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Service

Workshop Manual
Arosa 1997 ➤
001 Automatic gearbox
Edition 10.02

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, Housing
38 - Gears, Hydraulic controls
39 - Final drive, Differential

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2015 Seat S.A S01B0018620


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 ...................................................................... 1
2 ...................................................................... 2
3 Code letters, group numbers, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 ...................................................................... 6
5 General instructions for gearbox repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Identifying the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Torque converter: empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Torque converter seal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Torque converter: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

37 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Connect fault reader V.A.G 5051 and select the functions . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Electrical/electronic components and their location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Vehicle components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Gearbox electrical/electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Gear drive mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Gear drive mechanism: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 Selector lever cable: check and adjust (vehicles up to 06.00) . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Selector lever cable: check and adjust (vehicles from 07.00 onwards) . . . . . . . . . . . . . . . . 25
3.4 Gear drive mechanism: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . 26
3.5 Selector lever: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . . . . . . . 29
3.6 Selector lever: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . . . . . . . 32
3.7 Selector lever cable: dismantling and assembling (vehicles up to 06.00) . . . . . . . . . . . . . . 33
3.8 Gear drive mechanism: dismantling and fitting (vehicles from 07.00 onwards) . . . . . . . . . . 36
3.9 Selector lever cable: removing and fitting (vehicles from 07.00 onwards) . . . . . . . . . . . . . . 38
3.10 Gear selector knob: removing and fitting (vehicles from 07.00 onwards) . . . . . . . . . . . . . . 41
4 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1 Gearbox: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 ATF level: checking and filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1 ATF level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2 Replace ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3 Changing the ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Gearbox with control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 Control elements position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Gearbox: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 ATF radiator and ATF filling tube: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7.2 Planet gears: generalpermitted
assembly diagram
unless authorised . . .S.A.
by SEAT . . SEAT
. . . S.A
. . does
. . . not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
. . . .with
....... 60
7.3 I - ATF pump up to the large planet gear: general assembly diagram . . . . . . . . . . . . . . . .
respect to the correctness of information in this document. Copyright by SEAT S.A.
62
7.4 II - Cover for the gearbox casing up to the drive sprocket: general assembly diagram . . . . 63
7.5 Planet gears: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 General overview for the all adjustments to the planet gear . . . . . . . . . . . . . . . . . . . . . . . . 86
7.7 Reverse gear brake -B1- adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8 2nd and 4th gear brake -B2-: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9 Clutch clearance: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

38 - Gears, Hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95


1 ATF pump: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Contents i
Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

2 Free sprocket: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97


3 Clutch for 1st to 3rd gears -K1-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . 98
4 Reverse gear clutch -K2-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5 Clutch 3rd and 4th gear -K3-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . 104
6 Reverse gear brake -B1-: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7 2nd and 4th gear brake piston -B2- dismantling and assembling . . . . . . . . . . . . . . . . . . . . 109
8 Slide box: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.1 Slide box (vehicles up to 06.00): removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.2 Slide box (vehicles from 07.00): removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9 Parking lock: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

39 - Final drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121


1 Articulation flange seals: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Articulation flange seals: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2 Final drive: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.1 Final drive: general assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.2 Differential: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.3 Engine shaft: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3 Differential: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4 Final drive: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.1 Final drive: Overview of check steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.2 Adjustments to be carried out when changing components . . . . . . . . . . . . . . . . . . . . . . . . 139
4.3 Differential: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.4 Engine shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

ii Contents
Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

00 – Technical data
1 Identifying the gearbox
Location on the gearbox
The 001 4-speed automatic gearbox is fitted to the Arosa 1997 ▸,
combined with the 4 cylinder engine. Correspondence
⇒ page 3 , code letters, group numbers, ratios, equipment
Code letters and dates of manufacture of gearbox -arrow-
Example
ESK 10 05 0
I I I I
Codes Day Month Year of manufacture
2000
Any additional data refer to the manufacturing process.

Note!

The additional gearbox code letters are also on the customer ve‐
hicle service schedule.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. 1
Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

2 Notes on “Automatic gearbox 001”


Gear change
The 001 automatic 4-speed gearbox is fitted with four hydrauli‐
cally controlled gears. 3rd and 4th gear are controlled mechani‐
cally when the clutch cancellation of the torque converter is
closed, thus avoiding torque converter slipping.
Control unit -J217-
The control device has two programmes for two different driving
styles; sports (“SPORT” programme) and economic (“ECO” pro‐
gramme).
These two programmes are automatically connected by the con‐
trol device.
The automatic gearbox control unit -J217- receives information
from the components which influence the gear change. This is
transmitted to the slide box with the solenoid valves which in turn
activate the final control elements via hydraulic connections.
So that the cause of an electrical/electronic component failure or
a short circuit can be quickly discovered, the control unit is fitted
with a fault memory. Faults are recognised via electrical signals
and are memorised in the fault memory.
Torque converter
The torque converter is fitted with a cancelling clutch. The can‐
celling clutch closes according to load and speed, engaging 3rd
and 4th gears mechanically and with no slipping.

ATF
The ATF in the gearbox does not need to be changed. It does not
need to be changed during routine maintenance.
If it is necessary to top up, only use ATF fluid ref. no.:
G 052 990 A2
The ATF level in the planet gears and drive shaft is checked and
filled together ⇒ page 53 , ATF level: checking and filling.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

3 Code letters, group numbers, ratios, equipment


Automatic gearbox 001
Gear change Codes CMJ DPP
Torque converter Codes AAN AAN
Slide box Codes IIJ/BAH IIJ/BAH
Number of discs Inner Outer Inner Outer
-K1- clutch 5 5 5 5
-K2- clutch 2 2 2 2
-K3- clutch 3 3 3 5
Brake -B1- 5 4 5 4
Brake -B2- (band brake)
Piston ∅ mm
2nd gear (stepped piston) 50 + 31 50 + 31
4th gear 44 44
Allocation Model Arosa 1997 ▸ Arosa 1997 ▸
Engine 1.4 l 44 kW 1.4 l 44 kW

Gear change Codes CMJ DPP


Ratio 1st gear 2.875 2.875
2nd gear 1.510 1.510
3rd gear 1.000 1.000
4th gear 0.726 0.726
Reverse 2.656 2.656
Intermediate shaft Number of teeth Drive sprocket 49 49
Driven 53 53
sprocket
Ratio 1.082 1.082
Final drive Number of teeth Pinion wheel 20 20
Crown 81 81
Ratio
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4.05 4.05
∅ Drive
permitted shaft
unless flange
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with 90 mm Tripod
respect to the correctness of information in this document. Copyright by SEAT S.A.
CAN-Bus No No
Type of accelerator Mechanical Mechanical

Automatic gearbox 001


Gear change Codes EAS EHD
Torque converter Codes AAN AAN
Slide box Codes CCC CCC
Number of discs Inner Outer Inner Outer
-K1- clutch 5 5 5 5
-K2- clutch 2 2 2 2
-K3- clutch 3 5 3 5
Brake -B1- 5 4 5 4
Brake -B2- (band brake)
Piston ∅ mm

3. Code letters, group numbers, ratios, equipment 3


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Automatic gearbox 001


Gear change Codes EAS EHD
2nd gear (stepped piston) 50 + 31 50 + 31
4th gear 44 44
Allocation Model Arosa 1997 ▸ Arosa 2001 ▸
Engine 1.4 l 44 kW 1.4 l 44 kW

Gear change Codes EAS EHD


Ratio 1st gear 2.875 2.875
2nd gear 1.510 1.510
3rd gear 1.000 1.000
4th gear 0.726 0.726
Reverse 2.656 2.656
Intermediate shaft Number of teeth Drive sprocket 49 49
Driven 53 53
sprocket
Ratio 1.082 1.082
Final drive Number of teeth Pinion wheel 20 20
Crown 81 81
Ratio 4.05 4.05
∅ Drive shaft flange 90 mm 90 mm
CAN-Bus Yes Yes
Type of accelerator Electronic Electronic

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Automatic gearbox permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with 001
respect to the correctness of information in this document. Copyright by SEAT S.A.
Gear change Codes FMA
Torque converter Codes AAN
Slide box Codes CCC
Number of discs Inner Outer
-K1- clutch 5 5
-K2- clutch 2 2
-K3- clutch 3 5
Brake -B1- 5 4
Brake -B2- (band brake)
Piston ∅ mm
2nd gear (stepped piston) 50 + 31
4th gear 44
Allocation Model Arosa 2001 ▸
Engine 1.4 l 44 kW

Gear change Codes FMA


Ratio 1st gear 2.875
2nd gear 1.510
3rd gear 1.000
4th gear 0.726

4 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Gear change Codes FMA


Reverse 2.656
Intermediate shaft Number of teeth Drive sprocket 49
Driven sprocket 53
Ratio 1.082
Final drive Number of teeth Pinion wheel 20
Crown 81
Ratio 4.05
∅ Drive shaft flange 90 mm
CAN-Bus Yes
Type of accelerator Electronic

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Code letters, group numbers, ratios, equipment 5


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

4 Filling amount
Planet gears and final drive
Filling amounts Automatic gearbox 001
First load 5.7 l
(Permanent filling)
Lubricant ATF
Spare no.:
G 052 990 A2
The planet gears and drive shaft must be checked and filled to‐
gether as described ⇒ page 53 , ATF level: checking and filling.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

6 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

5 General instructions for gearbox re‐


pairs
To achieve a perfect and successful repair of the gearbox, it is
imperative to keep everything scrupulously clean and use the
correct tools in perfect working order. When carrying out repairs,
bear in mind basic safety rules.
Here is a summary of general instructions for certain repair jobs,
which would otherwise appear several times in the different sec‐
tions of this Workshop Manual. Thus, these instructions must be
taken into account for this Workshop Manual.
Gear change
♦ Before fitting the gearbox to the engine, make sure that the
dowel pegs between both elements are in good condition and
correctly seated
♦ Clean contact surfaces on fitting blocks, supports or waxed
components. The surfaces must be completely free from wax
or grease
♦ If the automatic gearbox has been replaced, check and top up
with ATF if necessary. Filling amounts and oil type specifica‐
tions ⇒ page 6
Oil seals
♦ Before fitting the radial oil seals, fill the space between the
sealing lips with grease
♦ Replace O-rings
♦ After fitting, check the ATF fluid level and top up if necessary
Sealing paste
♦ Clean contact surfaces thoroughly and apply -D 176 404 A2-
sealing paste
♦ Note the use-by date of the sealant.
♦ After applying the sealing paste, bolt up the components within
5 minutes
♦ After assembly, the sealant should be dry in approx. 30 mi‐
nutes Then fill with ATF
Safety locks

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

5. General instructions for gearbox repairs 7


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

♦ Renew all safety rings, taking care not to stretch them exces‐
sively when fitting
♦ The safety rings must be perfectly seated in their groove
♦ Renew all split pins
♦ On fitting split pins, the expansion groove should be facing the
direction of power transmission, as seen in the illustration
Bolts, nuts
♦ Always loosen and tighten nuts and bolts on covers and casing
in diagonal sequence
♦ For delicate parts, e.g. the slide box , always loosen and tight‐
en the bolts in stages and in diagonal sequence
♦ Tightening torques are specified for nuts and bolts without lu‐
brication
♦ Always replace any self-locking nuts and bolts
♦ Bolts with torque and stretch specifications must always be
renewed
♦ If the bolt threads have remains of locking paste, clean with a
wire brush. Then insert the bolts with -AMV 185 100 A1-
♦ The bolts and nuts of all threaded joints will be waxed when
fitted (if necessary)
Bearings
♦ Partially lubricate all gearbox bearings with ATF fluid before
fitting
♦ Fit new roller bearings as supplied, without lubrication, espe‐
cially the conical bearings
♦ Place the axial needle bearings in their correct position
⇒ page 65
♦ Bearings corresponding to the same shaft will be all replaced
together, especially conical bearings. If possible, use parts
from the same manufacturer
♦ Do not mix up the inner and outer rings of the same size bear‐
ings. The bearings come in matched pairs
♦ Heat the inner roller bearing ring to 100°C before press fitting
Removal of outer rings of roller bearings and bearing bushes with
tool set -T20140-
Remove the outer rings of the roller bearings
Protectedorbythe bearing
copyright. bush‐
Copying for private or commercial purposes, in part or in whole, is not
es as follows: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Measure (if possible) the internal diameter of the external ring
of the roller bearing or the bearing bush.
– Select the correct clamp from the tool set according to:
If the diameter measured is less than 30 mm:
– Fit the plunger for small clamps/10 and the correct clamp for
internal diameters.
If the diameter measured is more than 30 mm:
– Fit the plunger/28 and clamp /29 and the correct claws for the
internal diameter.
– Screw nut /5 and washer on the plunger.

8 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Place the tool on the outer ring of the roller bearing or the
bearing bush and fit the threaded legs so that they are firmly
secured.

Note!

The legs of bridge /1 have different-sized cut-outs -arrows- to fa‐


cilitate support on surfaces with different heights, edges or ribs.

– Adjust the threaded legs of the bridge /1 so that the bridge is


parallel to the surface of the casing.
– Open the clamps until the bar is housed below the exterior
roller bearing or the bearing bush.
– Action the extractor until the outer ring of the roller bearing or
bearing bush is extracted.

Note!

Due to the fact that on some occasions the space for the claw is
minimal, a first extraction should be carried out to remove the
bush, and then open the claws as far as possible to ensure the
maximum contact surface. Then continueProtected
with the extraction.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Piston rings
♦ Do not open excessively when removing or fitting
Shims
♦ Before fitting shims, check thickness measuring several points
of the surface with a micrometer
♦ The existence of different thicknesses allows the exact cali‐
bration of the thickness of the shim needed
♦ Check they have no lips and that they are not damaged. Only
fit shims in perfect state
Clutches and brakes

♦ Clutches K1, K2 and K3 should be dismantled for cleaning;


assign the faulty components (e.g. outer and inner discs) ac‐
cording to the gearbox code.
♦ Before fitting the piston, coat the sealing lips and oil seals with
ATF
♦ After fitting the clutches or brakes, it should be possible to turn
the piston in both directions by hand -arrow- . If this is not the
case, perhaps the sealing lips or oil seals are incorrectly fitted
or damaged.
– If this is the case, remove the piston again.
– Check for damage in the sealing lips or oil seals and replace
if necessary.
– Refit the piston and check again.
Slide box
♦ If any control elements are burnt, the slide box should be re‐
placed
Inner discs

5. General instructions for gearbox repairs 9


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

♦ Fit the new inner discs, before fitting soak in ATF for 15 mi‐
nutes.
Self-diagnosis
♦ Before carrying out repairs in the automatic gearbox, the pos‐
sible cause of the problem should be determined with preci‐
sion: ⇒ VAS 5051; Vehicle self-diagnosis

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

10 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

32 – Torque converter
1 Torque converter

1.1 Identifying the torque converter


There are various torque converters. They can be differentiated
by the code -arrow- .
Numbers allocated to torque converter/gearbox ⇒ page 3 , Code
letters, group numbers, ratios, equipment.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Torque converter code


(assembled gearbox)
– Remove the protection plate -arrow- .

1.2 Torque converter: empty


Special tools and workshop equipment required
♦ Oil extractor -SAT 1100-

1. Torque converter 11
Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

If dirt and abrasive particles are present in the ATF or if a general


revision is made of the gearbox, the converter should be emptied.
– The converter oil can also be syphoned off with the -SAT 1100-
unit.

1.3 Torque converter seal: removing and in‐


stalling
Special tools and workshop equipment required
♦ Extractor -T20143-

♦ Plunger -U-40002-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Using extractor -T20143- , disengage the torque converter


housing bracket from the torque converter.

12 Rep. Gr. 32 - Torque converter


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Using plunger -U-40002- , assemble the torque converter


housing bracket onto the torque converter.

1.4 Torque converter: removing and instal‐


ling
Special tools and workshop equipment required
♦ Holding tool -T20157-

1.4.1 Removing
– Place tool -T20157- onto one of the torque converter bolts and
fit it with its corresponding nut.
– Tilt the gear approx. 60°, and remove the torque converter,
while preventing the ATF from falling out.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.4.2 Fitting
Only use ATF with part number -G 052 990 A2- .
– Fill the converter with 1.5 litres of ATF.
– Fit the torque converter.

1. Torque converter 13
Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

The ATF pump is activated via the torque converter -arrows- .

– Tilt the gear approx. 60°, in such a manner that when the con‐
verter is inserted, the ATF does not fall out.
– Place the torque converter in the housing, taking into account
its position with
Protected respectCopying
by copyright. to the ATF orpump
for private sprocket.
commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Turn the gear intosuch
respect a wayofthat
the correctness the converter
information remains
in this document. level.
Copyright by SEAT S.A.

– Fit the converter into the cutouts of the ATF pump sprocket.

The converter has been correctly fitted when the measurement


between the joining flange and the contact surface of the conver‐
ter's guide stem is 18 mm.

14 Rep. Gr. 32 - Torque converter


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

37 – Controls, Housing
1 Connect fault reader -V.A.G 5051-
and select the functions
All functions which could previously be performed with -
V.A.G 1551/1552- can also be performed with the new tester -
VAS 5051- in the operating mode “vehicle self-diagnosis” : ⇒
Instruction manual for Vehicle Diagnosis, Testing and Information
System VAS 5051.
Special tools and workshop equipment required
♦ -VAS 5051- diagnosis operations central

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

Caution

♦ During the test drive, testing and measuring instruments


must always be installed in the rear seat
♦ While the vehicle is in motion, this equipment should only
be operated by a person other than the driver

Checking conditions
• Selector lever in position “P” and hand brake on
• Battery voltage must be at least 11.5 V
• All fuses correct, according to current flow diagrams
• All fuses in the battery box, correct
• Check earth connections for gearbox:
– Check the earth connections for corrosion and loose contacts
and, if necessary, repair them.
– The earth connection fixing point is situated under the battery.
– Check the battery earth strap and earth strap between the
bodywork and the starter motor.

1. Connect fault reader V.A.G 5051 and select the functions 15


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Connecting -VAS 5051-


– With the ignition switched off, fit the connector from diagnosis
cable -VAS 5051/1- or -VAS 5051/3- to the diagnosis connec‐
tion. Connectors for the diagnosis connection
⇒ Item 9 (page 18) .
Select operating mode
– Press button on display for “Vehicle self-diagnosis” .
Select vehicle system
– Press the button on the screen of the system that is to be
checked.
The control unit code and identification appear on the screen.
Select diagnostic function
All diagnosis functions available are indicated on the display.
– Press button on display for desired function.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note! permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

The display zones in the functions “04 - Basic setting” or “08 -


Read measured value block” , will be listed from top to bottom.

– Continue with the self-diagnosis of the vehicle system which


has to be checked with the descriptions of the repairs.

16 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

2 Electrical/electronic components and


their location
Gearbox electrical/electronic components ⇒ page 20

2.1 Vehicle components

Note!

If replacing any components labelled with * a basic adjustment should be carried out ⇒ VAS 5051, Vehicle self-
diagnosis

1 - Automatic gearbox control


unit -J217- *
❑ Location ⇒ page 18
❑ Dismantling and fitting
⇒ page 18 ,
❑ Checked by self-diag‐
nosis ⇒ VAS 5051,
Fahrzeug-Eigendiag‐
nose
2 - Engine control unit*
❑ Location: in the plenum
chamber, on the right
❑ Checking ⇒ VAS 5051,
Vehicle self-diagnosis
❑ Renew ⇒ Rep. Gr. 24 ;
Engine control unit
3 - Throttle valve control unit -
J338- *
❑ Location: in the throttle
valve
❑ With throttle valve po‐
tentiometer -G69-
❑ Removing and installing
⇒ Rep. Gr. 24 ; Injec‐
tion system: repairing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Electrical checking ⇒ respect to the correctness of information in this document. Copyright by SEAT S.A.
Rep. Gr. 24 ; Checking
components
❑ This can be checked
with the measured value
block ⇒ VAS 5051, Ve‐
hicle self-diagnosis
❑ The throttle potentiome‐
ter signal is transmitted
to the gearbox control
unit via the engine control unit
❑ If the self-diagnosis reveals a fault in the throttle valve control unit, also conduct a self-diagnosis of the
engine control unit
4 - Gearbox
❑ Gearbox electrical/electronic components ⇒ page 20
5 - Kick-down switch -F8-
❑ In vehicles up to 06.00
❑ Location ⇒ page 20

2. Electrical/electronic components and their location 17


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

❑ Dismantling and fitting ⇒ page 20


❑ In vehicles equipped with an electronic accelerator, the kick-down switch signal is generated in the ac‐
celerator pedal position senders -G79- and -G185-
❑ This can be confirmed during the electrical check ⇒ VAS 5051; Vehicle self-diagnosis
6 - Brake light switch -F-
❑ Location: in the brake pedal
❑ Removal, fitting and adjustment ⇒ Brake system; Rep. Gr. 45 ; Electrical/electronic components and
their location
❑ This can be checked with the measured value block and during the electrical check ⇒ VAS 5051, Vehicle
self-diagnosis
7 - Starter blocking relay -J207-
❑ Location: in the relay bracket plate ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
❑ The relay is coded with the number 53
8 - Magnet for selector lever locking -N110-
❑ Removing and installing:
❑ Vehicles up to 06.00 ⇒ Item 6 (page 30)
❑ Vehicles from 07.00 onwards ⇒ Item 14 (page 37)
❑ This can be checked with the measured value block and during the electrical check ⇒ VAS 5051; Vehicle
self-diagnosis
9 - Connection for diagnosis
❑ Up to 06.00 ⇒ page 19
❑ from 07.00 onwards ⇒ page 19

Removal and assembly of the automatic gearbox control unit -


J217-
Location: the gearbox control unit -arrow- is in the plenum cham‐
ber.

2.1.1 Removal
– Switch ignition off.
– Remove wiper arms and cowl panel: ⇒ Electrical system; Rep.
Gr. 92 ; Windscreen wiper system . copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected by

– Partially remove windscreen wiper


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
rods.
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Release the multiple connector and disengage from the con‐


trol unit.

18 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the bolts -arrows- , and move the control unit toward
the right to remove it.

2.1.2 Installation
– Secure the control unit.
– Fit the multiple connector to pins -1- and -2- in the control unit
and then block the multiple connector -arrow- .

Note!

When fitting it, make sure that the guides -1- fit into the pins in the
control unit

– Carry out basic adjustment: ⇒ VAS 5051; Vehicle self-diag‐


nosis

Diagnosis connection in vehicles up to 06.00


Location: the diagnosis connection is located behind the tray on
the driver side, on top of the fuseholder.

Diagnosis connection in vehicles from 07.00 onwards


Location: the diagnosis connection -arrow- is located in the cen‐
tral console.
– To access the connector, remove the casing from inside the
ashtray in the central console, by levering it.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Electrical/electronic components and their location 19


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Kick-down switch -F8-


Location: the kick-down switch -arrow- is incorporated in the ac‐
celerator cable and is located in front of the bulkhead wall, in the
engine compartment.

2.1.3 Removal and installation of the kick-


down switch
– For removal and assembly of the kick-down switch, the accel‐
erator cable should be removed and fitted, and then adjusted.
Vehicles from 07.00 onwards
The kick-down switch signal is generated in the electronic accel‐
erator and is transmitted to the gearbox control unit via the data
bus.
– Remove the electronic accelerator: ⇒ Rep. Gr. 20 ; Electronic
power control (EPC) .

2.2 Gearbox electrical/electronic components

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

20 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Bolt
❑ 6 Nm
2 - Previous resistance -N207-
❑ Location ⇒ page 23
❑ Checked by self-diag‐
nosis ⇒ VAS 5051; Ve‐
hicle self-diagnosis
❑ Uncouple the terminal
connector ⇒ page 23
❑ Only in vehicles up to
06.00
3 - Wiring harness
4 - Road speed sender -G68-
❑ Location, removal and
installation ⇒ page 22
❑ Checked by self-diag‐
nosis ⇒ VAS 5051; Ve‐
hicle self-diagnosis
5 - Bolt
❑ 6 Nm
6 - Bolt
❑ 6 Nm
7 - Gearbox rev. speed sender
-G38-
❑ With connection cable
❑ Location, removal and Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
installation ⇒ page 22
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Checked by self-diag‐
nosis ⇒ VAS 5051; Ve‐
hicle self-diagnosis
8 - Gearbox
9 - Wiring harness
❑ For solenoid valves and gearbox oil temperature sender (ATF) -G93-
❑ Location, removal and installation ⇒ page 22
10 - Multi-function switch -F125-
❑ Adjustment ⇒ page 23
❑ Checked by self-diagnosis ⇒ VAS 5051; Vehicle self-diagnosis
11 - Combi bolt
❑ 3 Nm
12 - Rod
❑ For the selector rod
13 - Nut
❑ 17 Nm

2. Electrical/electronic components and their location 21


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Wiring harness for solenoid valves and gearbox oil temperature


sender -G93- (ATF)
Location: the wiring harness is located in the oil sump beneath
the slide box.

2.2.1 Dismounting and installing of unless


theauthorised
wiringby SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted
harness respect to the correctness of information in this document. Copyright by SEAT S.A.

The wiring harness can be replaced with the gearbox installed,


without removing the slide box.
– Drain the gearbox oil (ATF) ⇒ page 57 , Changing the ATF.
– Remove oil sump ⇒ page 66 , Planet gears: dismantling and
assembling.
– Disconnect the wiring harness connector.
– Block the terminal connector -arrows- and remove it from the
gearbox casing.
– Unlock the solenoid valve connectors by pressing the tabs
-arrow 1- and pulling them off -arrow 2- .
Install in reverse order.
The cable colours correspond to the colours on the corresponding
solenoid valves.
– Install the oil sump ⇒ page 66 , planet gears: dismantling and
assembling.
– Replace the ATF oil ⇒ page 56 , Replace ATF.

Gearbox rev. speed sender -G38- and Road speed sender -G68-
Location: the senders are located in the upper part of the gearbox.
A - -G38-
B - -G68-
Removal and installation of the senders
– Separate the sender connector.
– Remove the bolt and the sender.
Install in reverse order.
– Replace the O-ring.
– Tighten to the torque of 6 Nm.

22 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Adjusting the multi-function switch -F125-


Prerequisites
• Adjusting selector lever cable, correct:
Vehicles up to 06.00 ⇒ page 24 .
Vehicles from 07.00 onwards ⇒ page 25 .
• Selector lever in “N”
• Loosened screws -arrows-
– Via the selection rod, guide a 4 mm bit -A- into the multifunction
switch's adjustment opening.
– In this position, tighten the multifunction switch's bolts -arrows-
to a torque of 3 Nm.
– Remove the bit.

Previous resistance -N207-


Location: the resistance is found in the upper part of the gearbox.
Only in vehicles up to 06.00
Separate the resistance connector
Uncouple the connector to measure the resistance.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Push the tab in the direction of the arrow.


– Remove the connector from the support next to the gearbox.

2. Electrical/electronic components and their location 23


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

3 Gear drive mechanism: repairing

Caution

Before carrying out any repairs, place the selector lever in “P”
and engage the hand brake

3.1 Gear drive mechanism: checking


Selector lever in “P” and hand brake on
• Brake pedal without depressing
The selector lever is locked and cannot be displaced from “P” .
The electromagnet for locking the selector lever locks it.
• Brake pedal depressed
The electromagnet for locking the selector lever releases the lev‐
er. A gear can be selected.
Selector lever in “N” and ignition on
• Brake pedal without depressing
The selector lever is locked and cannot be displaced from “N” .
The electromagnet for locking the selector lever locks it.
• Brake pedal depressed
The electromagnet for locking the selector lever releases the lev‐
er. A gear can be selected.
♦ In selector lever positions “1” , “2” , “3” , “D” and “R” it should
not be possible to activate the starter motor.
♦ At speeds of more than 5 km/h and changing the selector lever
to “N” , the selector lever locking electromagnet should not lock
the lever. The selector lever can select a different gear.
♦ At speeds of less than 5 km/h (almost stationary) and changing
the selector leverbyto
Protected “N” , Copying
copyright. the selector
for private lever locking
or commercial electro‐
purposes, in part or in whole, is not
magnet permitted
should lock the lever after approx. 1 second. The
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
selector lever can only be moved from “N” when the brake
pedal is depressed.

3.2 Selector lever cable: check and adjust


(vehicles up to 06.00)
Vehicles from 07.00 onwards ⇒ page 25 .

3.2.1 Checking
– Move the selector lever to “P” .

24 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the combi bolt -arrow- securing the selector lever ca‐
ble to the gear selector rod.
– Change the selector lever position from “P” to “1” .
• The gear actioning mechanism and the selector lever cable
should move freely; if necessary, replace the selector lever
cable or repair the gearbox actioning mechanism.

Note!

The safety washer of the selector lever on the gearbox counter‐


hold should always be renewed once removed.

3.2.2 Adjustment
– Move the selector lever to “P” .
– Raise the vehicle.
– Loosen the combi bolt securing the selector lever cable to the
gear selector rod.
– Move the selector rod shaft to “P” . The retaining lever should
engage in the park locking gear, the two front wheel are locked
(they cannot be turned together in one direction).
– Tighten the combi bolt to of the selector shaft to 23 Nm.
In case of malfunction, repeat the adjustment and check the ad‐
justment of the multifunction switch ⇒ page 23 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3.3 Selector lever cable: check and adjust


(vehicles from 07.00 onwards)

3.3.1 Checking
– Move the selector lever to “P” .

3. Gear drive mechanism: repairing 25


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Disengage the actioning cable by levering on the selector rod.


– Change the selector lever position from “P” to “1” .
• The gear actioning mechanism and the selector lever cable
should move freely; if necessary, replace the selector lever
cable or repair the gearbox actioning mechanism.

Note!

The safety washer of the selector lever on the gearbox counter‐


hold should always be renewed once removed.

3.3.2 Adjustment
– Move the selector lever to “P” .
– Move the selector rod shaft to “P” . The retaining lever should
engage in the park locking gear, the two front wheel are locked
(they cannot be turned together in one direction).
– Open the safety tab -arrow- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– In some cases it may be necessary to loosen the adjustment


nut -arrow- .
– Clip the selector lever cable to the selector rod shaft.
– Tighten the nut -arrow- to 13 Nm.
– Close the selector lever cable safety tab.
– Press the locking key on the knob of the selector lever and
move the lever back 5 mm. Release the selector lever.
The selector lever should return to “P” by itself.
– Place the selector lever in “N” , pulling forwards and back‐
wards 5 mm (check the same as for “P” ).
The selector lever should return to “N” by itself.
In case of malfunction, repeat the adjustment and check the ad‐
justment of the multifunction switch ⇒ page 23 .

3.4 Gear drive mechanism: dismantling and assembling (vehicles up to 06.00)

Note!

Lubricate all support points and sliding surfaces with grease ref no. -G 052 142 A2-

26 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Gear lever knob


2 - Allen head bolt
❑ 1.5 Nm
3 - Cover
❑ With selection scale
❑ To remove, lever from
behind in selector posi‐
tion “P” and then re‐
move from the front
groove in selector posi‐
tion “1”
4 - Protective strap
❑ Insert in the cover -3-
5 - Trim sleeve
6 - Safety washer
❑ Assembly
⇒ Item 3 (page 27)
7 - Selector lever
❑ Dismantling and assem‐
bling ⇒ page 29
❑ Dismantling and fitting
⇒ page 32
❑ Adjusting the magnet for
locking the selector lev‐
er -N110- ⇒ page 31
8 - Gasket
9 - Protective cover
❑ Do not dismantle to re‐
place the selector lever
cable or individual gear‐
box actioning compo‐
nents
❑ Remove ⇒ page 28
10 - Combi bolt
❑ 23 Nm
❑ 4 units
11 - Self-locking nut
❑ 15 Nm
❑ 3 units
❑ Always renew
12 - Spacers
13 - NutsProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ To secure respect the
to thecenter
correctnessconsole
of information in this document. Copyright by SEAT S.A.

14 - Nozzle
❑ Fit onto the selector lever box before fitting the selector lever cable ⇒ page 29
15 - Selector lever cable
❑ Dismantling and fitting ⇒ page 33
❑ Do not kink or bend; before fitting, grease the ring and the ends of the cable lightly
❑ Securing the selector lever cable to the selector lever ⇒ page 28
❑ Check and adjust ⇒ page 24

3. Gear drive mechanism: repairing 27


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

16 - Bolt
❑ 15 Nm
17 - Support
❑ For the gear selector cable in the mounting bracket
18 - Rod
❑ For the selector rod
19 - Washer
20 - Combi bolt
❑ 23 Nm
21 - Safety washer
❑ For the selector lever cable
❑ Always renew
22 - Support
❑ For the gear selector cable in the gearbox
23 - Bolt
❑ 15 Nm
24 - Support
❑ For the gear selector cable in the engine bay
25 - Gearbox

Removing the protection box


– Removing the gear selector knob ⇒ page 32 .
– Remove the trim sleeve.
– Removing the gear selector cover ⇒ Item 3 (page 27) .
– Unscrew the nuts securing the centre console
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ Item 13 (page 27) . to the correctness of information in this document. Copyright by SEAT S.A.
respect

– Removing the centre console: ⇒ Bodywork repairs, installa‐


tion work, interior; Rep. Gr. 68 ; Shelves, trims, covers and
trays .
– Disconnecting the selector lever locking electromagnet con‐
nector.
– Remove the front part of the exhaust pipe with catalytic con‐
verter: ⇒ Rep. Gr. 26 ; Exhaust system components: removal
and fitting .
– Remove the front and rear protective plates.
– Remove the bolts -arrows- of the protective cover.

Securing the selector lever cable to the selector lever


– Turn the locking lever downwards arrow -1- , insert the cable
ring arrow -2- into the selector lever, and secure it with a new
safety washer.

28 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Securing the wiring harness to the selector lever box


– Fit the wiring harness to the clips and in the selector lever box
-arrows- .

Fitting the nozzle to the selector lever box


– Before fitting the selector lever cable, fit the nozzle -arrow- .

3.5 Selector lever: dismantling and assembling (vehicles up to 06.00)


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

♦ Lubricate all support points and sliding surfaces with grease ref no. -G 052 142 A2-
♦ To replace individual components, the gear selector lever should be removed ⇒ page 32

3. Gear drive mechanism: repairing 29


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Selector lever
❑ Assembling
⇒ page 31
❑ Dismantling and fitting
⇒ page 32
2 - Scale illumination
❑ Connect the scale illu‐
mination connector
⇒ page 32
3 - Spring
4 - Push rod
❑ Lubricate contact surfa‐
ces
❑ To remove, unscrew the
star-head screw
⇒ Item 8 (page 30)
5 - Guide bush
❑ Fit after fitting the push
rod
6 - Magnet for selector lever
locking -N110-
❑ To remove, first remove
the gear selector from
the box ⇒ page 32
❑ Adjust ⇒ page 31
❑ Checking action
⇒ page 31
❑ This can be checked
with the measured value
block and during the
electrical check ⇒
VAS 5051; Vehicle self-
diagnosis
7 - Bolt
❑ 3 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 2 permitted
units unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Fit with -D 000 600 A2- locking paste
8 - Securing bolt
❑ Screwed to the push rod
❑ Engaged with component ⇒ Item 13 (page 31)
❑ Always renew
❑ To loosen the bolt, remove the selector lever locking magnet and the scale illumination. Hold the bolt in
a vice and loosen it by turning the selector lever
❑ Fit with -D 000 600 A2- locking paste
9 - Self-locking nut
❑ 10 Nm
❑ Always renew
10 - Spring
❑ Fit together with the locking lever ⇒ Item 11 (page 30) in the selector lever
11 - Locking lever
❑ To lock the selector lever in “P” or “N”
❑ Adjust ⇒ page 31

30 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

12 - Bush
13 - Engaging piece
❑ Before fitting in the selector lever box, assemble the selector lever ⇒ page 31
14 - Combi bolt
❑ Lubricate the shaft

Assemble the selector lever before fitting


Before fitting the selector lever in the selector lever box, adjust
the selector lever locking magnet -N110- ⇒ page 31 , and check
action ⇒ page 31 .
– Insert the bolt -arrow 1- and fit the bolts -arrow 2- of the se‐
lector lever locking magnet -N110- with -D 000 600 A2- locking
paste.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Adjusting the electromagnet for the selector lever locking -N110-


– Loosen the magnet securing bolts arrow -1- .
– Press the push rod and move the magnet longways, until there
is a distance -a- of 0.3 mm between the push rod and the
locking lever.
– Apply -D 000 600 A2- locking paste to the bolts arrow -1- and
tighten them to 3 Nm.
– Checking action ⇒ page 31 .

