SEAT Workshop Service and Repair Manuals

Removing

• ‒ → With the vehicle resting on its wheels loosen left-hand wheel hub/drive shaft bolt and left and right-hand wheel securing bolts.

Note:

Note radio coding for vehicles with coded radio.

• ‒ With the ignition switched off disconnect the battery earth strap (in engine compartment and if fitted, under driver's side).

=> Electrical system; Repair group 27

Vehicles with Diesel engine

• ‒ → Remove upper section of charge air pipe (arrow)

• ‒ → Remove upper engine cover (arrow)

• ‒ Remove air cleaner.
• ‒ → Lever gear selector cable -A- off gear selector lever.
• ‒ Lever gate selector cable -B- off relay lever.

• ‒ → Pull both cables out from retainer on gearbox, to do this press clips together (arrows).

• ‒ → Lever clip for pipe work out from slave cylinder (direction of arrow), pull pipe out and seal with 10 mm plug.
• ‒ Pull pipe work out of retainer on gearbox.

• ‒ → Pull off reverse light connector (arrow). Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox securing bolts.
• ‒ Remove engine/gearbox upper securing bolts.

• ‒ → Remove right-hand engine mounting nuts

• ‒ → Fit support bar 10-222A together with legs 10-222 A/5.

• ‒ → Fit support bar 10-222 A/5 with body bolts (arrows).
• ‒ Take weight of engine/gearbox assembly on the spindles.

• ‒ Remove insulation tray below engine/gearbox, if fitted.
• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

Vehicles with Diesel engine

• ‒ → Remove charge air pipe from charge air cooler (arrow)

• ‒ Remove both wheels

Remove/loosen left and right-hand wheel mountings as follows:

• ‒ → Press track rod off steering arm.

•     1 -    Hooks (commercially available) e.g. Kukko No. 1-90
•     2 -    Puller (commercially available) e.g. Kukko No. 20-10

• ‒ Tie up track rod

• ‒ → Separate left and right-hand wheel bearing housing/lower ball joint bolted connection.

• ‒ → Remove left and right-hand coupling link -1- on shock absorber.
• ‒ Detach brake hose and, if fitted, ABS sensor cable from retainers on shock absorber.

• ‒ Place drip tray underneath.
• ‒ → Lever left-hand drive shaft out from gearbox and pull out from wheel hub.

• ‒ → Insert sealing cap 3394 into gearbox.

• ‒ Pull right-hand drive shaft out of centre bearing by tugging outwards on wheel mounting.
• ‒ Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.

Vehicles up to January 97

• ‒ → Unbolt centre bearing from mounting on engine block (arrows) and pull with axle shaft out of gearbox or lever out if necessary.
• ‒ Insert sealing cap 3394 into gearbox.

Vehicles from January 97

• ‒ → Unbolt axle shaft bearing (arrows) and pull axle shaft out of gearbox.

• ‒ → Remove engine/gearbox support -arrows 1 to 3-.
• ‒ Insert sealing cap 3394 into gearbox.

Continuation for all vehicles

• ‒ → Remove pendulum support -1-, to do this remove bolt and nuts -A-.

Note:

The pendulum support can be secured to the subframe with one bolt.

• ‒ → Pull connector off road speed sender (arrow).

• ‒ Remove flywheel cover plate.

• ‒ → Separate gearbox mounting, to do this remove bolts -A- and -B-.
• ‒ Push engine/gearbox assembly as far as possible to right.
• ‒ Tilt engine/gearbox assembly, to do this raise right-hand spindle and lower left-hand spindle.

• ‒ → Remove mounting from gearbox console (arrows).

• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/21 for "006", gearbox and support elements as follows:
• ‒ Place adjustment plate 3282/21 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.

• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration V34-0296) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and secure with a bolt.
• ‒ Remove lower engine/gearbox securing bolts.
• ‒ Press gearbox off dowels and lower carefully.
• ‒ Change position of gearbox in the area of assembly carrier and body on left-hand side by lowering via the gearbox jack spindle.

Transporting the gearbox

Special tool 3336 may be used to transport the gearbox and also when setting up gearbox mount 3282.

• ‒ → Bolt gearbox lifting device 3336 to clutch housing.

• ‒ → Set support beam on sliding piece with locking pin (arrow).

No. of holes visible = 7

• ‒ Take gearbox out with workshop crane and gearbox lifting device 3336.

Installing

• ‒ Clean input shaft splines and lightly grease with G000 100 grease.

The clutch plate must be able to slide lightly to and fro on the input shaft.

