SEAT Workshop Service and Repair Manuals

Removing gearbox –  The vehicle should be checked if a coded radio is fitted in the vehicle. If necessary obtain radio anti-theft code first. –  With ignition switched off, disconnect battery earth strap → Electrical system; Rep. gr.27. –  Therefore, remove cover from engine.

–  Then pull off grommet -arrow- so that it is not damaged when supporting engine. –  Remove the entire air filter housing if it is located in the battery area → Rep. gr.23. –  Remove battery and battery tray → Electrical system; Rep. gr.27.

–  Remove relay lever together with cable end-piece. → Fig.. –  Remove circlip -1- that is attached to gear selector cable on relay lever -2-. –  Pull gear selector cable off pin -arrow-. –  Remove gearbox selector lever -2-.

–  Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire. Vehicles with pipe line between master and slave cylinder

–  Seal the supply hose leading to the clutch master cylinder using the sealing tool -T10249/1-.   Note The hose clamps -3094- that appear in the figure can be ignored. Vehicles with pipe/hose line between master and slave cylinder –  Seal hose to the pipe/hose line leading to clutch master cylinder using the sealing tool -T10249/1-. Continuation for all vehicles –  Pull out clip to stop for pipe/hose line or pipe line. –  Pull pipe/hose line or pipeline out from slave cylinder bleeder and seal.   Caution Do not operate clutch pedal any more.

–  Remove upper engine/gearbox connecting bolts -arrows-. –  Then remove upper securing bolt on starter. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

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

–  Remove earth strap -1- from bottom of gearbox. –  Release electrical connection -2- from the reverse light switch -F4-. –  Remove connectors and wires from starter. –  Remove starter -3- → Electrical system; Rep. gr.27. Therefore, remove following components: t  Windscreen wiper arms → Electrical system; Rep. gr.92 t  Plenum chamber cover → Rep. gr.50

–  Attach engine mount -U30025F- as shown using the required adaptors and hold the engine in its installation position.   Note

t  The supporting feet kit -U30025/5B- must be installed together with rubber buffers so that it points to the wing. The front part of the support must be in the retaining bracket bolt area of the front terminal. t  The retaining bracket securing bolts for the engine assembly can only be unscrewed when the engine is fixed to the engine mounting -U30025F-.

The right drive shaft will be removed in a later step. –  When the vehicle is resting on its wheels loosen the front right combi bolt -arrow- by max. 90°, so as not to damage the wheel bearing → Running gear, axles, steering; Rep. gr.40.

–  Remove front wheels → Running gear, axles, steering; Rep. gr.44. –  Remove front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  If front left vehicle level sender -G78- is present, remove it → Rep. gr.40.

–  Remove left charge air hose -arrow 1- and -arrow 2- → Rep. gr.21. –  Remove right charge air hose -arrow 2- → Rep. gr.21 –  Remove charge air pipe from engine → Rep. gr.21.

–  Remove cowling -arrow- together with radiator fans → Rep. gr.19. –  Remove particulate filter from engine → Rep. gr.26. –  Secure it to front wall of plenum chamber.

–  Remove pendulum support → Running gear, axles, steering; Rep. gr.40. –  Remove left and right coupling rods from anti-roll bar → Running gear, axles, steering; Rep. gr.40.

–  Unscrew nuts -arrows- for swivel joints on suspension links.

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

–  Remove left drive shaft from gearbox → Running gear, axles, steering; Rep. gr.40 and attach to anti-roll bar -A-.

–  Remove bolts -arrows- from left engine/gearbox mounting.

–  Lower gearbox by adjusting spindles. Dimension -a- = about 110 mm   Note When moving engine and gearbox assembly, observe coolant hoses between engine and heat exchanger, being careful not to stretch them.

–  Remove engine/gearbox connecting bolt -arrow-. –  Attach the support tool -T20138C- on the base -T20145-, and move these onto the engine and gearbox jack -SAT 1040- using the adapter for the hydraulic engine and gearbox jack -SAT 1001/1-. –  Fix the gearbox bracket -T20138C- to the gearbox casing.

l  Gearbox, engine on opposite side: attach an adjustment plate -3282/048- to each gearbox side bracket and the adjustment plate -3282/049- to the rear bracket.

l  Gearbox, on the side of the engine: insert centring mandrel -3282/050- in the gearbox opening. –  Remove bolts that fix the engine to the gearbox. –  Carefully push gearbox off engine.

–  Now tilt the gearbox to the left over the counterhold -T20138C- protection sleeve. –  Carefully lower gearbox, observing longitudinal member -arrows-.   Note Be careful of all lines when lowering gearbox.

–  When lowering the gearbox, pay special attention to the following points: l  The air conditioning compressor -2- must not contact -arrow- the refrigerant line -1-. l  The alternator must not contact the refrigerant line. l  The pressure pipe must not contact the radiator.