Checking the electromagnet for the selector lever locking -N110-


action
– Move the selector lever to “P” and apply 12 V to the magnet.
The selector lever should be locked and cannot be displaced
to another gear.
– Stop the electromagnet.
The push rod should not get caught on the locking lever and all
the gears should be selectable.
– Move the selector lever to “N” and check as in “P” .

3. Gear drive mechanism: repairing 31


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Connect the scale illumination connector


– Fit the support with the tab -arrow- until it engages.
– Fit the connector cable to the support and secure the connec‐
tor to the support.

3.6 Selector lever: dismantling and assem‐


bling (vehicles up to 06.00)

3.6.1 Removal
– Disconnect the battery earth strap.

Note!

For vehicles fitted with a coded radio, first check the anti-theft
code.

– Move the selector lever to “P” .


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the togear selector knob byin loosening the lateral se‐S.A.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect the correctness of information this document. Copyright by SEAT
curing bolt -arrow- .
– Remove the trim sleeve.
– Remove the selector lever cover by levering first from behind
and then remove from the front groove with selector lever in
“1” .
– Removing the centre console: ⇒ Bodywork repairs, installa‐
tion work, interior; Repair group 68; Shelves, trims, covers and
trays.

– Remove the selector lever cable safety washer.


– Turn the locking lever downwards -arrow 1- , and release the
selector lever cable -arrow 2- .

32 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Release the wiring harness from the clips on the selector lever
box and the cable clips -arrows- .
– Raise the vehicle.
– Remove the front part of the exhaust pipe with catalytic con‐
verter: ⇒ Rep. Gr. 26 ; Exhaust system components: removal
and fitting .
– Remove the front heat shield.

– Unscrew the attachment nuts from the centre console -ar‐


rows-.
– Move the selector lever to “1” .
– Remove the gear selector assembly from the selector lever
box.

3.6.2 Installation
Install in reverse order, taking the following into account:
– Before fitting the selector lever in the selector lever box, adjust
the selector lever locking magnet -N110- ⇒ page 31 , and
check action ⇒ page 31 .
– Fitting the front part of the exhaust pipe with catalytic convert‐
er: ⇒ Rep. Gr. 26 ; Exhaust system components: removal and
fitting
– Fitting the central console: ⇒ Bodywork repairs, installation
work, interior; Rep. Gr. 68 ; Shelves, trims, covers and trays .
– Checking the gear drive mechanism ⇒ page 24 .
Tightening torques
Nuts for securing the selector lever 15 Nm
Always renew
Knob securing bolt 1.5 Nm

3.7 Selector lever cable: dismantling and


assembling (vehicles up to 06.00)

3.7.1 Removal
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Disconnect the battery earth strap.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

For vehicles fitted with a coded radio, first check the anti-theft
code.

– Move the selector lever to “P” .

3. Gear drive mechanism: repairing 33


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the gear selector knob by loosening the lateral se‐


curing bolt -arrow- .
– Remove the trim sleeve.
– Remove the selector lever cover by levering first from behind
and then remove from the front groove with selector lever in
“1” .
– Move the selector lever to “N” .

– Remove the selector lever cable safety washer -arrow 2- .


– Turn the locking lever downwards -arrow 1- , and release the
selector lever cable.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove the selector lever cable safety washer -1- on the


gearbox bracket.
– Release the selector lever cable from the bracket in the engine
bay.

– Remove the bolt -arrow- securing the cable to the selector rod.
– Remove the front part of the exhaust pipe with catalytic con‐
verter: ⇒ Rep. Gr. 26 ; Exhaust system components: removal
and fitting .

34 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the exhaust system front bracket -arrows- .


– Remove the front heat shield.
– Release the selector lever cable from the bracket in the sub-
frame.

– Loosen the nut -arrow- and remove the selector lever cable
from the protection box.

3.7.2 Installation
♦ Check the selector lever cable sleeve for damage.
♦ Avoid bending or twisting the selector lever cable.
♦ Before fitting the cable, grease the ring on the end of the cable
lightly.
– Before fitting the selector lever cable, fit the nozzle -arrow- in
the selector lever box.
– Route the cable over the gearbox and insert it into the sub-
frame bracket and into the protection box.

– Tighten the securing bolt -arrow- .


– Move the selector lever to “N” .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Gear drive mechanism: repairing 35


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Turn the locking lever downwards -arrow 1- , insert the cable


ring -arrow 2- into the selector lever, and secure it with a new
safety washer.
– Insert the selector lever cable into the gearbox bracket and
secure it to the bracket in the engine bay.

– Fit a new selector lever cable safety washer -1- for the selector
lever cable on the gearbox bracket.
– Change the selector lever position from “P” to “1” . Do it by
pushing the selector lever push rod.
• The gear actioning mechanism and the selector lever cable
should move freely; if necessary, replace the selector lever
cable or repair the gearbox actioning mechanism.
– Adjusting the selector lever cable ⇒ page 24 .
– Fit the front heat shield.
– Fit the front bracket and tighten the bolts to 25 Nm.
– Fit the front part of the exhaust pipe with catalytic converter:
⇒ Rep. Gr. 26 ; Exhaust system components: removal and
fittingx .
– Fit the gear lever cover.
– Fit the trim sleeve.

– Fit the selector lever knob and tighten the bolt to 1.5 Nm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3.8 Gear drive mechanism: dismantling and fitting (vehicles from 07.00 on‐
wards)

36 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Gear lever knob


❑ Dismantling and fitting
⇒ page 41
2 - Trim sleeve
3 - Frame
❑ Remove with the plastic
lever -U-30800- . Be
careful with the edges of
the frame as they are
sharp and can cut
4 - Cover
❑ Dismantling
⇒ page 38
❑ Do not dismantle
5 - Gasket
6 - Bolt
7 - Protective cover
8 - Bolt
9 - Bolt
10 - Selector lever
❑ Separate the selector
lever from the protective
box ⇒ page 38
11 - Cover
12 - Bolt
❑ 25 Nm
❑ 4 units
13 - Nut
❑ 15 Nm
❑ 3 units
❑ Always renew
14 - Electromagnet for gear lever locking -N110-
❑ To remove, separate the selector leverbyfrom
Protected theCopying
copyright. protective box
for private ⇒ pagepurposes,
or commercial 38 in part or in whole, is not
❑ Checked on the vehicle by self-diagnosis
permitted unless ⇒ VAS 5051; Vehicle self-diagnosisor accept any liability with
authorised by SEAT S.A. SEAT S.A does not guarantee
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Fitting ⇒ page 38
15 - Safety washer
❑ Safety washer
16 - Nut
❑ 15 Nm
❑ Always renew
17 - Bush
❑ Always renew
18 - Support
❑ To secure the selector lever cable to the sub-frame
19 - Hexagon bolt
❑ 6 Nm
20 - Support
❑ To secure the gear selector cable in the engine bay

3. Gear drive mechanism: repairing 37


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

21 - Hexagon bolt
❑ 6 Nm
22 - Selector lever cable
❑ Dismantling and fitting ⇒ page 38
❑ Do not kink or bend; before fitting, grease the ring and the ends of the cable lightly
❑ Check and adjust ⇒ page 25

Fitting the electromagnet -N110-


– Fit the electromagnet control rod -arrow- into the square open‐
ing in the locking lever.

Separating the selector lever from the protective box


– Release carefully from both sides, levering at the junction
points.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3.9 Selector lever cable: removing and fit‐


ting (vehicles from 07.00 onwards)
Special tools and workshop equipment required
♦ Lever -U-30800-

3.9.1 Removal
– Disconnect the battery earth strap.

38 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Note!

For vehicles fitted with a coded radio, first check the anti-theft
code.

– Move the selector lever to “P” .


– Removing the gear selector knob ⇒ page 41 .
– Remove the trim sleeve.
– Remove the cover frame of the selector lever with lever -
U-30800- .

Note!

Be careful with the edges of the frame as they are sharp and can
cut

– Removing the centre console: ⇒ Bodywork repairs, installa‐


tion work,
Protected interior;
by copyright. Rep.
Copying Gr. or68
for private ; Shelves,
commercial trims,
purposes, in part covers
or in whole,and
is not
traysunless
permitted . authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Move the selector lever to “N” .
– Remove the selector lever cover by levering from the back and
front -arrow 1- , and pull upwards -arrow 2- to remove.
– Disconnecting the selector lever locking electromagnet con‐
nector.

– Remove selector lever cable ring -arrow- .


– Release the selector lever cable from the bracket in the engine
bay.

3. Gear drive mechanism: repairing 39


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Disengage the actioning cable by levering on the selector rod.


– Remove the front part of the exhaust pipe with catalytic con‐
verter: ⇒ Rep. Gr. 26 ; Exhaust system components: removal
and fitting

– Remove the exhaust system front bracket -arrows- .


– Remove the front heat shield.
– Release the selector lever cable from the bracket in the sub-
frame.
– Remove the cable from the protection box.

3.9.2 Installation

Note!

♦ Check the selector lever cable sleeve for damage.


♦ Avoid bending or twisting the selector lever cable.
♦ Before fitting the cable, grease the ring on the end of the cable
lightly.

– Route the cable over the gearbox and insert it into the sub-
frame bracket and into the protection box.
– Move the selector lever to “N” .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

40 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit a new bush and insert the cable ring into the selector lever
-arrow- .
– Insert the selector lever cable into the gearbox bracket and
secure it to the bracket in the engine bay.
– Change the selector lever position from “P” to “1” . Do it by
pushing the selector lever push rod.
• The gear actioning mechanism and the selector lever cable
should move freely; if necessary, replace the selector lever
cable or repair the gearbox actioning mechanism.
– Adjusting the selector lever cable ⇒ page 25 .
– Fit the front heat shield.
– Fit the front bracket and tighten the bolts to 25 Nm.
– Fit the front part of the exhaust pipe with catalytic converter:
⇒ Rep. Gr. 26 ; Exhaust system components: removal and
fitting
– Move the selector lever to “N” .
– Fitting the selector lever position illumination connector.
– Fit the gear selector cover by pressing down until it engages.
– Fitting the central console: ⇒ Bodywork repairs, installation
work, interior; Rep. Gr. 68 ; Shelves, trims, covers and trays .
– Fit the selector lever cover frame.

Note!

Be careful with the edges of the frame as they are sharp and can
cut.

– Fit the trim sleeve.


– Fitting the gear selector knob ⇒ page 41 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

3.10 Gear selector knob: removing and fitting


respect to the correctness of information in this document. Copyright by SEAT S.A.

(vehicles from 07.00 onwards)


There are different knobs that are removed and fitted in different
ways.
– Before any assembly work, push the gear lever bush down a
little.
– Note the colour of the plastic piece of the knob.
If it is black: Dismantling and fitting ⇒ page 42 .
If it is red-brown: This knob can substitute the one with black syn‐
thetic part.

3. Gear drive mechanism: repairing 41


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

3.10.1 Knob with red-brown plastic part: re‐


moval and installation
– Only pull the knob, without pressing the key.
If the button has entered the knob by mistake, it can be removed
using compressed air carefully.
– Before fitting make sure the button projects at least 10 mili‐
meters, dimension -a- .
To do this extract the key by hand overcoming the resistance, thus
it will not go in again.
– To fit, move the lever to “D” and press the knob in the selector
lever.

3.10.2 Removing the knob with black synthetic


part
– Move the selector lever to “R” .
– Push the sleeve -1- downwards.
– Extract key -2- out of the knob -3- just enough so that the little
lever -arrow- is hanging down.
– Now remove the gear selector knob.
Installation
– Move the selector lever to “R” .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

42 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Extract key -2- out of the knob -3- just enough so that the little
lever -arrow- is hanging down.
– Press the knob onto the gear lever as far as it will go. Assembly
position: the key should be facing the driver.
– Extract the key further and insert the little lever -arrow- into the
knob.
– Press the key so that the little lever is engaged with the rod
-4- . The key should jump again to the limit.
– Push the sleeve -1- upwards.
– Move the gear lever to “P” .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Gear drive mechanism: repairing 43


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

4 Gearbox: removing and installing

4.1 Gearbox: removing and installing

Special tools and workshop


equipment required
♦ Hydraulic column jack -SAT
1040-
♦ Torque spanners -SAT
8010-
♦ Holding tool -T20138-
♦ Base -T20145-
♦ Holding tool -T20155-
♦ Holding tool -T20156-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

44 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

♦ Support -U-30025 E-
♦ Kit -U-40020-
♦ Compression tool -
U-30042-

4.1.1 Removing
When carrying out any repair that involves disassembly of the
gearbox, drain the oil before proceeding with disassembly
⇒ page 57 , ATF level: checking or filling, changing ATF.
– Place the selector
Protected leverCopying
by copyright. in thefor“P” position.
private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– With the ignition switched off, disconnect battery earth strap.
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

For vehicles fitted with a coded radio, first check and record the
anti-theft code.

– Remove battery and battery retainer: ⇒ Electrical system;


Rep. Gr. 27 ; Battery

4. Gearbox: removing and installing 45


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Removing the air filter -arrows- (only in vehicles with an oval


filter). In vehicles from 07.00 onwards: ⇒ Rep. Gr. 24 ; Injec‐
tion system: repairing.

– Remove catch -1- on the actioning cable.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Disengage the actioning cable by levering with
permitted unless the selection
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
rod. In vehicles up to 06.00 ⇒ page 24 .respect to the correctness of information in this document. Copyright by SEAT S.A.
– Release the main round connector in the gearbox and the re‐
maining electrical connections.

– Seal off the ATF radiator hoses with tool -U-30042- .


– Release the clips on the ATF radiator hoses with tool -T20029-
and disengage them from the radiator.
– Cap off the radiator hoses

46 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the countersupport for the selector lever cable from


the gearbox -arrows- .

– Remove cable guide -1- from the eye -2- .

– Remove the cable guide -1- from the engine assembly bolt, by
pulling on it upwards -arrow- .
– Remove the upper bolts that secure the engine to the gearbox.
– Remove the upper bolt from the starter motor.

– Fit the bracket -U-30025E- .

Note!

Remove all cable brackets, cables and hoses that could interfere
with the fitting of support tool -U-30025E- .

– Slightly tension the engine assembly/gearbox via the spindles.


– Remove the front wheels.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Raise the vehicle. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove the front part of the exhaust pipe with catalytic con‐
verter: ⇒ Rep. Gr. 26 ; Exhaust system components: removal
and fitting .
– Unscrew the drive shafts from the gearbox joint flanges with
the correct spanner from tool -U-40020- and secure them
above.

4. Gearbox: removing and installing 47


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Uncouple the speedometer connector.


– Separate the support from the electrical cables in the rear part
of the engine.
– Removing the starter motor: ⇒ Electrical system; Rep. Gr.
27 ; Starter motor .
– Remove oil sump protective plate from the gearbox oil sump.
– Remove the protective plate from the torque converter.
– Remove ribbed belt covering.

– Remove the three bolts -arrows- securing the torque converter


to the flywheel. To do so, rotate the crankshaft 1 /3 and im‐
mobilise the flywheel with tool -T20156- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove the lower plate with the registry number from the
gearbox and place tool -T20155- so that the torque converter
is immobilised. Tighten the tool's threaded bolt by hand.

Note!

Ensure that the bolt on tool -T20155- is well tightened. If the bolt
is not tightened well, the converter could disengage from the
gearbox, and risk an accident when handling the gearbox during
disassembly.

– Disengage the hoses for the power assisted steering from their
brackets in the lower part of the radiator.

Note!

The connections for the power assisted steering must be secured,


without twisting or stretching them, so that they are out of the way
when removing and fitting the gearbox.

– Remove the pendulum support, removing bolts -A- and -B- .


– Remove the sub-frame: ⇒ Running gear, axles, steering; Rep.
Gr. 40 ; Front wheel suspension: repair (vehicles with roll bar) .

48 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the bolts securing the right part of the engine assem‐
bly from the cylinder block.

– Completely remove the left part of the engine support assem‐


bly.
– Remove bolt -A- .
– Remove the bolts -B- which secure the engine support as‐
sembly -1- to the bodywork.
– Remove bolts -C- from the gearbox console -2- .
– Using the spindles of the -U-30025 E- support tool, lower and
tilt the engine assembly, until the tensioning roller is positioned
slightly below the sill.
– Fit both base -T20138- and holding tool -T20161- to the hy‐
draulic column jack SAT 1040.

– Place tool -T20138- below the gearbox, in such a way that it


is positioned parallel and as close as possible to the gearbox.
– Secure the front part of tool -T20138- -arrow 1- with a bolt and
the right part -arrow 2- with a M10 bolt. The rear part
-arrow 3- gets fitted into one of the gearbox openings.

Note!

Lock the securing rods of tool -T20138- with the counterbolts and
tighten the central bolt.

– Remove the lower connecting bolts from the engine/gearbox.


– Separate the gearbox from the engine, pressing down on the
converter in order to disengage it from the flywheel.
– Lower
Protectedthe gearbox
by copyright. taking
Copying careor not
for private to damage
commercial purposes, any
in partcomponent.
or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!

Make sure that the torque converter does not become separated
from the gearbox.

4.1.2 Installation
Install in reverse order, taking the following into account:

4. Gearbox: removing and installing 49


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Installing the torque converter ⇒ page 13 , Torque converter:


removal and fitting.
– Make sure that the torque converter is in the correct position
and that is securely affixed with tool -T20155- .

Note!

While carrying out repairs, the converter should not slip out of
position.

– Before assembly, verify that the centering bushes are correctly


positioned between the engine and the gearbox.
– When installing the gearbox, ensure that the converter's threa‐
ded pins coincide with the bolt holes of the flywheel.
– Bring the gearbox closer to the engine, and move the -T20145-
base, and position the gearbox until it is in the correct location.
– Fit the subframe: ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Front wheel suspension: repair (vehicles with roll bar)
– Installing the drive shafts: ⇒ Running gear, axles, steering;
Rep. Gr. 40 ; IV - Drive shafts .

– Always replace the axle catch -1- des Wählhebelseilzuges im‐


mer ersetzen.
– Check the selector lever cable adjustment: Vehicles up to
06.00 ⇒ page 24 . Vehicles from 07.00 onwards ⇒ page 25 .
– Check the multifunction switch adjustment; and if necessary,
adjust ⇒ page 20 , Gearbox electrical/electronic components.
– Check the ATF level and top up ⇒ page 53 .
– Checking the connectors
Protected byof all theCopying
copyright. electrical connections
for private (vis‐ in part or in whole, is not
or commercial purposes,
ually). permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– After connecting the battery, depending on the version, vehicle


equipment will have to be encoded (encoding the radio, ad‐
justing the clock, etc.).
After assembly:
– Begin basic setting: ⇒ VAS 5051; Vehicle self-diagnosis
– Checking the gear drive mechanism ⇒ page 24 .
Tightening torques

50 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Gearbox to engine
Posi‐ Bolt Amount Tightening torque (Nm)
tion
1 M12×6 2 80
5
2 M10×7 1 45
5
3 M7×12 2 15
4 M12×7 1 80
0
5 M8×35 1 25
6 M8×35 1 25
7 M8×35 1 25
A - Adjustment bushes for centring the gearbox.
Tightening torques

Engine assembly brackets, engine side


A - 50 Nm
B - 60 Nm
C - 25 Nm
Always renew the bolts

Engine assembly brackets,Protected


gearbox side
by copyright. Copying for private or commercial purposes, in part or in whole, is not
A - 30 Nm + 90° permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

B - 20 Nm + 45°
C - 30 Nm
Always renew the bolts

4. Gearbox: removing and installing 51


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Pendulum support
A - 50 Nm
B - 20 Nm + 90°
Always replace nuts and bolts
Torque converter to the flywheel 60 Nm
Always renew the bolts
Driveshaft to flange connection 45 Nm
Always renew the bolts
Gearbox to engine bolt M12 80 Nm
Gearbox to engine bolt M10 60 Nm
Gearbox oil sump protective plate. 15 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

52 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

5 ATF level: checking and filling

Special tools and workshop


equipment required
♦ Torque spanners -SAT
8010-
♦ Drip tray -V.A.G 1306-
♦ Fault reader -V.A.G 1551-
♦ Cable -V.A.G 1551/3-
♦ Oil tester -V.A.G 1924-

Only use ATF fluid ref. no.:


G 052 990 A2

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

5. ATF level: checking and filling 53


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– If the ATF level is checked, always replace the oil seal


-arrow- of the ATF level control bolt.

5.1 ATF level: checking


Check prerequisites
• The gearbox must not be in emergency mode and the tem‐
perature of the ATF should no be more than 30 °C approx.
• Vehicle in horizontal position
• Gear selector lever in “P”

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

54 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Attach ATF -V.A.G 1924- filling system container to vehicle.


– Connect fault reader -V.A.G 1551- . Start the engine and select
gearbox electronics with “Address code” 02.
– Raise the vehicle.
– Place the collection recipient below the gearbox.
Indicated on the display:
Rapid data transfer HELP
Select function XX

– Press keys 0 and 8 to select the function “Read measured


value block” .
Indicated on the display:
Rapid data transfer Q
08 - Read measured value block

– Confirm entry with the Q key.


Indicated on the display:
Read measured value block
Input display group number XXX

– Press keys 0 , 0 and 2 (002 selects the “Display group num‐


ber 002” function).
– Confirm entry with the Q key.
Indicated on the display:
Read measured value block 2 ->
0% 4% 30°C 12.9 V

The third display zone shows the ATF temperature.

Note!

At the start of verification, the ATF temperature should not be


more than approx. 30 °C.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Set ATF at service temperature.


Test temperature: 35 °C up to 45 °C

– Unscrew the sealing screw for the ATF control -arrow- from
the oil sump.
The ATF left in the overflow tube comes out.
If ATF comes out through the opening:
it is not necessary to add ATF.
– Tighten the sealing screw with a new seal, to a torque of 15
Nm. The ATF check is now finalised.

5. ATF level: checking and filling 55


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

If ATF does not come out through the opening:


– Top up with ATF ⇒ page 56 .

5.2 Replace ATF


– Remove the cap which secures the plug, levering with a screw‐
driver -arrow- . On doing this the protection of the cap is broken
and it must always be replaced.
– Remove the filling hose cap.

– Refill ATF with -V.A.G 1924- until ATF comes out through the
control opening -arrow- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permittedCaution
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Either insufficient or excessive fluid can alter the functioning of


the gearbox

– Tighten the level plug with a new seal -arrow 1- to 15 Nm.


– Fit the cap in the filling tube until the safety tab is seated.
– Fit a new cap to the locking cap arrow -2- .
– Seat the cap.

Caution

Always replace the cap because it secures the sealing lid

56 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

5.3 Changing the ATF


– Unscrew the sealing screw for the ATF control -arrow- from
the oil sump.
– Unscrew the overflow tube (golden coloured) through the con‐
trol orifice.
– Let the ATF come out.
– Fit the overflow tube.
– Fit the sealing bolt by hand.
Refill with ATF ref. no.:

G 052 990 A2
– Approx. 2 litres of ATF (G 052 990 A2) through the filling tube.
– Then start the engine, and with the vehicle stationary, check
the selector in all positions.
– Then check the level of ATF and top up ⇒ page 53 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

5. ATF level: checking and filling 57


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

6 Gearbox with control elements


Placement of control elements

1 - Clutch 3rd and 4th gear -K3-


2 - Reverse gear brake -B1-
3 - Free sprocket
4 - Reverse gear clutch -K2-
5 - Clutch 1st and 3rd gear -K1-
6 - 2nd and 4th gear brake -B2-
7 - Torque converter clutch
cancellation incorporated into
the torque converter -ÜK-
Before working on the gear‐
box, you must first run the self-
diagnosis ⇒ VAS 5051; Vehi‐
cle self-diagnosis

6.1 Control elements position


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
In case of complaints about insufficient
permitted acceleration
unless authorised andS.Aspeed,
by SEAT S.A. SEAT does not guarantee or accept any liability with
or in general, in order to locate transmission
respect faults,
to the correctness the table
of information con‐ Copyright by SEAT S.A.
in this document.
tains information about which control elements are actuated with
each gear. This information can facilitate determining which con‐
trol elements are not functioning correctly.
All gears must be replaced hydraulically.
At certain speeds and throttle settings, 3rd and 4th gears are ac‐
tuated mechanically when the converter clutch cancellation en‐
gages.
Range B1 B2 K1 K2 K3 F ÜK
R X X
1H -X- X X
2H X X
3H X X

58 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Range B1 B2 K1 K2 K3 F ÜK
3M X X X
4H X X
4M X X X

X = pinion not working, brakes or clutches closed


-X- = -B1- is used as an engine brake only when the lever
is in “1”
H = hydraulic
M = mechanics

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

6. Gearbox with control elements 59


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

7 Gearbox: dismantling and assem‐


bling
Removing and fitting the ATF radiator and filling tube
⇒ page 60 .
General installation position for the planet gear ⇒ page 60 .
Dismantling and assembling the planet gear ⇒ page 66 .
Assembling the planet gear of the gearboxes up to 06.00
⇒ page 74
Assembling the planet gear of the gearboxes from 07.00 onwards
⇒ page 80
General overview for the all adjustments to the planet gear
⇒ page 86 .
Remove and fit slide box ⇒ page 111 .

7.1 ATF radiator andauthorised


ATFbyfilling
SEAT S.A.tube:
SEAT S.Aremoving
does not guaranteeand
or acceptinstalling
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1 - Gearbox casing
2 - O-ring
❑ Always renew
3 - Sealing screw
❑ 8 Nm
4 - Bolt
❑ 25 Nm
5 - O-ring
❑ Always renew
6 - ATF radiator
7 - O-ring
❑ Always renew
8 - O-ring
❑ Always renew
9 - ATF filling tube
10 - Bolt
❑ 8 Nm
11 - O-ring
❑ Always renew
12 - Sealing plug
13 - Cap
❑ Always replace the seal‐
ing cap, after checking
ATF level ⇒ page 53 ,
ATF level: checking and
completing

7.2 Planet gears: general assembly diagram


Dismantling and assembling the planet gear ⇒ page 66

60 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Assembling the planet gear of the gearboxes up to 06.00


⇒ page 74
Assembling the planet gear of the gearboxes from 07.00 onwards
⇒ page 80
General overview for the adjustment washer and the axial needle
bearings in the planet gear ⇒ page 65

I - ATF pump up to the large


planet gear: General installa‐
tion position ⇒ page 62
II - Gearbox casing cover up to
the drive sprocket: General in‐
stallation position ⇒ page 63

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Gearbox: dismantling and assembling 61


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

7.3 I - ATF pump up to the large planet gear: general assembly diagram

1 - Bolt
❑ 20 Nm
2 - ATF pump
❑ Dismantling and assem‐
bling ⇒ page 95
3 - Gasket
❑ For the ATF pump
4 - Brake strap -B2-
❑ Brake for 2nd and 4th
❑ Adjust ⇒ page 88
❑ Place in installation po‐
sition ⇒ page 66
❑ Place the sprocket pres‐
sure bar
⇒ Item 19 (page 63)
and adjusting screw
⇒ Item 6 (page 62) into
the moulded part of the
brake strap
5 - Nut
❑ 45 Nm
6 - Adjusting screw
❑ For brake strap -B2-
❑ Always renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Adjusting the brake respect to the correctness of information in this document. Copyright by SEAT S.A.
strap ⇒ page 88
7 - Shim
❑ Determine the thickness
of the shim by adjusting
clutch clearance be‐
tween -K2- and the ATF
pump ⇒ page 90
8 - Reverse gear clutch -K2-
❑ Dismantling and assembling ⇒ page 101
9 - Axial needle bearing
❑ Note installation position ⇒ page 65
10 - Clutch from 1st up to 3rd gear -K1- with turbine shaft
❑ Dismantling and assembling ⇒ page 98
11 - Axial needle bearing
❑ Note installation position ⇒ page 65
12 - Input shaft
13 - Axial needle bearing with washer
❑ Note installation position ⇒ page 65
14 - Large planet gear
15 - Engine shaft
❑ Dismantling and assembling ⇒ page 127
❑ The corresponding gearbox code is assigned to this spare part

62 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

16 - Gearbox casing
17 - Safety ring
18 - Cover
❑ With brake activating piston for 2nd and 4th gears
19 - Brake activating piston for 2nd and 4th gears
❑ For brake strap -B2-
❑ The corresponding gearbox code is assigned to this spare part
20 - Spring
21 - Spring

7.4 II - Cover for the gearbox casing up to the drive sprocket: general assembly
diagram

1 - Bolt
❑ 20 Nm
2 - Gearbox casing cover
❑ With piston and spring
support for reverse gear
brake -B1-
❑ Dismantling and assem‐
bling ⇒ page 107
3 - Axial needle bearing
❑ Note installation posi‐
tion ⇒ page 65
4 - Safety ring
5 - Plate spring
❑ Take note of assembly
position: large diame‐
ters should coincide Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
6 - Thrust disc -B1- respect to the correctness of information in this document. Copyright by SEAT S.A.

7 - Outer disc -B1-


❑ Number of outer discs -
B1- ⇒ page 3
8 - Inner disc -B1-
❑ Number of inner discs -
B1- ⇒ page 3
❑ Before installing, leave
in ATF 15 minutes
9 - Support disc -B1-
10 - Clutch 3rd and 4th gear -
K3-
❑ Dismantling and assem‐
bling ⇒ page 104
11 - Axial needle bearing
❑ Note installation position ⇒ page 65
12 - Satellite carrier
❑ When placing the free sprocket, turn toward the left (anti-clockwise)

7. Gearbox: dismantling and assembling 63


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

13 - Safety ring
❑ For the free sprocket ⇒ Item 15 (page 64)
14 - Thrust washer
❑ For the free sprocket ⇒ Item 15 (page 64)
15 - Free sprocket
❑ Dismantling and assembling ⇒ page 97
16 - 60 Nm
❑ Secure the drive sprocket
17 - Safety plate
❑ For the support bolt
❑ Always renew
❑ Introduce the 4 tabs of the safety plate into the gearbox housing recesses
18 - Safety ring
❑ For the ring wheel
❑ The ring tab fits into one of the spaces between the drive sprocket teeth
❑ For gearboxes from 07.00 onwards ⇒ page 64
19 - Ring wheel
❑ For gearboxes from 07.00 onwards ⇒ page 64
20 - Drive sprocket
❑ With roller bearings
❑ The bearings of the roller bearings cannot be removed from the drive sprocket
❑ For gearboxes from 07.00 onwards ⇒ page 64
21 - Gearbox casing

Ring wheel and drive sprocket from 07.00 onwards


– To remove them, press the safety ring.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

64 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

7.4.1 Installation position for the adjustment washer -F- and for the axial needle
bearings in the planet gear

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Measurement of the adjustment washer -F- and the axial needle


bearings
bearings/ washer ∅ internal ∅ external
mm mm
A 22.10 40.00
B 30.00 45.00
C 29.00 48.00
D 18.35 34.50
E from 32 to 34 49.50
F 53.30 70.00

7. Gearbox: dismantling and assembling 65


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

7.5 Planet gears: dismantling and assembling

Special tools and workshop


equipment required
♦ Bracket -AR-2203 A-
♦ Torque spanners -SAT
8010-
♦ Rotation tool -T10003-
♦ T20053 bracket
♦ Drip tray -V.A.G 1306-

7.5.1 Planet gears: remove


• Drain gearbox oilpermitted
before removing it from the vehicle
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Place the -V.A.G 1306- drip tray under the gearbox.


respect to the correctness of information in this document. Copyright by SEAT S.A.

– Drain gearbox oil by unscrewing the oil drain plug -1- .


– Drain ATF from the tray by unscrewing the sealing screw -2-
and the ATF overflow tube -3- .

66 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit the gearbox to support flange -T20053- -arrows- .


– Place into column -AR-2203A- , and secure support flange -
T20053- into openings nº 4 and 5.
– Remove the torque converter ⇒ page 13 , Torque converter:
removal and fitting.

– Unscrew bolt -arrow A- for the selector rod shaft.


– Remove the bolts -arrows B- from the gearbox for the multi‐
function switch.
– Remove the electrical connections and the gearbox senders.

– Remove the ATF radiator from the gearbox, removing the bolt
-arrow- .

– Remove the sump, unscrewing the bolts -arrow- .


Gearboxes up to 06.00

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Gearbox: dismantling and assembling 67


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove ATF temperature sender -A- .


– Unlock connectors from solenoid valves -arrows- , pressing
the tabs -arrow 1- and pulling them off -arrow 2- .
The cable colours correspond to the colours on the corresponding
solenoid valves.

– To remove the slide box, only loosen the indicated bolts


-arrows- .
When removing the slide box, the manual slide -1- remains in the
box.
– Secure the manual slide so that it does not fall out.
Gearboxes from 07.00 onwards

– Separate the ATF temperature sender -5- from its support.


– Separate solenoid valve connectors -2- and open the plate
flange -3- .
– Unlock connector from the solenoid valve -1- , pressing the
flange inwards and remove by pulling it backwards.
– Remove the slide box, by loosening only the bolts indicated
with arrows A, B, and C (of different lengths).
– Secure the manual slide -4- so that it does not fall out.
Continued for all gearboxes

– Remove O-rings -A- .


– Release the harness from the clips -arrows- , and remove the
solenoid valves' wiring harness.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

68 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the left and right articulation flanges ⇒ page 121 ,


Articulation flange oil seals: removal and fitting.
– Unscrew the converter housing's securing bolts (20 sets).
– Remove the converter housing.

– Remove the differential arrow -A- from the gearbox casing.


– Remove the O-ring -arrow B- from the gearbox casing.
– Remove the O-ring -arrow C- from the turbine shaft.

– Remove the bolts -arrows- from the ATF pump.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove the ATF
respect pump
to the gasket
correctness -1- from
of information the
in this gearbox
document. flange/
Copyright by SEAT S.A.
casing.
– Remove shim -2- from the reverse gear clutch -K2-. It may be
that the shim has remained adhered to the ATF pump.

7. Gearbox: dismantling and assembling 69


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Loosen the locknut -1- on the adjusting screw -2- for brake
strap -3- .
– Remove securing bolt -2- .
– Remove brake strap -3- .

– After removing the brake strap, secure it so that it cannot be


opened, e.g. with a wire stirrup -A- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove the reverse gear clutch -1- .

– Remove the clutch from 1st to 3rd gears -B- together with the
axial needle bearing -A- .

70 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the axial needle bearing -1- from the input shaft -2- .
– Remove the input shaft -2- .

– Remove the needle bearing -A- together with the large planet
gear -B- .

– Remove the engine shaft -1- from the gearbox casing.


– Rotate gearbox 180° in column -AR-2203A- .

– Progressively loosen the bolts for the cover in diagonal se‐


quence.
– Remove the gearbox casing cover, turning it in the direction of
the arrow to free it from the support for column -AR-2203A- .

Note!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

In the case that the cover is stuck to the gearbox tray, due to
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
sealant, softly tap it with a plastic hammer, while taking care since
the cap will jump due to the force of the springs.

7. Gearbox: dismantling and assembling 71


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the O-rings -arrows- from the gearbox casing.


– Remove the clutch -A- from 3rd and 4th gears together with
the axial needle bearing -B- .

– Remove the axial needle bearing -A- from the satellite carrier
-B- .
– Remove satellite carrier -B- .
Gearboxes up to 06.00

– Remove the safety ring from the ring wheel.


– Remove ring wheel from the drive sprocket.
Continued for all gearboxes

– Remove the safety ring for the reverse gear brake -B1- with a
screwdriver.
– Remove the washers, the thrust disc, the discs and the brake
support disc for the reverse gear -B1-.
Gearboxes up to 06.00

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

72 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the safety ring -A- for the free sprocket with a screw‐
driver.
– Remove the free sprocket from the gearbox casing together
with thrust washers -B- .

– Using a screwdriver, bend the safety plate tabs for securing


bolt -A- in such a way that they are made straight.

– Using tool -T10003- , unscrew the supporting screw from the


gearbox casing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove the drive sprocket -A- from the gearbox.


