -U30025F- must be attached to the engine rings. –  If engine cover blocks access, remove engine cover. –  Remove complete air filter housing if it is near battery → Rep. gr.23 or → Rep. gr.24. –  Remove battery and battery tray → Electrical system; Rep. gr.27.

–  Remove securing clip -1- for gear selector cable from gearbox selector lever -2- and pull cable off pin -arrow-.

–  Releasing cable end-piece from gate selector cable l  To avoid damage to gate selector cable, separate cable end-piece from gate selector cable before removal. –  Pull locking mechanism forwards in direction of -arrow 1- onto stop and then turn to left in direction of -arrow 2- to lock. –  Then press relay lever forwards (in direction of -arrow 3-). –  The relay lever is removed together with the cable end-piece at a later point.

–  Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.

–  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 the pressure line of the clutch circuit using sealing plugs from the engine sealing plug set -VAS 6122-.   Caution Do not operate clutch pedal after disconnecting pipe/hose assembly.

–  If fitted, remove earth strap -1- from top starter bolt. –  Unplug electrical connector -2- for reversing light switch -F4-. –  Remove connector and wire from starter.

–  Unscrew top engine/gearbox securing bolts -arrows-. –  Then separate the hoses and cables that may be in the area of the engine where the rings that grip the engine bracket -U30025F- go. First remove the following components: t  Windscreen wiper arms → Electrical system; Rep. gr.92 t  Plenum chamber cover → Rep. gr.50

–  Fit the engine bracket -U30025F- with the necessary adapters and attach as shown in the figure, and catch the motor in its installation position.   Note

t  The gearbox support -U30025/5B- must be mounted with the rubber blocks in the direction of the wing. Front bearing point in the area of the screw of the fixing plate of the front side. t  The screws that secure the subframe support can only be undone when the engine is supported using the engine bracket -U30025F-.

The left drive shaft will be removed in a later step. –  Loosen securing bolt -arrow- for drive shaft → Running gear, axles, steering; Rep. gr.40. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Gearbox for vehicles with start stop system Disengage the plug connector -arrow- of the gearbox neutral position sender -G701-. –  Remove starter → Electrical system; Rep. gr.27.

–  Remove right and left charge air hose -arrow 1- → Rep. gr.21.

–  Remove cowling -arrow- together with radiator fans → Rep. gr.19.

–  Remove coolant circulation pump -V50--arrow 1-; do not open coolant lines → Rep. gr.19. –  Remove the lambda probe wire from wiring guides of charge air pipe → Rep. gr.21. –  Release charge air pipe -arrow 2- → Rep. gr.21.

–  Remove engine/gearbox connecting bolts -arrows-.

–  Remove pendulum support.

–  If the front left vehicle level sender -G78- is installed, unbolt it from transverse link → Rep. gr.40.

–  Remove left coupling rod -1- from anti-roll bar and lay to side → Running gear, axles, steering; Rep. gr.40 –  Remove left drive shaft → Running gear, axles, steering; Rep. gr.40.

–  Remove drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40. –  Remove right drive shaft from gearbox and place aside → Running gear, axles, steering; Rep. gr.40.

–  Remove front part of exhaust system from engine → Rep. gr.26. –  Secure exhaust system so that lambda probe wire is not damaged. –  Separate exhaust system -arrows 1- and remove exhaust pipe bracket from subframe -arrows 2- → Rep. gr.26.

–  Remove hexagon bolts -arrows- on left engine/gearbox mounting -2- from bracket -1-. –  Remove earth strap from bracket -1-.

–  Lower the gearbox by about 50 mm to dimension -a-.   Note When moving engine and gearbox assembly, observe lines and hoses on engine, being careful not to stretch them.

–  Remove securing bolts -arrows- for bracket -1-. –  Remove bracket -1- from gearbox. –  Remove relay lever together with cable end-piece → Chapter –  Remove gearbox selector lever from selector shaft → Item. –  Thread off the right fastening screw of the sub-frame heat shield. –  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 bracket -T20138C- to the gearbox casing.

l  Gearbox, opposite to the engine: Secure the gearbox to using a screw (M10x20) -A-.

l  Gearbox, engine side: place the adjustment plate -3282/048- on the gearbox for both openings. –  Remove engine / gearbox connecting screws using the spanner -T10061-. –  Carefully push gearbox off engine. –  Release the gearbox from the dowel sleeves and carefully tilt towards subframe.

Then guide the right flange shaft past the notch -arrow 1- in the intermediate plate and on the flywheel -arrow 2-. –  Tilt gearbox further using spindles of gearbox bracket -T20138C-. l  Differential must face upwards. l  Pivot gearbox downwards in area of 6th gear.

–  Guide gearbox with differential over subframe -A- and swing out. –  If necessary, turn gearbox further upwards near differential using spindles of gearbox braket -T20138C-. –  Swivel gearbox further out and carefully lower.   Note On lowering the gearbox, handle any cables and pipes with care.