SEAT Workshop Service and Repair Manuals

Removing –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  With ignition switched off, disconnect earth strap of battery → Electrical system; Rep. Gr.27.

–  Remove air duct trim -1--arrows-. –  Remove battery trim -2-. –  Pull connector off coolant expansion tank. –  Unbolt coolant expansion tank and place to side. Do not open cooling system. –  Remove battery and battery tray → Electrical system; Rep. Gr.27. –  Remove air filter housing with intake hose → Rep. Gr.24.

–  Pull locking mechanisms on gate selector cable and gear selector cable forward to stop -direction of arrow 1- and then turn to left to lock -direction of arrow 2-.

–  Pull securing clip -arrow 1- off relay lever -A- and remove relay lever. –  Remove gearbox selector lever -B- by removing nut -arrow 2-. If necessary, use two arm puller, e.g. -Kukko 20/10-. Vehicles with turbo diesel engine –  Remove charge air cooling connecting pipe from intake connecting pipe → Rep. Gr.21. –  Remove retaining clip on cylinder head for charge air cooling connecting pipe → Rep. Gr.21. Continuation for all vehicles

–  Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094-. –  Pull pipe/hose line out of retainer on gearbox bracket. –  Remove cable support bracket from gearbox -arrows-. –  Then tie up gear selector cable and gate selector cable.

–  Pull connector off speedometer sender -arrow-, if fitted.

–  Lever out clip -arrow- for pipe/hose line to stop with a screwdriver. –  Pull out pipe/hose line in -direction of arrow-.   Note Do not depress clutch pedal. –  Remove upper engine/gearbox connecting bolts. –  Then remove upper securing bolt on starter. –  If there are hose and cable connections in area of engine support eye for support bracket -10 - 222 A-, remove these now.

–  Assemble support bracket -10 - 222 A- in conjunction with adapters -10 - 222 A /14- and -10 - 222 A /15-. –  Secure adapter -10 - 222 A /14- in threaded holes for battery carrier -arrows-.   Note For vehicles with turbo diesel engines, also use shackle -10 - 222 A /12- as shown in figure. –  Take up weight of engine/gearbox assembly on spindles.

–  Remove nuts for right engine mounting -arrows-. –  Remove front left wheel bolts. –  Raise vehicle. –  Remove left wheel. –  Remove noise insulation tray.

–  Remove bracket -1- from starter -arrow-. –  Pull off reversing light connector -2-. –  Remove starter -3- → Electrical system; Rep. Gr.27. –  Then remove air duct with fans → Rep. Gr.19. Vehicles with turbo diesel engine –  Remove charge air cooling connecting pipe -4- from charge air cooler and remove connecting pipe → Rep. Gr.21. Vehicles with 1.8 l injection engine (5 valves per cylinder) –  Remove air duct between charge air cooler and throttle valve module → Rep. Gr.21. Continuation for all vehicles –  Disconnect drive shafts from gearbox flange shafts. –  Raise right drive shaft and secure.

–  Separate -arrow- left coupling rod from anti-roll bar.

–  Separate threaded connection between left wheel bearing housing and lower swivel joint -arrow-. –  Swing wheel bearing housing outwards. –  Remove left drive shaft between subframe and gearbox. –  Lift drive shaft and secure to suspension strut with wire. Vehicles with 1.8 l injection engine (5 valves per cylinder) –  Remove bracket between turbocharger and cylinder block → Rep. Gr.21. Gearbox with bearing housing for flange shaft

–  Gearboxes are installed both with and without differential support -1-. –  If a differential support is installed, remove it (bolts -2-, -3- and -4-).

–  Remove bearing housing -1- with right flange shaft from gearbox carrier -2- and gearbox (bolts -A- and -B-). Gearbox without bearing housing for flange shaft

–  Unbolt bearing for right flange shaft (bolts -A-) from gearbox carrier -B- and pull flange shaft out of gearbox stub shaft. Continuation for all vehicles –  Separate exhaust system, remove catalytic converter and remove front exhaust pipe from exhaust manifold or turbocharger → Rep. Gr.26.

–  Remove exhaust system bracket from subframe -arrows-.

–  Remove pendulum support, removing bolts -1-, nut -2- and bolt -3-.

–  Unbolt hexagon bolts -arrows A- of left engine/gearbox mounting -2- from left bracket -1-. –  Loosen hexagon nut -arrow B-. The left bracket does not need to be removed from subframe in order to remove gearbox.

–  Remove left bracket -1- from gearbox -arrows A- and -arrow B-. Bolt -arrow B- is not visible in figure. –  Carefully tilt engine with gearbox until left bracket can be moved freely. –  Remove lower engine/gearbox connecting bolts except for bolt on right near differential → Anchor. To remove gearbox “02N”, set up gearbox support -3282- with adjustment plate -3282/33-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Attach support elements -A- and -C- (pin -3282/34-) as shown on adjustment plate..

–  Position gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox. –  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Secure gearbox to gearbox support -3282- using bolt -A-.

–  Screw pin -3282/34- into hole on gearbox for securing bolt of pendulum support. –  Remove engine/gearbox connecting bolt -arrow A-. –  Pull connector -A- off oil level and temperature sender -G266-. –  Press gearbox off dowel sleeves and carefully swing towards subframe. In the process, guide gearbox input shaft completely out of clutch pressure plate.

–  Take load off engine mounting by raising engine slightly using right spindle -1-. –  Carefully tilt engine. To do this, lower left spindle -2- of support bracket -10 - 222 A- approx. 50 mm.   Note To lower engine via spindles of support bracket -10 - 222 A-, use step ladder -VAS 5085-.

–  Secure tensioning strap -T10038- to front towing eye and to engine sump.   Note If the engine has no protrusion on the sump onto which the tensioning strap can be hung, secure tensioning strap in hole in crankcase. –  Pull engine forward carefully. –  Turn gearbox upwards near differential using spindles of gearbox support -3282-. –  Lower gearbox slightly and incline to left via the spindles of gearbox support -3282-.

–  Then carefully lower gearbox. In the process, guide stub shaft -A- past flywheel and gearbox housing past subframe -arrows-.   Note If the gearbox is to be renewed, the differential support must be later transferred to the new gearbox → .