Gearboxes from 07.00 onwards
– Using a screwdriver, bend the safety plate tabs for securing
bolt in such a way that they are made straight.

7. Gearbox: dismantling and assembling 73


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Using tool -T1003- , unscrew the supporting screw from the


gearbox casing.
– Remove the drive sprocket out of the gearbox casing.

– Remove the safety ring -A- for the free sprocket with a screw‐
driver.
– Remove the free sprocket from the gearbox casing together
with thrust washers -B- .
Remove the drive sprocket from the ring wheel ⇒ page 64 .

7.5.2 Planet gears up to 06.00: assembly


Assembly of planet gears from 07.00 onwards ⇒ page 80 .
Place the axial needle bearing in installation position ⇒ page 65
– Place drive sprocket -A- into the gearbox casing.
– Place a new safety plate fitting its tabs into the gearbox casing
recesses.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Using tool -T10003- , tighten securing bolt to 60 Nm.


– Secure the securing bolt with the safety plate.
– Fit the free sprocket together with thrust washers.
– Take note of assembly position when placing the free sprocket
⇒ page 97 .
– Secure the free sprocket with the safety ring.

74 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Place the ring wheel on top of the drive sprocket.


– Using a screwdriver, remove the ring securing the ring wheel
to the drive sprocket.

– Insert satellite carrier -B- into the ring wheel, and at the same
time, into the free sprocket.
– Place the axial needle shoulder -A- on top of satellite carrier
-B- , in such a way that the dark surface remains visible.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Checking action of free sprocket. permitted
The satellite carrier can only
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
be turned in an anti-clockwise direction.

– Fit discs -B1- in the following manner:


– Place a support disc -5- of the corresponding thickness on top
of the safety ring -6- .
– Insert inner discs -7- and outer discs -4- of -B1-.
– Place on top of thrust disc -3- .
– Insert the springs from plate -2- according to the installation
position (the large diameters face each other).
– Fit safety ring -1- .
– Verify the measurement of the reverse gear brake -B1-
⇒ page 88 .

– Place the clutch for the 3rd and 4th gear -A- .
– Put the O-rings -arrows- on top of the gearbox casing.

7. Gearbox: dismantling and assembling 75


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit the spring cage into the guide pivots for piston -B1-.
One of the guide pivots -A- is thicker than the others, supporting
in this way the spring cage.
– Completely fill the axial needle bearing -B- with ATF, so that
the bearing adheres when it is installed onto the cover for the
gearbox casing.
Place the axial needle bearing onto the cover in accordance with
the correct installation position (the dark surface remains visible).

– Cut the tube nozzle off at the front mark (nozzle diameter: ap‐
prox. 3 mm).
– Apply silicone sealing compound -D 176 404 A2- onto the
clean sealing surface of the cover. The bead should be 3-4
mm thick.

– Place the gearbox casing cover, turning it in the counterclock‐


wise to the arrow in order to avoid the support for column -
AR-2203A- .
– Tighten the bolts uniformly and in diagonal sequence to a tor‐
que of 20 Nm.
– Turn the gearbox 180°.

– Insert the pinion attack shaft -1- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

76 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Place large planet gear -B- into the gearbox casing.


– Place the axial needle bearing -A- onto the large planet gear
-B- in accordance with the correct installation position (the
smooth surface remains visible).

– Insert the input shaft -1- into the large planet gear.
– Place the axial needle bearing -1- onto the input shaft in ac‐
cordance with the correct installation position (the dark surface
remains visible).

– Insert the clutch for the 1st and 3rd gear -B- .

Note!

When inserted, the input shaft must completely enter the clutch
for the 1st and 3rd gear. If necessary, fit them together before
inserting them into the casing.

– Place the axial needle bearing -A- on the clutch for the 1st and
3rd gear in accordance with the correct installation position
(the dark surface remains visible).
When replacing individualpermitted
components of the planet gears, the
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

axial needle bearings must be respect


calibrated anew ⇒ page 90in ,thisAd‐
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
to the correctness of information document. Copyright by SEAT S.A.
just the clearance for the clutch.

– Place the reverse gear clutch -1- .


Recesses -A- must be placed on top of lugs -B- .

7. Gearbox: dismantling and assembling 77


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Place shim -2- on top of the reverse gear clutch -K1-.


When replacing individual components of the planet gears, the
shim must be calibrated anew ⇒ page 90 , Adjust the clearance
for the clutch.
– Fit gasket -1- of the ATF pump.

– Fit the brake strap in the following manner:


– Place the new adjusting screw -2- with counter nut -1- in the
gearbox.
Do not yet screw in the covered part of the screw threads. The
screw must be fitted after fitting the ATF pump ⇒ page 90 , Ad‐
justing the brake strap.
– Install brake strap -3- .
– Line up the ATF pump to the gearbox casing. Take note of the
position of the shim, the ATF pump gasket, and the ATF
pump's piston segments when installing.

– Tighten the ATF pump bolts -arrows- to a torque of 20


Protected Nm. Copying for private or commercial purposes, in part or in whole, is not
by copyright.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Enter the differential -arrow A- .


– Place the new O-rings -arrow B- into the gearbox casing and
-arrow C- into the turbine shaft.
– Apply silicone sealing compound -D 176 404 A2- onto the
clean sealing surface of the converter casing. The bead should
be 3-4 mm thick.
– Place the converter housing onto the gearbox casing; to do
so, take note of the adjusting bolt and ATF pump O-ring.
– Tighten the converter casing bolts to a torque of 30 Nm.

78 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Install the left and right articulation flanges -arrow-


⇒ page 121 , Articulation flange oil seals: removal and fitting.
– Install the connectors together with the solenoid valve wiring
harnesses.

– Fit the new O-rings -A- into the gearbox casing.

– Place the slide box on top and insert the toothed washer bolt
into the groove of the selected -1- slide box.
– Tighten bolts -arrows- to a torque of 8 Nm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Install ATF temperature sender -A- .


– Install the connectors -arrows- of the solenoid valves.
The cable colours correspond to the colours on the corresponding
solenoid valves.
Apply sealant paste -D 176 404 A2- to the oil sump in the following
manner:

7. Gearbox: dismantling and assembling 79


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Cut the tube nozzle off at the front mark (nozzle diameter: ap‐
prox. 3 mm).
– Apply silicone sealing compound -D 176 404 A2- onto the
clean sealing surface of the cover. The bead should be 3-4
mm thick.
– Assemble the oil sump and tighten the securing nuts in diag‐
onal sequence to a torque of 8 Nm.

– Fit the ATF radiator -arrow- into the gearbox and tighten the
bolt to a torque of 25 Nm.
– Install the torque converter ⇒ page 13 .
– Fitting the gearbox ⇒ page 44 .
– Fill ATF, then check the level of ATF and top up ⇒ page 53 .

7.5.3 Planet gears from 07.00 onwards as‐


sembly
Place the axial needle bearing in installation position ⇒ page 65 .
– Assemble the drive sprocket and the ring wheel.
Take note of assembly position when placing the free sprocket
⇒ page 97 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Fit the free sprocket together with
respect to the thrust ofwashers
correctness -B-
information in this.document. Copyright by SEAT S.A.

– Secure the free sprocket with the safety ring -A- .


– Place the drive sprocket with the ring wheel.
– Place a new safety plate fitting its tabs into the gearbox casing
recesses.

80 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Using tool -T10003- , tighten securing bolt to a torque of 60


Nm.
– Secure the securing bolt with the safety plate.

– Insert satellite carrier -B- into the ring wheel, and at the same
time, into the free sprocket.
– Place the axial needle shoulder -A- on top of satellite carrier
-B- , in such a way that the dark surface remains visible.
– Checking action of free sprocket. The satellite carrier can only
be turned in an anti-clockwise direction.

– Fit discs -B1- in the following manner:


– Place a support disc -5- of the corresponding thickness on top
of the safety ring -6- .
– Insert inner discs -7- and outer discs -4- of -B1-.
– Place on top of thrust disc -3- .
– Insert the springs from plate -2- according to the installation
position (the large diameters face each other).
– Fit safety ring -1- .
– Verify the measurement of the reverse gear brake -B1-
⇒ page 88 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– permitted
Assemble the clutch
unless authorised -A-S.A.
by SEAT forSEAT
theS.A
3rd and
does 4th gear.
not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Place the gearbox casing O-rings -arrows- .

7. Gearbox: dismantling and assembling 81


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit the spring cage into the guide pivots for piston -B1-.
One of the guide pivots -A- is thicker than the others, supporting
in this way the spring cage.
– Completely fill the axial needle bearing -B- with ATF, so that
the bearing adheres when it is installed onto the cover for the
gearbox casing.
Place the axial needle bearing onto the cover in accordance with
the correct installation position (the dark surface remains visible).

– Cut the tube nozzle off at the front mark (nozzle diameter: ap‐
prox. 3 mm).
– Apply silicone sealing compound -D 176 404 A2- onto the
clean sealing surface of the cover. The bead should be 3-4
mm thick.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Place the gearbox casing cover, turning it in the counterclock‐


wise to the arrow in order to avoid the support for column -
AR-2203A- .
– Tighten the bolts uniformly and in diagonal sequence to a tor‐
que of 20 Nm.
– Turn the gearbox 180°.

– Insert the pinion attack shaft -1- .

82 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Place large planet gear -B- into the gearbox casing.


– Place the axial needle bearing -A- onto the large planet gear
-B- in accordance with the correct installation position (the
smooth surface remains visible).

– Insert the input shaft -2- into the large planet gear.
– Place the axial needle bearing -1- onto the input shaft in ac‐
cordance with the correct installation position (the dark surface
remains visible).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Insert the clutch for the 1st and 3rd gear -B- .

Note!

When inserted, the input shaft must completely enter the clutch
for the 1st and 3rd gear. If necessary, fit them together before
inserting them into the casing.

– Place the axial needle bearing -A- on the clutch for the 1st and
3rd gear in accordance with the correct installation position
(the dark surface remains visible).
When replacing individual components of the planet gears, the
axial needle bearings must be calibrated anew ⇒ page 90 , Ad‐
just the clearance for the clutch.

– Place the reverse gear clutch -1- .


Recesses -A- must be placed on top of lugs -B- .

7. Gearbox: dismantling and assembling 83


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Place shim -2- on top of the reverse gear clutch -K1-.


When replacing individual components of the planet gears, the
shim must be calibrated anew ⇒ page ⇒ page 90 , Adjust the
clearance for the clutch.
– Fit gasket -1- of the ATF pump.

– Fit the brake strap in the following manner:


– Place the new adjusting screw -2- with counter nut -1- in the
gearbox.
Do not yet screw in the covered part of the screw threads. The
screw must be fitted after fitting the ATF pump ⇒ page 90 , Ad‐
justing the brake strap.
– Install brake strap -3- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Line up the ATF pump to the gearbox casing. Take note of the
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
position of the shim, the ATF pump gasket, and the ATF
pump's piston segments when installing.

– Tighten the ATF pump bolts -arrows- to a torque of 20 Nm.

– Enter the differential -arrow A- .


– Place the new O-rings -arrow B- into the gearbox casing and
-arrow C- into the turbine shaft.
– Apply silicone sealing compound -D 176 404 A2- onto the
clean sealing surface of the converter casing. The bead should
be 3-4 mm thick.
– Place the converter housing onto the gearbox casing; to do
so, take note of the adjusting bolt and ATF pump O-ring.
– Tighten the converter casing bolts to a torque of 30 Nm.

84 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Install the left and right articulation flanges -arrow-


⇒ page 121 , Articulation flange oil seals: removal and fitting.
– Install the connectors together with the solenoid valve wiring
harnesses.

– Fit the new O-rings -A- into the gearbox casing.

– Place the slide box on top and insert the securing disc bolt into
the groove of the selected -4- slide box.
– Take into account the length of the screws:
A - M6×80 mm
B - M6×68 mm
C - M6×40 mm
– Tighten the screws to a torque of 9 Nm.
– Install solenoid valve connectors -2- and hook the cables into
the support -3- .
– Attach ATF temperature sender -5- .
– Fit solenoid valve connector -1- .
Apply sealant paste -D 176 404 A2- to the oil sump in the following
manner:

– Cut the tube nozzle off at the front mark (nozzle diameter: ap‐
prox. 3 mm).
– Apply silicone sealing compound -D 176 404 A2- onto the
clean sealing surface of the cover. The bead should be 3-4
mm thick.
– Assemble the oil sump and tighten the securing nuts in diag‐
onal sequence to a torque of 8 Nm.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Gearbox: dismantling and assembling 85


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit the ATF radiator -arrow- into the gearbox and tighten the
bolt to a torque of 25 Nm.
– Install the torque converter ⇒ page 13 .
– Fitting the gearbox ⇒ page 44 .
– Fill ATF, then check the level of ATF and top up ⇒ page 53 .

7.6 General overview for the all adjustments to the planet gear

I - Reverse gear shaft -B1-


❑ A - Thrust disc
❑ Determine thickness
⇒ page 86 , Adjusting
the reverse gear shaft -
B1-
II - 2nd and 4th gear brake -B2-
❑ B - Brake strap
❑ Adjusting the brake
strap ⇒ page 88 , Ad‐
justing the 2nd and 4th
gear brake -B2-
III - Clutch clearance
❑ C - Axial needle bearing
❑ Determine thickness
⇒ page 90 , Adjusting
the clutch clearance be‐
tween -K1- and the ATF
pump
❑ D - Shim Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Determine thickness permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ page 90 , Adjusting
the clutch clearance be‐
tween -K2- and the ATF
pump

7.7 Reverse gear brake -B1- adjusting


Special tools and workshop equipment required
♦ Feeler gauge
– Installing components for reverse gear brake adjustment -B1-
in the gearbox casing ⇒ page 74 , Planet gears: assembly

86 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Gearbox casing
2 - Safety ring
3 - Support disc
4 - Inner disc -B1-
❑ Part number ⇒ page 3
5 - Outer disc -B1-
❑ Part number ⇒ page 3
6 - Thrust disc
❑ Installing for the adjust‐
ment
❑ Installing with the corre‐
sponding thickness af‐
ter making the measure‐
ment
7 - Plate spring
❑ Take note of assembly
position: large diame‐
ters should coincide
8 - Safety ring
9 - Spring support plate
❑ With springs
10 - Gearbox casing cover
❑ With piston -B1-
❑ Before removing or in‐
stalling the cover, first
remove road speed
sender -G68-
⇒ page 22 , Electrical/
electronic components
and their locations;
Gearbox electrical/elec‐
tronic components
11 - Bolt
❑ 20 Nm

Thrust disc -A- to be determined


– Installing all components for reverse gear brake adjustment -
B1- in the gearbox casing ⇒ page 86 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Gearbox: dismantling and assembling 87


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit the cover of the gearbox casing, turning it counter-clock‐


wise to the arrow.
– Tighten the bolts uniformly and in diagonal sequence to a tor‐
que of 20 Nm.

– Fill the pressure channel with compressed air -arrow- . When


the piston compresses the disc package, it must be audible.
In the case there is no air, the clutch pedal should return to its
resting position.

Measuring the play for the reverse gear brake -B1-


– Using a feeler gauge -A- , measure the play between the safety
ring -1- and the support disc -2- .
Play: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
min. = 0.8 mm respect to the correctness of information in this document. Copyright by SEAT S.A.

max. = 1.1 mm

7.8 2nd and 4th gear brake -B2-: adjusting


– Installing components necessary for 2nd and 4th gear brake
adjustment -B2- ⇒ page 74 , Planet gears: assembly

88 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Gearbox casing
❑ Planet gear installed up
to the reverse gear
clutch -K2- ⇒ page 74 ,
Planet gears: assembly
2 - Adjusting screw
❑ For brake strap -B2-
❑ Always renew
❑ Place on the moulded
part of the brake strap -
B2-
3 - Nut
❑ 45 Nm
4 - Brake strap -B2-
5 - Gasket
❑ For the ATF pump
6 - ATF pump
❑ Dismantling and assem‐
bling ⇒ page 95
7 - Bolt
❑ 20 Nm
8 - Spring
9 - Spring
10 - Brake activating piston for
2nd and 4th gears
❑ Place the pressure bar Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
onto the moulded part of permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

the brake strap


respect to the correctness of information in this document. Copyright by SEAT S.A.

11 - Cover
12 - Safety ring

– Tighten the ATF pump bolts -arrows- to a torque of 20 Nm.

7. Gearbox: dismantling and assembling 89


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Adjusting the brake strap -3-


– Tighten the adjusting screw -2- to a torque of 5 Nm.
– Unthread the adjusting screw 2 and a half turns.
– Tighten nut -1- to a torque of 45 Nm. When doing so, secure
the adjusting screw so that it does not turn at the same time.

7.9 Clutch clearance: adjusting


Special tools and workshop equipment required
♦ Depth gauge
– The planet gear set must be installed, with the exception of the
axial needle bearings ⇒ Item 3 (page 91) , the shim
⇒ Item 5 (page 91) , and the ATF pump
⇒ Item 7 (page 91)
– Install clutch clearance play without
– Adjusting the clutch play between -K1- and the ATF pump
⇒ page 91
– Adjusting the clutch play between -K2- and the ATF pump
⇒ page 93
– Take a measurement to verify the clutch play ⇒ page 94

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

90 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Gearbox casing
❑ Planet gear installed up
to the input shaft
⇒ page 74 , Planet
gears: assembly
2 - Clutch for 1st to 3rd gears -
K1- with turbine shaft
3 - Axial needle bearing with
washer
❑ Note installation posi‐
tion ⇒ page 65
❑ Do not install for the
clutch play adjustment
4 - Reverse gear clutch -K2-
5 - Shim
❑ Do not install for the
clutch play adjustment
6 - Gasket
❑ For the ATF pump
7 - ATF pump
8 - Bolt
❑ 20 Nm

7.9.1 Adjusting the clutch play between -K1-


and the ATF pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Determine the thickness of axial needle bearing -A-to the correctness of information in this document. Copyright by SEAT S.A.
respect

The thickness of the axial needle bearing is determined with the


separation measurement “x” and should be selected in accord‐
ance with the table ⇒ page 92 .
Separation measurement x = a - b
A - Axial needle bearing -A- (not installed when calibrating)
D - Gasket
1 - ATF pump
2 - Reverse gear clutch -K2-
3 - Clutch for 1st to 3rd gears -K1-
4 - Gearbox casing
Determine to

7. Gearbox: dismantling and assembling 91


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Placing straight edge “A” on the gearbox housing.


– Measuring with depth gauge “B” inside of -K1-.
Example:
Measured value 1 = 54.8 mm
– Fit gasket “C” on top of the pump flange in the gearbox casing.

– Measuring with depth gauge “B” on top of gasket “C” in the


gearbox casing.
Example:
Measured value 2 = 23.20 mm
Measured value 1 = 54.80 mm
- Measured value 2 = - 23.20 mm
Determined value to = 31.60 mm
Determine b

– Place straight edge “B” on the ATF pump.


– Measure with depth gauge “A” on top of the pump flange.
Example:
Measured value = 33.80 mm
- Straight edge = - 5.70 mm
Determined value b = 28.10 mm
Separation measurement x = a - b
= 31.60 mm - 28.10 mm = 3.50 mm
– Using the table, establish the thickness of the axial needle
bearing and determine the part number according to the Parts
Catalogue.
Table “Axial needle bearing”
Separation measurement “x” Axial needle bearing (mm)
(mm)
2.95 ... 3.14 2.70
3.15 ... 3.34 2.90
3.35 ... 3.54 3.10
3.55 ... 3.74 3.30
3.75 ... 3.94 3.50
3.95 ... 4.14 3.70
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

92 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

7.9.2 Adjusting the clutch play between -K2-


and the ATF pump
Determine the thickness of shim -B-
The shim thickness is determined by the separation measure‐
ment “y” and should be selected in accordance with the Table
⇒ page 94 .
Separation measurement y = c + d
B - Shim (not installed when calibrating)
D - Gasket
1 - ATF pump
2 - Reverse gear clutch -K2-
3 - Clutch for 1st to 3rd gears -K1-
4 - Gearbox casing
Determine c

– Placing straight edge “A” on the ATF housing.


– Measure with depth gauge “B” on top of the pump housing.
Example:
Measured value 1 = 34.00 mm

– Measure with depth gauge


Protected “A” onCopying
by copyright. top of the pump
for private flange.
or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Example: respect to the correctness of information in this document. Copyright by SEAT S.A.

Measured value 2 = 33.80 mm


Measured value 1 = 34.00 mm
- Measured value 2 = -33.80 mm
Determined value c = 0.20 mm
Determine d

– Placing straight edge “A” on the gearbox housing.


– Measure with depth gauge “B” on top of the ignition collar for
the reverse gear clutch -K2-.
Example:
Measured value 1 = 24.70 mm
– Fit gasket “C” on top of the pump flange in the gearbox tray.

7. Gearbox: dismantling and assembling 93


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Place straight edge “A” on top of the gearbox casing and


measure with depth gauge “B” on top of gasket “C” in the
gearbox casing.
Example:
Measured value 2 = 23.20 mm
Measured value 1 = 24.70 mm
- Measured value 2 = -23.20 mm
Determined value d = 1.50 mm
Separation measurement y = c + d
= 0.2 mm + 1.5 mm = 1.70 mm
– Using the table, establish the shim thickness of and determine
the part number according to the Parts Catalogue.
Table “Shims”
Separation measurement “y” Shims
(mm) (mm)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1.35 ... 1.54
respect to the correctness of information in this 0.80 Copyright by SEAT S.A.
document.
1.55 ... 1.74 1.00
1.75 ... 1.94 1.20
1.95 ... 2.14 1.40
2.15 ... 2.34 1.60
2.35 ... 2.54 1.80
2.55 ... 2.74 2.00
2.75 ... 2.94 2.20
– To verify, measure the clutch play after installing the ATF
pump ⇒ page 94 .

7.9.3 Verification measurement (clutch play)


– The clutch play can be measured after installing the ATF
pump.
– Fit the bracket for the clock gauge into the gearbox tray and
place the clock gauge with 1 mm of pretension on top of the
turbine shaft.
– Move the turbine shaft up and down, and read the play with
the clock gauge.
Play:
min. = 0.25 mm
max. = 0.55 mm

94 Rep. Gr. 37 - Controls, Housing


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

38 – Gears, Hydraulic controls


1 ATF pump: dismantling and assem‐
bling
Special tools and workshop equipment required
♦ -T20026- bracket

♦ Clock gauge
♦ Feeler gauge

1 - Piston ring
❑ Checking the correct
adjustment
❑ Do not over-expand
2 - Bolt
❑ 10 Nm
3 - Steered wheel support
4 - Outer sprocket
❑ Check for wear
⇒ page 96 and
⇒ page 96
5 - Inner sprocket
❑ Check for wear
⇒ page 96 and
⇒ page 96
6 - ATF pump housing
7 - O-ring
❑ Always renew
8 - Torque converter seal
❑ Dismantling and fitting

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. ATF pump: dismantling and assembling 95


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

⇒ page 13

Axial deterioration of the outer and inner sprockets with respect


to the ATF pump housing
– Place tool -T20026- together with the measuring device on top
of the ATF pump housing.
– If the measured value exceeds the wear limit indicated in the
table, the pump should be replaced.
Measured dimen‐ Wear limit (mm)
sion
Height difference be‐ 0.04
tween the ATF pump
housing and the out‐
er sprocket
Height difference be‐ 0.04
tween the ATF pump
housing and the in‐
ner sprocket

Measure the play between the outer and inner sprockets


A - Feeler gauge of 0.15 mm
– When it becomes possible to insert the feeler gauge between
the outer and inner sprockets, the pump should be replaced.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

96 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

2 Free sprocket: dismantling and assembling

1 - Thrust washer
❑ Place on the cage item
⇒ Item 2 (page 97)
❑ The smooth face out‐
wards
2 - Cage with securing ele‐
ments
❑ Fit to the outer ring of
the free sprocket
⇒ page 97
3 - Outer ring for free sprocket
❑ Assembly position: The
letters and the bevel
-arrow- should be facing
the satellite holder

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Assemble the free sprocket


– Fit the outer ring -arrow C- on the workbench so that the bevel
-arrow B- faces downwards.
– Fit the cage -arrow D- onto the outer ring so that the conical
guide tabs -arrow A- are facing downwards.
– Push the securing elements inwards at the same time as the
cage is fitted to the outer ring with the guide tabs.
– Fit the thrust washers onto the cage.
– Checking action of free sprocket:
• Place the free sprocket in assembly position (the letters and
the bevel facing upwards).
• Place the satellite holder into the cage.
Turn the satellite holder to the left- “free sprocket open”
Turn the satellite holder to the right- “free sprocket closed”

2. Free sprocket: dismantling and assembling 97


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

3 Clutch for 1st to 3rd gears -K1-: dis‐


mantling and assembling
Special tools and workshop equipment required
♦ Plunger -T20023-

Checking clutch action ⇒ page 100

1 - Safety ring
❑ Remove by levering
with a screwdriver
2 - Support disc
❑ Fitting ⇒ page 99 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Determine thickness permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ page 99
3 - Inner disc
❑ Fitting ⇒ page 99
❑ Part number ⇒ page 3 ,
Code letters, group
numbers, ratios, equip‐
ment
4 - Outer disc
❑ Fitting ⇒ page 99
❑ Part number ⇒ page 3 ,
Code letters, group
numbers, ratios, equip‐
ment
5 - Plate spring
❑ Fitting ⇒ page 99
❑ The convex side (small
diameter) should face
the clutch bell housing
6 - Safety ring
❑ Dismantling and fitting
⇒ page 99
7 - Oil seal
❑ Always renew
8 - Piston cover
❑ Before fitting, soak in oil
seals with ATF
9 - Spring
❑ Place between the piston and the piston cover

98 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

10 - Oil seal
❑ Always renew
❑ The sealing lip should be facing the clutch bell housing
11 - Oil seal
❑ Always renew
12 - Piston
❑ The corresponding gearbox code is assigned to this spare part
❑ Before fitting, moisten the sealing lips with ATF
❑ On fitting, turn the piston slightly
❑ After fitting, it should be possible to rotate the piston in the clutch bell housing
13 - Clutch bell housing with turbine shaft
14 - Piston ring
❑ Checking the correct adjustment
❑ Do not over-expand

Removing and installing the safety ring


– Push the spring piston cover downwards with tool -T20023-
until the safety ring can be fitted into the recess.

Fitting the inner and outer discs


The convex side of the plate spring (small diameter) should face
the clutch bell housing.
– Fit the outer discs -2- and inner discs -4- onto the plate spring
-3- .
– Fit the support disc -5- onto the last inner disc.
– Fit the safety ring -1- in the recess of the clutch bell housing.

Determining the thickness of the support disc


– Using a feeler gauge “A” , measure the play between the safety
ring and the support disc.
Component Dim. Wear limit
Clutch K1 0.45 ... 0.85 mm 1.05 mm
– If the wear limit is reached with the used clutch, it will be nec‐
essary to change the discs and select a new
Protected support
by copyright. disc.for private or commercial purposes, in part or in whole, is not
Copying
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Choose the discs and the support disc according to the gear‐
respect to the correctness of information in this document. Copyright by SEAT S.A.
box code.

3. Clutch for 1st to 3rd gears -K1-: dismantling and assembling 99


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Checking the clutch action


– Before fitting the piston, moisten the sealing lips and oil seals
with ATF.
– Turn the piston slightly when fitting,.
– Once the piston is fitted to the clutch or brakes, it should be
possible to turn it easily by hand in both directions -arrows- .
– If this is not the case, perhaps the sealing lips or oil seals are
incorrectly fitted or damaged.
– Check the lips or oil seals for damage and replace if neces‐
sary.
– Refit the piston and check again.

– Blow compressed air into the pressure channel -arrow- .


– Seal the orifice on the opposite side.
– The clutch piston should compress the disc package.
– Release the air pressure. The discs should return to their rest‐
ing position.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

100 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

4 Reverse gear clutch -K2-: disman‐


tling and assembling
Special tools and workshop equipment required
♦ Plunger -T10002-

♦ Kit -U-40450A-

Checking the clutch action ⇒ page 103

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Reverse gear clutch -K2-: dismantling and assembling 101


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Safety ring
❑ Mark when dismantled
and assemble in the
same position
2 - Support disc
❑ Fitting ⇒ page 103
❑ Determine thickness
⇒ page 103
3 - Inner disc
❑ Fitting ⇒ page 103
❑ Part number ⇒ page 3
4 - Outer disc
❑ Fitting ⇒ page 103
❑ Part number ⇒ page 3
5 - Safety ring
❑ Remove by levering
with a screwdriver
❑ Fitting ⇒ page 102
6 - Spring support plate
❑ With springs
❑ Fitting ⇒ page 102
7 - Oil seal
❑ Always renew
8 - Piston
❑ Choose the spare part
according to the gear‐
box code
❑ Fitting ⇒ page 102
9 - Oil seal
❑ Always renew
❑ The sealing lip should be facing the clutch bell housing
10 - Clutch bell housing

Fitting the safety ring


– Place the support plate and springs on the clutch piston -K2-.
– Fit the safety ring onto the support plate.
– With the aid of tools -T10002- and -U-40450A/3- , push the
safety ring downwards carefully together with the plate until
the safety ring can be heard to engage in the groove.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

102 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Fitting the inner and outer discs


The ring oil seal lip should be facing the clutch bell housing.
– Fit the outer discs -3- and inner discs -4- onto the clutch bell
housing.
– Fit the support disc -2- onto the last inner disc.
– Fit the safety ring -1- in the groove of the clutch bell housing.

Checking the clutch action


– Fit the shim between the clutch -K2- and the ATF pump.
– Fit the clutch -K2- onto the ATF pump and press downwards.
– Blow compressed air into the pressure channel -arrow- .
– The clutch piston should compress the disc package.
– Release the compressed air. The discs should return to their
resting position.

Determining the thickness of the support disc


– Using a feeler gauge “A” , measure the play between the safety
ring and the support disc.
Component Dim. Wear limit
Clutch K2 0.5 ... 0.8 mm 1 mm
– If the wear limit is reached with the used clutch, it will be nec‐
essary to change the discs and select a new appropriate
support disc.
– Choose the discs and the support disc according to the gear‐
box code.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Reverse gear clutch -K2-: dismantling and assembling 103


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

5 Clutch 3rd and 4th gear -K3-: disman‐


tling and assembling
Special tools and workshop equipment required
♦ Plunger -T20023-

Take note of the number of discs and their assembly position


when dismantling ⇒ page 105
Checking the clutch action ⇒ page 105

1 - Safety ring
❑ Remove by levering
with a screwdriver
2 - Support disc
❑ Fitting ⇒ page 105
❑ Determine thickness
⇒ page 106
3 - Inner disc
❑ Fitting ⇒ page 105
❑ Part number ⇒ page 3
4 - Outer disc
❑ Fitting ⇒ page 105
❑ Part number ⇒ page 3
5 - Safety ring
❑ Dismantling and fitting
⇒ page 105
6 - Spring support plate
❑ With springs
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7 - Oil sealrespect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Always renew
8 - Oil seal
❑ Always renew
9 - Piston
❑ The corresponding
gearbox code is as‐
signed to this spare part
❑ Before fitting, moisten
the sealing lips with ATF
❑ On fitting, turn the piston
slightly
❑ After fitting, it should be possible to rotate the piston in the clutch bell housing

104 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

10 - Clutch bell housing

Removing and installing the safety ring


– Push the piston cover downwards with tool -T20023- until the
safety ring can be fitted.

Note that the amount and assembly positions of the discs are dif‐
ferent
I - -K3- with 5 exterior discs
II - -K3- with 3 exterior discs
A - Safety ring

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Fitting the inner and outer discs
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Fit the outer discs -4- and inner discs -3- onto the clutch bell
housing.
– Fit the support disc -2- onto the last inner disc.
– Fit the safety ring -1- in the groove of the clutch bell housing.

Checking the clutch action


– Place the axial needle bearing on the gearbox casing cover.
– Fit the clutch -K3- onto the gearbox casing cover and press
downwards.
– Blow compressed air into the pressure channel -arrow- .
– The clutch piston should compress the disc package.
– Release the air pressure. The discs should return to their rest‐
ing position.

5. Clutch 3rd and 4th gear -K3-: dismantling and assembling 105
Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Determining the thickness of the support disc


– Using a feeler gauge “A” , measure the play between the safety
ring and the support disc.
Component Dim. Wear limit
Clutch K3 1.8 ... 2.2 mm 2.4 mm
– If the wear limit is reached with the used clutch, it will be nec‐
essary to change the discs and select a new appropriate
support disc.
– Choose the discs and the support disc according to the gear‐
box code.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

106 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

6 Reverse gear brake -B1-: dismantling and assembling

1 - Gearbox casing
2 - Safety ring
❑ Remove by levering
with a screwdriver
3 - Support disc
❑ Determine thickness
⇒ page 86
❑ Fitting ⇒ page 108
4 - Inner disc -B1-
❑ Part number ⇒ page 3
5 - Outer disc -B1-
❑ Part number ⇒ page 3
6 - Thrust disc
7 - Plate spring
❑ Note fitting position: the
large diameters should
coincide ⇒ page 108 ,
8 - Safety ring
❑ Remove by levering
with a screwdriver
9 - Spring support plate
❑ With springs
❑ Fitted onto the piston
-12- ⇒ page 108
10 - Oil seal
❑ Always renew
11 - Oil seal
❑ Always renew
12 - Piston -B1-
❑ The corresponding gearbox code is assigned to this spare part
❑ Remove ⇒ page 108
❑ Before fitting the oil seals, moisten them with ATF
13 - Piston ring
❑ Checking the correct adjustment
❑ Do not over-expand
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
14 - Gearbox casing
respect cover of information in this document. Copyright by SEAT S.A.
to the correctness

15 - O-ring
❑ Always renew
16 - Sealing screw
❑ 8 Nm

6. Reverse gear brake -B1-: dismantling and assembling 107


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Removing the brake piston -B1-


– Remove the piston from the gearbox casing by levering with
a screwdriver in several places.

Place the support plate and springs on the piston -B1-


– Fit the spring cage into the guide pivots for piston -B1-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
One of the guide pivots -A- of eachpermitted
group is thicker
unless than
authorised theS.A.
by SEAT oth‐
SEAT S.A does not guarantee or accept any liability with
ers, supporting in this way the spring cage.
respect to the correctness of information in this document. Copyright by SEAT S.A.

Fitting the outer and inner discs


– Place the support disc -5- on the safety ring -6- that secures
the free gear.
– Fit the outer discs -4- and inner discs -7- onto the gearbox
casing.
– Fit the thrust disc -3- onto the last inner disc.
– Fit the springs of plate -2- in their corresponding positions, so
that the large diameters coincide.
– Fit the safety ring -1- in the groove of the gearbox casing.

108 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

7 2nd and 4th gear brake piston -B2- dismantling and assembling

1 - Safety ring
❑ Dismantling and fitting
⇒ page 110
2 - O-ring
❑ Always renew
3 - O-ring
❑ Always renew
4 - Cover
❑ Remove from the gear‐
box casing once the
safety ring has been ex‐
tracted
5 - O-ring
❑ Always renew
6 - 4th gear actioning piston
❑ The corresponding
gearbox code is as‐
signed to this spare part
7 - O-ring
❑ Always renew
8 - O-ring
❑ Always renew
9 - Piston cover
❑ 2nd gear actioning pis‐
ton
❑ The corresponding
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
gearbox code
respect iscorrectness
to the as‐ of information in this document. Copyright by SEAT S.A.
signed to this spare part
10 - 2nd gear actioning piston
❑ The corresponding
gearbox code is as‐
signed to this spare part
11 - Spring
12 - Spring
13 - Brake strap -B2-
❑ Place in the assembly position ⇒ page 110 ,
14 - Adjusting screw
❑ For brake strap -B2-
15 - Nut, 45 Nm
❑ 45 Nm
16 - Gearbox casing

7. 2nd and 4th gear brake piston -B2- dismantling and assembling 109
Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Removing and installing the safety ring


– Fit a 300 mm clamp -A- as in the illustration.
– Press the cover with the screw of the clamp -A- .
– Remove the safety ring -B- by levering with a screwdriver.

