SEAT Workshop Service and Repair Manuals

Installing gearbox   Note t  Refer to procedure „Removing gearbox“ for required special tools → Chapter. t  Always renew self locking nuts and bolts t  Renew bolts which must be tightened further to a torque 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 clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease. –  All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. –  Check if the centring sleeves are installed in the engine for the purpose of centring the engine with the gearbox and insert these if they are not installed. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

–  Ensure that intermediate plate is hooked into sealing flange and pushed onto dowel sleeves -arrows-. –  Check release bearing for wear; if necessary, renew slave cylinder with release bearing → Chapter. –  Move engine assembly onto the engine and gearbox jack -SAT 1040- and put it in installation position. –  Now tilt the gearbox to the left over the counterhold -T20138C- protection sleeve.

–  Then carefully raise gearbox further, observing longitudinal member.   Note When installing the gearbox, do not damage any cables or lines. –  Then rotate the gearbox via the counterhold -T20138C- spindle until it is in installation position.

Securing bolts of gearbox carrier -A- are unscrewed (shown here on a different gearbox).

–  Swivel manual gearbox to ensure that the bevel box does not come into contact with the shoulder -A- of the gearbox carrier and that the charge air control pressure unit -arrow- is not touched. –  Align the gearbox to the engine and fit. –  Screw in lower bolts that fix the engine to the gearbox and tighten to the corresponding tightening torque → Chapter.

–  Screw in engine/gearbox connecting bolt -arrow- next to bevel box -A- and tighten to specified torque → Chapter. –  Once the gearbox is screwed to the engine underneath, remove the gearbox support -T20138C- from the gearbox. –  Centre engine assembly so as to bring it to the correct installation position. To do this, lift until gearbox is fully in contact with left engine/gearbox mounting.

–  Screw in new hexagon bolts -arrows- for left engine/gearbox mounting and tighten to specified torque → Chapter.   WARNING First remove the engine mounting -U30025F- once all engine assembly bracket bolts have been tightened to the corresponding tightening torque.

–  Screw in upper engine/gearbox securing bolts -arrows- and tighten to specified torque → Chapter.

–  Install starter -3- → Electrical system; Rep. gr.27. –  Connect electrical connection -2- on the reverse light switch -F4-. Attach earth strap -1- to gearbox → Chapter.

–  If a retainer -1- is installed, secure earth strap with a nut -2-.

–  Gearboxes for vehicles with start-stop system: connect connector of -gearbox neutral position sender-arrow -G701-.

–  Bolt bevel box carrier to engine and bevel box, observing tightening sequence of bolts -arrows 1- and -arrows 2- → Chapter. Presentation of bolt heads may deviate from illustration.

–  If removed, install coolant hoses -1- and -2- of auxiliary heater. Do not open pipes → Auxiliary heater; Rep. gr.82.

–  Renew retaining ring -arrow A- and O-ring -arrow B- on stub shafts. Lubricate splines of stub shafts using grease -G 000 100-. Then install drive shafts → Running gear, axles, steering; Rep. gr.40.

–  Mount drive shaft heat shield, if present, on bevel box (nuts -1-) → Running gear, axles, steering; Rep. gr.40. –  Reassemble exhaust system → Rep. gr.26

–  Bolt propshaft onto bevel box -arrows- → Rep. gr.39. –  Install subframe/suspension links using steering box → Running gear, axles, steering; Rep. gr.40.

–  Attach pendulum support to gearbox; bolt -1- and bolt -2- → Running gear, axles, steering; Rep. gr.40 –  If front left vehicle level sender connectors -G78- are present, connect them → Rep. gr.40.

–  Release the connector -1- from the oil level and temperature sender -G266-.

–  Install charge air hose -arrow 1- and -arrow 2- → Rep. gr.21.

–  Remove sealing tool -T10249/1- from supply hose.   Note The hose clamps -3094- that appear in the figure can be ignored.

–  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. –  Fold back the supply hose to its original form as required. –  Bleed clutch system → Chapter. –  Check for correct installation position of vacuum hose for brake system, install vacuum hose if necessary → Rep. gr.47.

–  Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque → Item.

–  Fit gearbox selector lever -2- → Item and tighten securing nuts to specified torque → Item. –  Spread a small amount of grease on pin -arrow- of gearbox selector lever -2-. Allocate grease using → Electronic parts catalogue (ETKA). –  Mount gear selector cable; renew securing clip -1- each time it is removed. –  Install relay lever together with cable end-piece → Fig.. –  Adjust selector mechanism → Chapter –  Install battery tray and battery → Electrical system; Rep. gr.27 –  Install the complete air filter housing, if previously removed → Rep. gr.23. –  If necessary, install engine cover. –  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 gearbox oil level → Chapter . –  Check gear oil in bevel box → Chapter+. –  Secure front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Install noise insulation → General body repairs, exterior; Rep. gr.50. –  Install wheels → Running gear, axles, steering; Rep. gr.44. –  For vehicles with front sender for vehicle level, check headlight adjustment → Electrical system; Rep. gr.94.