SEAT Workshop Service and Repair Manuals

Removing

• ‒ → With the vehicle resting on its wheels loosen left-hand wheel hub/drive shaft bolt and left and right-hand wheel securing bolts.

Note:

Note radio coding for vehicles with coded radio.

• ‒ With the ignition switched off disconnect the battery earth strap (in engine compartment and if fitted, under driver's side).

=> Electrical system; Repair group 27

• ‒ → Remove air cleaner upper section to do this loosen clips -A- and hose -B-.
• ‒ Remove air cleaner lower section.

• ‒ → Remove trim for air guide (arrows).

• ‒ → Press pipe off above mounting eye for support device 10- 222 A (arrow).

• ‒ → Remove vacuum hose (arrow -A-) to brake servo at intake manifold.
• ‒ Pull connector (arrow -B-) off intake air temperature sender G72.

• ‒ → Fit support device 10-222A together with legs 10-222 A/5.

• ‒ → Bolt legs 10-222 A/5 to body (arrows).
• ‒ Take weight of engine/gearbox assembly on the spindles.

• ‒ → Remove nuts for right-hand engine mounting (arrows).

• ‒ Remove insulation tray below engine/gearbox, if fitted.
• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

• ‒ → Lever clip (arrow -A-) for pipe out from slave cylinder (direction of arrow), pull pipe (arrow -B-) out and seal with 10 mm plug.

• ‒ Remove both wheels

Remove/loosen left and right-hand wheel mountings as follows:

• ‒ → Press track rod off steering arm.

•     1 -    Hooks (commercially available) e. g. Kukko No. 1-90
•     2 -    Puller (commercially available) e.g. Kukko No. 20-10

• ‒ Tie up track rod

• ‒ → Separate left and right-hand bolted connection for wheel bearing housing/lower swivel joint.

• ‒ → Remove left and right-hand coupling link -1- on shock absorber.
• ‒ Detach brake hose and, if fitted, ABS sensor cable from retainers on shock absorber.

• ‒ Place drip tray underneath.
• ‒ → Lever left-hand drive shaft out of gearbox and pull out of wheel hub.

• ‒ → Insert sealing cap 3394 into gearbox.

Vehicles up to January 97

• ‒ → Pull right-hand drive shaft out of centre bearing by tugging outwards on wheel mounting.
• ‒ Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.
• ‒ Unbolt centre bearing from mounting on engine block (arrows -A-) and pull with axle shaft (arrow -B-) out of gearbox, lever out if necessary.
• ‒ Insert sealing cap 3394 into gearbox.

Vehicles from January 97

• ‒ Pull right-hand drive shaft out of centre bearing by tugging outwards on wheel mounting.
• ‒ Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.
• ‒ → Unbolt axle shaft bearing (arrows) and pull axle shaft out of gearbox.

• ‒ → Remove engine/gearbox support -arrows 1 to 3-.
• ‒ Insert sealing cap 3394 into gearbox.

Continuation for all vehicles

• ‒ → Remove pendulum support -1-, to do this remove bolt and nuts -A-.

Note:

The pendulum support can be secured to the assembly carrier with one bolt or with three bolts.

• ‒ → Separate gearbox mounting, to do this remove bolts -A- and -B-.
• ‒ Push engine/gearbox assembly as far as possible to right.
• ‒ Tilt engine/gearbox assembly, to do this raise right-hand spindle and lower left-hand spindle.

• ‒ → Remove mounting from gearbox console (arrows).

• ‒ → Pull connector off road speed sender (arrow).

• ‒ Remove flywheel cover plate.

• ‒ → Lever gear selector cable -A- and gate selector off and press out from mounting on gearbox.
• ‒ Push pipework between master and slave cylinder out of mounting on gearbox.

• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/21 for "006", gearbox and support elements as follows:

• ‒ Place adjustment plate 3282/21 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.

• ‒ → Remove engine/gearbox securing bolts (arrows).

• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration N34-0296 on previous page) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and secure gearbox with bolt.

• ‒ → Remove engine/gearbox securing bolts (arrows).

• ‒ Press gearbox off dowels and lower until the reversing light connector (arrow) can be reached.
• ‒ → Pull reversing light connector off (arrow).
• ‒ Lower gearbox carefully.
• ‒ Charge position of gearbox in area of assembly carrier and left-hand body when lowering via gearbox jack spindle.

Transporting the gearbox

Special tool 3336 may be used to transport the gearbox and also when setting up gearbox mount 3282.

• ‒ → Bolt gearbox lifting device 3336 to clutch housing.

• ‒ → Set support beam on sliding piece with locking pin (arrow).

No. of holes visible = 7

• ‒ Take gearbox out with workshop crane and gearbox lifting device 3336.