Release the brake strap -B2-


– After dismantling, secure the brake strap, e.g. with a wire stir‐
rup -A- so it cannot open.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

110 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

8 Slide box: removing and installing


Assembly procedure ⇒ page 66 , Planet gears: dismantling and
assembling

Caution

Do not start the engine or tow the vehicle without the sump
fitted or without ATF

– Slide box in vehicles up to 06.00 ⇒ page 111


– Slide box in vehicles from 07.00 onwards ⇒ page 114

Note!

♦ The slide box or wiring harness can also be removed with the
gearbox fitted
♦ The solenoid valves can be replaced
♦ Do not use fluffy cloths
♦ After refitting the sump, check the level of ATF and top up
⇒ page 53
♦ After assembly, carry out basic setting ⇒ VAS 5051; Vehicle
self-diagnosis

8.1 Slide box (vehicles up to 06.00): removing and installing


Vehicles from 07.00 onwards ⇒ page 114
Notes to consider before removing the slide box ⇒ page 111

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

8. Slide box: removing and installing 111


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Sealing screw
❑ 15 Nm
❑ Always renew the seal
⇒ page 113
❑ ATF level: checking and
topping up ⇒ page 57
2 - O-ring
❑ Always renew
3 - Solenoid valve -N90-
❑ Grey
❑ Identification
⇒ page 114
4 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always renew permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

5 - O-ring
❑ Always renew
6 - Solenoid valve -N93-
❑ Pink
❑ Identification
⇒ page 114
7 - O-ring
❑ Always renew
8 - Solenoid valve -N91-
❑ Blue
❑ Identification
⇒ page 114
9 - Support
❑ For the solenoid valves
10 - Nut
❑ 9 Nm
11 - O-ring
❑ Always renew
12 - Solenoid valve -N89-
❑ Yellow
❑ Identification ⇒ page 114
13 - Solenoid valve -N88-
❑ Green
❑ Identification ⇒ page 114
14 - O-ring
❑ Always renew
15 - Bolt
❑ 8 Nm
16 - Slide box
❑ Dismantling and fitting ⇒ page 66 , Planet gears: dismantling and assembling
❑ Identification ⇒ page 113
17 - Manual slide
❑ Secure so that it does not come out when removing the slide box

112 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

18 - Wiring harness
❑ For the solenoid valves
19 - O-ring
❑ Always renew
❑ For the wiring harness connector
20 - Connector
❑ For the wiring harness
❑ Remove ⇒ page 66 , Planet gears: dismantling and assembling
❑ Engage on fitting to the gearbox casing
21 - O-ring
❑ Always renew
❑ Dismantling and fitting ⇒ page 66 , Planet gears: dismantling and assembling
22 - Gearbox casing
23 - Bolt
❑ 9 Nm
24 - ATF strainer
❑ To replace, it is necessary to remove the sump and fit it again
25 - Magnet
❑ Fit to the sump filler neck
26 - Overflow pipe
❑ Remove to let the ATF come out ⇒ page 57 , ATF level: checking and filling; Changing ATF
27 - Bolt
❑ 8 Nm
28 - Sump
❑ Assembly procedure ⇒ page 66 , Planet gears: dismantling and assembling

Renew the plug oil seal


– Cut the seal -arrow- with a pair of cutting pliers, always renew
the seal.
– After the repairs, fit the plug by hand with a new o-ring and fill
with ATF.º
– Fill with ATF, check ATF level and top up ⇒ page 57 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Identification of therespect
slidetoboxthe correctness of information in this document. Copyright by SEAT S.A.

The code is stamped on a plate -arrow- , which should always be


assigned to its corresponding slide box.

8. Slide box: removing and installing 113


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Identification of the solenoid valves


A - Solenoid valve -N88- (green)
B - Solenoid valve -N89- (yellow)
C - Solenoid valve -N90- (grey)
D - Solenoid valve -N91- (blue)
E - Solenoid valve -N93- (pink)
1 - Nut for securing the solenoid valves. Tightening torque 9 Nm

8.2 Slide box (vehicles from 07.00): removing and installing


Notes to consider before removing the slide box ⇒ page 111

1 - Sealing screw
❑ 15 Nm
❑ Always renew the seal
⇒ page 115
❑ Check the ATF level and
top up ⇒ page 57
2 - Overflow pipe
❑ Remove to let the ATF
come out ⇒ page 57 ,
ATF level: checking and
filling; Changing ATF
3 - Bolt
❑ 8 Nm
4 - Sump
❑ Assembly procedure
⇒ page 66 , Planet
gears: dismantling and
assembling
5 - Magnet
❑ Fit to the sump filler
neck
6 - Bolt
❑ 8 Nm
7 - ATF strainer
❑ Dismantling and fitting
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ page
respect 116
to the correctness of information in this document. Copyright by SEAT S.A.

8 - Bracket
❑ With solenoid valves: -
N88- , -N89- , -N90- , -
N91- , -N92-
❑ Dismantling and fitting
⇒ page 116
9 - Bolt
❑ M6×35 mm
❑ 8 Nm
10 - Bolt
❑ M6×68 mm

114 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

❑ 8 Nm
11 - Bolt
❑ M6×12 mm
❑ 8 Nm
12 - Solenoid valve -N93-
❑ Dismantling and fitting ⇒ page 116
13 - Bolt
❑ M6×75 mm
❑ 8 Nm
14 - Disc-shaped washer
15 - Sleeve
16 - O-ring
❑ Always renew
17 - O-ring
❑ Always renew
18 - Bolt
❑ 8 Nm
19 - Slide box
❑ Identification ⇒ page 116 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Dismantling and fitting ⇒ page 66 , Planetrespect
gears: dismantling and assembling
to the correctness of information in this document. Copyright by SEAT S.A.

20 - Manual slide
❑ Secure so that it does not come out when removing the slide box
21 - O-ring
❑ Always renew
❑ For the wiring harness connector
22 - Gearbox casing
23 - Connector
❑ For wiring harness
❑ Dismantling and fitting ⇒ page 66 , Planet gears: dismantling and assembling
❑ Engage on fitting to the gearbox casing
24 - O-ring
❑ Always renew
❑ For the wiring harness connector
25 - Wiring harness
❑ For the solenoid valves

Renew the plug oil seal


– Cut the seal -arrow- with a pair of cutting pliers, always renew
the seal.
– After the repairs, fit the plug by hand with a new o-ring and fill
with ATF.
– Fill with ATF, check ATF level and top up ⇒ page 57 .

8. Slide box: removing and installing 115


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Identification of the slide box


The code is stamped on the plate -arrow- , which should always
be assigned to its corresponding slide box.

Dismantling and fitting solenoid valve -N93-


– Remove bolt -1- and remove the valve cable.
– Remove bolts -arrows- .
– Uncouple the connector -2- .
– Remove valve -N93- -3- .
– Replace the O-ring.
Follow the directions given in reverse order to disassemble, taking
the following into account:
– Tighten bolts -1- and -arrows- to 8 Nm.

Dismantling and fitting the bracket with solenoid valves -N88- to


-N92-
– Removing solenoid valve -N93- ⇒ page 116 .
– Uncouple the connector -1- .
– Remove bolts -A- , -B- and -C- .
Follow the directions given in reverse order to disassemble, taking
the following into account:
– Tighten bolts -A- , -B- and -C- to 8 Nm.

Removing and installing the ATF strainer


– Do not mix up bolts -A- - and -B- ; fit them in their original
positions.
– Tighten bolts -A- and -B- to 8 Nm.
– Fit brackets -1- and -2- and plate -3- as described in the illus‐
tration.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

116 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

9 Parking lock: dismantling and assem‐


bling
Special tools and workshop equipment required
♦ Extractor -T20143-

♦ Plunger -T20153-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

♦ To remove and assemble the parking lock, remove the engine shaft along with the parking lock wheel and
the slide box
♦ Adjusting the multi-function switch ⇒ page 23

9. Parking lock: dismantling and assembling 117


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Oil seal
❑ For the selector rod
❑ Remove ⇒ page 119
❑ Fit ⇒ page 119
2 - Selector rod
❑ Dismantling and fitting
⇒ page 119
❑ When transporting the
gear, avoid axial blows
to the control lever shaft,
as this could sever the
screw
⇒ Item 3 (page 118)
3 - Bolt
❑ 10 Nm
❑ Fit the selector rod
⇒ Item 2 (page 118) to
the the gearbox casing
4 - Control piece spring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Do not press excessive‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ly respect to the correctness of information in this document. Copyright by SEAT S.A.

5 - Bolt
❑ 5 Nm
6 - Control part
7 - Support sleeve
❑ For control part
⇒ Item 6 (page 118)
❑ Release with a drift
❑ Insert, tapping it after fit‐
ting the control part
⇒ page 119
8 - Support sleeve
❑ For the rod ⇒ Item 9 (page 118)
❑ Release with a drift
❑ Insert after placing the rod ⇒ page 119
9 - Rod
❑ Replace with the meshing lever item ⇒ Item 10 (page 118) before fitting it to the selector rod
10 - Meshing lever
❑ Place into the selector rod along with the rod
11 - Bolt
❑ 27 Nm
12 - Support tab
❑ For the meshing lever
13 - Bolt
❑ 5 Nm
14 - Cover
❑ Secure the shaft for the retention lever
15 - Shaft for the retention lever
❑ It can be fitted and removed by hand

118 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

16 - Recuperation spring
❑ Dismantling and fitting ⇒ page 120
17 - Retention lever
❑ Dismantling and fitting ⇒ page 120

Removing the control lever shaft oil seal


– Lever it with tool -T20143- to remove it.

Fitting the selector rod oil seal


– Fill the space between the lips of the new oil seal with universal
grease.
– Insert the oil seal to the limit with tool -T20153- .

Remove and fit tensioning sleeves -1-


Releasing
– Release the tensioning sleeves on rod -4- by tapping them with
a drift, and tapping control element -5- enough to remove the
selector rod -2- .
Fitting
– After inserting the selector rod into the control element and into
the rod, fit the sleeves Protected
by tapping them.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Fit selector rod with bolt -3- , tightening to a torque of 10 Nm.
respect to the correctness of information in this document. Copyright by SEAT S.A.

9. Parking lock: dismantling and assembling 119


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Removing and installing retaining lever -3- together with the re‐
cuperation spring
Removing
– Unscrew the bolt -arrow-.
– Remove cover -1- , and remove the retaining lever shaft.
– Remove the recuperation spring -2- and the retention lever.
Fitting
Follow the directions given in reverse order to disassemble, taking
the following into account:
– Hook the angular end of the spring into the lever and leave the
other end in such a way that it is in contact with the gearbox
housing.
– Tighten the bolt -arrow- to 5 Nm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

120 Rep. Gr. 38 - Gears, Hydraulic controls


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

39 – Final drive, Differential


1 Articulation flange seals: removing
and installing

1.1 Articulation flange seals: removing and


installing
(Gearbox fitted to vehicle)

Special tools and workshop


equipment required
♦ Kit -U-40020-
♦ Kit -U-40100-
♦ Compression tool -T20005-
♦ Plunger -T20134-
♦ Pressure hose -T20133-
♦ Torque spanners -SAT
8010-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.1.1 Removing
In order to avoid the planet gears from falling toward one side of
the differential, always assemble/remove only one of the articu‐
lation flanges.
– With the ignition switched off, disconnect the battery earth
strap.

1. Articulation flange seals: removing and installing 121


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Note!

For vehicles fitted with a coded radio, first check the anti-theft
code.

– Remove the insulation tray, if fitted: ⇒ Bodywork Repairs, in‐


stallation work, exterior; Rep. Gr. 50 ; Bodywork, front .
Articulation flange oil seal, right
– Remove the protective cover for the driveshaft, if fitted.
– Remove the bolts securing the driveshafts to the gearbox
flanges, with the correct spanner on tool -U-40020- .
– Pull driveshaft to one side and secure it, taking care that it is
not damaged.
Articulation flange oil seal, left
– Remove the bolts securing the driveshafts to the gearbox
flanges, with the correct spanner on tool -U-40020-
– Turn the steering toward the right.
– Release the ball joint from the left-hand wheel bearing casing
with tool -T20147- .

Note!

Leave the hexagon nut on the ball joint threads to protect them.

– Fold the swinging arm down to remove the ball joint from the
wheel bearing casing.
– Fold the wheel spindle outwards.
– Remove the left driveshaft from between the sub-frame and
the gearbox.
Articulation flange oil seals, right/left:
– Place a container under the gearbox.

– Remove the articulation flange bolt; to do this, thread two bolts


into the flange and immobilize the shaft with a lever.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

122 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– If the gearbox is out of the vehicle, remove the articulation


flange oil seal with tool -U-40100/4- . Activate the hammer until
the oilseal is removed.
– If the gearbox is fitted in the vehicle, remove the articulation
flange oil seal by levering it with a screwdriver.

Note!

Take care not to damage the oil seal housing in the gearbox.

1.1.2 Fitting
– Fill the space between the lip seal and the dust guard with -G
052 128 A1- grease.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Note!
respect to the correctness of information in this document. Copyright by SEAT S.A.

With the gearbox removed, use tools -U-40450A/3- and -


U-40450A/6- to fit the seal into the housing.

– With the gearbox fitted, use tool -T20134- to fit the new seal,
threading the spindle into the differential's threaded part.
– Rotate the nut until the new seal is well fitted.
– Fit the articulation flange with the spring, thrust washer, and
conical ring.

– Fit securing bolt to articulation flange. Use tool -T20005- and


tighten the bolt to 25 Nm.
Articulation flange oil seal, left
– Place the driveshaft in the engine bay, and fit it into the wheel
hub.

1. Articulation flange seals: removing and installing 123


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit the ball joint into the wheel bearing housing. Lock the ball
joint with a Torx -T40- key and tighten the new self-locking nut
to 20 Nm + 90°.
1 - Torx -T40- (shortened approx. 10 mm)
2 - -SAT 8010/18A-
3 - -SAT 8010-

Note!

Make sure that the ball joint dust sleeve is not damaged or twisted.

Articulation flange oil seal, right


– Fit the protective cover for the driveshaft, in case it is fitted, to
the engine and tighten to a torque of 35 Nm.
Articulation flange oil seals, right/left
– Fit driveshaft to gearbox flange and tighten bolts to 70 Nm in
two stages (I - 10 Nm, II - 70Nm), with the correct spanner from
tool -U-40020- .
– Checking gearbox oil level ⇒ page 53 .
– Install the insulation tray, if fitted: ⇒ Bodywork Repairs, in‐
stallation work, exterior; Rep. Gr. 50 ; Bodywork, front
– Connect the earth battery strap.

Note!

When the battery is re-connected, depending on which version,


the vehicle equipment will have to be encoded.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

124 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

2 Final drive: removing and installing

2.1 Final drive: general assembly diagram

1 - Planet gears
❑ Dismantling and assem‐
bling ⇒ page 66
2 - Engine shaft
❑ Dismantling and fitting
⇒ page 66 , Planet
gears: dismantling and
assembling
❑ Dismantling and assem‐
bling ⇒ page 127
❑ Adjust ⇒ page 142
❑ Number of teeth
⇒ page 3 , Code letters,
group numbers, ratios,
equipment
3 - Differential Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismantling andpermitted
fittingunless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

⇒ page 126
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Dismantling and assem‐


bling ⇒ page 133
❑ Adjust ⇒ page 140
4 - Driven sprocket
❑ Dismantling and fitting
⇒ page 127
5 - Drive sprocket
❑ Dismantling and fitting
⇒ page 60 , Planet
gears: dismantling and
assembling

2. Final drive: removing and installing 125


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

2.2 Differential: removing and installing

1 - Bolt
❑ 30 Nm
2 - Torque converter casing
3 - Articulation flange oil seal
❑ Before fitting, fill the
space between the seal‐
ing lips with universal
grease
❑ Dismantling and fitting
⇒ page 121
4 - Bolt
❑ 22 Nm
❑ Before fitting, apply -G
052 128 A1- sealing
paste
5 - Right-hand articulation
flange
❑ Do not mix up left and
right-hand articulation
flanges, they are differ‐
ent lengths.
6 - Articulation flange pressure
spring
7 - Thrust washer
❑ Assembly position: col‐
lar towards the spring,
core towards the conical
ring
8 - Conical ring
❑ With slots for the thrust
washer
❑ Assembly position: con‐
ical side facing the dif‐
ferential casing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
9 - Safety ring
❑ Maintains the position of the conical ring, thrust washer and pressure spring of the articulation flange
when dismantled
10 - Articulation flange
❑ Do not mix up left and right-hand articulation flanges, they are different lengths
11 - Differential
❑ Dismantling and assembling ⇒ page 133
12 - Pin
❑ To centre the gearbox casing and the torque converter
13 - Gearbox casing
❑ Before assembling the gearbox casing and the torque converter, apply -D 176 404 A2- sealing compound
onto the sealing surfaces
14 - Guide bush
❑ For the speedometer control
15 - Speedometer control

126 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

2.3 Engine shaft: dismantling and assembling

Special tools and workshop


equipment required
♦ Kit -T20022-
♦ Rotation tool -T20024-
♦ Plunger -T20061-
♦ Kit -U-40100-
♦ Kit -U-40200A-
♦ Kit -U-40300-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Final drive: removing and installing 127


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

♦ Torque spanners -SAT


8010-
♦ Plunger -T20052-
♦ Kit -T20140-

Note!

♦ To remove the engine shaft, first remove the planet gear until the large planet, once the torque converter
casing has been dismantled ⇒ page 60 , Planet gears: dismantling and assembling
♦ To avoid premature wear and noise, the roller bearings on a shaft should be replaced at the same time

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

128 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Torque converter casing


2 - Shim
❑ Determine thickness
⇒ page 142 , crown/pin‐
ion sprocket: adjusting
3 - Outer ring of roller bearing
❑ Release ⇒ page 129
❑ Fit ⇒ page 130
4 - Inner ring of roller bearing
❑ Release ⇒ page 130
❑ Fit ⇒ page 130
5 - Engine shaft
❑ Number of teeth
⇒ page 3 , Code letters,
group
unlessnumbers, ratios,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
equipment
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Adjust ⇒ page 142


6 - Parking lock sprocket
7 - Driven sprocket
❑ Number of teeth
⇒ page 3 , Code letters,
group numbers, ratios,
equipment
❑ Release ⇒ page 130
❑ Fit ⇒ page 131
8 - Nut
❑ 145 Nm
❑ Always renew
❑ Loosen and tighten
⇒ page 132
❑ Secure ⇒ page 132
9 - Inner ring of roller bearing
❑ Release ⇒ page 131
❑ Fit ⇒ page 131
10 - Outer ring of roller bearing
❑ Release ⇒ page 131
❑ Fit ⇒ page 132
11 - Gearbox casing

Removing the outer ring of the roller bearing from the torque con‐
verter housing
– Remove the outer ring of the small roller bearing with tool -
T20140-
Procedure for extracting the outer ring ⇒ page 8 , General in‐
structions for gearbox repairs.

2. Final drive: removing and installing 129


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Fitting the outer ring of the roller bearing into the torque converter
housing
– Place the torque converter casing on a workbench, so it is to‐
tally flat.

Removing the inner ring of the roller bearing

Note!

If the bearing cage breaks on extraction, use tool -T20022- with


claws -T20022/44- to remove the internal bearing ring

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Inserting the inner ring of the roller bearing by pressure


– Place tool - U-40100/3- under the driven sprocket, without
damaging the inner ring of the roller bearings.
– Fit tool -T20024- inside tool -T20152- , and rest it on the inner
ring of the roller bearing.

Remove the driven sprocket by pressure


– Fit tool -U-40100/2- between the driven sprocket and the park‐
ing lock gear.
– Place tool -T20061- over the threaded shaft of the crown pin‐
ion shaft.

130 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Fit the driven sprocket


– Fit tool -U-40300/1- to the layshaft under the crown pinion
shaft so as not to damage the bearing.
– Fit tool -U-40200/15- above the driven sprocket so that the
shaft in within the tool.

Removing the inner ring of the roller bearing


– Place the engine shaft in a vice with protected jaws.
– Remove the inner ring with tool -T20022- and claws -
T20022/44- .

Fitting the inner ring of the roller bearing


– Place tool -U40100/3- between the crown pinion and the roller
bearing without damaging them.
– Fit tool -T20024- inside tool -T20152- , and rest it on the inner
ring of the roller bearing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Remove the outer ring of the roller bearing from the gearbox cas‐
ing
– Remove the outer ring of the small roller bearing with tool -
T20140-
Procedure for extracting the outer ring ⇒ page 8 , General in‐
structions for gearbox repairs.

2. Final drive: removing and installing 131


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Fitting the outer ring of the roller bearing into the gearbox casing

Loosen and tighten the hexagon nut


– Hold the engine shaft in a vice with protected jaws -A- .
– Tighten with torque spanner -SAT 8010- -B- to 145 Nm.

Secure the hexagon nut


– Secure the collar of the hexagon nut with a punch in the ma‐
chined grooves of the engine shaft -arrows- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

132 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

3 Differential: dismantling and assembling

Special tools and workshop


equipment required
♦ -T20022- Kit
♦ Pressure tool -T20047-
♦ Plunger -T20052-
♦ -U-40100- Kit
♦ -U-40200 A- Kit
♦ -U-40300- Kit

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Differential: dismantling and assembling 133


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

♦ Plunger -T20027-
♦ -T20140- Kit
♦ Plunger -T20152-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

To avoid premature wear and noise, the roller bearings on a shaft should be replaced at the same time

134 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

1 - Torque converter casing


❑ Dismantling and fitting
⇒ page 126
❑ Oil pipe: removing and
installing ⇒ page 136
2 - Thrust washer
❑ For satellite
3 - Satellite
❑ Fitting ⇒ page 136
4 - Thrust washer
❑ For the planet gear
5 - Planet gear
❑ Fitting ⇒ page 136
6 - Threaded component
7 - Support sleeve
❑ To hold the satellite
shaft
❑ Extract and replace with
a punch
8 - Satellite shaft
❑ Extract by striking with a
punch
❑ On fitting, do not dam‐
age the thrust washers
9 - Outer ring of roller bearing
❑ Remove ⇒ page 137
❑ Fit into the differential
housing ⇒ page 137
10 - Inner ring of roller bearing
❑ Remove ⇒ page 136
❑ Fit into the gearbox casing ⇒ page 136
11 - Gearbox casing
❑ Differential: removing and installing ⇒ page 126
12 - Bolt
❑ 80 Nm
13 - Differential casing
14 - Crown
❑ Number of teeth ⇒ page 3 , Code letters, group numbers, ratios, equipment
15 - Speedometer drive sprocket permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Fit the projections of the drive sprocket into the groove in the differential casing, flat side facing outwards
respect to the correctness of information in this document. Copyright by SEAT S.A.

16 - Inner ring of roller bearing


❑ Remove ⇒ page 137
❑ Fit ⇒ page 137
17 - Outer ring of roller bearing
❑ Remove ⇒ page 138
❑ Fit ⇒ page 138
18 - Shim
❑ Determine thickness ⇒ page 140

3. Differential: dismantling and assembling 135


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Removing and fitting the oil pipe -1-


– Remove the bolts -arrows- from the oil pipe clamps.
– Remove the oil pipe from the torque converter casing.
– On fitting, press the oil pipe into the torque converter box by
hand as far as it will go.

Fitting planet gears


– Lubricate the satellite thrust washers and the satellites and fit
them.
– Fit the satellites and insert the satellite shaft by tapping.
– Fit a new support sleeve.
– Lubricate the planet gear thrust washers and fit them.
– Fit the threaded component to the planet gears.
– Fit the satellite gears at 180° and rock them -arrow- .

Removing the inner ring of the roller bearing


– Fit tool -U-40300/11- to the base and remove the inner ring of
the roller bearing with extractor -U-40100/1- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Fitting the inner ring of the roller bearing into the gearbox casing
– Use tool -T20047- with tool -T20152- to fit the inner ring of the
roller bearing.
– Bolt up tool -T20047- until the inner ring of the roller bearing
is fitted.

136 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Removing the outer ring of the roller bearing


– Fit tool -U-40300/13- to the shaft, fit tool -U-40100/1- on it and
remove the outer ring of the roller bearing.

Fitting the outer ring of the roller bearing into the differential casing
– Use tool -T20152- with tool -T20027- to fit the outer ring.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Removing the inner ring of the roller bearing
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Locate tool -U-40300/13- on the differential.


– Place extractor -U-40100/1- on tool -U-40300/13- . Remove
the bearing.

Note!

If the bearing cage breaks on extraction, use tool -T20022- with


claws -T20022/48- to remove the internal bearing ring

Inserting the inner ring of the roller bearing by pressure


– Fit the inner ring of the roller bearing into the differential casing
with tools -T20052- and -T20024- .

3. Differential: dismantling and assembling 137


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Fitting the outer ring of the roller bearing into the torque converter
housing
– Remove the outer ring of the small roller bearing with tool -
T20140-
Procedure for extracting the outer ring ⇒ page 8 , General in‐
structions for gearbox repairs.

Press fitting the outer ring of the roller bearing into the torque
converter housing

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

138 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

4 Final drive: adjusting

4.1 Final drive: Overview of check steps

1 - Drive sprocket
2 - Engine shaft
❑ Adjust ⇒ page 142
3 - Engine shaft roller bearings
❑ Always replace together
❑ On replacing the roller
bearing, re-establish the
thickness of the shim
4 - Engine shaft shim
❑ Determine thickness
⇒ page 142
5 - Differential
❑ Adjust ⇒ page 140
6 - Differential shim
❑ Dicke bestimmen
⇒ page 140
7 - Differential roller bearing
❑ Always replace together
❑ On replacing the roller
bearing, re-establish the
thickness of the shim
8 - Driven sprocket

4.2 Adjustments to be carried out when


changing components
If work is carried out on the gearbox, it will only be necessary to
readjust the engine shaft and the driven sprocket or the differen‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
tial casing
respect when parts
to the correctness havein been
of information replaced
this document. that
Copyright directly
by SEAT S.A. influence
the differential adjustment. To avoid unnecessary work check the
following table:
Should be adjusted
Component replaced Differential Engine shaft with the driven
⇒ page 140 sprocket ⇒ page 142
Gearbox casing X X
Torque converter casing X X
Driven sprocket X
Engine shaft X

4. Final drive: adjusting 139


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Should be adjusted
Engine shaft roller bearings X
Differential casing with sprocket X
Differential roller bearing X

4.3 Differential: adjusting

Special tools and workshop


equipment required
♦ Bracket -T20020-
♦ Kit -T20140-
♦ Kit -U-40200 A-
♦ Kit -U-40300-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Adjust the differential when one of the following elements has
been replaced:
♦ Gearbox casing
♦ Torque converter casing
♦ Differential
♦ Differential roller bearings
Prerequisites:
• Remove the planet gears from the ATF pump, including the
large planet ⇒ page 66 , Planet gears: dismantling and as‐
sembling

140 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

• Remove the engine shaft ⇒ page 66 , Planet gears: disman‐


tling and assembling

4.3.1 Adjusting
– Fit the outer ring of the roller bearing to the torque converter
housing without shims tools, using tool -U-40200/10- and -
U-40300/12- .
– Fit the differential in the gearbox casing.
– Fit the torque converter casing on top and tighten the bolts to
30 Nm.

– Fit the dial gauge bracket.


– Adjust the dial gauge to “0” with a pre-tension of 1 mm.
– Move the differential up and down.
– Read the play measured on the gauge and take note.

Note!

When measuring, do not turn the differential, because the roller


bearings may settle and the reading
Protected could
by copyright. be for
Copying erroneous.
private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Determining thickness of shim
The pre-tension of the bearings is obtained by adding a constant
pressure value (0.16 mm) to the obtained measurement value.
Example
Measured value 0.94 mm
+ Pressure (const. value) 0.16 mm
=Thickness of shim 1.1 mm
– Unbolt the torque converter casing and remove the differential
from the gearbox casing.

4. Final drive: adjusting 141


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Remove the outer ring of the small roller bearing with tool -
T20140-
Procedure for extracting the outer ring ⇒ page 8 , General in‐
structions for gearbox repairs.
– Determining shim thicknesses according to the table:
Spare no.: ⇒ Parts Catalogue.
Table “Shims” :
Shims (mm)
0.12 0.40 0.72
0.14 0.44 0.76
0.16 0.48 0.80
0.20 0.52 0.84
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

0.24 0.56 respect to the correctness 0.88


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
of information in this document. Copyright by SEAT S.A.
0.28 0.60 0.92
0.32 0.64 0.98
0.36 0.68 1.44
If the thickness needed is greater than that indicated on the table,
two shims can be used to attain the value.

– Press fit the outer ring of the roller bearing to the torque con‐
verter housing with established shims (in the example 1.1 mm)
using tools -U-40200/10- and -U-40300/12- .

4.4 Engine shaft: adjusting

142 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

Special tools and workshop


equipment required
♦ Bracket -T20020-
♦ Kit -T20140-
♦ Kit -U-40200 A-
♦ Kit -U-40300-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Adjust the engine shaft when one of the following elements has
been replaced:
♦ Gearbox casing
♦ Torque converter casing
♦ Driven sprocket
♦ Engine shaft
♦ Roller bearings
Prerequisites
• Remove the planet gears from the ATF pump, crown pinion
included ⇒ page ⇒ page 66 , Planet gears: remove
• Remove the sump and the slider box ⇒ page 66 , Planet gears:
remove

4. Final drive: adjusting 143


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

4.4.1 Adjusting
– Fit the outer ring of the roller bearing to the torque converter
housing without shims tools, using tool -U-40200/10- and -
U-40300/14- .
– Insert the engine shaft into the gearbox casing.
– Fit the torque converter casing on top and tighten the bolts to
30 Nm.

– Fit universal support -T20020- and measuring device (meas‐


uring range 3 mm) with an extension -A- of 100 mm approx.
– Adjust the dial gauge to “0” with a pre-tension of 1 mm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

144 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Move the crown pinion shaft up and down with a screwdriver


at the driven sprocket.
– Read the play measured on the gauge and take note (exam‐
ple: 1.02 mm).

Note!

When measuring the crown pinion shaft do not turn it, because
the roller bearings may settle and the reading would be errone‐
ous.

Determining thickness of shim


The pre-tension of the bearings is obtained by adding a constant
pressure value (0.18 mm) to the obtained measurement value.
Example:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Measured value permitted unless authorised by SEAT S.A. SEAT S.A 1.02doesmmnot guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
+ Pressure (const. value) 0.18 mm
=Thickness of shim 1.2 mm
– Determining shim thicknesses according to the table:
Spare no.: ⇒ Parts Catalogue.
Table “Shims”
Shims (mm)
0.10 0.44 0.72
0.20 0.48 0.76
0.24 0.52 0.80
0.28 0.56 0.84
0.32 0.60 0.88
0.36 0.64 0.94
0.40 0.68
If the thickness needed is greater than that indicated on the table,
two shims can be used to attain the value.
– Remove the converter housing.
– Remove the engine shaft.

– Remove the outer ring of the small roller bearing with tool -
T20140-
Procedure for extracting the outer ring ⇒ page 8 , General in‐
structions for gearbox repairs.
– Determining shim thicknesses according to the parts cata‐
logue:

4. Final drive: adjusting 145


Arosa 1997 ➤
001 Automatic gearbox - Edition 10.02

– Fit the outer ring of the roller bearing with the correct shim (in
this example 1.2 mm).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

146 Rep. Gr. 39 - Final drive, Differential


Service

Workshop Manual
Arosa 1997 ➤
02J 5-speed manual gearbox
Edition 10.00

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final drive, Differential

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2015 Seat S.A S01B02J8620


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 ...................................................................... 1
1.1 Identification initials, assignation of groups, reductions, filling amounts . . . . . . . . . . . . . . 1
2 Power transmission diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Calculating the “i” reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General instructions for repairing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Mechanism for working the clutch: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Assembly chart -foot pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Neutral overrun spring: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Neutral overrun spring: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Assembly chart-hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Clutch pump: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 Clutch system: bleeding the air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Declutching unit: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Clutch: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Mechanism for working the gearbox: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Position for assembly of the mechanism for working the gearbox . . . . . . . . . . . . . . . . . . . . 24
1.2 Handle and cover of the gear stick: dismounting and assembling . . . . . . . . . . . . . . . . . . . . 27
1.3 Gear stick and protective box: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4 Mechanism and working cables: dismounting and assembling; assembly chart . . . . . . . . 30
1.5 Mechanism for working the gearbox: dismounting and assembling . . . . . . . . . . . . . . . . . . 31
1.6 Mechanism for working the gearbox: adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 02J Gearbox: Dismount and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 02J Gearbox: Dismount and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Checking the oil level for the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Gearbox: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Order for dismounting and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Cover of the gearbox casing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3 Working for the gearbox and casing: dismounting and assembly . . . . . . . . . . . . . . . . . . . . 46
4.4 Primary shaft, secondary shaft, differential gear and gearbox forks: dismounting and
assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.5 Sequence for assembly: Gearbox dismounting and assemble . . . . . . . . . . . . . . . . . . . . . . 48
5 Gearbox casing and clutch casing: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 Gear selector axle: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 Gearbox forks: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Main shaft: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2 Main shaft: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Secondary shaft: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
83
4 Secondary shaft: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
respect to the correctness of information in this document. Copyright by SEAT S.A.
94
5 Axle for reverse gear pinion: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . 98

39 - Final drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101


1 Retainers for coupling flanges: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Retainers for coupling flanges: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . 101

Contents i
Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

2 Differential: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104


3 Adjustments Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4 Differential crown: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 Differential crown: dismounting and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5 Differential: adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

ii Contents
Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

00 – Technical data
1 Identifying the gearbox
Location in the gearbox
The 02J 5-speed gearbox is assembled in the Arosa 1999 ▸ in
combination with the three cylinder Turbo Diesel engine.
Identification initials and date of manufacture -arrow 1- , type of
gear-change -arrow 2- .
Assignment of reduction groups ⇒ page 1

Type of gear-change
02J manual 5-speed gearbox -arrow 2- .

Identification initials and date of manufacture for the gearbox


-arrow-
Example: XXX XX XX X
I I I I
I I I I
Identification Day Month Year of manufac‐
letters ture
The additional data refers to the manufacturing process.

Note!

The identification letters for the gearbox also appear on the ve‐
hicle data sheet.

1.1 Identification initials, assignation of groups, reductions, filling amounts


Manual gearbox 02J 5-speed gear-change
Identification letter ESP/EXB
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Corresponding to of information in this


Type Arosa by 1997
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness document. Copyright SEAT S.A.
Engine 1,4 ltr. - 55 kW
Reduction: Drive train 60 : 19 = 3.158
Z2 : Z1 :
gear 33 : 10 = 3.300
2nd gear 35 : 18 = 1.944
3rd gear 34 : 26 = 1.308

1. 1
Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Manual gearbox 02J 5-speed gear-change


Identification letter ESP/EXB
4th gear 34: 35 = 0.971
5th gear 34 : 45 = 0.756
6th
gear —
Reverse gear 17 : 10 x 36 : 20
=3.060
Speedometer 13 : 22 = 0.591

Identification letters ESP/EXB


Specification API GLS SAE 75 W
Amount for filling 2.0 Liter
Clutch control Hydraulic
Clutch disk ∅ mm 215 mm
Articulated train flange ∅ mm Tripod
itotal in the longest gear 2.387 mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

2 Power transmission diagram


Name
The -arrows- indicate the vehicle's running direction.

1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Main shaft
5 - Secondary shaft /drive pin‐
ion shaft
6 - Differential

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Reductions
The -arrows- indicate the vehicle's running direction.

2. Power transmission diagram 3


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
R - Reverse gear
A - Train drive
T - Operation of the speedom‐
eter

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

3 Calculating the “i” reduction ratio


The reduction ratio between two pinions is obtained by dividing
the number of cogs in the pinion driven by the number of cogs in
the drive pinion.
Example:

5th gear Tapered unit


Drive Pin‐ 45 (Z1 Main) 19 (Z1 Pinion)
ion
(main)
Driven 34 (Z2 Secondary) 60 (Z2 Crown)
Pinion
(secon‐
dary)
i = Z2 : Z1 1)
Hence, you can find:
ig = Reduction ratio in a gear
ig = Z2 SecondaryZ1 Main = 3445 = 0.756
ia = Reduction ratio for the cone unit
ia = Z2 CrownZ1 Pinion = 6019 = 3.158
itotal = Total reduction ratio
It is obtained by multiplying the reduction ratios from the highest
gear and the cone unit.
itotal = iG x iA = 0.756 x 3.158 = 2.387
1) Z1 = Number of cogs on the drive pinion, Z2 = number of cogs on the driven
pinion.

