SEAT Workshop Service and Repair Manuals

Bevel box: installing, all vehicles with turbo diesel engine (Common Rail, 2nd generation) Refer to procedure „Removing bevel box“ for required special tools → Chapter.

–  Remove sealing cap -T10381- from the gearbox. –  Grease splines of differential for manual gearbox with grease for clutch plate splines -G 000 100-. –  Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft and differential are centred when brought together. –  If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox.   Note Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.

–  Screw in upper securing bolts (-arrows-) for joining bevel box to gearbox and tighten to 40 Nm then turn through a further 90°.

–  Screw in lower securing bolts (-arrows-) for joining bevel box to gearbox and tighten to 40 Nm then turn through a further 90°.

–  Tighten countersunk bolt for right stub shaft to 35 Nm.

–  Then install new retaining ring -arrow A- and new O-ring -arrow B-. –  Check gear oil in bevel box → Chapter+.

–  Bolt gearbox carrier for bevel box to engine and bevel box, adhering to correct tightening sequence -A- and -B- → Fig.. –  Install turbocharger support -arrow- → Rep. gr.21 –  Install particulate filter → Rep. gr.26.

–  If they are present, install coolant hoses -1- and -2- of auxiliary heater. Do not open pipes → Auxiliary heater; Rep. gr.82. –  Lubricate splines of stub shaft using grease -G 000 100- Then install drive shaft → Running gear, axles, steering; Rep. gr.40.

–  Fit shaft heat shield, if present, for bevel box (nuts -1-) → Running gear, axles, steering; Rep. gr.40.

–  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.

–  Connect the connector -1- to the oil level and temperature sender -G266-. –  Install noise insulation → General body repairs, exterior; Rep. gr.50. Torque settings

Bevel box to gearbox t  Renew bolts.

→ Item

Installing bevel box carrier Allocation of bolts for bevel box carrier to engine and bevel box

Item	Bolt	Units
A	M10 x 21	3
B	M10 x 45	3

–  Screw in all bolts hand-tight. –  Tighten bolts -B- to 40 Nm. –  Tighten bolts -A- to 40 Nm.