Installing

• ‒ Clean input shaft splines and lightly grease with G000 100 grease.

The clutch plate must be able to slide lightly to and fro on the input shaft.

• ‒ Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/21 for "006" gearbox and support elements as follows:

• ‒ Place adjustment plate 3282/21 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.
• ‒ Place gearbox on gearbox jack.
• ‒ Align adjustment plate and gearbox parallel and secure with a bolt.

• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration N34-0296 on previous page) on adjustment plate points to front of vehicle.

• ‒ → Reconnect reversing light connector (arrow).
• ‒ Install gearbox, press engine slightly forward if necessary.
• ‒ Install all engine/gearbox securing bolts.

• ‒ Press gear selector cable and gate selector cable in mounting on gearbox onto stop.

Installation position:

The gear selector cable crosses over the gate selector cable.

• ‒ → Press gear selector cable -A- onto gear stick lever.
• ‒ Press gate selector cable -B- onto gate selector lever.

• ‒ Press pipe work into retainer on gearbox and insert into slave cylinder.
• ‒ → Press clip -A- for pipe -B- in.

• ‒ → Install mounting to gearbox console (arrows).

• ‒ Align engine/gearbox in installation position.
• ‒ → Assemble gearbox mounting. To do this screw bolts -A- and -B- in.
• ‒ Remove support bar 10-222A.

→ Pendulum support to gearbox

For start of production a steel pendulum support was produced with two bushes for mounting to subframe - Length of bushes = 90 mm.

After a short run-up period the support will be substituted for an aluminium support -1- with one bush (arrow) - Length of bush = 90 mm.

Due to modifications to pendulum support mounting a shorter bush has been introduced - Length of bush = 85 mm.

• ‒ Allocate pendulum support to subframe mounting:

• ‒ 1)Secure pendulum support with one bush into front subframe drilling.

From 09.03.98 a longer bolt -A- has been introduced. The drilling in the pendulum support has been adapted to the longer bolt.

→ Allocation

The new bolt cannot be installed in the old pendulum support.

If the pendulum support is renewed, the new bolt -A- must be installed.

• ‒ → Reconnect road speed sender connector (arrow).
• ‒ Install flywheel cover plate.
• ‒ Bolt on earth wire.
• ‒ Install starter.

=> Repair group 27; Removing and installing starter.

• ‒ Take sealing caps 3394 out from shaft openings.
• ‒ → The securing ring -A- must be replaced before installing left-hand shaft.
• ‒ Push left-hand shaft in (direction of arrow), carefully drive in with synthetic head hammer if necessary.

Vehicles up to January 97

• ‒ Replace securing ring on splines for right-hand drive shaft before installing axle shaft.
• ‒ Carefully insert axle shaft into gearbox, do not damage sealing ring.
• ‒ → Bolt axle shaft bearing on securely (arrows).
• ‒ Push right-hand drive shaft onto axle shaft splines, carefully drive on with a synthetic head hammer if necessary.

Vehicles from January 97

• ‒ → Fit support onto engine/gearbox.
• ‒ First tighten bolts -arrows 1 to 3- in ascending order hand tight, then tighten to tightening torque.
• ‒ Replace securing ring of axle shaft splines.
• ‒ Carefully insert axle shaft into gearbox, do not damage sealing ring.

• ‒ → Bolt axle shaft bearing on securely (arrows).
• ‒ Push right-hand drive shaft onto axle shaft splines, carefully drive on with a synthetic head hammer if necessary.

Continuation for all vehicles

• ‒ → Install left and right-hand coupling links -1- to shock absorber.
• ‒ Press brake hose and, if fitted, the ABS sensor cable in retainer on shock absorber.

• ‒ → Assemble left and right-hand bolted connection for wheel bearing housing/lower swivel joint.
• ‒ Press left and right-hand track rods on steering arm.
• ‒ Install both wheels.

• ‒ Install insulation tray below engine/gearbox, if fitted.
• ‒ → Install nuts fo right-hand engine mounting.
• ‒ Install air cleaner.
• ‒ Reconnect earth strap to battery.
• ‒ Bleed clutch system.
• ‒ Check gearbox oil .
• ‒ Adjust gear change linkage .

Note:

Note radio coding for vehicles with coded radio.

Tightening torques

→ Gearbox to engine

    1)    Flywheel cover plate

Items A + B - Dowel sleeves

Vehicles up to January 97

Vehicles from January 97

→ Support to engine/gearbox

• ‒ First tighten bolts -arrows1 to 3- in ascending order hand tight, then tighten to tightening torque.

→ Axle shaft bearing to support

Continuation for all vehicles

Gearbox to body