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Calculating the “i” reduction ratio 5


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4 General instructions for repairing the


gearbox
In order to repair the gearbox successfully, it is essential to work
under maximum conditions of cleanliness and care as possible.
Additionally, all tools used should be in excellent working order.
When carrying out repairs, all basic safety standards must be fol‐
lowed.
What follows is a summary of a number of general guidelines for
certain repair operations, which would otherwise appear several
times in many sections of this Repairs Manual. Therefore, these
guidelines are valid and must be taken into account for this Re‐
pairs Manual.
Gearbox
♦ Before assembling the gearbox in the engine, make sure that
the centring sleeves arranged between the engine and the
gearbox are in proper condition and fit correctly.
♦ In the event of replacing the gearbox, fill it with oil up to the
lower edge of the filling hole. Amounts
Protected by copyright.for filling
Copying for and
privatetype of oil purposes, in part or in whole, is not
or commercial
⇒ page 1 . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Seals
♦ Always replace the O-ring seals.
♦ Before applying sealing products (sealing liquid), clean the
contact surfaces well and apply -AMV 188 200 03- sealing
paste.
Retainers
♦ Before they are fitted, cover them lightly with oil for gears on
the outer diameter and fill the space between the watertight
lips with grease.
♦ Once the retainers have been assembled, check the oil level
for the gearbox and fill up if necessary.
Safety rings

6 Rep. Gr. 00 - Technical data


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

♦ Always replace the safety rings; try not to stretch them out of
shape when putting them into place.
♦ The safety rings must fit perfectly into the bottom of the inser‐
tion slot.
♦ Always replace the elastic guide pins.
♦ When assembling the plastic guide pins, their slot must be
positioned longitudinally with respect to the direction of the
drive, as shown in the figure.
Bolts and nuts
♦ Always loosen and tighten the bolts and nuts in a cross-shape
for attaching covers and casings.
♦ With delicate parts, such as, for example, the clutch press, do
not tilt them and carry out the operation gradually.
♦ Self-locking bolts and nuts must always be replaced.
Bearings
♦ When new conical bearings are assembled, they shall be as‐
sembled as they arrive, without greasing.
♦ The needle bearings must be assembled with the thickest side
of the plate facing towards the assembly axle-tool.
♦ All the bearingspermitted
for theunless
gearbox must be put into place slightly
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
oiled for the gears. Take
respect special care ofwhen
to the correctness oiling
information them
in this for the
document. Copyright by SEAT S.A.
friction torque measurements.
♦ The bearings belonging to the same shaft must be replaced
together. Use parts from the same manufacturer as far as
possible.
♦ For putting the bearings into place, they must first be heated
to a temperature of approximately 100 °C. Use the -SAT 1416-
electrical blower and the -SAT 4002- digital thermometer to
check the temperature.
♦ Do not confuse or exchange the outer tracks for the bearings
of the same size; the bearings come in pairs.
Adjustment washers
♦ Before assembling the adjustment washers, their thickness
must be checked by measuring them with a micrometer at
several points on their surface.
♦ The presence of washers with different tolerances allows the
precise thickness of the washer that is needed to be achieved.
♦ The washers must not have rough edges or defects.
♦ Assemble only adjustment washers that are in perfect condi‐
tion.
Synchronising rings
♦ Do not mix synchronising rings together with different gears.
If they must be used again, place them in the same gear as
before.
♦ Check them for wear and replace them if necessary.
♦ For their assembly, cover them with oil for gears.
Gears
♦ Before assembling them, clean them very carefully. They must
first be heated to a temperature of approximately 100 °C. Use
the -SAT 1416- electrical blower and the -SAT 4002- digital
thermometer to check the temperature.

4. General instructions for repairing the gearbox 7


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

30 – Clutch
1 Mechanism for working the clutch: repair

Note!

♦ Disconnect the ground strip from the battery.


♦ In vehicles with a coded radio, consult the code before disconnecting the ground strip from the battery.
♦ Lubricate all the support points and contact surfaces with -G 052 142 A2- lubricant.
♦ Do not work the pedals or open the installation during the repair work.

I - Assembly chart -foot pedals


⇒ page 9
II - Assembly chart -hydraulics
⇒ page 13

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

8 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1.1 Assembly chart -foot pedals

1 - Support for pedals


❑ Before dismounting it,
dismount the steering
column ⇒ Drive train,
drive axles; Rep. Gr.
48 ; Airbag, steering
wheel, steering column .
2 - Hexagonal bolt, 25 Nm
3 - Brake light switch
❑ When dismounting or
assembling the switch,
press down the brake
pedal by hand as far as
you can.
❑ Before dismounting the
brake pedal, dismount
the switch by turning it
90º to the right and re‐
move it through the as‐
sembly opening.
❑ For its assembly, guide
the switch through the
assembly opening and
fix it into place by turning
it 90º to the left.
❑ Check the working of
the brake light.
4 - Hexagonal self-blocking
nut, 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 5 units
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ For attaching the pedal
support to the servo-
brake.
5 - Clutch pedal switch
❑ When dismounting or
assembling the switch, press down the clutch pedal by hand as far as you can.
❑ Before dismounting the clutch pedal, dismount the switch by turning it 90º to the right and remove it
through the assembly opening.
❑ For its assembly, guide the switch through the assembly opening and fix it into place by turning it 90º to
the left.
6 - Rubber plug
❑ Fit it into place in the support for the pedals.
7 - Housing for neutral overrun spring
❑ Dismount by turning it to the right.
❑ Assemble by turning it to the left.
8 - Neutral overrun spring
❑ Dismounting and assembling ⇒ page 13 .
9 - Stop for the clutch pedal
❑ Position for assembly ⇒ page 16
10 - Dashboard
11 - Seal
❑ Always replace

1. Mechanism for working the clutch: repair 9


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

12 - Flexible tube
13 - Clutch pump
❑ Dismounting and assembling ⇒ page 16 .
14 - Hexagonal self-blocking nut, 25 Nm
❑ Always replace.
15 - Housing
❑ Dismount and assemble ⇒ page 13
16 - Axle for clutch and brake pedals
17 - Washer
18 - Bearing sleeve
❑ For clutch pedal
❑ Lubricate with -G 052 142 A2- grease
19 - ClutchProtected
pedalby copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Dismount and
respect assemble
to the ⇒information
correctness of page 11 . document. Copyright by SEAT S.A.
in this

20 - Bearing sleeve
❑ For housing the drive column
21 - Bearing sleeve
❑ For brake pedal
❑ Put it into the bearing sleeve ⇒ Item 20 (page 10) and then put the brake pedal into place.
22 - Washer
23 - Hexagonal nut, 25 Nm
24 - Brake pedal

10 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1.2 Neutral overrun spring: dismounting and assembling

Special tools and workshop


equipment required
♦ Dynometric keys -SAT
8010-
♦ Tool for dismounting/as‐
sembling clutch pedal over‐
run spring -T20117-
♦ Pliers for releasing the rod
for working the clutch pedal
at the pump -T20059A-

1.2.1 Dismounting

Note!

If the vehicle has a coded radio, first note down the code.

– With the ignition disconnected,Protected


remove the ground
by copyright. strip
Copying for from
private or commercial purposes, in part or in whole, is not
the battery. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Extract the objects-holder tray and the lower casing from the
driver's side ⇒ Bodywork, assembly works; Rep. Gr. 68 ; ob‐
jects-holder, coverings, show covers .

1. Mechanism for working the clutch: repair 11


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Take out the bolts that attach the fuse box support to the
dashboard.
– Move the fuse box support downwards -arrow 1- and fix it into
place in this position.
– Extract the nuts that attach the relay plate by moving it care‐
fully to the left.
– Uncouple the clutch pedal from the control pump working rod
⇒ page 16 and press down the working rod to the stop in the
direction of the engine housing.
– Dismount the neutral overrun spring ⇒ page 13 .

– Take out the hexagonal nut -arrow 1- which attaches the pedal
axle to the steering column.
– Carefully remove the pedal axle -arrow 2- . Fix the brake pedal
into its position at the same time with an M 8 bolt or a pin with
the same Ø through the right hand side -arrow 1- .
– Carefully move the pedal axle to the left, and try not to damage
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

the electrical cables.


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

Do not move the brake pedal or the steering column. They remain
loose once the pedal axle has been extracted.

– Remove the clutch pedal.

1.2.2 Assembly
Perform the operations described for the dismounting in the re‐
verse order taking into account the following points:
– Lubricate the axle and the bearing sleeve before their assem‐
bly using -G052 142 A2- lubricating grease.
– Fit the clutch and brake axle up to the stop; if necessary, move
the brake pedal a little to make its assembly easier, and at the
same time extract the pin or the bolt used earlier.
– Put the washer into place with its nut and tighten at the re‐
quired torque.
Tightening torque: 25 Nm
– Assemble the neutral overrun spring ⇒ page 13 .
– Push the clutch pedal in the direction of the -arrow- in order to
fit it into the housing over the pedal, make sure that it has been
fitted into place properly.

Note!

The housing -A- must be over the working bar -B- of the clutch
pump.

12 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1.3 Neutral overrun spring: dismounting and


assembling
Special tools and workshop equipment required
♦ Tool for assembling -T20117-

1.3.1 Dismounting:
– Dismount the covers from the lower part on the driver's side
⇒ Bodywork, assembly works; Rep. Gr. 68 ; objects-holder,
coverings, show covers .
– Release the clutch pump control lever from the housing for the
clutch pedal ⇒ page 16 .
– In order to dismount the clutch pedal, tighten the neutral over‐
run spring with the aid of the clutch pedal and fit in into place
from below with the tool -T20117- .
– Put the clutch pedal into the rest position towards the dash‐
board, at the same time remove the neutral overrun spring
downwards together with the tool -T20117- .

1.3.2 Assembly:
– Put the clutch pedal into the rest position, towards the dash‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
board.respect to the correctness of information in this document. Copyright by SEAT S.A.
– First put the neutral overrun spring into place downwards to‐
gether with the tool -T20117- , on the rear side support of the
pedal support -arrow B- .
– Tress down the clutch pedal until the neutral spring and the
assembly tool remain in the pivot for the pedal housing
-arrow A- .
– Move the clutch pedal to the rest position and at the same time
remove the assembly tool.

– Press the clutch pedal in the direction of the arrow in order to


fit the housing over the pedal coupling, make sure that it has
been fitted into place properly.

1.4 Assembly chart-hydraulics

1. Mechanism for working the clutch: repair 13


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1 - Brake liquid tank


2 - Flexible tube for reflux
3 - Elbow
4 - Reflux flexible tube
❑ Lower part
5 - Clutch pump
❑ Dismounting and as‐
sembling ⇒ page 16
6 - Clip
❑ Dismounting and as‐
sembling ⇒ page 16
7 - Clutch pedal
❑ Dismounting and as‐
sembling ⇒ page 11
8 - Housing
❑ Replace only with the
clutch pump dismoun‐
ted ⇒ page 15
❑ Dismount ⇒ page 15
9 - Hexagonal self-blocking
nut, 25 Nm
❑ Always replace.
10 - O-ring seal
❑ Fit it into the connection
for the tube
❑ Put it into place with
brake liquid
11 - Set of pipes and flexible
tube
❑ Consult the Spares Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Catalogue in order to assign it permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
12 - Support for the pipes
❑ Fix in onto bodywork
13 - Protective hood
14 - Air bleed valve
❑ Bleeding the air from the clutch ⇒ page 18
15 - Small clutch pump
❑ Before dismounting it, the following parts must be dismounted:
❑ Gearbox cable from the link rod of the selector lever ⇒ page 30
❑ Return level and drag element for the gear selection cable ⇒ page 24
❑ After the assembly, the gear operating mechanism must be adjusted ⇒ page 33
16 - Clip
17 - Hexagonal bolt, 25 Nm
18 - Gear box
19 - O-ring seal
❑ Fit it into the connection for the tube
❑ Put it into place with brake liquid

14 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

20 - Support for the flexible tube


❑ It must be fixed into place on the support for the gear control operating cables.

Take out the housing -A- by levering in the direction of the arrow

Fit the housing -A- to the rod for working the clutch pump in the
direction of the arrow

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Mechanism for working the clutch: repair 15


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1.5 Clutch pump: dismounting and assembling

Special tools and workshop


equipment required
♦ Dynometric keys -SAT
8010-
♦ Tool for dismounting/as‐
sembling clutch pedal over‐
run spring -T20117-
♦ Pliers for releasing the rod
for working the clutch pedal
at the pump -T20059A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.5.1 Dismounting
– Dismount the engine cover.

Note!

In order to carry out these jobs, it is necessary to remove the


ground strip from the battery. For this purpose, you must check
whether the vehicle has a coded radio on board, consulting,
where appropriate, the anti-theft code.

– With the ignition disconnected, remove the ground strip from


the battery.

16 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Take out the connector from the sensor for the coolant liquid
level -arrow 1- .
– Take out the side cover for the cooling water tank by pulling it
upwards.
– Disconnect the cooling water tank -arrow 2- and move it to one
side without forcing any flexible tube.

Note!

♦ Do not open the cooling system.


♦ When handling the brake liquid tubes, take care not to allow
any liquid to spill onto the bodywork.

– Dismount the covers from the lower part on the driver's side
⇒ Bodywork, assembly works; Rep. Gr. 68 ; objects-holder,
coverings, show covers .
– Unblock the clutch pedal, of the rod for working of the pump
as described below:

– Place the tool -T20059A- on the flanges of the housing


-arrow- , using the tips -T20059A/1- with a Ø of 5.6 with the
cross-shaped reeding, in such a way that the longest tip will
remain on the right side of the pedal.
– Compress the flanges of the housing with the tool -T20059A- ,
and move the clutch pedal towards the dashboard at the same
time.

– Extract the flexible tube for reflux -A- which leads to the brake
liquid tank and block it up.
– Extract the clip -B- that attaches the piping/flexible tube to the
clutch pump, by levering it out with a screwdriver.
– Take out the piping/flexible tube unit -C- from the clutch pump
and block it up.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Mechanism for working the clutch: repair 17


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Turn the stop -A- for the clutch pedal in the direction of the
arrow 1 and remove it from its housing.
– Turn the housing -B- for the neutral overrun spring in the di‐
rection of the -arrow 2- and remove it from its housing.
– Remove the nuts that attach the clutch pump: Always replace.
– Then turn the pump in the direction of the arrow 3 in order to
remove it from the support block, by passing the rod through
the left of the clutch pedal.

1.5.2 Assembly
Perform the operations in the reverse order to those described for
the dismounting, taking the following into account:

Note!

The attachment nuts for the clutch should always be replaced.

Tightening torque: 25 Nm
– Position for assembly:
– The bead -arrow 1- of the stop for the clutch pedal must be
facing towards the clutch pump -B-by. copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– The appendage -arrow 2- of therespect
spring
to thehousing
correctness-C- must re‐
of information in this document. Copyright by SEAT S.A.
main mounted in the bottom left corner of the part for attaching
the pump.

– Couple the clutch pedal to the rod for working the clutch pump:
To do so, the housing -A- must be put into place on the rod for
working -B- the clutch pump.
– Push the clutch pedal in the direction of the arrow in order to
fit the housing over the clutch pedal, make sure that it is fixed
into place properly.
– After the assembly of the clutch pump, bleed the air from the
system ⇒ page 18 .

1.6 Clutch system: bleeding the air


Special tools and workshop equipment required

18 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

♦ Apparatus for filling and bleeding the air for the brakes -SAT
1150-

♦ In order to bleed the air, you must use, if required, the flexible
tube for bleeding -V.A.G 1238/B3- , which is 670 mm long.
♦ Use only new brake liquid as per the standards US FMVSS
116 DOT 4.
– Connect the flexible pressure tube to the brake liquid tank.
– Join the flexible tube for bleeding to the storage bottle in the
device for bleeding the brakes.
– Place the flexible tube for bleeding -A- in the air bleeding valve
for the small pump in the clutch and open the valve.
– After completing the operation for bleeding out the air, the
clutch pedal should be worked several times.

Note!

Try to prevent the brake liquid from spilling onto the bodywork or
any other part that it might damage.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Mechanism for working the clutch: repair 19


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

2 Declutching unit: repair

1 - Gearbox
2 - Spherical pivot, 25 Nm
❑ Grease with -MoS2- lu‐
bricant
3 - O-ring seal for main shaft
❑ Replace ⇒ page 58
4 - Guide sleeve
❑ With vulcanised O-ring
seal
❑ Change the guide
sleeve and the O-ring
seal together should the
latter be damaged
❑ Grease the guide sleeve
with -MoS2- lubricant
through the area of the
declutching collar
5 - Attachment spring
❑ Attach it to the declutch‐
ing lever
6 - Lag screw, 20 Nm
7 - Declutching lever
8 - Declutching collar
❑ Do not wash the collar.
It should only be
cleaned with a cloth
❑ Replace noisy clutch
collarsProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Grease the contact
respect to the correctness of information in this document. Copyright by SEAT S.A.
points with the declutch‐
ing lever with -MoS2- lu‐
bricant
9 - Bolt with collar, 20 Nm
10 - Small clutch pump
11 - Pusher
❑ Grease the tip of the pusher with -MoS2- lubricant.
12 - Assembly bolt
❑ Secure the declutching lever when assembling the gearbox.
❑ It must be unscrewed after assembling the gearbox.

Note!

If there is no assembly bolt


⇒ Item 12 (page 20) an M8×25 bolt
may be used.

20 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

3 Clutch: repair
(Gearbox dismounted)

Special tools and workshop


equipment required
♦ Dynometric keys -SAT
8010-
♦ Centre the clutch disk with
the tool -U-10050-8/F-
♦ Tool for blocking the engine
wheel -T20075A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

♦ Replace the disks and clutch presses that have damaged or loose riveted joints.
♦ Make the disk match the corresponding clutch press, as per the Microfiche for Spares and the identification
letters for the engine.

3. Clutch: repair 21
Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1 - The engine wheel


❑ Make sure that the cen‐
tring linchpins are well
placed.
❑ The contact surface with
the clutch disk should
not have any grooves
and they must be free
from oil and grease.
2 - Disk of clutch
❑ Diameter ⇒ page 1
❑ Position for assembly:
the spring housing must
remain facing towards
the clutch press.
❑ Grease the notches
slightly.

Note!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Clean the notches in the main
respect to the correctness of information in this document. Copyright by SEAT S.A.
shaft, and in the clutch disk used,
remove the corrosion and apply
a very fine layer of grease Spare
No. -G 000 100- , on the notches
in the main shaft.
♦ Then the clutch disk must be
moved back and forth over the
main shaft until the hub slides
smoothly across the shaft. Re‐
move the remains of excess
grease.

3 - Clutch press
❑ Dismounting and as‐
sembling ⇒ page 23
❑ Check the ends of the diaphragm ⇒ page 23

Note!

The clutch press is now greased


and protected against corrosion.
Only the contact surface can be
cleaned, otherwise the useful life of
the clutch is reduced.

4 - Bolt
❑ Consult the microfiche for Spares in order to assign it.
❑ Loosen and tighten in a cross in several stages until achieving the recommended torque.
❑ Tightening torque 20 Nm

22 Rep. Gr. 30 - Clutch


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Dismounting and assembling the clutch press and centring the


clutch disk
– Loosen and then tighten the bolts in a cross and in several
stages, using the tool -T20075- for blocking the engine.
– Centring the clutch disk, to do so, use the tool -U-10050-8-
with the adapter F.

Note!

The contact surface of the clutch press and the lining of the clutch
disk must rest completely over the wheel of the engine. Tighten
the attachment bolts uniformly and in a cross to prevent damage
to the drill holes for centring the clutch press and the anchors bolts
for centring the wheel of the engine.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Checking
permitted the ends
unless authorised of the
by SEAT diagram
S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
• Wear is allowed of up to half of the thickness at the ends of
the diagram -arrows- .

3. Clutch: repair 23
Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

34 – Controls, Housing
1 Mechanism for working the gearbox:
repairing

1.1 Position for assembly of the mechanism for working the gearbox
-Arrow A- movement for the connection of gears.
-Arrow B- movement for the selection of gears.

A - Cable for changing gears


B - Cable for selecting gears
C - Heat protection plate
❑ It must be dismounted
before dismounting the
working for the gearbox
1 - Selection link rod
2 - Return lever

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Mechanism for working the gearbox: dismounting and assem‐


bling ⇒ page 31
Mechanism for working the gearbox: adjust ⇒ page 33

24 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Note!

♦ In order to carry works on the mechanism for working the gearbox in the engine span, the negative terminal
must be disconnected from the battery.
♦ In vehicles fitted with a coded radio, first consult the anti-theft code.

I - Handle and cover for the


gear stick: dismounting and
assembling ⇒ page 27
II - Gear stick and protective
box: repair ⇒ page 28
III - Cables for the mechanism
for working: dismounting and
assembling; general chart for
assembly ⇒ page 30

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Mechanism for working the gearbox: repairing 25


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Special tools and workshop


equipment required
♦ Dynometric keys -SAT
8010-
♦ Pliers for clamps -T20072-
♦ Gear stick linchpin gauge -
T10027-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

26 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1.2 Handle and cover of the gear stick: dismounting and assembling

1 - Handle for the gear stick


❑ Dismount and assemble
together with the cover
2 - Cover
❑ Remove from the han‐
dle ⇒ page 27
❑ Attach to the handle be‐
fore assembling it
⇒ page 27
❑ Dismount and assemble
together with the handle
for the gear stick
3 - Attachment sleeve
4 - Clamp
❑ For attaching the handle
to the gear stick
❑ Tighten ⇒ page 28
5 - Rubber protection
❑ It is fitted into the flanges
for attaching the cover

Assemble the handle of the gear stick


– Turn the cover inside out and insert the handle of the gear stick
inside it -arrow- .
– Put the attachment sleeve into its housing.

Note!

The flanges for the attachment sleeve must remain fitted into the
housing in the handle.

– Put the clamp over the handle


Protected and assemble
by copyright. it on
Copying for private the gearpurposes, in part or in whole, is not
or commercial
stick, fitting it in aspermitted
far asunless
it willauthorised
go. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Mechanism for working the gearbox: repairing 27


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Tighten the clamp -arrow- for the handle of the gear stick

Note!

To tighten the clamp, tool -T20072- can also be used.

– Fit the cover into the central console.

1.3 Gear stick and protective box: repair

Note!

Lubricate the support points and the slide surfaces with grease -G 052 142 A2- .

1 - Safety washer
❑ Dismount and assemble
⇒ page 29
2 - Sleeve
3 - Compression spring
4 - Sleeve
5 - Torx Bolt, 5 Nm
6 - Top
7 - Half bearing
8 - Shock absorber
9 - Gear stick guide
10 - Shock absorber washer
11 - Seal
❑ Between the protective
box and the body
❑ Self-adhesive
❑ Stick it onto the protec‐
tive box
12 - Gear stick
13 - Plastic nut Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For attaching the con‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
sole to the protective
box.

28 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

14 - Shock absorber
15 - Protective box for the gear
stick
16 - Bearing sleeve
17 - Bolt, 25 Nm
18 - Shaft
19 - Guide sleeve
20 - Compression spring
❑ Assembly ⇒ page 29
21 - Selection bracket
22 - Bolt Torx, 5 Nm
23 - Lower plate
❑ In order to dismount it, open the flanges
24 - Safety washer
25 - Cable for changing gears
❑ Fit the selection bracket into place
❑ Position for assembly ⇒ page 24
26 - Cable for changing gears
27 - Bearing sleeve
❑ It fits into a single position
28 - Safety washer

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Dismounting and assembling the safety washer
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– For dismounting and assembling the safety washer, pull the
gear stick in the direction of the arrow -A- and at the same time
press downwards until reaching the stopper for the separating
sleeve with a screwdriver in the direction of the arrow -B -.

Note!

Do not tilt the separating sleeve when pressing it down. It must


be able to easily access the slot for housing the safety washer in
the gear stick.

Assembly of the compression spring


– Put the spring into place in such a way that the part -A- will
remain under the pivot -arrow- .
– Then pull back the part B towards the gear stick until it stays
on the upper part of the pin -arrow- .

1. Mechanism for working the gearbox: repairing 29


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1.4 Mechanism and working cables: dismounting and assembling; assembly


chart

Note!

Lubricate the support points and the sliding surfaces with grease -G 052 142 A2- .

1 - Cable for changing gears


❑ Fit into the guide for the
gear stick
❑ Position for assembly
⇒ page 24
2 - Cable for selecting gears
❑ It is connected to the se‐
lection bracket
❑ Position for assembly
⇒ page 24
3 - Safety washer
4 - Safety washer
❑ Do not damage the ca‐
bles when dismounting
it
5 - Protective box for the gear
stick
6 - Support
7 - Hexagonal bolt, 25 Nm
❑ For the support for the
gear connection cables
8 - Hose
❑ Housing for the support
for the gear connection
cables to the gearbox
9 - Separating piece
10 - Part for attaching the cable
❑ In order to attach the ca‐
ble for the gearbox to
the return lever
11 - Part for attaching the cable
❑ In order to attach the cable for the gearbox to the link rod for selection
12 - Return lever
❑ Position for assembly ⇒ page 31 .
13 - Bearing sleeve
14 - Safety washer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Guide block
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
16 - Selection linking rod
❑ With counterweight
❑ Put it into place in such a way that the uninterrupted division of the cogs matches the selection axle
❑ Once it has been put into place, adjust the mechanism for working the gearbox ⇒ page 33
❑ Position for assembly ⇒ page 31 .

30 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

17 - Hexagonal nut, 25 Nm

Position for assembling the link rod for selection and the return
lever
1- Lever for connection: With counterweight.
2- Lever for selection: It is fitted into the guide of the lever for
connection by means of a block -arrow- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.5 Mechanism for working the gearbox:


dismounting and assembling

1.5.1 Dismount
– Remove the cable for selection -A- and the cable for changing
gears from the gearbox -B- , by levering with a flat key.
1 - Flat head key size 13

Note!

If necessary, dismount the air filter.

– Dismount the cable holder from the gearbox -arrows- , if nec‐


essary, remove the flexible tube support from the clutch hy‐
draulic system.

1. Mechanism for working the gearbox: repairing 31


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Remove the cover from the central console by carefully mov‐


ing it forwards.

– Turn the cover inside out and remove the handle from the gear
stick, by loosening the clamp -arrow- .

– Unthread the attachment nuts from the central console


-arrow- .
– Raise the vehicle.
– If there is one, dismount the soundproofing casing located be‐
neath the engine/gearbox.
– Dismount the two brackets located under the system of es‐
cape. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove the exhaust gas system through
respect the double
to the correctness hose
of information clipdocument. Copyright by SEAT S.A.
in this
behind the front exhaust pipe ⇒ Rep. Gr. 26 ; Components
for the exhaust system; dismount and assemble .
– Dismount the front and rear heat insulation plate.
– Remove the protective box by pulling it downwards.
– Extract the bolts that hold down the protective box for the op‐
erating mechanism to the bodywork.
– Turn the protective box for the gearbox lever downwards and
remove it together with the cables, attempting not to cause
damage to any mechanical part or to the bodywork.

1.5.2 Assemble
Carry out the operations described the assembly in reverse order
to that for dismounting, taking into account the following.

32 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Whenever the same cables are used again, the attachment parts
for them must be changed.
– Apply a small amount of grease to the oil catcher in the part
for attaching the cable for changing gears -A- and the cable
for selection -B- .

Note!

The outer seal lips -arrows- of the oil-catcher must be completely


free from grease.

– Fit the cable for changing gears into the link rod for selection
and the cable of selection into the return lever -arrows- .
– Adjusting the mechanism for working the gearbox
⇒ page 33 .
Tightening torques
– Attachment of the protective box to the bodywork: 25 Nm
– Attachment of the cross bar to the bodywork: 25 Nm
– Counter support for the gearbox cables: 25 Nm

1.6 Mechanism for working the gearbox: ad‐


just
Special tools and workshop equipment required
♦ Linchpin -T10027-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

♦ In order to properly adjust the working for the gearbox , the


following points must be taken into account:
♦ The gearbox, the working of the clutch and the clutch must all
be in perfect working condition.
♦ The working of the gear change must be smooth and without
difficulties.

– Place the gear stick into neutral.

1. Mechanism for working the gearbox: repairing 33


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Pull forwards, to the end, of the safety mechanism for the gear
cables and for selection of gears -arrow 1- and block it into
place by turning it to the left -arrow 2- .
Fix the selector rod into place for adjusting it: by performing the
following steps:

– Push the gear stick downwards -arrow 1- .


– Turn and push the elbow -A- in the direction of the -arrow 2-
until the rod its locked into place.

Note!

In this position the inner end of the elbow -A- is housed in the gear
stick by blocking it into the adjust position.

– Remove the cover from the central console, by carefully mov‐


ing it forwards.
Fix the gear lever into place for adjusting it: by performing the
following steps:
– Put the gear stick into the neutral position.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Place the linchpin -T10027- into the hole -B- through the hole
-A- .

Note!

In order to make it easy to put the tool -T10027- into place, move
the gear stick until the two holes face each other.

34 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Turn the safety mechanism for the gearbox cables and for gear
se ection to the right in the direction of the -arrows- , up to the
end.
– The spring presses the safety mechanism to the outlet posi‐
tion.

– Turn the elbow -A- in the direction of the arrow, until returning
it to its original position.
– Remove the linchpin -T10027- and assemble the cover for the
gear stick on the central console.

1.6.1 Checking the functioning of the mecha‐


nism for working the gearbox
The gear stick must be in the position for neutral, in the track for
3rd / 4th gear. The lower part of the gear stick must be in an upright
position.
– Work the clutch pedal: Connect and disconnect all the gears
several times, make sure especially that the reverse gear con‐
nection works properly.

Note!

If, when putting a gear into position several times it still sticks, you
must check the selector lever unit in the following manner:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Engage the first gear.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Move the gear stick to the left up to the end and then release
it again.
– At the same time, the switch axle for the gear box must be
examined (2nd mechanic).
– When moving the gear stick, it must perform a run of approx‐
imately 1 mm. Direction of the -arrow- .
– If, when engaging a gear over and over again, there are still
blocks or interferences, or should the run of the gear stick not
be the right one, perform the adjustment again for the mech‐
anism for working the gear box ⇒ page 33 .

1. Mechanism for working the gearbox: repairing 35


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

2 02J Gearbox: Dismount and assem‐


ble

2.1 02J Gearbox: Dismount and assemble

Special tools and workshop


equipment required
♦ Crossbar for supporting en‐
gine and gearbox -
U-30025-
♦ Hydraulic jack for steering
column -SAT 1001-
♦ Set of cog wrenches XZN -
U-40020-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2.1.1 Dismounting
– Extract the cover from the engine.

Note!

To carry out this work, it is necessary to remove the ground strip


from the battery. For this purpose, you must check whether the
vehicle has a coded radio on board, where appropriate you should
consult anti-theft code.

– With the ignition disconnected, release the ground strip from


the battery.
– Dismount the battery and its support.

36 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Disconnect the cable for selection -A- and the gear connection
cable from the gearbox -B- by levering out with a fixed key for
16 mm.

– Extract the cable holder for the gear connection in the gearbox
-arrows- if necessary, first remove the flexible pressure tube
from the hydraulic control system for the clutch.

– Extract the central nut from the counterweight -1- from the se‐
lection lever and remove it by uncoupling it from the shoe
arrow -of the return lever -2- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Extract the clutch pump, from the gearbox casing, move it and
attach it again.

Note!

♦ Do not work the clutch pedal during the repair work.


♦ Do not open the brake pressure system.

2. 02J Gearbox: Dismount and assemble 37


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Uncouple the connector -arrow 1- from the starter.


– Uncouple the connector for the reverse gear lights -arrow 2- .
– Dismount the cables support A from the starter -arrow 3- .
– Extract the upper attachment bolt from the starter.

– Uncouple the connector from the speedometer transmitter


-arrow- .
– Extract the upper bolts that hold down the engine.

– Uncouple the flexible tubes and cables that might remain in


the area of the engine where the rings are located that are
used to couple the hooks for the support device -U-30025- .
– Couple up the support device -U-30025- and pre-tighten the
engine drive unit using the screws.
– DismountProtected
the starter ⇒ Rep. Gr. 27 ; starter: dismount and
by copyright. Copying for private or commercial purposes, in part or in whole, is not
assemble . unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
respect to the correctness of information in this document. Copyright by SEAT S.A.
– If it has one, dismount the heat insulation cover from the en‐
gine for the inner right homokinetic seal.
– Turn the wheels to the left.
– Uncouple the bearings from the flanged axles and attach them
in such a way that they will remain as high as possible without
damaging the protection for the surfaces.

– Extract the small protective plate -A- from the engine wheel
located behind the right flanged axle -arrows- if it were as‐
sembled.
– Remove the exhaust fume system through the double clip that
is located behind the front exhaust pipe ⇒ Rep. Gr. 26 ; Ex‐
haust system; dismount and assemble .

38 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Dismount the pendular support -arrows A- and -B- .

– Extract the support for holding the hexagonal bolts -arrow-


from the left support for the engine drive unit.
– Put the drive engine unit into a sloped position, to do so, lower
it using the left screw from the tool -U-30025- .

Note!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
When lowering the engine drive unit,
respect make
to the sureofthat
correctness the oil
information sump
in this document. Copyright by SEAT S.A.
is not resting on the unit holder.

In this position, you must be able to gain access to the bolts


-arrows- that attach the console to the gearbox -A- .
– Dismount the console from the gearbox -arrows A- .

– Place the hydraulic jack for the steering column -SAT 1001-
under the gearbox in such a way that the gearbox is held up.
– Dismount the lower bolts for engine/gearbox connection.
– With the help of another mechanic, separate the gearbox from
the engine guide sleeves at the same time as it is moved for‐
wards in order to make it easier to remove it. Move the gearbox
until removing it from the engine and extract it from the vehicle
without causing damage to any of the parts.

Note!

When lowering the gearbox, take into account the piping on the
servo-drive and gearbox support side as well as the piping for the
cooling circuit on the upper part.

2. 02J Gearbox: Dismount and assemble 39


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

2.1.2 Assembly

Note!

♦ Before assembling the gearbox, the declutching lever must be


pressed down towards the gearbox casing and attached into
place with an assembly bolt or an M 8 x 35 bolt. The bolt must
be removed after assembling the gearbox. The hole is closed
by the third attachment bolt for the counter support of the op‐
erating cables.
♦ If the gearbox had to be replaced, the speedometer transmit‐
ter, the lever for selection and that for return must be used
again in the new gearbox. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Clean the notches in the main shaft and lubricate them slightly
with lubricant grease -G 000 100- .
– The clutch disk must be able to move from one side to the other
over the main shaft.
– Check whether there are adjustment sleeves for centring the
gearbox in the engine block; if not, install them.
– Make sure that the intermediate plate is properly housed in the
base of the engine.
– Centre the drive engine unit in order to put it into the position
for assembly.
– Assemble the gearbox unit in the engine, free from stresses,
putting it into place by shaking.
– Put the two bolts partially into place that attach the gearbox to
the engine.
– The assembly shall be made in the opposite way to that for
dismounting.

Note!

Do not remove the support device -SAT 1001- until the bolts for
the left console of the gearbox have been tightened with their
recommended torque.

Tightening torques

40 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Gearbox to the engine


Pos. Bolt Amount Nm
12)
M 12 x 55 3 80
2 M 12 x 150 2 80
3 M 10 x 50 2 40
43) M 12 x 50 2 80
54) M 6 x 12 1 10
2) Double bolt
3) Additional bolt for attaching the starter
4) Small plate for protecting the inertia wheel

Pos. A+B adjustment sleeves

Attaching the console -A- to the gearbox.


Bolts -arrows- 50 Nm
– Replace the bolts.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Attaching the gearbox to the bodywork
Bolts -arrows- 50 Nm
– Replace the bolts.

Rear support for the gearbox


Bolt -A- : 80 Nm
Bolt -B- : 50 Nm
– Replace bolts.

Note!

Assemble the support for the engine drive unit without tightening
⇒ Rep. Gr. 10 ; Engine; dismount and assemble .

