SEAT Workshop Service and Repair Manuals

Removing –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  With ignition switched off, disconnect earth strap of battery → Electrical system; Rep. Gr.27.

–  Remove air duct trim -1--arrows-. –  Remove battery trim -2-. –  Pull connector off coolant expansion tank. –  Unbolt coolant expansion tank and place to side. Do not open cooling system. –  Remove battery and battery tray → Electrical system; Rep. Gr.27. –  Remove air filter housing with intake hose → Rep. Gr.24.

–  Pull locking mechanisms on gate selector cable and gear selector cable forward to stop -direction of arrow 1- and then turn to left to lock -direction of arrow 2-.

–  Pull securing clip -arrow 1- off relay lever -A- and remove relay lever. –  Remove gearbox selector lever -B- by removing nut -arrow 2-. If necessary, use two arm puller, e.g. -Kukko 20/10-.

–  Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094-. –  Pull pipe/hose line out of retainer on gearbox bracket. –  Remove cable support bracket from gearbox -arrows-. –  Then tie up selector cable and gate cable.

–  Pull connector off speedometer sender -arrow-.

–  Lever out clip -arrow- for pipe/hose line to stop with a screwdriver. –  Pull out pipe/hose line in -direction of arrow-.   Note! Do not depress clutch pedal. –  Remove upper engine/gearbox connecting bolts. –  Then remove upper securing bolt on starter. Vehicles with turbo diesel engine –  Remove charge air cooling connecting pipe from intake connecting pipe → Rep. Gr.21. –  Remove retaining clip on cylinder head for charge air cooling connecting pipe → Rep. Gr.21. Continuation for all vehicles –  If there are hose and cable connections in area of engine support eye for support bracket -10 - 222 A-, remove these now.

–  Assemble support bracket -10 - 222 A- in conjunction with adapters -10 - 222 A /14- and -10 - 222 A /15-. –  Secure adapter -10 - 222 A /14- in threaded holes for battery carrier -arrows-.   Note! For vehicles with turbodiesel engines, also use shackle -10 - 222 A /12- as shown in figure. –  Take up weight of engine/gearbox assembly on spindles.

–  Remove nuts for right engine mounting -arrows-. –  Remove front left wheel bolts. –  Raise vehicle. –  Remove left wheel. –  Remove noise insulation tray.

–  Remove bracket -1- from starter -arrow-. –  Pull off reversing light connector -2-. –  Remove starter -3- → Electrical system; Rep. Gr.27. –  Then remove air duct with fans → Rep. Gr.19. Vehicles with turbo diesel engine –  Remove charge air cooling connecting pipe -4- from charge air cooler and remove connecting pipe → Rep. Gr.21. –  Remove right drive shaft. → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40;. Continuation for all vehicles –  Disconnect drive shafts from gearbox flange shafts.

–  Separate -arrow- left coupling rod from anti-roll bar.

–  Separate threaded connection between left wheel bearing housing and lower swivel joint -arrow-. –  Swing wheel bearing housing outwards. –  Remove left drive shaft between subframe and gearbox. –  Lift drive shaft and secure to suspension strut with wire. –  Separate exhaust system, remove catalytic converter and remove front exhaust pipe from exhaust manifold or turbocharger. → Rep. Gr.26

–  Remove exhaust system bracket from subframe -arrows-. Vehicles with turbo diesel engine

–  Unbolt vacuum unit -1- for charge air control valve from turbocharger -arrows- and tie up. → Rep. Gr.21 –  Place drip tray under gearbox and engine. –  Unbolt oil return line -A- for turbocharger from engine. → Rep. Gr.21 Continuation for all vehicles

–  Unbolt bevel box carrier from engine and bevel box -A- and -B-.

–  If small cover plate -A- for flywheel behind bevel box -arrows- is installed, remove it. –  Mark position of propshaft relative to bevel box flange.

–  Unbolt propshaft from bevel box flange -arrows-.

–  Remove pendulum support, removing bolts -1-, nut -2- and bolt -3-.

–  Position engine and gearbox jack -V.A.G 1383/A- with universal support -V.A.G 1359/2 - under gearbox and exert slight counter pressure. A -  Wooden block

–  Unbolt hexagon bolts -arrows A- of left engine/gearbox mounting -2- from left bracket -1-. –  Loosen hexagon nut -arrow B-.   Note! Use step ladder -VAS 5085-. The left bracket does not need to be removed from left subframe in order to remove gearbox. –  Remove left bracket -1- from gearbox -arrows A- and -arrow B-.

Bolt -arrow B- is not visible in figure. –  Remove engine and gearbox jack -V.A.G 1383/A- with universal support -V.A.G 1359/2 - from beneath gearbox. –  Carefully press engine and gearbox forwards. –  Carefully tilt engine with gearbox until left bracket can be moved freely.

–  Remove lower engine/gearbox connecting bolts except for bolt -arrow- near bevel box.

Gearbox with threaded hole in gearbox housing -arrow- To remove gearbox “02N”, set up gearbox support -3282- with adjustment plate -3282/33-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements-A - and -C- (pin -3282/34-) on adjustment plate as shown.

–  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox. –  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Then screw pin -3282/34- into hole in gearbox for securing bolt of pendulum support (figure below). –  Secure gearbox to gearbox support -3282- using bolt -A-. Gearbox without threaded hole in gearbox housing -arrow- → Fig. To remove gearbox “02N”, set up gearbox support -3282- with adjustment plate -3282/58-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A - and -C- (pin -3282/34-) on adjustment plate as shown.

–  Position gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox.

–  Secure the two safety supports -3282/59- as shown in figure. –  Take special care in attaching the safety support -3282/59- on left of gearbox -arrow-. Continuation for all

–  Remove engine/gearbox connecting bolt -arrow-. –  Press gearbox off dowel sleeves and carefully swing towards subframe. In the process, guide gearbox input shaft completely out of clutch pressure plate. –  Pull off connector -A-.

–  Take load off engine mounting by raising engine slightly using right spindle -1-. –  Carefully tilt engine. To do this, lower left spindle -2- approx. 50 mm on support bracket -10 - 222 A-.   Note! To lower engine via spindles of support bracket -10 - 222 A-, use step ladder -VAS 5085-.

–  Secure tensioning strap -T10038- to front towing eye and to engine sump.   Note! If the engine has no protrusion on the sump, secure tensioning strap -T10038- in hole in crankcase. –  Pull engine forward carefully. –  Turn gearbox upwards near bevel box using spindles of gearbox support -3282-. –  Lower gearbox slightly and tilt to left via spindles of gearbox support -3282-.

–  Then carefully lower gearbox further, observing the following: I -  Guide bevel box -1- past sump -2- as illustrated -arrow A-. II -  At the same time, guide gearbox past subframe -arrows B-.