SEAT Workshop Service and Repair Manuals

Engine: Fitting t  Engine/gearbox mountings → Anchor t  Tightening torques → Anchor   Note t  When fitting, replace the self-locking nuts and bolts. t  Renew bolts which have a specified tightening angle, as well as seals and gaskets. t  Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue. t  Clean input shaft splines and, for used clutch plates, hub splines; remove corrosion and apply a thin coat of grease → Parts Catalogue to the 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. Premise l  Engine fitted on the engine support -T20205-. Procedure: Installation is carried out in the reverse order of removal while noting the following: –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary.

–  Check that the intermediate plate is fitted on sealing flange and is slid onto the dowel sleeves -arrows-. –  Check that the clutch plate is properly cantered → 5-speed manual gearbox 0AF; Rep. Gr.30 –  Check wear to the clutch release bearing and replace if necessary. –  Lightly grease the clutch release collar, release collar sleeve and the input shaft teeth → Parts Catalogue. –  Bolt gearbox onto engine.   Note t  The tightening torques listed on this page apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Do not use degreased parts. t  Tolerance for tightening torques:

Engine/gearbox mountings

Pos.	Plug	Nm
1 → Note → Note, 2 → Note → Note	M12×55	80
3 → Note, 4 → Note	M12×165	80
5 → Note	M12×105	80
6 → Note, 7 → Note	M10×50	40
8 → Note	M10×70	40

1)  M8 thread bolt 2)  Renew bolt A -  Dowel sleeves to centre –  Insert the engine/gearbox assembly into the body. –  When inserting the engine assembly with the stand -T20205- ensure that there is sufficient clearance with regard to the bodywork.

–  Screw in the bolts of the engine mountings -arrows- manually. Secure with new bolts → Chapter .

–  Screw the bolts into the assembly mounting (on the gearbox side) -arrow- by hand. Secure with new bolts → Chapter . –  Align the engine using a shaking movement so that the supports are not under any tension.   Note The bolts are tightened to the specified torque only after adjusting the engine mountings . –  Remove the support -T20205- from the engine. –  Install drive shafts → Running gear, front-wheel and four-wheel drive; Rep. Gr.40.

–  Secure the pendulum support -1- with the bolts -arrows- to the gearbox and subframe. –  Use new screws Engine code BMT –  Install the front exhaust section with the particle filter → Chapter. All vehicles (continued) –  Install the exhaust system, and adjust it without tension → Chapter. –  Install the air conditioner compressor → air conditioning system; Rep. Gr.87. –  Connect the coolant hoses → Chapter. –  Installing Poly-V belt → Chapter. –  Electrical connections and cable routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Fit the clutch slave cylinder → 5-speed manual gearbox 0AF; Rep. Gr.30   WARNING Do not press on the clutch pedal before fitting the slave cylinder. –  Move the lock carrier in service position: → Bodywork, exterior fitting work; Rep. Gr.50. –  Installing and adjusting the selector mechanism on the gearbox → 5 speed manual gearbox 0AF; Rep. Gr.34.   WARNING When assembling the supercharger air pipes, do not use an oil-based lubricant. –  Fit the supercharger air system hoses and observe the assembly instructions → Chapter. –  Adjust engine mountings . –  Fit the battery → Electrical system; Rep. Gr.27. –  Check oil level → Fig. –  Fill up coolant → Chapter.   Note t  The used coolant already removed can only be reused if the cylinder head or the engine block have not been replaced. t  Do not re-use soiled coolant.   WARNING Do not use a battery charger to start the engine! The control units of the vehicle may be damaged. –  Check the headlight settings → Electrical system; Rep. Gr.94. –  Carry out a test drive and interrogate the fault memory → Vehicle diagnosis, testing and information system VAS 5051, Tightening torques

Component		Nm
Bolts and nuts	M6	10
	M7	15
	M8	20
	M10	45
	M12	65
discrepancies:
Gearbox mounting to gearbox		60 + 90° (1/4 turn (90°) → Note
Left supercharger air tube to the oil sump		10
Pendulum support to gearbox		40 + 90° (1/4 turn (90°) → Note
Pendulum support to subframe		100 + 90° (1/4 turn (90°) → Note
Lock carrier to the bodywork		10
Terminal + to starter motor		16
Earth wire to gearbox		22
Front supercharger air tube to the engine block		22

3)  Replace bolts