Bearing to flanged axle: 40 Nm


Support for cables to gearbox: 25 Nm
Counterweight to the selection link rod: 25 Nm
From the thermal insulation cover of the bearing to the engine: 35
Nm

2. 02J Gearbox: Dismount and assemble 41


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

3 Checking the oil level for the gearbox


Specifications for the oil for gears ⇒ page 1 .
– Dismount the soundproofing case, lower part, if the vehicle
has one.
– Unscrew the inspection cover for the oil level -arrow- .
– The oil level is correct when the oil reaches the lower edge of
the filling inlet.
– Tighten the inspection cover for the oil level -arrow- .
Tightening torque: 25 Nm
In order to completely fill the tank with new oil you must:
– Unthread the control top for the oil level. Fill with oil up to the
inner edge of the hole for filling.
– Tighten the control top for the oil level and put the engine into
gear, let the gearbox tick over for about 2 minutes by engaging
a gear.
– Stop the engine, unthread the control top and check the oil
level again, fill up if necessary.
Tightening torque: 25 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

42 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4 Gearbox: dismounting and assembling


Assembly chart

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox casing
❑ Repair ⇒ page 58
7 - Gearbox operation
❑ Connection forks
❑ Dismount and assemble
⇒ page 66
8 - Control pinion for 1st gear
and reverse gear
9 - Primary shaft
❑ Dismount and assemble
⇒ page 70
10 - Secondary shaft
❑ Dismount and assemble
⇒ page 83
11 - Differential gear
❑ Dismount and assemble
⇒ page 104
12 - Clutch casing
❑ Repair ⇒ page 58

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Gearbox: dismounting and assembling 43


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4.1 Order for dismounting and assembling the gearbox

I - Cover of the gearbox casing


and 5 th gear ⇒ page 45
II - Gearbox casing and gear
selector axle ⇒ page 46
III - Primary shaft, secondary
shaft, differential gear and
gear forks ⇒ page 47

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

44 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4.2 Cover of the gearbox casing and 5th gear


Assembly chart

1 - Hexagonal bolt, 10 Nm
❑ For the cover of the
gearbox casing
2 - Cover of the gearbox casing

Note!

♦ If the cover of the gearbox casing


is mounted with the gearbox al‐
ready mounted in the vehicle, the
oil level must be checked for the
gearbox in the following way:
♦ Loosen the top of the oil level
control in the gearbox.
♦ Refill with oil for gearboxes until
achieving the proper level. Type
of oil and amounts for filling
⇒ page 1 Technical data; Identi‐
fication initials, assigning of Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
groups, reductions, filling permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
amounts. respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Tighten the inspection cover for


the oil level in the gearbox.
♦ Tightening torque: 25 Nm.
♦ Turn on the engine, engage a
gear and leave it running for 2
minutes.
♦ Stop the engine and refill with oil
for gearboxes until achieving the
proper level.

3 - Seal
4 - Torx Bolt M10, 80 Nm
❑ Replace
❑ A collar at the head of the bolt keeps the plate spring in the right position.
5 - Plate spring
❑ Position for assembly ⇒ page 56
6 - Bolt. 25 Nm
❑ For attaching the anchor bolts for the fork for 5th gear to the gearbox casing

7 - Anchor bolt for the 5th gear fork


8 - Fork for the 5th gear
9 - Movable sleeve for 5th gear
❑ Position for assembly ⇒ page 56
❑ Adjustment ⇒ page 57
10 - Synchroniser unit and pinion for 5th gear
❑ Check for wear ⇒ page 55

4. Gearbox: dismounting and assembling 45


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

11 - Needle bearing
12 - 5th gear pinion
❑ Position for assembly ⇒ page 54

4.3 Working for the gearbox and casing: dismounting and assembly
Assembly chart

1 - Bolt. 25 Nm
2 - Coupling flange
❑ Dismount and assemble
⇒ page 50
3 - Torx Bolt. 30 Nm
❑ For supporting the re‐
verse gear axle
❑ Self-blocking
❑ Always replace
4 - O-ring seal
❑ Always replace
5 - Support bolt
6 - Bolt. 25 Nm
7 - Bolt. 25 Nm
8 - Closing cover
9 - Gearbox casing
❑ Repair ⇒ page 58
10 - Clutch casing
❑ In case of replacement,
see adjustment chart
⇒ page 109
11 - Hexagonal Bolt. 25 Nm +
90º
12 - Gear selector axle
❑ Repair ⇒ page 63
13 - Bolt. 25 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

46 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4.4 Primary shaft, secondary shaft, differential gear and gearbox forks: dis‐
mounting and assembling
Assembly chart

1 - Differential gear
❑ Dismount and assemble
⇒ page 104
2 - Seal ring
❑ 4 units
❑ Always replace
3 - Secondary shaft
❑ Dismount and assemble
⇒ page 83
4 - Support for reverse gear
axle
❑ Dismount and assemble
⇒ page 98
5 - Reverse gear shaft
❑ Dismount and assemble
⇒ page 51
6 - Primary shaft
❑ Dismount and assemble
⇒ page 70
7 - Fork for reverse gear
❑ Position for assembly
⇒ page 53
8 - Bolt. 25 Nm
9 - Forks for operating gearbox
❑ Dismount and assemble
⇒ page 66
10 - Clutch casing
❑ Repair ⇒ page 58 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

11 - Nut. 25 Nm + 90º
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ 4 nuts for attaching the


secondary shaft
12 - Coupling flange
❑ Dismount and assemble ⇒ page 101
13 - Bolt. 25 Nm

4. Gearbox: dismounting and assembling 47


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4.5 Sequence for assembly: Gearbox dismounting and assemble

Special tools and workshop


equipment required
♦ Gearbox-differential sup‐
port column -AR-2203A-
♦ Case of extractors for gears
-U-40100-
♦ Case for repairing gears -
U-40200-
♦ Electrical blower -SAT
1416-
♦ Set of notched spanners
XZN -U-40020-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4.5.1 Dismounting
– Attach the gearbox onto the column -AR-2203A- . Use drill
holes Nos. 1 and 6.
– Empty the gearbox oil. Unscrew the top off for emptying the
gearbox oil.
– Dismount the release bearing and the release fork.
– Remove the bolts for attaching the guide sleeve.
♦ Remove the bolts attaching the guide sleeve with a suitable
diameter spanner from tool -U-40020- .
♦ Remove the guide sleeve, with a vulcanised O-ring seal.

48 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Unscrew the cover for the gearbox casing -arrow- and remove
the seal.

– Remove the bolts -arrow- and take out the fork for the 5th gear.

Note!

Before lifting out the movable one, remove the spring and the
block body. Next put the movable one back in, without the fork,
over the body of the synchroniser.

– In order to be able to loosen the two bolts -A- that attach the
5th gear pinion and the synchroniser, perform the following
steps: push the movable sleeve for the 5th gear downwards
-arrow 1- . Also connect the 1st gear by pushing the selector
lever inwards -arrow 2- and turning -arrow 3- .
– The primary and secondary shafts remain blocked since two
gears are connected; the synchronising bushing and the 5th
gear pinion do not turn. Unscrew the bolts -A- and take them
out.
– Remove the movable sleeve for the 5th gear.

– Dismount the synchronising bushing and the 5th gear pinion.


Use the tool -U-40100/1- .
– Remove the needle bearing for the 5th gear pinion.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Gearbox: dismounting and assembling 49


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Remove the 5th gear pinion. Use the tool -U-40100/1- .

Note!

♦ In order to remove the 5th gear pinion, first heat to about 80


ºC using the electrical blower -SAT 1416- .
♦ During the removal work, check that the legs of the extraction
device do not bend outwards. Check that the 5th gear pinion
is not damaged.

– Remove the right-hand and left-hand coupling flanges.


– Remove the coupling flanges together with the springs, the
thrust washers and the tapered rings.

– Dismount the two bolts -arrows- for supporting the reverse


gear axle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Put the gear selector axle into neutral. Extract the attachment
bolts -arrow- and remove the gear selector axle from the gear‐
box casing.

50 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Dismount the close cover -A- and the support bolts -B- from
the lower part of the gearbox, first extracting the bolts -1- and
-2- .

– Dismount the support bolts -A- from the upper part of the gear‐
box and the bolts -B- for attaching the gearbox casing to the
clutch casing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Dismount the bolts -A- for attaching the clutch casing to the
gearbox casing.

Note!

Do not remove the nuts -B- for attaching the secondary shaft.

– Separate the gearbox casing by hitting lightly with a plastic


hammer. Do not damage the surfaces for fitting them together.

4. Gearbox: dismounting and assembling 51


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Extract the forks -A- together with the connection guides.


– Remove the bolt -B- and extract the fork for the reverse gear.

– Extract the nuts for attaching the secondary shaft -B- .


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Note! respect to the correctness of information in this document. Copyright by SEAT S.A.

Place the gearbox axles in an upright position before completing


the removal of all the bolts -B- .

– Extract from the clutch casing, in the following order, the re‐
verse gear axle -A- , the main shaft -B- and the secondary shaft
-C- .
– Withdraw the differential unit from the clutch casing.

52 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4.5.2 Assembly
– Place the differential into the clutch casing.

Note!

The seal rings must always be replaced. The figure only shows 3
of the 4 bolts with their seal rings.

– Place the main shaft, the secondary shaft and the axle for the
reverse gear pinion together.
– Partially tighten the 4 nuts in a cross for the bearing cover for
the secondary shaft, finish tightening up to their tightening tor‐
que.
Tightening torque: 25 Nm + 90º

Note!

Clean the remains of the safety agent from the support thread for
the reverse gear axle. To do so, use a threaded tap.

– Put the support for the reverse gear axle into place.

– Assemble the fork for the reverse gear.


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Position for assembling the axle and
permitted theauthorised
unless reverse gearS.A.
by SEAT fork.
SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Assemble the forks together with the connection guides.

– Screw in a stud bolt -A- M 8 x 100 mm into the support for the
reverse gear axle so that it will be aligned after putting the
gearbox casing into place.
– Align the connection guides.
– Check that the blocks of the gearbox forks are housed in their
respective movable sleeves.
– Check that the magnet is not broken or cracked and put it into
its housing in the clutch casing.
– Assemble the gearbox casing over the clutch casing.

4. Gearbox: dismounting and assembling 53


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Screw in the bolts for attaching the clutch casing to the gear‐
box casing.
Tightening torque: 25 Nm + 90º
– Assemble the bolts for the reverse gear axle support -arrow-
as stated below:
– Place the bolt -a- , unscrew the stud bolt -A- M 8 x 100 mm -
Figure V34-2008 - assemble the bolt -b- and tighten it by hand.
Order for tightening:
1. Bolt -a- 30 Nm
2. Bolt -b- 30 Nm

– Assemble the support anchor bolts -arrow- for the gearbox


forks. Use a screwdriverProtected
to align the connection
by copyright. guides
Copying for private in suchpurposes, in part or in whole, is not
or commercial
a way that each support anchor bolt may be put into its hous‐
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
ing.
– Assemble the seal cover for the gear selector axle.
Assemble the gear selector axle in the following way:
– Put the connection guides into the position for neutral.

– Put the boss -arrow 2- onto the gearbox casing trimming. As‐
semble the gear selector axle so that the connection finger
-arrow 1- will fit between the connection guides.
– Screw in the bolts for attaching the gear selector axle to the
gearbox casing.
Tightening torque: 25 Nm
5th gear pinion
Position for assembly:

– The existing trimming on the inner diameter of the pinion must


face towards the gearbox casing.

54 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Fit onto the secondary shaft for the 5th gear, using the tool -
U-40200/20- .
Check for wear on the 5th gear synchroniser ring
– Before the check for wear, clean the synchroniser ring and the
5th gear pinion very carefully

– Put the synchroniser ring onto the 5th gear pinion. Press the
synchroniser ring down over the pinion and measure the gap
“a” with a thickness gauge.
Synchronisier ring Measure “a” on new Limit for wear
synchroniser
5th gear 1.1 … 1.7 mm 0.5 mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Put the 5th gear intounless
permitted place with bythe
authorised needle
SEAT S.A. SEATbearing.
S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Put the 5th gear synchroniser ring over the moving pinion.
– Before the assembly, mount the body for the synchroniser/
moving body of the 5th gear ⇒ page 76 .
– Place the 5th gear pinion on the main shaft.

– Put the synchroniser ring over the 5th gear pinion.


– Assemble the 5th gear synchroniser unit by carrying out the
following steps:
– Place the movable sleeve -2- over the synchroniser bushing
-3- so that the trimmings coincide -A- for housing the block pins
-4- for both components and that the cogs with pointed ends
of the movable sleeve are situated in the same direction as the
largest boss -B- of the bushing.
– Assemble the pins for blocking -4- and fit them into place with
the springs -1- by offsetting them 120º between each other and
under the steps for the blocking pins.

4. Gearbox: dismounting and assembling 55


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Position for assembling the 5th gear synchronised/movable body


– Put the 5th gear pinion into the main shaft in such a way that
the pointed cogs of the movable pinion -arrow 1- and the high
collar of the synchronised body -arrow 2- face towards the
gearbox casing.
– The housings for the synchronising body -arrow 3- are aligned
with the block parts of the synchronised ring.

5th gear synchronised ring with blocking parts built in -arrow-

– Fit in the movable sleeve set and synchroniser bushing onto


the 5th gear pinion. Use the tool -U-40200/20- .

Note!

When fitting the movable sleeve unit and synchroniser bushing


onto the 5th gear pinion, check that the 5th gear synchroniser ring
can turn freely.

– Partially screw in the bolts for attaching the synchroniser bush‐


ing and the 5th gear pinion.

Position
Protectedfor assembly
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– The concave
respect side ofofthe
to the correctness plateinsprings
information -arrow-
this document. must
Copyright beS.A.
by SEAT facing
towards the synchroniser bushing and the 5 gear pinion. th

56 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Before tightening the bolts attach the synchroniser bushing and


the 5th gear pinion -arrows- two gears must be connected
⇒ page 49 .
The primary and secondary shafts are blocked since two gears
are engaged; the synchroniser bushing and the 5th gear pinion do
not turn. Tighten the bolts -A- .
Tightening torque: 80 Nm
– Assemble the connection fork for 5th gear.

Adjust the movable sleeve and the fork for the 5th gear
– Engage the 5th gear and untighten the bolt -1- Press the mov‐
able sleeve in the direction of the arrow, then tighten the bolt
-1- .
Tightening torque: 25 Nm

Note!

Between the movable sleeve and the moving pinion, there cannot
be apermitted
gap ofunless
over 0.15 mm. If necessary, repeat the adjustment
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

process. respect to the correctness of information in this document. Copyright by SEAT S.A.
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Disengage the 5th gear. The movable ring must be placed in


neutral, the ring synchronised in this must position must be
able to turn freely.
– Check whether all the gears can be engaged easily.

– Put the seal for the gearbox casing cover into place -arrow- .
– Tighten the bolts for attaching the gearbox casing cover.
Tightening torque: 10 Nm
– Assemble the guide sleeve for the clutch release bearing and
attach it to the casing with the three lag bolts ⇒ page 21 .
Tightening torque: 20 Nm

– Assemble the thrust washers, the springs, the tapered rings


and the coupling flanges.

4. Gearbox: dismounting and assembling 57


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

5 Gearbox casing and clutch casing: repair


Assembly chart

1 - Gearbox casing
❑ In the event of replace‐
ment, see adjustment
chart ⇒ page 109
2 - Secondary shaft needle
bearing
❑ For secondary shaft
❑ Dismount ⇒ page 60
❑ Assemble and fix into
place ⇒ page 61
3 - Lid for control of oil level. 25
Nm
❑ Without magnet
4 - Primary shaft needle bear‐
ing
❑ In the event of replace‐
ment, see adjustment
chart ⇒ page 79
5 - Outer track, tapered roller
bearing for main shaft
❑ Dismount and assemble
⇒ page 70
❑ In the event of replace‐
ment, see adjustment
chart ⇒ page 109
6 - Outer track, tapered roller
bearing for secondary shaft
❑ Dismount and assemble
⇒ page 94
❑ In the event of replace‐
ment, see adjustment
chart ⇒ page 109 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7 - Adjustment washer for sec‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
ondary shaft
❑ In the event of replacement, see adjustment chart ⇒ page 96
8 - Outer track, tapered roller bearing for main shaft
❑ Dismount and assemble ⇒ page 70
❑ In the event of replacement, see adjustment chart ⇒ page 109
9 - Axial/radial needle bearing for reverse gear axle
❑ Dismount and assemble ⇒ page 98
10 - Centring bushes
❑ 2 units
11 - Bush-bearing for the start motor
❑ Remove ⇒ page 61
❑ Assemble ⇒ page 62
❑ It may be replaced with the gearbox mounted.
12 - Clutch casing
❑ In the event of replacement, see adjustment chart ⇒ page 109

58 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

13 - Guide sleeve
❑ With retainer for main shaft and vulcanised O-ring seal
❑ Dismount ⇒ page 61
❑ Assemble ⇒ page 61
❑ In order to replace the retainer for the main shaft it is necessary that the guide sleeve be dismounted.
❑ Replace the guide sleeve if the O-ring seal is damaged.
14 - Bolt for attaching the guide sleeve. 20 Nm
❑ Self-blocking
❑ Always replace
❑ Tightening torque: 20 Nm
15 - Retainer for right coupling flange
❑ Replacement with the gearbox mounted in the vehicle ⇒ page 101
16 - Plate sleeve
❑ For coupling flange retainer ⇒ Item 15 (page 59)
❑ Dismount ⇒ page 62
❑ Assemble ⇒ page 62
17 - Shaft for operating speedometer 30 Nm
18 - Top for emptying oil. 25 Nm
❑ Without a magnet
19 - Outer track for the tapered roller bearing in the differential
❑ Dismount and assemble ⇒ page 62
❑ In the event of replacement, adjust the differential ⇒ page 113
20 - Magnet
❑ It is held between the casings for the gearbox and the clutch
21 - Outer track for the tapered roller bearing in the differential
❑ Dismount and assemble ⇒ page 106
❑ Protected
In thebyevent ofCopying
copyright. replacement, adjust the
for private or commercial differential
purposes, in part or in⇒ page
whole, 113
is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
22 - Adjustment
respect to thewasher
correctnessfor differential
of information in this document. Copyright by SEAT S.A.

❑ Finding the thickness ⇒ page 115


23 - Retainer for left flange
❑ Replacement with the gearbox mounted in the vehicle ⇒ page 101

5. Gearbox casing and clutch casing: repair 59


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Special tools and workshop


equipment required
♦ Gearbox repairs case -
U-40200-
♦ Gearbox repairs case -
U-40300-
♦ Taps for Ø 11 and Ø 14 with
plunger -U-40087-
♦ Tool for assembling starter
sleeve -U-40027-
♦ Support column for gear‐
box-differential -
AR-2203A-

Dismounting the needle bearing for the secondary shaft


– Dismount the needle bearing from the gearbox casing using
tool -U-40200/10- and the tool -U-40300/1- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

60 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembling and fitting the needle bearing for the secondary shaft
– Assemble the needle bearing in the gearbox casing using tool
-U-40200/10- and the tool -U-40300/12- .
– Fit the bearing by making three marks with a marking hammer
set out with 120º between each other.

Dismount the retainer for the main shaft in the guide sleeve
– Dismount the retainer for the main shaft in the guide sleeve by
carrying out the following steps:
– Place the guide sleeve over tool -U-40300/9- .
– Dismount the retainer for the main shaft in the guide sleeve
using tool -U-40300/2- with side A facing towards the sleeve
and tool -U-40200/10- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Assemble the retainer for the main shaft in the guide sleeve
– Assemble the retainer for the main shaft in the guide sleeve,
carrying out the following steps:
– Place the guide sleeve over the tool -U-40300/9- .
– Assemble the retainer for the main shaft in the guide sleeve
using tool -U-40300/2- with side B facing towards the sleeve
and tool -U-40200/10- .

Dismounting the sleeve-bearing for the start-up motor


– Place the top of tool -U-40087- on the sleeve and tighten it
right to the end.
– Work the initiator until extracting the sleeve.

5. Gearbox casing and clutch casing: repair 61


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembling the sleeve-bearing for the start-up motor


– Lubricate the sleeve-bearing with oil.
– Fit it into the clutch casing, with tool -U-40027- side B, right up
to the top.

Dismounting the plate sleeve for the coupling flange retainer


– Remove the sleeve by levering out carefully with a screwdriv‐
er.
♦ If the sleeve is damaged or has defects, it must be replaced.

Assembling the plate sleeve for the coupling flange retainer


– Impregnate the contact surface of the sleeve with sealing
paste.
– Fit in the sleeve using tool -U-40200/13- with the trimming of
the tool facing towards the sleeve and tool -U-40200/10- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

62 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

6 Gear selector axle: repair


Special tools and workshop equipment required
♦ Gear repair case -U-40200-

♦ Gear repair case -U-40300-

Assembly chart

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

6. Gear selector axle: repair 63


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1 - Selection axle
2 - Stop ring
3 - Ball bearing sleeve
❑ Dismount ⇒ page 65
❑ Assemble ⇒ page 65
4 - Seal ring
❑ Remove by levering
with a screwdriver
❑ Assemble ⇒ page 65
5 - Connection top
6 - Crown
❑ The bead faces towards
the switch for the re‐
verse gear light
❑ Apply a fine layer of -
MoS2- grease onto the
bead
7 - Hexagonal nut, 25 Nm
❑ Self-blocking
❑ Always replace
8 - Support
❑ For the reverse gear
light switch.
9 - Bolt
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

10 - Top
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Vent top for the gear‐


box.
11 - Sleeve
❑ Fit it to the end, if it
comes as an individual
component
12 - Selection lever
❑ Position for assembly: The cog of the gear stick only fits in with the cog of the gear stick in one position
❑ It can be changed with the gear stick mounted in the vehicle
❑ Position for assembly ⇒ page 31
13 - Return lever
14 - Nut, 15 Nm
15 - Drag part
❑ With the axle for housing the return lever
❑ Position for assembly ⇒ page 31
16 - Bolt
❑ Insert it into the drag part.
17 - O-ring seals
❑ Assemble them on the axle of the drag parts.
18 - Separating part
❑ Insert it on the return lever
19 - Bolt for blocking, 40 Nm
20 - Seal top

64 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Dismounting the sleeve from the connection top


– Before extracting the ball bearing sleeve, break the plastic
holder and remove the ball bearings.
– The extraction of the ball bearing sleeve is done with the tool
-U-40300/4- without expanding.

Fit the ball bearing sleeve into the connection top

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Fit in the seal ring to the end

6. Gear selector axle: repair 65


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

7 Gearbox forks: repair


Special tools and workshop equipment required
♦ Gear repair case -U-40300-

♦ Pliers for opening elastic rings -A-81124-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Assembly Chart

66 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

1 - Gear switch anchor bolt


❑ Identification
⇒ page 68
❑ After assembling the
safety washer, the
blocks must be able to
move slightly.
2 - Pressure washer
❑ Separate the pressure
washer by levering
carefully with a screw‐
driver.
❑ Assembly ⇒ page 68
❑ Always replace
3 - 5th gear fork
❑ Adjust ⇒ page 57
4 - 5th gear connection hub
5 - Bolt, 25 Nm
6 - 5th gear connection guide
7 - Safety ring
8 - Washer
9 - Connection guide for 3rd
and 4th gears
10 - Connection guide for 1st
and 2nd gears
11 - Connection guide for re‐
verse gear
12 - Fork for 3rd and 4th gears
❑ With switch anchor bolt
for gears ⇒ page 69
13 - Switch anchor bolt for gears
❑ Identification ⇒ page 68
❑ After the assembly of the safety washer, the blocks must be able to move slightly
14 - Ball bearing
15 - Inner ring of the ball bearing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismount ⇒ page 68 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Fitting ⇒ page 68 respect to the correctness of information in this document. Copyright by SEAT S.A.

16 - 1st /2nd gear fork


❑ With blocks for the gearbox forks ⇒ page 69
17 - Reverse gear switch anchor bolt
❑ Identification ⇒ page 68
❑ After the assembly of the safety washer, the blocks must be able to move slightly.
18 - Safety ring
19 - Support for reverse gear fork
20 - Reverse gear fork
21 - Spring
22 - Sliding block

7. Gearbox forks: repair 67


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Identifying the blocks for the gearbox forks


Gap height -a-
1- 1st and 2nd gears = 12.1 mm
2- 3rd and 4th gears = 7.7mm
3- 5th gear = 12.1 mm

Assembly of the pressure washers


– Press down the pressure washer into the groove for the block
with a box spanner with a handle.

Note!

After the assembly of the safety washer, the blocks should be able
to move slightly.

A - Box spanner with handle, with 10 mm


B - Protective grips

Dismount the ball bearing

Note!

When dismounting and assembling the bearings, do not bend the


forks.

Fit in to the top of the inner ring of the ball bearing

Note! Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
When dismounting and assembling the bearings, do not bend the
forks.

68 Rep. Gr. 34 - Controls, Housing


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Fork with blocks mounted


Gap height -a- (mm)
1st /2nd gear fork 87.2 … 87.9
3rd /4th gear fork 96.0 … 96.7

Identification of the blocks for the gearbox forks ⇒ page 68 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Gearbox forks: repair 69


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

35 – Gears, Shafts
1 Main shaft: dismounting and assembling
Assembly Chart

1 - Clutch casing
2 - Outer track, tapered roller
bearings
❑ Dismounting
⇒ page 72
❑ Assembling
⇒ page 73
3 - Tapered roller bearing
❑ Dismounting
⇒ page 73
❑ Assembling Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 73
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4 - Main shaft
❑ Adjusting the main shaft
⇒ page 77
5 - 3rd gear pinion
❑ Dismounting
⇒ page 74
❑ Assembling
⇒ page 74
❑ Position for assembly:
the collar must remain
facing towards the 4th
gear pinion.
6 - Safety ring
❑ Use tool -A-81124- for
extracting the safety
ring.
❑ Always replace
7 - 4th gear pinion
❑ Dismount it together
with the tapered roller
bearing ⇒ Item 8 (page 70) , the stop washer ⇒ Item 9 (page 70) and the sleeve for the needle bearing
⇒ Item 13 (page 71) , ⇒ page 73
❑ Assembling ⇒ page 74
❑ Position for assembly: the collar must remain facing towards the 3rd gear pinion.
8 - Tapered roller bearing
❑ Dismount it together with the 4th gear pinion ⇒ Item 7 (page 70) , the stop washer ⇒ Item 9 (page 70)
and the sleeve for the needle bearing ⇒ Item 13 (page 71) , ⇒ page 73
❑ Assembling ⇒ page 75
9 - Stop washer
10 - Outer track, tapered roller bearing
❑ Dismounting ⇒ page 75
❑ Assembling ⇒ page 75

70 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

11 - Adjustment washer
❑ For the main shaft
❑ Finding the thickness ⇒ page 77
12 - Gearbox casing
13 - Sleeve for needle bearing
❑ Dismount together with the 4th gear pinion ⇒ Item 7 (page 70) , the tapered roller bearing
⇒ Item 8 (page 70) and the stop washer ⇒ Item 9 (page 70) , ⇒ page 73
❑ Before assembling it, put the stop washer into place ⇒ Item 9 (page 70)
❑ Assembling ⇒ page 75
14 - Needle bearing
15 - 5th gear pinion
❑ Dismount it together with the 5th gear synchroniser unit ⇒ page 45

16 - 5th gear synchroniser ring


❑ Check the wear ⇒ page 45
17 - Spring
❑ Position for assembly ⇒ page 76
18 - Blocking pins
❑ Assembling ⇒ page 76
19 - Synchronised boss
❑ Assembling ⇒ page 76
20 - Movable sleeve for 5th gear
❑ Assembling ⇒ page 76 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
21 - Plate spring permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Position for assembly: the concave side must remain facing towards the 5th gear pinion ⇒ page 45

22 - Bolt for attaching the 5th gear pinion. 80 Nm


❑ The head of the bolt has a slot for housing the plate spring ⇒ Item 21 (page 71)
❑ Assembly ⇒ page 45

1. Main shaft: dismounting and assembling 71


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Special tools and workshop


equipment required
♦ Case for extractors for
gearboxes -U-40100-
♦ Gearbox repair case -
U-40200-
♦ Pliers for opening elastic
rings -A-81124-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Dismounting the outer track of the tapered roller bearing


– Dismounting the outer track of the tapered roller bearing from
the main shaft in the clutch casing using tool -U-40200/20- .

72 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembling the outer track of the tapered roller bearing


– Assemble the outer track of the tapered roller bearing for the
main shaft in the clutch casing, using tool -U-40200/10- and
tool -U-40200/11- .

Dismounting the tapered roller bearing


– Place the tool -U-40100/4- between the bearing and the main
shaft pinion.
– Place the main shaft on tool -U-40100/4- , as shown on the
drawing. Work the press in order to extract the bearing.

Assembling the tapered roller bearing


– Assemble the bearing over the main axle using tool -
U-40100/3- with the help of a press.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Place the main shaft with the tapered bearing over the base
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
of the tool -U-40100/3- , as shown in the drawing. Operate the
press until the bearing is mounted in its position.

Dismounting the 4th gear pinion, the tapered roller bearing, the
stop washer and the sleeve for the needle bearing
The 4th gear pinion is dismounted together with the tapered roller
bearing, the stop washer and the sleeve for the needle bearing.
– Assemble the tool -U-40100/3- in the main shaft, underneath
the 4th gear pinion.
– Put the main shaft and the tool -U-40100/3- over the press as
shown in the drawing.
– Work the press until the tapered roller bearing and the 4th gear
pinion and the stop washer remain outside of the coupling.

1. Main shaft: dismounting and assembling 73


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Dismounting the 3rd gear pinion


– Assemble the tool -U-40100/3- in the main shaft, underneath
the 3rd gear pinion.
– Put the main shaft and the tool -U-40100/3- over the press as
shown in the drawing.
– Work the press until the 3rd gear pinion is removed from the
main shaft.

Assembling the 3rd gear pinion


– Assemble the tool -U-40100/3- underneath the 3rd gear pinion.
– Place the tool -U-40100/3- with the pinion in a press, as shown
in the drawing. Assemble the main shaft inside the pinion. The
cogs of the pinion and the main shaft should match.
Position for assembly:
The collar of the pinion should remain facing towards the 4th gear
pinion.
– Work the press until the pinion remains assembled in its po‐
sition.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Assembling the 4th gear pinion


– Assemble the tool -U-40100/3- underneath the 4th gear pinion.
– Place the tool -U-40100/3- with the 4th gear pinion in a press,
as shown in the drawing . Assemble the main shaft inside the
pinion. The cogs of the pinion and the main shaft should
match.
Position for assembly:
The collar of the pinion should remain facing towards the 3rd gear
pinion.
– Work the press until the pinion remains assembled in its po‐
sition.

74 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembling the tapered roller bearing


– Assemble the tool -U-40100/3- over the base of the 2nd gear
pinion and the main axle.
– Put the stop washer into place before placing the sleeve for
the needle bearing.
– Put the tool -U-40100/3- on the press as is shown in the draw‐
ing.
– Fit in the tapered roller bearing, using tool -U-40200/19- . Work
the press until the bearing is assembled in its position.

Assembling the sleeve for the needle bearing


– Assemble the tool -U-40100/3- over the base of the 2nd gear
pinion and the main axle.
– Place the shaft of the main axle with the 2nd gear pinion and
tools -U-40100/3- and -U-40300/8- on a press as is shown in
the drawing.
– Work the press until the sleeve is mounted in its position.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Dismounting the outer track of the tapered roller bearing


– Extract the outer track of the tapered roller bearing of the main
shaft in the gearbox casing using tool -U-40200/10- .

Assembling the outer track of the tapered roller bearing


– Assemble the outer track of the tapered roller bearing for the
main shaft in the gearbox casing using tool -U-40200/10- and
tool -U-40200/11- .

Note!

If the main shaft has been adjusted, the stop washer must be
assembled before assembling the outer track for the tapered roller
bearing.

1. Main shaft: dismounting and assembling 75


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembling the 5th gear synchroniser unit


– Assemble the 5th gear synchroniser unit by carrying out the
following steps:
– Place the movable sleeve -2- over the synchroniser sleeve
-3- in such a way that the trimmings coincide -Afor housing the
block pins -4- for both components and that the pointed cogs
of the movable sleeve are situated in the same direction as the
most pronounced edge -B-of the bushing.
– Assemble the blocking pins -4- and fix them in place with the
springs -1- spreading them out 120º away from each other and
under the projections of the blocking pins.

Assemble the springs in the 5th gear synchroniser unit


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check that the pointed cogsunless
permitted -A- authorised
of the movable
by SEAT S.A.sleeve
SEAT S.A are
does not guarantee or accept any liability with
facing in the same direction as tothe
respect most pronounced
the correctness of information inboss
this document. Copyright by SEAT S.A.
-B- of the bushing.
– Check that the blocking pins are assembled correctly
⇒ page 76 .
– Place the springs spread out 120º from each other, under‐
neath the projections -C- of the blocking pins. The bent ends
of the springs -arrows- must be located outside of the pins for
blocking.

76 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

2 Main shaft: adjusting

Special tools and workshop


equipment required
♦ Case for repairing gearbox‐
es -U-40200-
♦ All-purpose support for
tester -T20020-
♦ Support column for gear‐
box-differential -
AR-2203A-
♦ Dynometric keys -SAT
8010-

Adjust the main shaft when any of the following components have
been replaced:
♦ Gearbox casing
♦ Clutch casing
♦ Main shaft
♦ 4th gear pinion
♦ Tapered roller bearings in the main shaft
So as to avoid unnecessary adjustment work, consult the Chart
for Adjustment ⇒ page 109 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Main shaft: adjusting 77


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Assemble the outer track of the tapered roller bearing for the
main shaft in the gearbox casing without the adjustment wash‐
er, using tool -U-40200/10- and tool -U-40200/13- .
– Place the main shaft into its housing in the clutch casing.
– Assemble the gearbox casing over the clutch casing and tight‐
en the bolts for attaching them.
Tightening torque: 25 Nm + 90º

– Place tool -T20020- with a tester over the gearbox casing.


Place the end of it over the main shaft.
– Turn the main shaft a few times in order to settle the tapered
roller bearings.
– Adjust the tester to “0” with a prior stress of 1 mm.

Note!

The adjustment to “0” for the tester must be repeated each time
that the measurement is made, otherwise, the tester will not go
back to the initial position.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

78 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– On the lower part of the gearbox, put pressure on the main


shaft in the direction of the tester.
– Note the reading given on the tester (Example: 1.21 mm).

Note!

The tester does not return to the initial position.

