SEAT Workshop Service and Repair Manuals

Removing gearbox –  The vehicle should be checked if a coded radio is fitted in the vehicle. If necessary obtain radio anti-theft code first. –  With ignition switched off, disconnect battery earth strap → Electrical system; Rep. gr.27. –  Remove engine cover.

–  Then pull off grommet -arrow- so that it is not damaged when supporting engine. –  Remove the entire air filter housing if it is located in the battery area → Rep. gr.23. –  Remove battery and battery tray → Electrical system; Rep. gr.27.

–  Remove relay lever together with cable end-piece. → Fig.. –  Remove circlip -1- that is attached to gear selector cable on relay lever -2-. –  Pull gear selector cable off pin -arrow-. –  Remove gearbox selector lever -2-.

–  Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.

Vehicles with pipe line between master and slave cylinder –  Seal the supply hose leading to the clutch master cylinder using the sealing tool -T10249/1-. Vehicles with pipe/hose line between master and slave cylinder –  Seal hose to the pipe/hose line leading to clutch master cylinder using the sealing tool -T10249/1-. Continuation for all vehicles –  Pull out clip to stop for pipe/hose line or pipe line. –  Pull pipe/hose line or pipeline out from slave cylinder bleeder and seal.   Caution Do not operate clutch pedal any more.

–  Remove upper engine/gearbox connecting bolts -arrows-. –  Loosen wheel bolts on front left and front right. –  Raise vehicle. –  Remove front wheels. –  Remove front wheel housing liners → General body repairs, exterior; Rep. gr.66. –  Then remove upper securing bolt on starter. –  Remove connectors and cables from top of starter → Electrical system; Rep. gr.27. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Gearboxes for vehicles with start-stop system: release connector of -gearbox neutral position sender-arrow -G701-.

–  Remove earth strap -1- from bottom of gearbox. –  Release electrical connection -2- from the reverse light switch -F4-. –  Remove starter -3- → Electrical system; Rep. gr.27.

–  Separate connection -arrow 1- or -arrow 2- on charge air hose.

–  Remove pendulum support from gearbox, bolt -1- and bolt -2-.

–  Release the connector -1- from the oil level and temperature sender -G266-. –  If front left vehicle level sender connectors -G78- are present, release them → Rep. gr.40.

–  Remove left and right coupling rods from anti-roll bar → Running gear, axles, steering; Rep. gr.40. –  Unscrew nuts -arrows- for swivel joint on suspension links.

–  Remove exhaust system bracket from subframe -arrows-. –  If present, remove exhaust system support from gearbox. –  Detach exhaust system behind particulate filter → Rep. gr.26 and place on tunnel bridge. –  Fix position of subframe prior to removal → Running gear, axles, steering; Rep. gr.40. –  Remove subframe using steering box → Running gear, axles, steering; Rep. gr.40. ⇒ next illustration –  Secure support bridge -T10323- via inner rear threaded holes for the subframe. –  Use the subframe securing bolts for this purpose.

–  Mark position of propshaft with flexible coupling relative to bevel box flange with paint. –  Unbolt propshaft from bevel box -arrows- → Rep. gr.39.

–  Lie a cloth -A- on the support bridge -T10323-, so as not to damage the propshaft paint. –  Move front section of propshaft to rear up to stop and install the shaft on the support bridge -T10323-.

–  Remove drive shaft heat shield from bevel box (nuts -1-) → Running gear, axles, steering; Rep. gr.40.

–  Remove drive shafts from gearbox and bevel box → Running gear, axles, steering; Rep. gr.40. –  Swivel drive shafts into the wheel housing. The surface protection of the shafts must not be damaged. Secure both drive shafts to suspension strut using tensioning strap -T10038-.

–  To gain more clearance in vehicles with supplementary heaters, remove coolant hoses -1- and -2- for supplementary heater from engine and bevel box. Do not open pipes → Auxiliary heater; Rep. gr.82.

–  Remove bolts -arrows 1- for gearbox carrier on bevel box. –  Remove bolts -arrows 2- for gearbox carrier on engine. Remove the following components: t  Windscreen wiper arms → Electrical system; Rep. gr.92 t  Plenum chamber cover → Rep. gr.50

–  Attach engine mount -U30025F- as shown using the required adaptors and hold the engine in its installation position.   Note

t  The supporting feet kit -U30025/5B- must be installed together with rubber buffers so that it points to the wing. The front part of the support must be in the retaining bracket bolt area of the front terminal. t  The retaining bracket securing bolts for the engine assembly can only be unscrewed when the engine is fixed to the engine mounting -U30025F-. –  Take up weight of engine/gearbox assembly on spindles.

–  Remove bolts -arrows- from left engine/gearbox mounting. –  Lower gearbox by adjusting spindles.

Dimension -a- = about 90 mm   Note When moving engine and gearbox assembly, observe coolant hoses between engine and heat exchanger, being careful not to stretch them.

–  Remove engine/gearbox connecting bolts -arrow- next to bevel box -A-. –  Attach the support tool -T20138C- on the base -T20145-, and move these onto the engine and gearbox jack -SAT 1040- using the adapter for the hydraulic engine and gearbox jack -SAT 1001/1-. –  Fix the gearbox bracket -T20138C- to the gearbox casing.

l  Gearbox, engine on opposite side: attach an adjustment plate -3282/048- to each gearbox side bracket and the adjustment plate -3282/049- to the rear bracket.

l  Gearbox, on the side of the engine: insert centring mandrel -3282/050- in the gearbox opening. –  Unscrew bolts that connect the engine and gearbox. –  Carefully push gearbox off engine. –  Now tilt the gearbox left via the counterhold -T20138C- spindle.

–  Carefully push gearbox off engine, taking the longitudinal member -arrows- into account. –  Lower gearbox carefully. –  Carefully swivel left side of gearbox towards the front end.   Note Be careful of all lines when lowering gearbox.