| Proper tools and the maximum possible care and cleanliness are essential for satisfactory gearbox repairs. Naturally, the normal basic safety regulations should be followed during repairs. |
| General instructions for certain repair work that appear repeatedly in the Repair Manual are summarised below. They apply for this individual Workshop Manual. |
| Guided fault location, vehicle self-diagnosis and measurement module |
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| Only use test equipment from SEAT: Vehicle diagnostic, testing and information system -VAS 505X-. |
| The different diagnosis sequences can be called up via the Guided functions and the Guided fault finding. The most important functions are: |
| 1. Read out the measurement value before the report of the repair. |
| The measurement value must be read out before one addresses the customer service department or the importer. |
| Keep note of the readings in a diagnostic report, so that the required gearbox data is available for damage analysis. |
| 2. Complete basic setting |
| The mechatronic detects the other control units in the vehicle via the signal if the databus. |
| The mechatronic adapts important functions with this procedure. Important configurations and programmed values are also taken over again. In this manner the synchronisation points and the »reference points« for the shift lever and the gearshift mechanisms can be adapted. |
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| The option Complete basic setting may not be selected: |
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| when this is requested in the „Guided Fault Finding“, |
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| after correcting a registered fault, |
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| after fitting another gearbox, |
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| after fitting a clutch or |
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| after fitting a mechatronic. |
| 3. Removal position, basic setting |
| With this function, the control elements of the selector mechanism are „moved to the removal position“. The mechatronic unit can now be removed. A test drive has to be carried out for the teaching process after installing a mechatronic unit. |
| 4. Idle run basic setting |
| With this function, the control elements of the selector mechanism are „moved to the idling position“. This function has to be carried out before towing a vehicle away. |
| Environmental and waste disposal regulations for oil |
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| ATF, gear oil and any other type of oil must be handled with care. |
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| Dispose of extracted oil with respect to the environment. |
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| Always adhere to statutory environmental and waste disposal regulations. |
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| Always follow the instructions shown on the oil container. |
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| If the oil sump has been removed or if gear oil is needed, do not start the engine or tow the vehicle. |
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| Thoroughly clean unions and adjacent areas before removing. |
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| When assembling check that fitting sleeves are correctly positioned. |
| O-rings, oil seals and gaskets |
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| Always renew O-rings, oil seals and gaskets. |
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| After removing gaskets, check the contact surfaces of the casing and shaft for feathering or damage caused by the removal process. |
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| Thoroughly clean housing joint surfaces before assembling. |
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| Always replace paper gaskets, completely disposing of the used gasket and thoroughly cleaning the contact surfaces. |
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| Lightly lubricate the outer circumference and sealing lip of oil seals with gear oil before installing. |
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| Coat the O-rings with gear oil or Vaseline before fitting to avoid crushing during assembly. |
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| Never use other lubricants in the gear oil area. Otherwise there is a danger of operation faults in the hydraulic gear mechanism. |
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| The open side of the oil seal should face the side containing the fluid. |
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| When installing a new oil seal, position the seal such that the sealing lip does not contact the shaft in the same place as the old seal (make use of installation depth tolerances). |
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| Do not overstretch retaining rings. |
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| Renew circlips which have been damaged or over-tensioned. |
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| Securing rings must be well seated in the groove. |
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| The bolts are removed in reverse order to the tightening sequence. |
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| If no tightening sequence is specified, nuts and bolts used to fix covers and casings should be tightened and loosened in stages and in diagonal pairs. |
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| Renew self-locking nuts. |
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| Specified torques given are for unlubricated nuts, bolts and screws. |
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