♦ The adjustment washer needed is found by means of the fol‐


lowing Table ⇒ page 79 .
Example:
♦ Set in the tester = 1,21 mm.
♦ According to the Table for a set for the main shaft from 1.200
to 1.224 mm, a thickness of 1.175 mm would correspond to it.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Main shaft: adjusting 79


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Table of adjustment washers


Height Adjustment washer
measured for bearing Thickness Spares No.
set (mm) (mm)
0.671 … 0.699 0.650 02A 311 140
0.700 … 0.724 0.675 02A 311 140 A
0.725 … 0.749 0.700 02A 311 140 B
0.750 … 0.744 0.725 02A 311 140 C
0.775 … 0.799 0.750 02A 311 140 D
0.800 … 0.824 0.775 02A 311 140 E
0.825 … 0.849 0.800 02A 311 140 F
0.850 … 0.874 0.825 02A 311 140 G
0.875 … 0.899 0.850 02A 311 140 H
0.900 … 0.924 0.875 02A 311 140 J
0.925 … 0.949 0.900 02A 311 140 K
0.950 … 0.974 0.925 02A 311 140 L
0.975 … 0.999 0.950 02A 311 140 M
1.000 … 1.024 0.975 02A 311 140 N
1.025 … 1.049 1.000 02A 311 140 P
1.050 … 1.074 1.025 02A 311 140 Q
1.075 … 1.099 1.050 02A 311 140 R
1.100 … 1.124 1.075 02A 311 140 S
1.125 … 1.149 1.100 02A 311 140 TT
1.150 … 1.174 1.125 02A 311 140 AA
1.175 … 1.199 1.150 02A 311 140 AB
1.200 … 1.224 1.175 02A 311 140 AC
1.225 … 1.249 1.200 02A 311 140 AD
1.250 … 1.274 1.225 02A 311 140 AE
1.275 … 1.229 1.250 02A 311 140 AF
1.300 … 1.324
Protected 1.275for private
by copyright. Copying 02A 311 140purposes,
or commercial AG in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1.325 … 1.349 1.300
respect to the correctness 02Ain311
of information 140 Copyright by SEAT S.A.
this document.
02A 311 140
1.350 … 1.374 1.325 02A 311 140
02A 311 140 A
1.375 … 1.399 1.350 02A 311 140 A
02A 311 140 A
1.400 … 1.424 1.375 02A 311 140 A
02A 311 140 B
1.425 … 1.449 1.400 02A 311 140 B
02A 311 140 B
1.450 … 1.474 1.425 02A 311 140 B
02A 311 140 C
1.475 … 1.499 1.450 02A 311 140 C
02A 311 140 C
1.500 … 1.524 1.475 02A 311 140 C
02A 311 140 D
1.525 … 1.549 1.500 02A 311 140 D
02A 311 140 D
1.550 … 1.574 1.525 02A 311 140 D
02A 311 140 E
1.575 … 1.599 1.550 02A 311 140 E
02A 311 140 E
1.600 … 1.624 1.575 02A 311 140 E
02A 311 140 F
1.625 … 1.649 1.600 02A 311 140 F
02A 311 140 F
1.650 … 1.674 1.625 02A 311 140 F
02A 311 140 G

80 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Height Adjustment washer


1.675 … 1.699 1.650 02A 311 140 G
02A 311 140 G
1.700 … 1.724 1.675 02A 311 140 G
02A 311 140 H
1.725 … 1.749 1.700 02A 311 140 H
02A 311 140 H
1.750 … 1.774 1.725 02A 311 140 H
02A 311 140 J
1.775 … 1.791 1.750 02A 311 140 J
02A 311 140 J
– Once the adjustment washer needed has been foand, remove
the comparator.
– Remove the bolts that attach both casings and take out the
gearbox casing.
– Remove the main shaft from the casing.

– Remove the outer track of the tapered roller bearing for the
main shaft in the gearbox casing using tool -U-40200/10- and
tool -U-40200/13- .
– Place the adjustment washer with the thickness calculated (in
this case, 1.175 mm) into the housing for the outer track of the
tapered roller bearing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Assemble the outer track of the tapered roller bearing of the


main shaft in the clutch casing using tool -U-40200/10- and
tool -U-40200/13- .
– Carry out a measurement for control.
Measurement for control
– Place the main shaft into its housing in the clutch casing.
– Assemble the gearbox casing over the clutch casing and tight‐
en the bolts for attaching them.
Tightening torque: 25 Nm + 90º

2. Main shaft: adjusting 81


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Place the tool -T20020- over the gearbox casing with a tester.
– Place the end of the tester on the main shaft.
– Turn the main shaft a few times in order to settle the tapered
roller bearings.
– Adjust the tester to “0” with a pretension of 1 mm.
– On the lower part of the gearbox, put pressure on the main
shaft in the direction of the tester.
– The bearing play should range between a minimum of 0.01
mm and a maximum of 0.1 mm.

Note!

If it is not possible to note any play in the bearing, but however


the first shaft has quite a visible play that allows a smooth turn,
the adjustment is right.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

82 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

3 Secondary shaft: dismounting and assembling


Assembly Chart

1 - Nut, 25 Nm + 90º
❑ 4 units
❑ For attaching the secon‐
dary shaft
2 - Clutch casing
3 - Adjustment washer
❑ For the secondary shaft
❑ Finding the thickness
⇒ page 94
4 - Outer track, tapered roller
bearing
❑ Dismounting
⇒ page 86
❑ Assembling
⇒ page 87
5 - Tapered roller bearing
❑ Dismounting
⇒ page 87
❑ Assembling
⇒ page 87
6 - Secondary shaft
❑ It is coupled with the pin‐
ion for the control drive
trains; in the event of re‐
placement they should
be changed together.
❑ In the event of replace‐
ment ï Identification ini‐
tials, assignation of
groups, reductions,
amounts for filling
⇒ page 1
❑ Adjustment for the sec‐
ondary shaft ⇒ page 94
7 - Tapered roller bearing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Dismounting ⇒ page 88 respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Assembling ⇒ page 88
8 - Seal ring
❑ 4 units
❑ Always replace
❑ For the bolts for attaching the cover for the secondary shaft bearing ⇒ Item 9 (page 83)
9 - Cover for the secondary shaft bearing
❑ It includes the outer track for the tapered roller bearing ⇒ Item 7 (page 83) .
❑ The cover for the secondary shaft bearing must be replaced together with the outer track for the tapered
roller bearing and the tapered roller bearing ⇒ Item 7 (page 83) .
10 - Stop washer
❑ The edge of the washer must be facing towards the tapered roller bearing.

3. Secondary shaft: dismounting and assembling 83


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

11 - 1st gear pinion


❑ Before assembling the 1st gear pinion assemble the stop washer ⇒ Item 10 (page 83) .

12 - Needle bearing for 1st gear pinion


13 - Synchroniser ring for 1st gear
❑ Identification ⇒ page 90 and ⇒ page 90
❑ Check for wear ⇒ page 88
❑ Check that the flanges have no signs of wear.
14 - Synchroniser unit for 1st and 2nd gears
❑ Dismounting the secondary shaft ⇒ page 88 .
❑ Desmontagem ⇒ page 89
❑ Assembling the components ⇒ page 89 and ⇒ page 89 .
❑ Position for assembly ⇒ page 89 .
❑ Assembly of the secondary shaft ⇒ page 90 .
15 - Safety ring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Use tool -A-81124- for extracting thepermitted
safety ring.
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Always replace
respect to the correctness of information in this document. Copyright by SEAT S.A.

16 - Outer synchroniser ring for 2nd gear


❑ Identification ⇒ page 90 and ⇒ page 90 .
❑ Check for wear ⇒ page 90 .
❑ Assembly: the trimmings of the synchroniser ring must always be fitted with the pins in the synchroniser
unit for 1st and 2nd gear ⇒ Item 14 (page 84) .
17 - Intermediate synchroniser ring for 2nd gear
❑ Place it on the outer synchroniser ring ⇒ Item 16 (page 84) .
❑ Position for assembly ⇒ page 91 .
❑ Replace it if it shows signs of wear or cracks.
18 - Inner synchroniser ring for 2nd gear
❑ Identification ⇒ page 90 and ⇒ page 90 .
❑ Check for wear ⇒ page 91
❑ Check that the flanges do not show any signs of wear.
❑ Position for assembly ⇒ page 91 .
19 - 2nd gear pinion
❑ Position for assembly ⇒ page 91 .
20 - Needle bearing for 2nd gear pinion
21 - Stop washer
22 - Sleeve for needle bearing
❑ Dismounting, together with the 2nd gear pinion ⇒ page 88 .
❑ Assembling ⇒ page 92
23 - Needle bearing for 3rd gear pinion
24 - 3rd gear pinion
25 - Synchroniser ring for 3rd gear
❑ Check for wear ⇒ page 88
26 - Synchroniser unit for 3rd and 4th gears
❑ Dismounting the secondary shaft ⇒ page 87 .
❑ Dismounting the synchroniser unit ⇒ page 92
❑ Assembling the components ⇒ page 92 and ⇒ page 92 .

84 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

❑ Position for assembly ⇒ page 92


❑ Assembly for the secondary shaft ⇒ page 93 .
27 - Casquilho Sleeve for needle bearingrolamento de agulhas
❑ Dismounting together with the synchroniser unit for 3rd and 4th gears ⇒ Item 26 (page 84) ,
⇒ page 87
❑ Assembling ⇒ page 93
28 - Needle bearing for 4th gear pinion
29 - Synchroniser ring for 4th gear
❑ Check for wear ⇒ page 88
30 - 4th gear pinion
31 - Stop washer
32 - Needle bearing for the secondary shaft
❑ Dismounting and assembling ⇒ page 58
33 - Gearbox casing
34 - Sleeve for needle bearing
❑ Dismounting ⇒ page 87
❑ Assembling ⇒ page 93
35 - 5th gear pinion
❑ Dismounting and assembling ⇒ page 45
36 - Plate spring
❑ Position for assembly: the concave side must remain facing towards the 5th gear pinion.

37 - Bolt for attaching the 5th gear pinion


❑ The head of the bolt includes a housing for the plate spring ⇒ Item 36 (page 85)
❑ Assembly ⇒ page 45

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Secondary shaft: dismounting and assembling 85


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Special tools and workshop


equipment required
♦ Case for extractors for
gearboxes -U-40100-
♦ Gearbox repair case -
U-40200-
♦ Gearbox repair case -
U-40300-
♦ Pliers for opening elastic
rings -A-81124-

Dismounting the outer track for the tapered roller bearing


– Dismount the outer track for the tapered roller bearing by car‐
rying out the following steps:
– Assemble the grips -U-40300/17- on the tool -U-40300/16-
using its attachment bolts. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Place the set of tools on the lower part of the outer track of the
respect to the correctness of information in this document. Copyright by SEAT S.A.

tapered roller bearing. Expand the tool -U-40300/16- by tight‐


ening the bolt -1- .
– Place the extractor tool -U-40300/15- on the clutch casing and
tighten the axle of the extractor in the tool -U-40300/16- .
– Turn the nut -2- until extracting the outer track of the tapered
roller bearing.

86 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assemble the outer track of the tapered roller bearing


– Assemble the outer track of the tapered roller bearing of the
secondary shaft, on the clutch casing, with the tool -
U-40200/12- and the tool -U-40200/10- .

Dismounting the tapered roller bearing


– Assemble the tool -U-40100/4- on the secondary shaft ander‐
neath the front pinion.
– Place the secondary shaft and the tool -U-40300/2- on the
press, as is shown on the drawing.
– Work the press until the tapered roller bearing is extracted.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Assembling the tapered roller bearing


– Assemble the tool -U-40100/3- on the secondary shaft ander‐
neath the front pinion.
– Place the tool -U-40200/19- on the press as is shown on the
drawing.
– Work the press until the tapered roller bearing is mounted in
its position.

Dismounting the sleeve for the needle bearing, the 4th gear pin‐
ion, the synchroniser unit for 3rd and 4th gears and the 3rd gear
pinion of the secondary shaft
The 3rd gear pinion will be assembled jointly with the sleeve for
the needles bearing, the 3rd and 4th gear synchroniser unit and
the 4th gear pinion.
– Place the tool -U-40100/3- on the secondary shaft ander the
3rd gear pinion.
– Place the secondary shaft with the tool -U-40100/3- on the
press as is shown in the drawing.
– Work the press and extract at the same time the sleeve for the
needle bearing, the 4th gear pinion, the synchroniser unit for
3rd and 4th gears and the 3rd gear pinion.

3. Secondary shaft: dismounting and assembling 87


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Dismounting the sleeve for the needle bearing, the 2nd gear pin‐
ion, the synchroniser unit for 1st and 2nd gears and the 1st gear
pinion of the secondary shaft
– Remove the safety ring using the tool -A-81124- .
– Assemble the tools -U-40100/3- and -U-40300/10- on the sec‐
ondary shaft anderneath the 2nd gear pinion.
– Put the secondary shaft and the tools -U-40100/3- and -
U-40300/10- over the press, as is shown.
– Work the press and extract at the same time the sleeve for the
needle bearing, the 2nd gear pinion, the synchroniser unit for
1st and 2nd gears and the 1st gear pinion of the secondary
shaft.

Dismounting the tapered roller bearing


– Assemble the tool -U-40100/4- anderneath the tapered roller
bearing
– Place the tool -U-40100/4- over the press, as is shown.
– Work the press until extracting the tapered roller bearing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Assembling the tapered roller bearing


– Assemble the tools -U-40100/3- and -U-40200/18- with side
-A- facing towards the tapered bearing, over the secondary
shaft.
– Place the secondary shaft using tools -U-40100/3- and -
U-40200/18- over the press, as shown in the drawing.
Position for assembly:
The side with the smallest external diameter of the tapered roller
bearing must be facing towards tool -U-40200/18- .
– Put the tool -U-40200/4- between the press and the secondary
shaft.
– Work the press until the tapered roller bearing is mounted in
its position.

Control for wear on the synchroniser rings for the 1st , 3rd and
4th gears
– Before the control for wear, carefully clean the synchroniser
rings and their corresponding pinions.
– Place the synchroniser ring onto the cone of the corresponding
pinion. Press down the synchroniser onto the pinion and
measure the gap height “a” with a gauge.
Synchroniser ring Measurement “a” in Wear limit
a new synchroniser
1st gear 1.0 … 1.7 mm 0.5 mm
3rd gear
4th gear

88 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Dismounting and assembling the synchroniser unit for 1st and


2nd gears
– In order to dismount the synchroniser unit for 1st and 2nd gears,
remove the springs -1- and move the movable sleeve -B- com‐
pletely upwards.
– Assemble the synchroniser unit for 1st and 2nd gears by car‐
rying out the following steps:
– Place the movable sleeve -2- onto the synchroniser hub -3- so
that the trimmings for housing the blocking pins -4- for both
components coincide.
Position for assembly:
– Mount the movable sleeve over its boss in such a way that
after they are assembled they will be located so that the widest
collar of the synchroniser boss -A- and the inner teeth of the
movable sleeve -B- are facing in opposite directions.
– Assemble the blocking pins -4- and fix them into place with the
springs -1- placing them at 120° from each other.

Dismounting and assembling the synchroniser unit for 1st and


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
nd
2 gears permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– With the synchroniser unit assembled, mount the springs at
120° from each other. The bent ends of the springs must re‐
main inside the blocking pins.

Position for assembling the synchroniser unit for 1st and 2nd gears
– The cogs -1- of the movable sleeve must be facing towards
the gear teeth -A- for housing the synchroniser unit for 3rd and
4th gears.
– The collar -2- of the synchroniser hub must be facing towards
the pinion -B- for the 1st gear.

3. Secondary shaft: dismounting and assembling 89


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembly of the synchroniser unit for the 1st and 2nd gears in the
secondary shaft
– Place the synchroniser ring for the 1st gear on the 1st gear
pinion.
– Assemble the synchroniser unit for the 1st and 2nd gears in the
secondary shaft by carrying out the following steps:
– Place the tool -U-40100/3- and the tool -U-40200/19- in a
press with side A facing upwards.
– Place the secondary shaft on the tool -U-40200/19- .
– Place the tool -U-40300/9- between the press and the secon‐
dary shaft.
– Turn the synchroniser ring so that the parts of the block for the
synchroniser unit coincide with the housings of the pins for the
synchroniser ring.
– Work the press until the synchroniser unit for the 1st and 2nd
gears is mounted in its position.
– Mount the safety ring using the tool -A-81124-
⇒ Item 15 (page 84) .

Identification of the synchroniser rings for 1st and 2nd gears


– Synchroniser ring for 1st gear: 3 cogs cut down to half size
-arrow- .
– Synchroniser ring for 2nd gear: 2 or 3 cogs cut down to half
size -arrow- .
– The synchroniser ring for the 2nd gear is only supplied as a
spare part, with 2 cogs cut down to half size.

Identification of the synchroniser rings for 1st and 2nd gears


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Synchroniser ring for
permitted unless 2nd gear:
authorised by SEAT3 trimmings
S.A. -arrows-
SEAT S.A does . or accept any liability with
not guarantee
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Synchroniser ring for 1st gear: without trimmings.

Control for the wear on the outer synchroniser ring for the 2nd gear
– Before the control for wear, carefully clean the synchroniser
rings and their corresponding pinions.
– Place the synchroniser ring onto the cone of the corresponding
pinion. Press down the synchroniser onto the pinion and
measure the gap “a” with a gauge.
Synchroniser ring Measurement “a” in Wear limit
a new synchroniser
2nd gear 1.2 … 1.8 mm 0,5 mm

90 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Position for the assembly of the intermediate synchroniser ring


for the 2nd gear
– The bosses -arrows- must be facing towards the pinion for
1st gear -A- .

Control for the wear on the inner synchroniser ring for the 2nd
gear
– Before the control for wear, carefully clean the synchroniser
rings and their corresponding pinions.
– Place the synchroniser ring onto the cone of the corresponding
pinion. Press down the synchroniser onto the pinion and
measure the gap “a” with a gauge.
Synchroniser ring Measurement “a” in Wear limit
a new synchroniser
2nd gear 0.75 … 1.25 mm 0,3 mm

Position for the assembly of the inner synchroniser ring for 2nd
gear
– The bosses -arrows 1- of the synchroniser ring for the 2nd gear
-A- must fit in the trimmings -arrows 2- of the synchroniser ring
-B- .

Position for assembling the 2nd gear pinion


– The collar -A- of the 2nd gear pinion must be facing towards
the 1st gear -B- pinion.
– The trimmings arrows of the 2nd gear pinion -A- must fit into
the bosses of the intermediate synchroniser ring ⇒ page 91 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Secondary shaft: dismounting and assembling 91


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembling the sleeve for the needle bearing


– Assemble the needle bearing for the 2nd gear pinion and the
stop washer in the secondary shaft.
– Place the tool -U-40100/3- and tool -U-40200/19- in a press
with side -A- facing upwards.
– Place the secondary shaft onto the tool -U-40200/19- .
– Place the tool -U-40300/8- with side -B- facing towards the
sleeve and the tool -U-40300/9- , between the press and the
secondary shaft.
– Work the press until the sleeve for the needle bearing is moun‐
ted in its position.

Dismounting and assembling the synchroniser unit for 3rd and


4th gears
– In order to dismount the synchroniser unit for 3rd and 4th gears,
remove the springs -1and move the movable sleeve -3com‐
pletely upwards.
– Assemble the synchroniser unit for 3rd and 4th gears by car‐
rying out the following steps:
– Place the movable sleeve -3- onto the synchroniser hub -4- so
that the trimmings for housing the blocking pins -2- for both
components coincide.
– Assemble the blocking pins -2- and fix them into place with the
springs -1- placing them at 120° from each other.

Dismounting and assembling the synchroniser unit for the 3rd and
4th gears in the secondary shaft
– The movable sleeve must be mounted on the synchroniser
hub.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Place the springs at unless
permitted 120°authorised
from eachby SEATother. The
S.A. SEAT S.Abent ends
does not of or accept any liability with
guarantee
the springs must remain
respect toinside the blocking
the correctness pins.
of information in this document. Copyright by SEAT S.A.

Position for assembling the synchroniser unit for 3rd and 4th gears
– The collar with bevel -arrow- of the synchroniser hub must be
facing towards the 4th gear pinion.

92 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembly of the synchroniser unit for the 3rd and 4th gears in the
secondary shaft
– Assemble the synchroniser unit for the 3rd and 4th gears in the
secondary shaft by carrying out the following steps:
– Assembling o casquilho para rolamento de agulhas.
– Place the secondary shaft on the tool -U-40200/19- .
– Situar o utensílio-ferramenta -U-40300/9- entre a prensa e o
veio secundário.
– Turn the synchroniser ring so that the parts of the block for the
synchroniser unit coincide with the housings of the pins in the
synchroniser ring.
– Work the press until the synchroniser unit for the 3rd and 4th
gears is mounted in its position.

Assembling the sleeve for the needle bearing


– Place the tool -U-40100/3- and the tool -U-40200/19- in a
press with side A facing upwards.
– Place
Protected the secondary
by copyright. shaftor on
Copying for private the tool
commercial -U-40200/19-
purposes, . is not
in part or in whole,
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Place
respect tothe tool -U-40300/8-
the correctness with
of information in side -B-
this document. facingby towards
Copyright SEAT S.A. the
sleeve and tool -U-40300/9- , between the press and the sec‐
ondary shaft.
– Work the press until the sleeve for the needle bearing is moun‐
ted in its position.

Assembling the sleeve for the needle bearing


– Place the tool -U-40100/3- and the tool -U-40200/19- in a
press with side A facing upwards.
– Place the secondary shaft on the tool -U-40200/19- .
– Place the tool -U-40300/8- with side A facing towards the
sleeve, between the press and the secondary shaft.
– Work the press until the sleeve for the needle bearing is moun‐
ted in its position.

3. Secondary shaft: dismounting and assembling 93


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4 Secondary shaft: adjustment

Special tools and workshop


equipment required
♦ Gearbox repair case -
U-40200-
♦ Gearbox repair case -
U-40300-
♦ Multi-purpose stand for the
-T20020- comparator
♦ Dynometric keys -SAT
8010-

Adjust the secondary shaft when any of the following components


have been replaced:
♦ Clutch casing
♦ Secondary shaft
♦ Tapered roller bearing in the secondary shaft
So as to avoid unnecessary adjustment work, consult the Chart
for Adjustment ⇒ page 109 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Dismount the outer trackpermitted
of theunless
tapered roller
authorised bearing
by SEAT byS.A
S.A. SEAT car‐
does not guarantee or accept any liability with
rying out the following steps: respect to the correctness of information in this document. Copyright by SEAT S.A.
– Assemble the grips -U-40300/17- on the tool -U-40300/16-
using its attachment bolts.
– Place the set of tools on the lower part of the outer track of the
tapered roller bearing. Expand the tool -U-40300/16- by tight‐
ening the bolt -1- .
– Turn the nut -2- until extracting the outer track of the tapered
roller bearing.

94 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Assemble the outer track of the tapered roller bearing of the


secondary shaft, in the clutch casing, with an adjustment
washer 0.65 mm thick, using tool -U-40200/10- and tool -
U-40200/12- .
– Put the secondary shaft into its housing in the gearbox casing.
– Tighten the bolts for attaching the secondary shaft to the gear‐
box casing.
Tightening torque: 25 Nm + 90º

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Secondary shaft: adjustment 95


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Place tool -T20020- with a comparator over the clutch casing.


Place the end of it over the secondary shaft.
– Adjust the comparator to “0” with a prior tension of 1 mm.
– Alternatively move the secondary shaft in the direction of the
comparator.
– Note down the reading obtained on the comparator. Example,
0.30 mm.

Note!

When taking the measurement do not turn the secondary shaft.


The tapered roller bearings do not settle and they give a false
reading.

Calculating the adjustment washer


The thickness of the adjustment washer to be mounted is found
by adding the reading values obtained with the comparator, the
thickness of the adjustment washer mounted earlier and a set
value.
Example:
Reading obtained with the comparator 0.30
mm
Thickness of the washer already mounted 0.65
mm
Set value 0.20
mm
Thickness of the adjustment washer needed 1.15
mm
The adjustment washer needed is to be found using the following
Table:
Adjustment Table
Thickness (mm) Spare No.
0.65 020 311 391 P
0.70 020 311 391 Q
0.75 020 311 391
0.80 020 311 391 A
0.85 020 311 391 B
0.90 020 311 391 C
0.95 020 311 391 D
1.00 020 311 391 E
1.05 020 311 391 F
1.10 020 311 391 G
1.15 020 311 391 H
1.20 020 311 391 J
1.25 020 311 391 K
1.30 020 311 391 L
1.35 020 311 391 M
1.40 020 311 391
Protected N  Copying for private or commercial purposes, in part or in whole, is not
by copyright.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
The diversity of the adjustment washers available allows you to
find exactly the right thickness needed to perform a proper ad‐
justment of the secondary shaft.

96 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Should the thickness of the adjustment washer needed be


thicker than the thicknesses that appear in the Table, two ad‐
justment washers may be fitted, the thicknesses for which
when added together, correspond to the reading required.
– Once the adjustment washer needed has been determined,
remove the comparator.
– Separate the secondary shaft.
– Dismount the outer track for the tapered roller bearing by car‐
rying out the following steps:
– Assemble the grips -U-40300/17- on the tool -U-40300/16-
using its attachment bolts.
– Place the set of tools on the lower part of the outer track of the
tapered roller bearing. Expand the tool -U-40300/16- by tight‐
ening the bolt -1- .
– Place the extractor tool -U-40300/15- on the clutch casing and
tighten the axle of the extractor into the tool -U-40300/16- .
– Turn the nut -2- until extracting the outer track of the tapered
roller bearing.
– Remove the washer that is 0.65 mm thick.

– Place the adjustment washer with the thickness calculated.


Example, 1.15 mm, in the housing for the outer track of the
tapered roller bearing of the secondary shaft.
– Assemble the outer track of the tapered roller bearing of the
secondary shaft, in the clutch casing, using tool -U-40200/10-
and the tool -U-40200/12- .
– Lubricate the tapered roller bearing with oil for gearboxes.
– Place the secondary shaft into its housing in the gearbox cas‐
ing.
– Tighten the bolts for attaching the secondary shaft to the gear‐
box casing.
Tightening torque: 25 Nm + 90º

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Secondary shaft: adjustment 97


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

5 Axle for reverse gear pinion: dismounting and assembling


Assembly Chart

1 - Clutch casing
2 - Axial/radial needle bearing
❑ Dismounting
⇒ page 99
❑ After the dismounting,
the axial/radial needle
bearing must always be
replaced.
❑ Assembling
⇒ page 100
3 - Reverse gear pinion
4 - Safety ring
❑ Use the tool -A-81124-
for extracting the safety
ring
❑ Always replace
5 - Reverse gear moving pinion
❑ Position for assembly:
the collar of the pinion
must face towards the
reverse gear pinion.
6 - Axle for reverse gear pinion
❑ Dismounting
⇒ page 47 .
7 - Axial/radial needle bearing
❑ Dismounting
⇒ page 100 .
❑ After the dismounting,
the axial/radial needle
bearing must always be
replaced.
❑ Assembling
⇒ page 100 .
8 - Support for the reverse gear axle
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismounting and assembling ⇒ page 47 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

98 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Special tools and workshop


equipment required
♦ Case for extractors for
gears -U-40100-
♦ Gearbox repair case -
U-40200-
♦ Gearbox repair case -
U-40300-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Dismounting the axial/radial needle bearing


– Dismount the axial/radial needle bearing by carrying out the
following steps:
– Place the tool -U-40300/6- on the lower part of the axial/radial
needle bearing.
– Expand the grips of tool -U-40300/6- by tightening the bolt
-1- .
– Place the extractor tool -U-40300/15- on the clutch casing and
tighten the axle of the extractor in the tool -U-40300/6- .
– Turn the nut -2- until extracting the axial/radial needle bearing.

5. Axle for reverse gear pinion: dismounting and assembling 99


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assembling the axial/radial needle bearing


– Assemble the axial/radial needle bearing in the clutch casing
with the tool -U-40200/10- and tool -U-40300/7- .

Dismounting the axial/radial needle bearing for supporting the re‐


verse gear shaft
– Place the tool -U-40100/3- under the support for the reverse
gear axle.
– Dismount the axial/radial needle bearing from the support for
the reverse gear shaft, with the tool -U-40200/10- and the tool
-U-40200/5- .

Assembling the axial/radial needle bearing for supporting the re‐


verse gear shaft
– Place the tool -U-40100/3- under the support for the reverse
gear axle.
– Assemble the axial/radial needle bearing from the support for
the reverse gear axle, with the tool -U-40200/10- and the tool
-U-40300/7- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

100 Rep. Gr. 35 - Gears, Shafts


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

39 – Final drive, Differential


1 Retainers for coupling flanges: dis‐
mounting and assembling

1.1 Retainers for coupling flanges: dis‐


mounting and assembling
(Gearbox mounted in the vehicle)

Special tools and workshop


equipment required
♦ Set of notched spanners
XZN -U-40020-
♦ Case for extractors for
gears -U-40100-
♦ Tool for holding coupling
flanges -T20005-
♦ Case for dismounting/as‐
sembling hub-bearing and
coupling flanges-drive train
-U-40450A-

1.1.1 Dismounting
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Bear in mind the general instructions for the repair of the gearbox
⇒ page 6 .

1. Retainers for coupling flanges: dismounting and assembling 101


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Note!

♦ Remove the negative terminal from the battery.


♦ In vehicles that are fitted with a coded radio, first consult the
anti-theft code.

Retainer for right coupling flange:


– Dismount the counterweight from the unit holder.
♦ Mark the position for the assembly of the counterweight.
Right or left retainer for coupling flange:
– Extract the attachment bolts from the drive train to the gearbox
flange.
♦ Use a spanner with a suitable diameter from the tool -
U-40020- .
– PutProtected
the drive train to one side and support it appropriately and
try not to damage it.by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Empty the oil from the gearbox.
– Remove the attachment bolt from the coupling flange.
– Take out the coupling flange together with the spring, the
thrust washer and the tapered ring.

– Dismount the retainer for the coupling flange using the tool -
U-40100/2- . Work the hammer until extracting the retainer.

Note!

Try not to cause any damage to the housing for the retainer in the
gearbox.

1.1.2 Assembly
– Lubricate the retainer properly.

102 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Fit in the retainer using the tools -U-40450A/3- and -


U-40450A/10- .
♦ Try not to introduce the retainer tilted.
– Assemble the coupling flange together with the spring, the
thrust washer and the tapered ring.

– Assemble the bolt for attaching the coupling flange. Use the
tool -T20005- .
Tightening torque: 25 Nm
– Assemble the coupled differential shaft on the gearbox flange.
♦ Use a spanner with the appropriate diameter from tool -
U-40020- .
Tightening torque: 45 Nm
Retainer for right coupling flange:
– Assemble the counterweight -A- on the unit holder.
♦ Position for assembly: According to the mark made for the
dismounting. If no mark has been made, the counterweight
must be assembled on the unit holder so that the greatest dis‐
tance between the edge of the counterweight and the attach‐
ment bolts is facing forwards.
– Check the oil level in the gearbox ⇒ page 42 .
– Remove the negative terminal from the battery.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Retainers for coupling flanges: dismounting and assembling 103


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

2 Differential: dismounting and assembling


Assembly chart

1 - Gearbox casing
2 - Bolt
3 - Differential box
❑ In the event of replace‐
ment, consult the Ad‐
justments Chart
⇒ page 109 .
4 - Crown for the riveted differ‐
ential
❑ Factory riveted
❑ Assembly with bolts
⇒ page 112
❑ In the event of replace‐
ment, the crown of the
differential and the sec‐
ondary shaft must be re‐
placed together.
❑ Dismounting and as‐
sembly ⇒ See crown of
the differential: dis‐
mounting and assem‐
bling ⇒ page 110
5 - Plate washer
6 - Nut. 70 Nm
7 - Adjustment washer
❑ Determine the thickness
⇒ page 115
8 - Outer track, tapered roller
bearing
❑ Dismount ⇒ page 106
❑ permitted
Assemble ⇒ page 107
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

9 - Tapered roller bearing


respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Dismount ⇒ page 107


❑ Assemble ⇒ page 107
10 - Differential unit
❑ In the event of replacement, the crown of the differential and the secondary shaft must be replaced
together. Consult the Adjustments Chart ⇒ page 109 .
❑ Factory riveted crown
❑ Drilling of the rivets and assembly with bolts ⇒ page 110 .
11 - Pinion for working the speedometer
❑ Dismount it by levering with a flat screwdriver
❑ Assembly: fit it in up to the top in the differential box before assembling the tapered roller bearing
⇒ Item 12 (page 104)
12 - Tapered roller bearing
❑ Dismount ⇒ page 107
❑ Assemble ⇒ page 107
13 - Outer track, tapered roller bearing
❑ Dismount ⇒ page 106

104 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

❑ Assemble ⇒ page 107


14 - Clutch casing
15 - Bush
❑ Retainer for the coupling flange
❑ Dismount and assemble ⇒ page 58
16 - Retainer for the coupling flange
❑ Replace ⇒ page 101
17 - Bolt. 25 Nm
❑ Screw in with the threaded part for attaching the coupling flanges ⇒ Item 25 (page 105)
18 - Coupling flanges
❑ Dismount and assemble ⇒ page 101
19 - Spring for coupling flange
❑ Assemble it behind the coupling flange
20 - Front washer
❑ Position for assembly: Collar facing towards the spring, core facing towards the tapered ring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
21 - Tapered ring permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ With trimmings for fitting the front washer
❑ Position for assembly: tapered side facing towards the differential box
22 - Safety ring
❑ Keeps the tapered ring, the washer and the spring for the coupling flange in position when the latter is
dismounted.
23 - Set of friction washers
❑ Coat them with gearbox oil before assembling them
24 - Differential side gear
❑ Assemble ⇒ page 108
25 - Threaded part for attaching the coupling flanges
❑ Assemble ⇒ page 108
26 - Axle for satellites
❑ Dismount it by striking with a punch.
27 - Elastic linchpin
❑ Dismount it by striking with a suitable punch
❑ Assemble ⇒ Fit it up to the stop
28 - Satellite
❑ Assemble ⇒ page 108
29 - Differential side gear
❑ Assemble ⇒ page 108

2. Differential: dismounting and assembling 105


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Special tools and workshop


equipment required
♦ Case of tools for repairing
gearboxes -U-40200-
♦ Case of tools for repairing
gearboxes -U-40300-
♦ Pincer extractor tool with
grippers -T20022-

Dismount the outer track of the tapered roller bearing

Note!

The procedure and the tools needed for dismounting the outer
tracks of the tapered roller bearings are the same in the gearbox
casing and in the clutch casing.

– Extract the outer track of the tapered roller bearing from the
gearbox casing with tool -U-40200/10- and -U-40300/14- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

106 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assemble the outer track for the tapered roller bearing

Note!

The procedure and the tools needed for assembling the outer
tracks for the tapered roller bearings are the same as for the
gearbox casing and the clutch casing.

– Assemble the outer track for the tapered roller bearing in the
clutch casing using tool -U-40200/10- and tool -U-40300/12- .

Dismount the tapered roller bearing


– Place tool -U-40300/13- on the differential.
– Place the extractor tool -U-40100/1- over the -U-40300/13-
trying to ensure that the grippers are inserted in the notches
that are located in the differential box.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Extract the bearing. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ If the bearing holder is broken during the extraction process,


use tool -T20022- for extracting the inner ring from the bearing.

Assemble the tapered roller bearing

Note!

♦ Before assembling the bearing in the differential box, heat it to


approximately 100 ºC with the electrical blower -SAT 1416- .
The temperature may be checked with the digital thermometer
-SAT 4002- .
♦ The procedure and the tools needed for assembling the ta‐
pered roller bearings are the same on both sides of the differ‐
ential box.

– Assemble the pinion for working the speedometer.


– Place the tool -U-40300/13- into a press.
– Place the differential unit over the tool -U-40300/13- .
– Place the tool -U-40300/11- with side B facing towards the
bearing, over the differential unit.
– Work the press until the tapered roller bearing is mounted in
its position.

2. Differential: dismounting and assembling 107


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

Assemble sun gears and planetary gears


– Impregnate the friction washers with gear oil and assemble in
the differential housing.
– Fit the differential side gears -Aand attach them with the cou‐
pled flanges -B- .
– Introduce a planetary gear and turn it 180°.
– Place a second planetary gear opposite the first.
– In this position, turn the planetary gears towards the inside of
the differential housing by means of the coupled flanges until
they coincide with the holes in the planetary gear shaft.
– Insert the planetary gear shaft until it goes through the first
planetary gear.
– Assemble the threaded parts to secure the coupled flanges
and completely insert the planetary gear shaft right to its final
position.
– Attach the spring pin to secure the planetary gear shaft.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

108 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

3 Adjustments Chart
It is only necessary to adjust the main shaft, the secondary shaft
or the differential when the parts have been replaced that affect
the adjustment for the gearbox. In order to avoid useless adjust‐
ment work, consult the following Table.
The following must be adjusted:
Primary Secondary Differential
shaft shaft ⇒
⇒ page 77 ⇒ page 94 page 113
Part replaced Gearbox casing x x
Clutch casing x x x
Primary shaft x
Secondary shaft (Front pinion-differential x
crown)
Differential box x
Tapered roller bearingin the main shaft x
Tapered roller bearingin the secondary shaft x
Tapered roller bearingin the differential x
4th gear pinion x

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Adjustments Chart 109


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

4 Differential crown: dismounting and


assembling

4.1 Differential crown: dismounting and assembling

Special tools and workshop


equipment required
♦ Electrical blower -SAT
1416-
♦ Digital thermometer -SAT
4002-
♦ Case for tools to repair
gearboxes -U-40300-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4.1.1 Dismount

Note!

