SEAT Workshop Service and Repair Manuals

Installing –  All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid using a thread chaser. –  Always renew self-locking bolts and nuts. –  Clean input shaft splines and lightly coat with grease -G 000 100-. The clutch plate must slide easily to and fro on the input shaft. –  Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. –  Ensure that intermediate plate is correctly seated on engine. Gearbox with bearing housing for flange shaft

A differential support -arrow 2- is installed with some gearboxes having a bearing housing -arrow 1-. If gearbox is renewed, it must be transferred to new gearbox at a later point. Gearbox without bearing housing for flange shaft

If a differential support -arrow 1- is installed, the spacer sleeve -arrow 2- must also be installed. The differential support and spacer sleeve are then secured with bolts -A- and -B- to gearbox before gearbox is installed. Torque setting, bolt -A- → Item Torque setting, bolt -B- → Item To install gearbox “02N”, set up gearbox support -3282- with adjustment plate -3282/33-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Attach support elements -A- and -C- (pin -3282/34-) as shown on adjustment plate.. –  Align adjustment plate and gearbox parallel to one another. –  Screw pin -3282/34- into hole in gearbox for securing bolt of pendulum support ( → Anchor, figure N34-1334).

–  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Secure gearbox to gearbox support -3282- using bolt -A-.

–  Position gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Tilt gearbox to left via spindles of gearbox support -3282- and turn upwards in vicinity of differential.

–  Then carefully raise gearbox and guide it past subframe -arrows- and stub shaft -A- past flywheel.

–  Carefully loosen tensioning strap -T10038-. –  Remove tensioning strap from front towing eye and engine sump.

–  Raise engine about 50 mm using left spindle -2- of support bracket. –  Lower right spindle -1- until engine contacts engine mounting.   Note! t  To raise engine via spindles of support bracket -10 - 222 A-, use step ladder -VAS 5085-. t  If left bracket has been removed from left subframe, it must now be reinstalled. –  Using spindles of gearbox support -3282-, tilt gearbox downwards in vicinity of differential. –  Align gearbox to engine and join.

–  Screw in engine/gearbox connecting bolt -arrow- and tighten to specified torque → Chapter, table. –  Press connector -A- onto oil level and temperature sender -G266-. –  After gearbox has been bolted to engine, remove gearbox jack from gearbox. –  Screw in lower engine/gearbox securing bolts and tighten to specified torque → Chapter, table. –  Align engine and gearbox in installation position. To do this, tighten left spindle of support bar -10 - 222 A-.

–  Install left bracket -1- on gearbox using new hexagon bolt -arrows A- and -arrows B- and tighten to specified torque → Chapter. Hexagon bolt -arrow B- is not visible in figure.

–  Screw new hexagon bolts -arrows A- for left assembly mounting -2- into bracket -1- and tighten to specified torque → Chapter. –  Screw new hexagon nut -arrow B- onto stud of bracket and tighten to specified torque → Chapter.

–  Install nuts for right engine mounting -arrows- and tighten to specified torque → Repair group 10; Removing and installing engine; Assembly mounting.   Caution Do not remove support bracket -10 - 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque. Gearbox with bearing housing for flange shaft –  Renew O-ring on stub shaft. –  Grease following parts with constant velocity joint grease -G 052 738 A2-: t  Splines of right flange shaft, t  Area around O-ring on stub shaft.

–  Install bearing housing -1- with right flange shaft and differential support -2-. –  First tighten all securing bolts hand-tight. –  First tighten flange shaft bearing to gearbox carrier by tightening bolts -A-. –  Then tighten differential support securing bolts to specified torque → Item and → Item. –  Then bearing housing must be tightened to specified torque → Item.

Do not install engine/gearbox bolt -1- until differential support -2- has been installed → Chapter. –  Screw in upper engine/gearbox securing bolts and tighten to specified torque → Chapter, table. Gearbox without bearing housing for flange shaft –  Screw in upper engine/gearbox securing bolts and tighten to specified torque → Chapter, table.

–  Renew O-ring -A-. –  Grease right flange shaft splines and area of O-ring on stub shaft -arrow- with constant velocity joint grease -G 052 738 A2-. –  Carefully insert flange shaft in stub shaft, taking care not to damage O-ring!

–  Bolt flange shaft bearing to gearbox carrier -B- and tighten bolts -A- to specified torque → Chapter, figure N34-1569, item D. Continuation for all vehicles

–  Install pendulum support using new hexagon bolts -1- and tighten to specified torque → Running gear, axles, steering - front and four-wheel drive; Repair group 40; Repairing front suspension –  Insert hexagon bolt -3- and nut -2- and tighten to specified torque → Running gear, axles, steering - front and four-wheel drive; Repair group 40; Repairing front suspension –  Attach front exhaust pipe to exhaust manifold and install catalytic converter → Rep. Gr.26.

–  Attach exhaust system bracket to subframe -arrows- → Rep. Gr.26.

–  Assemble threaded connection between left wheel bearing housing and lower suspension link -arrow- → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40.

–  Attach left coupling rod to anti-roll bar -arrow- → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40. Vehicles with 1.8 l injection engine (5 valves per cylinder) –  Install bracket between turbocharger and cylinder block → Rep. Gr.21. Continuation for all vehicles –  Attach drive shafts to gearbox → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40. Vehicles with 1.8 l injection engine (5 valves per cylinder) –  Install air duct between charge air cooler and throttle valve module → Rep. Gr.21. Vehicles with turbo diesel engine

–  Attach charge air cooling connecting pipe -4- to charge air cooler and intake pipe → Rep. Gr.21. –  Install retaining clip on cylinder head for charge air cooling connecting pipe → Rep. Gr.21. Continuation for all vehicles

–  Then insert starter -3- and tighten lower bolt → Electrical system; Rep. Gr.27. –  Push on reversing light connector -2-. –  Install bracket -1- on starter -arrow-.

–  If fitted, attach connector to speedometer sender -arrow-.

–  Push pipe/hose line in -direction of arrow- and press down clamp -arrow-.

–  Press pipe/hose line -A- into retainer on gearbox bracket. –  Remove hose clamp -3094-. –  Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque → Item. –  Then install upper securing bolt for starter → Electrical system; Rep. Gr.27.

–  Assemble gear selector lever -B--arrow 2-. –  Tighten hexagon nut -arrow 2- to specified torque → Item. –  Insert relay lever -A- and secure with securing clip -arrow 1-. –  Connect gear selector cable and gate selector cable to respective cable end-pieces. –  Adjust selector mechanism → Chapter. –  Install air filter → Rep. Gr.24. –  Install wheel → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.44. –  Install battery and battery holder → Electrical system; Rep. Gr.27.

–  Install battery trim -2-. –  Install air duct trim -1--arrows-. –  Bolt on coolant expansion tank. –  Push connector onto coolant expansion tank. –  Connect earth strap to battery.   Note! Note radio code for vehicles with coded radio. –  Bleed clutch system → Chapter. –  Check gear oil → Chapter. –  Install engine cover. –  Install noise insulation tray.