SEAT Workshop Service and Repair Manuals

Installing gearbox Installation is carried out in the reverse sequence; note the following:   Note t  Renew bolts which are tightened by turning through a specified angle. t  Renew seals, gaskets and self-locking bolts and nuts. t  Renew locking plate and securing clip for selector lever cable. t  Hose connections and air pipes and hoses must be free from oil and grease before fitting. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the charge air hoses can be connected securely, you must spray the screws on used screw-type clips with rust remover prior to installation. t  Re-attach all cable ties at the same locations when re-installing. l  Gearbox assembly mounting tightening torques → Anchor –  Check needle bearing in crankshaft → Rep. gr.13. –  Clean splines of input shaft and hub; remove corrosion. –  Grease splines with a very small amount of grease for clutch plate splines; for grease for clutch plate splines refer to → Electronic spare parts catalogue. It is essential to remove excess grease.

–  Check that dowel sleeves -A- are correctly seated in cylinder block.

–  Lift the gearbox very carefully. –  Join gearbox to engine, taking care not to trap wiring or other connections. –  Screw the gearbox to the engine → Anchor.

–  Install subframe. Note their assembly sequence in doing so → Fig..   WARNING Do not remove support -U 30025E- until all the bolts on the mechanical assemblies mounting have been tightened to corresponding torque and the subframe has been mounted. –  Screw the bracket of the pair of bevelled gears to the engine and the bevelled gear, tightening torque and sequence → Anchor.

–  Install selector lever cable → Chapter.

Caution The seal -arrow- in the propshaft flange can be damaged. Press the engine - gearbox unit to the dashboard; in doing so, carefully feed the pinion of the bevelled gear into the flange for the cardan shaft. –  Push propshaft horizontally onto guide pin → Rear final drive 0AV and 0BR; Rep. gr. 39. –  Install subframe → Rep. gr.40.

–  Screw the pendulum support to the gearbox with bolts -2- and -3-.

–  Screw the cardan shaft with flexible disk on to the pair of bevelled gears → Rear final drive 0AV and 0BR; Rep. gr.39. –  Install drive shafts → Rep. gr.40.

–  Adjust assembly mountings → Rep. gr.10. –  Remove the support -U 30025E- from the engine. –  Follow the steps required after connecting the battery → Rep. gr.27. –  Check adjustment of selector lever cable and adjust if necessary → Chapter. –  Checking gear oil level and topping up → Chapter –  Check coolant level → Rep. gr.19. Tightening torques (installing gearbox)   Note t  The tightening torques listed on this page apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts. t  Additional lubricants may be used, for example engine or gear oils, but they should never contain graphite. t  Use is never to be made of degreased parts. t  Tolerance for specified torques is ± 15%.

Engine / gearbox mountings:

Item	Bolt.	Nm
1, 3 1)	M12 x 55	80
2	M10 x 45 Starter motor mounting → Rep. gr.27	40
4	M10 x 45 Starter motor mounting → Rep. gr.27	40
5	M12 x 65	80
6, 7, 8	M10 x 50	40
9	M12 x 70	80
10	M12 x 55	80
A	Dowel sleeves to centre
1)	The bolts Pos. 3 can only be reached through the opening after removing the starter motor.

Other tightening torques l  → Chapter „Assembly overview: Assembly mountings“ l  Mount the bracket of the pair of bevelled gears → Anchor.