SEAT Workshop Service and Repair Manuals

Installation Installation is carried out in the reverse sequence; note the following:   Note t  When performing repair work, renew self-locking nuts and bolts. t  Replace bolts that are submitted to goniometric tightening, along with seals, O-rings and gaskets. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Spare parts catalogue.. t  All cable ties which were opened or cut during removal must be renewed at the same points. t  Clean the input shaft grooves, and if the clutch plates are worn, also those of the hub; eliminate corrosion and apply a very fine layer of approved lubricating grease to the grooves → Spare parts catalogue. Then, move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. Always remove excess grease. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary.

–  Ensure that intermediate plate is connected to sealing flange and housed in dowel sleeves -arrows-. –  Check that clutch plate is centred → Chapter. –  Check if the clutch release plate, is worn or noisy; in case of doubt replace it along with the slave cylinder → Chapter.

–  Replace the O-ring for the right insert axle and grease the journal with universal grease → Parts catalogue. –  Place support tool -T20138C- and the base - T20145-on the gearbox. –  Fit the previous assembly onto 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 → Remark → Remark, 2 → Remark → Remark	M12×55	80
3 → Remark, 4 → Remark	M12×165	80
5 → Remark	M12×105	80
6 → Remark, 7 → Remark	M10×50	40
8 → Remark	M10×70	40

1)  M8 threaded pin with bolts 2)  Replace bolt A  -  Dowel sleeves to centre

–  Initially, the bolts -arrows- securing the subframe to the gearbox are screwed in by hand; use new bolts.

–  Tighten the pendulum arm support first to the gearbox and then to the subframe -bolts 1 … 3-; use new bolts to secure it. –  Tighten the left hand side wheel drive shaft to the flanged shaft → Rep. gr.40. –  Install and adjust the exhaust system free of stress → Rep. gr.26. –  Fit the high pressure sender -G65- with a new O-ring → Rep. gr.87.

–  When installing air pipes with plug-in connector, ensure that securing clip -arrow- audibly engages into retaining lug -A-. –  Check the subframe adjustment and adjust if necessary → Rep. gr.10.

–  Tighten the bolts -arrows- for subframe/gearbox. Rest of installation is carried out in the reverse sequence, observing the following: –  Remove the hydraulic shut off adapters.

–  Press in pipe and hose assembly -4- with new O-ring -3- on the bleeder screw connection until securing clip -2- is audibly secured. –  Pull pipe and hose assembly to check it is properly secured.   WARNING The clutch pedal should not be pressed before bleeding the air from the clutch system. –  Bleeding clutch system → Chapter –  Fit and adjust the control cables in the gearbox → Chapter. –  Fill manual gearbox with gear oil and check oil level → Chapter . –  Fit the battery → Rep. gr.27. –  Check the headlight setting → Rep. gr.94.