• ‒ Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
• ‒ Ensure that the intermediate plate is correctly positioned on engine.
• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/21 for "006" gearbox and support elements as follows:

• ‒ Place adjustment plate 3282/21 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.
• ‒ Place gearbox on gearbox jack.
• ‒ Align adjustment plate and gearbox parallel with one another and secured with a bolt.

• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration N34-0296 on previous page) on adjustment plate points to front of vehicle.
• ‒ Insert gearbox.
• ‒ Install lower engine/gearbox securing bolts and bolts for starter when doing this insert starter.

• ‒ → Install mounting on gearbox console (arrow).

• ‒ Align engine/gearbox in installation position.
• ‒ → Assemble gearbox mounting, to do this screw in bolts -A- and -B-.
• ‒ Remove support bar 10-222A.

→ Pendulum support to gearbox

For start of production a steel pendulum support was produced with two bushes for mounting to subframe - Length of bushes = 90 mm.

After a short run-up period the support will be substituted for an aluminium support -1- with one bush (arrow) - Length of bush = 90 mm.

Due to modifications to pendulum support mounting a shorter bush has been introduced - Length of bush = 85 mm.

• ‒ Allocate pendulum support to subframe mounting:

• ‒ 1)Secure pendulum support with one bush into front subframe drilling.

From 09.03.98 a longer bolt -A- has been introduced. The drilling in the pendulum support has been adapted to the longer bolt.

→ Allocation

The new bolt cannot be installed in the old pendulum support.

If the pendulum support is renewed, the new bolt -A- must be installed.

• ‒ → Reconnect road speed sender connector (arrow).
• ‒ Install flywheel cover plate.
• ‒ Install starter completely.

=> Repair group 27; Removing and installing starter.

• ‒ Take sealing caps 3394 out from shaft openings.
• ‒ → The securing ring -A- must be replaced before installing left-hand shaft.
• ‒ Push left-hand shaft in (direction of arrow), carefully drive in with synthetic head hammer if necessary.

Vehicles up to January 97

• ‒ Replace securing ring of axle shaft splines.
• ‒ Carefully insert axle shaft into gearbox, do not damage sealing ring.

• ‒ → Bolt axle shaft bearing on securely (arrows).
• ‒ Push right-hand drive shaft onto axle shaft splines, carefully drive on with a synthetic head hammer if necessary.

Vehicles from January 97

• ‒ → Fit support onto engine/gearbox.
• ‒ First tighten bolts -arrows 1 to 3- in ascending order hand tight, then tighten to tightening torque.
• ‒ Replace securing ring of axle shaft splines.
• ‒ Carefully insert axle shaft into gearbox, do not damage sealing ring.

• ‒ → Bolt axle shaft bearing on securely (arrows).
• ‒ Push right-hand drive shaft onto axle shaft splines, carefully drive on with a synthetic head hammer if necessary.

Continuation for all vehicles

• ‒ → Fit left and right-hand coupling links -1- to shock absorber.
• ‒ Press brake hose and if fitted ABS sensor cable in retainer on shock absorber.

• ‒ → Bolt wheel bearing housing and lower swivel joint together.
• ‒ Screw left and right-hand track rods to steering arm.
• ‒ Install both wheels.

Vehicles with Diesel engine

• ‒ Install charge air hose and engine cover

• ‒ Install insulation tray below engine/gearbox, if fitted.
• ‒ → Fit right-hand engine mounting nuts.

• ‒ Reconnect reversing light connector.

• ‒ Install upper engine/gearbox securing bolts.
• ‒ Bolt on earth wire.
• ‒ Press gear selector cable and gate selector cable into mounting on gearbox onto stop.

→ Installation position:

The gear selector cable -A- crosses over the gate selector cable -B-.

• ‒ → Press gear selector cable -A- onto gear stick lever.
• ‒ Press gate selector cable -B- onto gate selector lever.

• ‒ Press pipe work into retainer on gearbox and insert into slave cylinder.

• ‒ → Press in clip (arrow) for pipe work.
• ‒ Install air cleaner.
• ‒ Reconnect earth strap to battery.
• ‒ Bleed clutch system.
• ‒ Check gearbox oil .
• ‒ Adjust gear change linkage .

Note:

Note radio coding for vehicles with coded radio.

Tightening torques

Vehicles up to January 97

Vehicles from January 97

→ Support to engine/gearbox

• ‒ First tighten bolts -arrows1 to 3- in ascending order hand tight, then tighten to tightening torque.

→ Axle shaft bearing to support

Continuation for all vehicles

Gearbox to body