SEAT Workshop Service and Repair Manuals

Installing   Note t  The special tools required can be obtained from the work sequence „removing and installing the gearbox“ → Chapter. t  Renew self-locking nuts and bolts. t  Renew the bolts tightened with specified tightening angle. t  All cable ties which were opened or cut during removal must be renewed at the same points. t  Clean input shaft splines and, on used clutch plate, hub splines. Remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. Excess grease must be removed. –  If the gearbox is to be renewed, transfer the gearbox selector lever and relay lever to the new gearbox. –  Carefully use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  Clean splines of input shaft and apply a thin coat of grease for clutch plate splines -G 000 100-. The clutch plate must slide easily to and fro on the input shaft. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary. If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

–  Observe that the intermediate plate is fitted on sealing flange and is slid onto the dowel sleeves -arrows-. –  Check release bearing for wear; if necessary, renew slave cylinder with release bearing → Chapter. –  Fit the previous assembly onto the hydraulic jack -SAT 1040- and place it in installation position.   Note When lifting the gearbox, care should be taken not to damage any cables and pipes. –  If necessary, turn gearbox further upwards near differential using spindles of gearbox braket -T20138C-.

–  Then carefully raise gearbox further, observing longitudinal member -arrows-. –  If necessary, tilt gearbox further using spindles of gearbox bracket -T20138C-. –  Guide gearbox with differential over subframe -A-.

–  If necessary, turn gearbox further upwards near differential using spindles of gearbox braket -T20138C-.

l  Then the right flange shaft must be guided past the flywheel -arrow 2- and the notch in the intermediate plate -arrow 1-. –  Place intermediate plate onto dowel sleeves on engine if necessary. –  Align the gearbox to the engine and fit. –  Then rotate the gearbox via the counterhold -T20138C- spindle until it is in installation position. –  Align gearbox on engine dowel sleeves and join. –  Screw in lower engine/gearbox securing bolts and tighten to specified torque → Chapter. –  Once the gearbox is screwed to the engine underneath, remove the gearbox support -T20138C- from the gearbox. –  Screw in upper engine/gearbox securing bolts and tighten to specified torque → Chapter. –  Attach gearbox selector lever to selector shaft of gearbox → Fig. and tighten hexagon nut to specified torque → Item. –  Install relay lever together with cable end-piece → Chapter.

–  Install bracket -1- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque → Chapter.

–  Align engine and gearbox in installation position. To do so, raise engine/gearbox until gearbox bracket -1- makes full contact with gearbox mounting (left) -2-. –  Screw new hexagon bolts -arrows- for left assembly mounting -2- into bracket -1- and tighten to specified torque → Chapter.   Note Install engine/gearbox mountings stress-free → Rep. gr.10.   WARNING Only remove the gearbox bracket -T20138C- once the respective tightening torque has been applied to all fixing screws of the subframe.

–  If small cover plate -A- for flywheel is present, install it -arrows- → Chapter.   Note

t  There are threaded inserts, e.g. „HeliCoil“ in the bolting holes for the pendulum support. t  Distinguishing feature: Groove on the first thread pitch -arrow-. t  Note the fixing screw and the respective tightening torque → Running gear, axles, steering; Rep. gr.40

–  Remove the pendulum support → Running gear, axles, steering; Rep. gr.40. –  Then install drive shafts → Running gear, axles, steering; Rep. gr.40.

–  Install drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40.

–  Attach the coupling rod to the anti-roll bar -1- → Running gear, axles, steering ; Rep. gr.40.

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

–  Connect the connector -1- to the oil level and temperature sender -G266-. –  Assemble exhaust system → Rep. gr.26.

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

–  Install right and left charge air hose -arrow 1- → Rep. gr.21. –  Then install starter and secure with lower bolt → Electrical system; Rep. gr.27. –  Secure wiring retainer to lower starter bolt. –  Install upper starter bolt; attach connector and wiring to starter → Electrical system; Rep. gr.27.

–  Attach earth strap -1- to upper starter bolt. –  Push connector -2- onto reversing light switch -F4-.

–  Gearbox for vehicles with start stop system Plug on the connector -arrow- to the gearbox neutral position sender -G701-. –  Push pipe/hose line or pipe line -A- to stop into slave cylinder breather and press down clip -arrow-.

–  Test line by tugging on it. –  Hydraulic clutch system: bleeding of air → Chapter. –  Check for correct installation position of vacuum hose for brake system, install vacuum hose if necessary → Rep. gr.47.

–  Install selector cable support bracket on gearbox and tighten bolts and nut -arrows- to specified torque → Item. –  Insert gate selector cable in cable end-piece.

–  Spread a small amount of grease on pin -arrow- of gearbox selector lever -2-. Allocate grease using → Electronic parts catalogue (ETKA). –  Renew securing clip -1- each time it is removed. –  Adjust selector mechanism → Chapter. –  Install battery tray and battery → Electrical system; Rep. gr.27 –  Install complete air filter housing → Rep. gr.23 or → Rep. gr.24.

–  Then press on grommet -arrow-. –  Fit the cover on the engine. –  Connect battery and follow procedure after connecting battery → Electrical system; Rep. gr.27. –  Mount plenum chamber cover → Body; Rep. gr.50 –  Mount windscreen wiper arms → Electrical system; Rep. gr.92. –  Check gear oil → Chapter. –  Install front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Install noise insulation → General body repairs, exterior; Rep. gr.50. –  For vehicles with front left sender for vehicle level -G78-, the headlight adjustment has to be checked → Electrical system; Rep. gr.94.