SEAT Workshop Service and Repair Manuals

Installation Installation is carried out in the reverse order, noting the following:   Note t  Always replace self-locking nuts and bolts during assembly. t  Replace bolts that are submitted to goniometric tightening, along with seals and gaskets. t  Secure the connecting pieces of the hose lines with clamps according to the → Electronic spare parts catalogue „ETKA“. t  All cable clamps that become loose or cut when removing must be re-installed in the same place when installing. t  Clean the cogs of the input shaft and, if the clutch plates are worn, the hub cogs; eliminate corrosion and apply a very fine layer of lubricating grease to the cogs → Electronic spare parts catalogue „ETKA“. Then move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. It is essential to remove excess grease. –  Check whether there are adjusting sleeves in the engine for centring the engine/gearbox assembly and fit if necessary.

–  Ensure that intermediate plate is connected to sealing flange and housed in dowel sleeves -arrows-. –  Check that clutch plate is centred. –  Check clutch release collar for wear and replace if necessary. –  Apply lubricating grease → Electronic spare parts catalogue „ETKA“ to the contact points of the clutch release lever on the spherical pivot. –  Carefully raise gearbox together with counterhold -T20138C -, the base -T20145- and the hydraulic jack -SAT 1040- and place it in installation position. –  Screw the gearbox to the engine.

Tightening torques for engine/gearbox connection:

Item	Bolt	Nm
1, 2	M12×65	80
3 → Remark, 4 → Remark	M12×135	80
5 … 7	M10×60	40
8	M12×90	65

1)  M8 threaded pin with bolts A  -  Dowel sleeves to centre

–  Insert heat shield -2- so that lower lug hooks onto engine block and secure it at its upper part with bolt -1- .   Note This is shown in the figure with the gearbox removed.

–  Fit and hand tighten bolts -arrows- of mechanical assemblies mounting on gearbox. Use new bolts.

–  Bolt first pendulum support to gearbox, then to subframe -bolts 1 ... 3-. Use new bolts. –  Bolt the articulated semiaxles to the flanged shafts → Rep. gr.40. –  Install and adjust the exhaust system free of stress → Rep. gr.26. –  Check the subframe adjustment and adjust if necessary → Rep. gr.10.

–  Tighten bolts -arrows- for gearbox side mechanical assemblies mounting to 60 Nm + 90°. Installation is done in the reverse order. –  Fit the slave cylinder → Chapter. –  Fit and adjust the control cables in the gearbox → Chapter. –  Replace gearbox oil and check fill level → Chapter. –  Fit the battery → Rep. gr.27.