SEAT Workshop Service and Repair Manuals

Installation –  Clean the input shaft and clutch plate splines. –  Apply a thin layer of -G 000 100- grease to the input shaft splines. –  Move the clutch plate backwards and forewards on the input shaft until it slides freely. Remove excess grease. –  Check that the gearbox/engine dowel pegs are fitted to the engine, if not, fit them. –  Check that the intermediate plate is correctly seated. –  Place the gearbox on the -SAT 1001 A- engine/gearbox jack. –  Fit the gearbox to the engine taking care to cause no damage.   Note! On fitting the gearbox make sure that the input shaft and the adjustment bushes are correctly located. –  Fit the gearbox to engine bolts, at the lower part of the clutch housing.   Note! Do not tighten the engine to gearbox securing bolts yet. –  Lower the vehicle. –  Raise the engine, using the left hand spindle of the -U-30025 B- support tool, until it is level. –  Tighten the gearbox to engine bolts, at the lower part of the clutch housing, to the correct torque settings. –  Raise the vehicle. –  Tighten the the gearbox to engine bolts, at the lower part of the clutch housing, to the correct torque settings.

–  Fit bolts -arrows- to the rear gearbox support and tighten to the correct torque setting. –  Lower the vehicle.

–  Fit the gearbox front support. Tighten the front gearbox support bolts -arrows 2- to the gearbox. –  Loosen the -U-30025 B- support tool so that the supports are not in tension.

–  Tighten bolt -arrow- on the rear gearbox support.   Note! Make sure that the tabs of the metal/rubber bush are correctly located in the engine supports.

–  Tighten the bolt -arrow- on rear right hand side engine support.   Note! Make sure that the tabs of the metal/rubber bush are correctly located in the engine supports. –  Fit receiving plate -A-, if used.

–  Tighten bolt -arrow 1- on front engine support.   Note! Make sure that the tabs of the metal/rubber bush are correctly located in the engine supports. –  Remove support tool -U-30025 B-. –  Fitting the starter motor: → Electrical system; Rep. Gr.27

–  Fit the driveshafts to the gearbox flanges with the correct spanner from tool -U-40020-. –  Fit counterweight -A- to the sub-frame. t  Assembly position: According to the mark made duing disassembly. If no mark was made, the counterweight should be fitted to the sub-frame in such a way that the greatest distance between the edge of the counterweight and the securing bolts faces the front

–  Fit the connecting finger to the gearbox connecting shaft as described below: –  Clean the threaded hole in the connecting finger with an M8 tap. –  Insert a new bolt -1- in the connecting finger. –  Insert the connecting finger into the connecting shaft. The bolt should be located in the recess -2-.

–  Fit the heat shield to the gearbox and tighten bolt -arrow 1-.

–  Bolt connector bracket to its location on the gearbox housing -arrow 2-. –  Fit the reversing light connector -arrow 1-. –  Fit the earth cable to the engine to gearbox bolt. –  Fit the PAS pipe bracket. –  Fit the cable bracket for the starter motor and speedometer sender.

–  Connect the speedometer sender -arrow-. –  Fit the clutch cable to its location on the clutch release lever. Clutch cables with automatic adjustment → Chapter   Note! t  The return spring is only used to secure the clutch release lever and the clutch release bearing

t  The return spring -arrow- must not be fitted if the vehicle has a clutch cable with automatic adjustment. The return spring will interfere with the correct functioning of the automatic adjustment mechanism –  Checking the functioning of the clutch cable with automatic adjustment → Chapter Clutch cables without automatic adjustment → Chapter –  Carrying out clutch pedal adjustment → Chapter   Note!

The return spring -arrow- must be fitted if the vehicle has a clutch cable without automatic adjustment. –  Install air cleaner: → Rep. Gr.24 –  Adjust gear change action → Chapter –  Check gearbox oil level → Chapter –  Connect the negative terminal of the battery.