♦ Protect the tapered roller bearings and the pinion for working
the speedometer in order to avoid possible damage or scraps
of metal from getting inside.
♦ Before and after drilling the rivets, clean the differential box
very carefully.

110 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Drill the head of the rivets on the side opposite the pinion for
working the speedometer using a 12 mm ∅ bit.
– Remove the rivets from their housing with the help of a punch.
– Place the differential box into a press.

– Place the tool -U-40300/13- over the differential.


– Work the press until the differential box comes away from the
crown.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4.1.2 Assembly
– Before assembling the crown of the differential, consult sec‐
tion for Identification initials, assignation of groups, reductions,
amount for filling ⇒ page 1 .
– Carefully clean the surfaces of contact for the crown of the
differential and of the differential box. Use a wire brush and a
scraper. Never use emery cloth or sandpaper. The surfaces
for contact must be completely free from oil and grease.
– Check the position for the assembly of the crown with regards
to the differential box.
Position for assembly:
The inner groove -A- in the crown of the differential must be facing
towards the opposite side to the housing for the differential side
gears.
– Heat the crown of the differential with the electrical blower -
SAT 1416- to 150 ºC. Check the temperature with the digital
thermometer -SAT 4002- .

4. Differential crown: dismounting and assembling 111


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Assemble the crown of the differential over the differential box


whilst respecting the position for assembly. Use two bolts -A-
from the repair set for guiding the crown into its housing.

Note!

♦ To correctly assemble the differential crown wheel onto the


differential housing, you must act rapidly and without interrup‐
tions and screw them right in.
♦ If both parts lock or get stuck on being assembled, interrupt
the assembly process and begin again.

– Screw down both components with the special replacement


screws ⇒ Replacement Parts Microfiche .
Tightening torque: 70 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

112 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

5 Differential: adjust

Special tools and workshop


equipment required
♦ Case for repairing gearbox‐
es -U-40200-
♦ Case for repairing gearbox‐
es -U-40300-
♦ Multi-purpose stand for the
tester -T20020-
♦ Dynometric keys -SAT
8010-

Adjust the differential when any of the following components have


been replaced:
♦ Gearbox casing
♦ Clutch casing
♦ Differential box
♦ Tapered roller bearings in the differential
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
So as to avoid unnecessary adjustment work,
permitted consult
unless the
authorised Chart
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
for Adjustment ⇒ page 109 . respect to the correctness of information in this document. Copyright by SEAT S.A.

5. Differential: adjust 113


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Extract the outer track of the tapered roller bearing from the
gearbox casing and clutch casing using tool -U-40200/10- and
tool -U-40300/14- .

Note!

♦ The procedure and the tools needed for dismounting the outer
tracks of the tapered roller bearings are the same in the gear‐
box casing and in the clutch casing.
♦ The tapered roller bearings and their corresponding outer
tracks come in pairs. Do not mix them up or exchange them
with other bearings.

– Assemble the outer track of the tapered roller bearing in the


differential into the gearbox casing and clutch casing using tool
-U-40200/10- and tool -U-40300/12- .

Note!

The procedure and the tools needed for dismounting the outer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
tracks of the tapered roller bearings are the samerespectin thecorrectness
to the gearbox of information in this document. Copyright by SEAT S.A.
casing and in the clutch casing.

– Place the differential over the clutch casing.


– Assemble the gearbox casing onto the clutch casing and tight‐
en the 5 bolts for attaching them in the area of the differential.
Tightening torque: 25 Nm

114 Rep. Gr. 39 - Final drive, Differential


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Place the tool -T20020- with a tester onto the gearbox casing.
Place the end of the tool on the differential and fit the tool -
U-40300/13- between them.
– Adjust the tester to “0” with a prior stress of 1 mm.
– Move the differential alternatively in the direction of the arrows.
– Write down the reading obtained on the tester (Example, 0.70
mm).
Calculation for the adjustment washer
The thickness of the adjustment washer to be assembled is found
by adding the valued from the reading obtained with the tester
and a set value (0.40 mm).
Example:
Reading obtained with the tester 0.70 mm
Set value 0.40 mm
Thickness of the adjustment washer 1.10 mm
The adjustment washer needed is found by using the following
Table:
Thickness (mm) Spares No.
0.65 02A 409 210  
0.70 02A 409 210 A
0.75 02A 409 210 B
0.80 02A 409 210 C
0.85 02A 409 210 D
0.90 02A 409 210 E
0.95 02A 409 210 F
1.00 02A 409 210 G
1.05 02A 409 210 H
1.10 02A 409 210 J
1.15 02A 409 210 K
1.20 02A 409 210 L
1.25 02A 409 210 M
The diversity of by
Protected the adjustment
copyright. washers
Copying for that exist
private or commercial allows
purposes, the
in part or nec‐
in whole, is not
essary thickness
respect to becorrectness
determined precisely
of information for making
in this document. a byproper
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
to the Copyright SEAT S.A.
adjustment of the differential.
– Should the thickness of the adjustment washer needed be
thicker than the thickness that appear in the Table, two ad‐
justment washers may be fitted, the thickness for which when
added together, correspond to the reading found.
– Once the adjustment washer needed has been determined,
remove the tester.
– Extract the bolts that attach both casings and separate the
gearbox casing.
– Separate the differential.

5. Differential: adjust 115


Arosa 1997 ➤
02J 5-speed manual gearbox - Edition 10.00

– Extract the outer track for the tapered roller bearing from the
gearbox casing with tool -U-40200/10- on the tool -
U-40300/14- .
– Place the adjustment washer with the thickness calculated (in
the example, 1.10 mm) in the housing for the outer track of the
tapered roller bearing in the gearbox casing.
– Should two adjustment washers be needed, place the washer
that is thicker first.

– Assemble the outer track of the tapered roller bearing of the


differential in the gearbox casing, with the adjustment washer,
with tool -U-40200/10- and tool -U-40300/12- .
– Place the differential over the gearbox casing.
– Assemble the gearbox casing over the clutch casing and tight‐
en the bolts for attaching them.
Tightening torque: 25 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

116 Rep. Gr. 39 - Final drive, Differential


Service

Workshop Manual
Arosa 1997 ➤
3-cyl. diesel engine, mechanics
Engine ID AMF

Edition 01.03

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
21 - Charging
23 - Mixture preparation, Injection
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
26 - Exhaust system permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
28 - Glow plug system

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2015 Seat S.A S01AAMF8620


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


1 Engine: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Engine: fixing to the trestle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Installation: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Engine unit supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Vehicles with air conditioning: additional instructions and installation work . . . . . . . . . . . . 7

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Engine: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Poly-V belt: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Sealing flanges and engine flywheel: removing and in-stalling . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Crankshaft seal - pulley side: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Sealing flange - pulley side: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
18
3 Stabiliser bar and axle support: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
22
3.1 Stabiliser bar: removing and in-stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Crankshaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Piston and connecting rod: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Position of the piston at TDC: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Dimensions of pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35


1 Cylinderhead: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Toothed belt: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Toothed belt: removing, installing and tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Compression: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Valve control: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Valve seats: re-cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Valve guides: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Valve guides: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4 Valve stem seals: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Camshaft: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.6 Camshaft seal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Lubrication system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Oil sump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Oil pressure and oil pressure switch: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1 Cooling system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.1 Cooling system components, bodywork side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.2 Cooling system components, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.4 Coolant: draining and filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Contents i
Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.5 Radiator: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82


1.6 Coolant pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.7 Coolant thermostat: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87


1 Fuel supply system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Fuel tank and accessory parts: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Fuel filter: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Safety measures for work on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Fuel radiator: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.6 Fuel tank: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Accelerator control: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.8 Accelerator pedal position sender: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.9 Accelerator pedal position sender: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.10 Tandem pump: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1.11 Tandem pump: respect toremoving and
the correctness installing
of information . . . . . . Copyright
in this document. . . . . . by
. .SEAT
. . . S.A.
. . . . . . . . . . . . . . . . . . . . . . . . 102

21 - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1 Supercharging system with exhaust gas turbocompressor . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Exhaust gas turbocompressor with attachments: removing and installing . . . . . . . . . . . . . . 106
1.2 Intercooler system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.3 Supercharging pressure control hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . 110
1.4 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Supercharging system: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Pressure unit for supercharging pressure control valve: test . . . . . . . . . . . . . . . . . . . . . . . . 112
2.2 Pressure unit for supercharging pressure control valve: removing and installing . . . . . . . . 112
2.3 Supercharging pressure control: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119


1 Direct diesel injection system: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.2 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.3 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.4 Intake manifold flap: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.5 Injector-pump unit: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.6 O-rings for injector-pump unit: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . 123
1.7 Pump-injector set: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2 Components and functions: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.1 Voltage supply of the direct diesel injection system: testing . . . . . . . . . . . . . . . . . . . . . . . . 131
2.2 Engine revs sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.3 Intake manifold pressure sender and altimetric sender: testing . . . . . . . . . . . . . . . . . . . . . . 132
2.4 Coolant temperature sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.5 Brake light and brake pedal switches: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.6 Clutch pedal switch: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.7 Intake manifold temperature sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.8 Temperature sender fuel: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.9 Air mass meter: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.10 Intake manifold flap switch-over: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.11 Injector-pump unit valves: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.12 Hall camshaft position sender: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3 Supplementary signals: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.1 Speed signal: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.2 Signals from/to air conditioning: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.3 Rev signal: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

ii Contents
Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

3.4 Data bus: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154


4 Engine control unit: replacing, encoding and adapting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.1 Engine control unit: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.2 Engine control unit: encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.3 Engine control unit: adapting to the electronic immobiliser . . . . . . . . . . . . . . . . . . . . . . . . 158

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160


1 Exhaust system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.1 Exhaust pipe front with catalyst and accessory parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.2 Silencer with holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Exhaust recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.4 Exhaust recirculation system components: removing and installing . . . . . . . . . . . . . . . . . . 162
1.5 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.6 Mechanical exhaust recirculation valve: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.7 Exhaust recirculation: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169


1 Pre-heating system: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.1 Glowplugs: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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respect to the correctness of information in this document. Copyright by SEAT S.A.

Contents iii
Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

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respect to the correctness of information in this document. Copyright by SEAT S.A.

iv Contents
Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

00 – Technical data
1 Technical data

1.1 Engine number


The engine number (“code letters” and “correlative number” ) is
stamped on the engine block next to the engine/gearbox joint.
There is also a sticker with “the engine code letters” and “the cor‐
relative number” on the toothed belt shield.
The engine code letters are also on the vehicle data plate.

1.2 Engine characteristics


Code letters AMF
Exhaust emissions in accordance with D3 Standard
Displacement l 1.4
Output kW/rpm 55/4000
Engine torque Nm/rpm 195...2200
Cylinder bore ∅ mm 79.5
Stroke mm 95.5
Compression 19.5
Cetane number min. 49
Firing order 1-2-3
Catalyst X
Exhaust recirculation X
Supercharging X
Intercooler X

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respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Technical data 1
Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

10 – Removing and installing engine


1 Engine: removing and installing

Special tools and workshop


equipment required
♦ Coupling tool -U-30034-
♦ Adjustable flanges for fixing
engine to trestle -T20082-
♦ (Mobile) engine support
trestle -Ar-2204 A-
♦ Flexible clamp pliers -
T20029-
♦ Shop lift -V.A.G. 1202 A-
♦ Tray -V.A.G. 1306-

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respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Torque spanners -SAT 8010-

2 Rep. Gr. 10 - Removing and installing engine


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Multiple toothed spanner set -U-40020-

♦ Lubricating grease -G 000 100-


♦ Cable clamp

1.1 Removing: instructions


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Note! respect to the correctness of information in this document. Copyright by SEAT S.A.

For this work it is necessary to remove the battery earth strap. In


doing so, check whether the vehicle has a coded radio and, if so,
consult the antitheft code.

– The engine is removed with the gearbox, forwards.


– With the ignition off, remove the battery earth strap.
– All wire holders that are opened or cut while removing the en‐
gine must be reinstalled in the same place when installing the
engine.
– Remove the soundproofing cover from engine.
– Remove the fuel supply and return hoses from the fuel filter.
– Remove the connection line between the intercooler and the
intake manifold air intake.
– Remove the connection line between the air mass meter and
the turbocompressor.
– Remove the battery.
– Remove the battery support.
– Remove the connector from the heat switch and the radiator
fan.
– Drain the coolant ⇒ page 80
– Remove radiator hoses from the engine and the heater with
strip clamp pliers -T20029- .

1.1.1 Vehicles with air conditioning


– Bear in mind the additional instructions and installation work
⇒ page 7
– Remove the lockholder plate and the accessory parts: ⇒
Bodywork-Installation work; Rep. Gr. 50 ; Bodywork, front
Lockholder plate with accessory parts: removing and installing
– Remove all the wiring from the gearbox, alternator and starter
motor and leave them out in the open.
– Remove all other necessary wiring from the engine and leave
it out in the open.

1. Engine: removing and installing 3


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Detach the vacuum and breather hoses and from the engine.
– Remove the shift control from the gearbox: ⇒ 5-speed manual
gearbox 02J; Rep. Gr. 34 ; Shift control: repairing
– Hydraulic clutch slave cylinder (pump): removing ⇒ 5-speed
manual gearbox 02J; Rep. Gr. 30 ; Clutch control: repairing

Note!

Do not depress the clutch pedal.

– Remove the front exhaust pipe from the turbocompressor.


– Remove the Poly-V belt ⇒ page 13 .
– Unbolt the gearbox swing support -1- .
– Remove the articulated half-shafts from the gearbox: ⇒ Run‐
ning gear, axles, steering; Rep. Gr. 40 ; Articulated half-shaft:
removing and installing
– Detach and remove the connection line between the inter‐
cooler and the exhaust turbocompressor next to the oil sump.
– Remove the power steering vane pump from its support and
place it on its side; the hoses remain connected. ⇒ Running
gear, axles, steering; Rep. Gr. 48 ; Synoptic installation chart:
vane pump, reserve tank, hydraulic lines.

– Attach coupling unit -U-30034- as shown in the illustration and


raise slightly with shop lift -V.A.G. 1202 A- .

Caution

Check that the hooks are closed with the safety catches.

– Loosen the bolts that hold the engine unit to the gearbox and
engine supports -arrows- .
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– Lower the engine unit until it is out of the gearbox housing.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove the engine unit forwards, turning it and then lowering
it slightly.

Note!

Handle the engine unit very carefully when removing it from the
vehicle to avoid damaging the bodywork.

1.2 Engine: fixing to the trestle


For assembly work the engine must be fixed to engine support -
Ar-2204- A with flanges -T20082- .

1.2.1 Work sequence


– Remove the flanges from the gearbox.

4 Rep. Gr. 10 - Removing and installing engine


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– With the shop lift and engine lift -U-30034- , secure the engine
to engine support -Ar-2204 A- with flanges -T20082- as
shown.

Caution

Check that the hooks are closed with the safety catches.

1.3 Installation: instructions


Follow instructions for removal in reverse order, taking into ac‐
count the following:
– Check the clutch disengagement collar for wear and replace
it if necessary.
– Lightly grease the disengagement collar, the guide sleeve for
the collar and the primary shaft spline with -G 000 100- .
– Make sure the alignment sleeves for the engine unit are in
place; if not, install them.
– When installing the engine unit make sure there is sufficient
play with the half-shafts.
– Align the engine support unit, shaking it so that there no stress
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points; if necessary, loosen the respect


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
engine support
to the atofthe
correctness body‐
information in this document. Copyright by SEAT S.A.
work too.

Note!

Tightening torques for the engine unit supports ⇒ page 6 .

– Electrical connections and wiring: ⇒ Electrical system; Rep.


Gr. 97
– Fit the connection line between the intercooler and the turbo‐
compressor next to the oil sump.
– Install the articulated half-shafts: ⇒ Running gear, axles,
steering; Rep. Gr. 40 ; Articulated half-shaft: removing and
installing.
– Install the power steering vane pump: ⇒ Running gear, axles,
steering; Rep. Gr. 48 ; Installation Chart: vane pump, reserve
tank, hydraulic lines Power steering vane pump: removing and
installing.
– Install the swing support.
– Install the front exhaust pipe ⇒ page 160 , Exhaust system
components: removing and installing.
– Install the hydraulic clutch slave cylinder (pump) ⇒ 5-speed
manual gearbox 02J; Rep. Gr. 30 ; Clutch control: repairing.
– Install the shift control: ⇒ 5-speed manual gearbox 02J; Rep.
Gr. 34 ; Clutch control: repairing.
– Install the shift control: ⇒ 5-speed manual gearbox 02J; Rep.
Gr. 34 ; Shift control: repairing.
– If necessary, adjust the gearbox cable: ⇒ 5-speed manual
gearbox 02J; Rep. Gr. 34 ; Shift control: repairing.

1. Engine: removing and installing 5


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Install the lockholder plate with the accessory parts: ⇒ Body‐


work-Installation work, exterior; Rep. Gr. 50 ; Bodywork, front
Lockholder plate with accessory parts: removing and instal‐
ling.
– Attach all coolant hoses to the engine.
– Install the Poly-V belt ⇒ page 13
– Install the connection lines of the air mass meter/turbocom‐
pressor, intercooler/turbocompressor (oil sump side) and in‐
tercooler/air intake line.
– Fill coolant ⇒ page 80
– Check and, if necessary, correct headlamp adjustment: ⇒
Millimetric maintenance
– Road test the vehicle and consult the fault memory: ⇒ Vehicle
diagnosis, testing and information system VAS 5051

1.4 Tightening torques


Bolted connection Tightening tor‐
que
Bolts, nuts M6 10 Nm
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permitted unless authorised by SEAT S.A. SEAT S.A does M8not guarantee or 20 Nm
accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
M10 45 Nm
M12 60 Nm
Different tightening torques
Front exhaust pipe to exhaust turbocompres‐ 25 Nm
sor

1.5 Engine unit supports

1.5.1 Tightening torques


Engine unit supports, engine
A 1) = 20 Nm + 90° (1/4 turn)
B 1) = 40 Nm + 90° (1/4 turn)
1) = replace

Engine unit supports, gearbox


A 2) = 40 Nm + 90° (1/4 turn)
B 2) = 20 Nm + 90° (1/4 turn)
C 2) = 40 Nm + 90° (1/4 turn)
2) = replace

6 Rep. Gr. 10 - Removing and installing engine


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Swing support
A 3) = 90 Nm + 90° (1/4 turn)
B 3) = 40 Nm + 90° (1/4 turn)
C 3) = 90 Nm + 90° (1/4 turn)
3) = replace

1.6 Vehicles with air conditioning: additional


instructions and installation work

Note!

♦ In order to remove the engine, the air conditioning cooling


agent circuit must be opened.
♦ To avoid damaging Protected
the condenser
by copyright.or the cooling
Copying agent
for private or hoses/
commercial purposes, in part or in whole, is not
lines, make sure the linesunless
permitted areauthorised
not pinched or twisted.
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Drain the cooling agent from the air conditioning cooling agent
circuit. ⇒ Heating, air conditioning; Rep. Gr. 87 ; Repairs in
the cooling agent circuit, which may only be done in shops with
qualified mechanics (Official Repair Shops specialised in air
conditioning).
– Open the air conditioning cooling agent circuit at the top of or
bottom of the condenser and at dashboard plate ⇒ Heating,
air conditioning; Rep. Gr. 87 ; Repairs in the cooling agent
circuit, which may only be done in shops with qualified me‐
chanics (Official Repair Shops specialised in air conditioning).

Note!

Do not remove the air conditioning compressor.

1. Engine: removing and installing 7


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

13 – Crankshaft group
1 Engine: disassembly and assembly

Note!

♦ When repairing the engine, if significant quantities of metal shavings and particles due to wear or abrasion,
e.g. damage to the mount or connecting rod bearings are found in the oil, in order to avoid further damage,
not only must the oil lines be cleaned carefully but the oil radiator must also be replaced.
♦ Before installation work, oil the support and slide surfaces.

I ⇒ page 8 II ⇒ page 10 III ⇒ page 12

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respect to the correctness of information in this document. Copyright by SEAT S.A.

Part I

8 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - Upper part of the toothed


belt shield
2 - Toothed belt
❑ Before removing, mark
the direction of rotation
❑ Check for wear
❑ Do not fold
❑ Remove and install
⇒ page 38
3 - 20 Nm + 45° (1/8 turn)
4 - Tensioning roller
5 - 100 Nm
6 - 25 Nm
7 - Camshaft pinion
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8 - Hub respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ With sender rotor


❑ For loosening and tight‐
ening, use countersup‐
port -T10051-
❑ For removing, use ex‐
tractor -T10052-
❑ Remove and install
⇒ page 55 Camshaft:
removing and installing
9 - 10 Nm
10 - Rear toothed belt shield
11 - Plug
❑ Replace if worn
12 - Toothed belt tensioner
13 - Return roller
14 - Coolant pump
❑ Remove and install ⇒ page 83
15 - Toothed belt-crankshaft pinion
16 - 120 Nm + 1/4 turn (90°)
❑ Replace
❑ For loosening and tightening use countersupport -T20018A-
❑ Do not oil or grease the thread or the collar
❑ Retighten in various stages
17 - 15 Nm
❑ For the vane pump
18 - 20 Nm
19 - Lower toothed belt shield
20 - Pulley/vibration dampener
❑ Installation is only possible in one position - the holes are arrayed asymmetrically
21 - 10 Nm + 1/4 turn (90°)
22 - Middle toothed belt shield

1. Engine: disassembly and assembly 9


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Part II

1 - Cylinderhead cover
❑ With oil filler hole
❑ If the cylinderhead cov‐
er is worn, the oil filler
hole must also be re‐
placed
❑ Before fitting it, clean
the filling surface well
with a clean cloth
2 - To turbocompressor
3 - 10 Nm
❑ First tighten all the bolts
by hand
❑ Then, tighten the two
upper bolts first and
then the other bolts in a
crossing pattern from in‐
side out to the correct
tightening torque
4 - Pressure regulator valve
❑ To the engine block vent
5 - Plug
❑ Replace the gasket if

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10 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

worn
6 - Ring gasket
❑ Replace if worn
7 - Oil filler hole
❑ Replace
8 - Support
❑ With fuel line
9 - Cylinderhead cover gasket
❑ Replace if worn
10 - 20 Nm
11 - Ring
12 - 10 Nm
13 - Middle connector
❑ For the pump injector
14 - From the brake servo
15 - Tandem pump
❑ For the fuel supply and the vacuum
❑ Remove and install ⇒ page 102
❑ Test ⇒ page 100
16 - 25 Nm
17 - Supply hose
❑ From the fuel filter ⇒ page 89
❑ White or white mark
❑ Check for firm seating
❑ Immobilise with elastic strip clamps
18 - Return hose
❑ To the fuel filter ⇒ page 89
❑ Blue or blue mark
❑ Check for firm seating
❑ Immobilise with elastic strip clamps
19 - Gasket
❑ Replace
20 - Bolt, 10 Nm
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21 - Support
22 - Hexagonal conical nut
23 - Cylinderhead gasket
❑ Replace
❑ Check the identification ⇒ page 34
❑ After replacing it, change all the coolant
24 - Hall sender -G40-
❑ For the camshaft position
❑ For removing, remove the sealing plug from the rear of the toothed belt shield
❑ Test: ⇒ page 119

1. Engine: disassembly and assembly 11


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

25 - Cylinderhead bolt
❑ Replace
❑ Follow the installation order when loosening and tightening ⇒ page 39 , cylinderhead: removing and
installing
❑ Before installation, fit the washers on the cylinderhead ⇒ Item 4 (page 53) , Valve activation: repairing
26 - Pump injector
❑ Remove and install ⇒ page 119

Part III

1 - 45 Nm
2 - Engine support
3 - Engine block Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Sealing flanges and en‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
gine flywheel: removing
and installing
⇒ page 16
❑ Piston and connecting
rod: disassembly and
assembly ⇒ page 30
4 - Connection sleeve, 40 Nm
❑ For the turbocompres‐
sor oil return line
❑ Replace
5 - Spacer bushing
6 - Rubber bushing
7 - Support
❑ For connectors of the
camshaft position Hall
sender -G40- and en‐
gine revs sender -G28-
8 - 10 Nm
9 - Gasket
❑ Replace
10 - Oil filter support
❑ Disassemble and as‐
semble ⇒ page 69
11 - 15 Nm + 1/4 turn (90°)
❑ Replace
❑ Fit the upper left and

12 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

lower right bolts first and


then tighten the four bolts in a cross pattern
12 - O-ring
❑ Replace
13 - 15 Nm
14 - 15 Nm + 1/4 turn (90°)
❑ Test ⇒ Vehicle diagnosis, testing and information system VAS 5051
15 - Connection sleeve
❑ For coolant thermostat
16 - Coolant thermostat
❑ Remove and install ⇒ page 84
17 - 45 Nm
❑ Follow the tightening order ⇒ page 79
18 - Compact support
❑ For alternator, air conditioning compressor, power steering vane pump and Poly-V belt tensioner
19 - Tensioner
❑ For the Poly-V belt
20 - 25 Nm
21 - Oil sump
❑ Before installation, clean the sealing surface
❑ Install with silicone-base sealant -D 176 404 A2- ⇒ page 70
❑ To remove the oil sump the gearbox must be removed ⇒ 5-speed manual gearbox 02J; Rep. Gr. 34 ;
Gearbox: removing and installing
22 - 15 Nm
❑ To remove the bolts that hold the sump (gearbox side), the gearbox must be removed ⇒ 5-speed manual
gearbox 02J; Rep. Gr. 34 ; Gearbox: removing and installing
23 - Cover
❑ With gasket
❑ Clean the filter if dirty
24 - Axle support
❑ Before installation check that alignment sleeve for centring the engine block is there and that it is fitted
on the axle support
❑ Remove and install ⇒ page 24
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25 - Shield
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ For the articulated half-shaft

1.1 Poly-V belt: removing and installing


Special tools and workshop equipment required

1. Engine: disassembly and assembly 13


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Pin -T10060-

♦ Spanner e/c 15

1.1.1 Remove
– Remove the soundproofing sump: ⇒ Bodywork-installation
work; Rep. Gr. 50 ; Bodywork, front Installation Chart
– Remove the soundproofing cover from the engine.
– Remove the connection line between the intercooler and the
intake manifold air intake.
– Remove the air mass meter unit and lay it to one side.
– Mark the direction of rotation of the Poly-V belt.
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– Pivot the tensioning roller in the direction of the arrow (see
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

illustration).
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Immobilise the tensioner with pin -T10060- .


– Remove the Poly-V belt.

1.1.2 Install
– Install in reverse order.

14 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

♦ Before installing the Poly-V belt check that the units (alterna‐
tor, air conditioning compressor, vane pump) are well fitted.
♦ When installing the Poly-V belt check that the rotation direction
is correct and that it is correctly seated on the pulleys.
♦ On vehicles without air conditioning, fit the Poly-V belt on the
alternator last.
♦ On vehicles with air conditioning, fit the Poly-V belt on the air
conditioning compressor last.

After finishing the work:


– Start the engine and check the functioning of the belt.
Routing of the belt without air conditioning compressor

Routing of the belt with air conditioning compressor

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Engine: disassembly and assembly 15


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2 Sealing flanges and engine flywheel: removing and in-stalling

Note!

⇒ 5-speed manual gearbox 02J; Rep. Gr. 30 ; Clutch: repairing

1 - Seal
❑ Do not apply more oil or
grease to the seal lip
❑ Before installation clean
excess oil from the
crankshaft journal with a
clean cloth
❑ Replace the crankshaft
seal - pulley side
⇒ page 17
2 - Sealing flange
❑ Must fit in alignment
sleeves
❑ Remove and install
⇒ page 18
❑ Install with silicone-
base sealant -D 176 404
A2- ⇒Protected
page by18copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
3 - Engine block
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Crankshaft: removing
and installing
⇒ page 28
❑ Piston and connecting
rod: disassembly and
assembly ⇒ page 30
4 - Engine flywheel
❑ To remove and install
the engine flywheel, im‐
mobilise with the -
T20075A-
5 - 60 Nm + 1/4 turn (90°)
❑ Replace
6 - Intermediate plate
❑ Must fit in alignment
sleeves
❑ Do not bend or damage during in-stallation work
7 - 15 Nm
8 - Sealing flange with seal
❑ Always replace the unit
❑ Do not apply more oil or grease to the seal lip
❑ Before installation clean excess oil from the crankshaft journal with a clean cloth
❑ Use the support sleeves supplied for installation
❑ The support sleeve can only be removed after fitting the sealing flange over the crankshaft journal

16 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.1 Crankshaft seal - pulley side: replacing

Special tools and workshop


equipment required
♦ Seal extractor -T20031B-
♦ Countersupport -T20018A-
♦ Plungers for fitting seals -
T20081B-
♦ Torque spanners -SAT
8010-

2.1.1 Remove
– Remove the Poly-V belt ⇒ page 13
– Remove the toothed belt ⇒ page 38
– Remove the toothed belt-crankshaft pinion. To do so, immo‐
bilise the toothed belt pinion with countersupport -T20018A- .
– Hand tighten the middle bolt in the crankshaft all the way to
guide the extractor.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Sealing flanges and engine flywheel: removing and in-stalling 17


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Oil the threaded head of the extractor -T20031B- / ∅ 35, apply


it and, pressing hard, screw it as far as possible into the seal.
– Turn the inner bolt interior against the crankshaft until the seal
comes out.

2.1.2 Install

Note!

The seal lip may not be further oiled or greased.

– Eliminate the excess oil on the crankshaft journal with a clean


cloth.
– Fit the seal over the guide sleeve of the -T20081B/6- and fit
the unit on the crankshaft journal.
– Fit the seal with the pressure sleeve -T20081B/1- all the way
with the centre bolt.
– Install the crankshaft pinion and immobilise it with counter‐
support -T20018A- .
– Toothed belt, install, tighten ⇒ page 38 .
– Install the Poly-V belt ⇒ page 13
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2.2 Sealing flange - pulley side: removing and installing

18 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Countersupport -T20018A-
♦ Plungers for fitting seals -
T20081B-
♦ Torque spanners -SAT
8010-
♦ Hand drill with plastic rotat‐
ing brush
♦ Silicone sealant -D 176 404
A2-
♦ Flat scraper

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2.2.1 Remove
– Remove the Poly-V belt ⇒ page 13
– Remove the toothed belt ⇒ page 38
– Remove the toothed belt-crankshaft pinion. To do so, immo‐
bilise the toothed belt pinion with the -T20018A- .
– Drain the engine oil.
– Remove the oil sump ⇒ page 71
– Remove the bolts that hold the front sealing flange.
– Remove the sealing flange. If necessary, loosen it with taps
from a rubber mallet.
– Eliminate excess sealant from the engine block with a flat
scrapper.
– Cover the seal with a clean cloth.

2. Sealing flanges and engine flywheel: removing and in-stalling 19


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– With a rotating plastic brush, eliminate excess sealant from the


sealing flange (use shop goggles).
– Clean the contact surfaces of oil and grease.

2.2.2 Install

Note!

♦ Check the use-by date on the sealant.


♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone-base sealant.

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

20 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Cut the nozzle of the tube at the front mark (nozzle diameter:
approx. 3 mm).
– Apply the silicone-base sealant to the clean contact surface of
the sealing flange, as shown in the illustration. The bead must:
♦ Sealant bead thickness: 2...3 mm

Note!

♦ The sealant bead must be no thicker: otherwise it could get


into the oil sump, clog the filter in the shaft support cover and
drip on the sealing surface of the crankshaft seal.
♦ Before applying the sealant, clean the sealing surface with a
clean cloth.

– Immediately fit the sealing flange and tighten all the bolts
slightly.

Note!

Use the guide sleeve of the -T20081B/6- to fit the sealing flange
with the seal fitted.

– Tighten the sealing flange bolts in a crossing pattern. Tight‐


ening torque: 15 Nm
– Clean the excess sealant.
– Install the oil sump ⇒ page 71

Note!

After installing the oil sump, let the sealant dry for approx. 30 mi‐
nutes, after which the engine oil can be filled.

– Installation of the toothed belt and setting distribution timing


⇒ page 38
– Install the Poly-V belt ⇒ page 13

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Sealing flanges and engine flywheel: removing and in-stalling 21


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

3 Stabiliser bar and axle support: removing and installing

Note!

Before installation work, oil the support and slide surfaces.

1 - Chain
❑ Check the installation
position ⇒ page 24 ,
Stabiliser bar: removing
and installing
2 - 100 Nm + 1/4 turn (90°)
❑ Replace
❑ Retighten in several
stages
❑ For loosening and tight‐
ening, use the -T10061-
3 - Counterweight
❑ Installation is only pos‐
sible in one position
4 - Chain wheel
❑ For stabiliser bar
❑ Installation is only pos‐
sible in one position
5 - Alignment sleeve
6 - 20 Nm + 1/4 turn (90°)
❑ Replace
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
7 - Chain wheel
❑ For oil pump
❑ Installation is only pos‐

22 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

sible in one position


8 - Cover
❑ With gasket
❑ Clean the filter if dirty
9 - 5 Nm
10 - O-ring
❑ Replace
❑ Check for firm seating
❑ Apply a little oil for the installation
11 - 15 Nm
12 - Oil pump
❑ With discharge valve 11.5 bar
❑ Before installation, check that the two alignment sleeves for centring are in place
13 - Stabiliser bar
❑ Remove and install ⇒ page 24
14 - Axle support
❑ Before installation check that alignment sleeve for centring the engine block is there and that it is fitted
on the axle support
❑ Remove and install ⇒ page 24
15 - O-ring
❑ Replace
❑ Check that it seats firmly on the axle support
16 - Engine block
17 - Pinion/return pulley
18 - 20 Nm
19 -byChain
Protected tensioner
copyright. withorslide
Copying for private rail purposes, in part or in whole, is not
commercial
❑ To remove lock with -T10060-
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Remove and install ⇒ page 24
20 - 9 Nm

3. Stabiliser bar and axle support: removing and installing 23


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

3.1 Stabiliser bar: removing and in-stalling

Special tools and workshop


equipment required
♦ Pin -T10060-
♦ Tool -T10061-
♦ Torque spanners -SAT
8010-
♦ Flat spanner (e/c 24/27)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3.1.1 Remove
– Remove the Poly-V belt ⇒ page 13
– Remove the toothed belt ⇒ page 38
– Remove the oil sump ⇒ page 71
– Remove the pulley side sealing flange ⇒ page 18
– Remove the cover bolts.
– Free the cover from the axle support.

24 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Immobilise the chain tensioner with pin -T10060- -arrow- .


– Unbolt the pinion/return pulley -1- from the axle support.
– Remove the fixing bolts -2- of the chain tensioner and remove
the tensioner.
– Remove the chain from the pinions and place the chain on a
clean surface.

– Immobilise the stabiliser bar as shown in the illustration with a


flat spanner (e/c 24/27) -1- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note!
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

The spanner must be centred with the counterweight of the sta‐


biliser bar, and perpendicular to the stabiliser bar.

– Loosen the fixing bolt -2- of the counterweight.

Note!

The fixing bolt -2- of the counterweight only needs to be loosened,


not removed completely.

– Unbolt the axle support -3- of the engine block and remove it
along with the stabiliser bar.
– Place the axle support on a clean surface.
– Remove the fixing bolt of the counterweight.
– Remove the counterweight and the pinion of the stabiliser bar.
– Turn the stabiliser bar unit it can be removed from its housing.

3.1.2 Installation
– Oil the rolling surfaces of the stabiliser bar.
– Fit the stabiliser bar in its housing.
– Fit the pinion and the counterweight over the stabiliser bar.

Note!

Installation of the pinion and the counterweight is only possible in


one position.

– Hand-tighten the bolt that fixes the counterweight and the pin‐
ion.
– Hand-tighten the axle support, taking up all play with the en‐
gine block.

3. Stabiliser bar and axle support: removing and installing 25


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

♦ During installation of the axle support check that the alignment


sleeve is fitted on the engine block and the O-ring on the axle
support.
♦ Fit the axle support such that it is flush with the outer edge of
the engine block on the pulley side.

– Bolt the stabiliser bar support to the engine block Tightening


torque: 15 Nm
– Check that the axle support is flush with the outer edge of the
engine block on the pulley side.
– Immobilise the stabiliser bar with a flat spanner (e/c 24/27)
-1- as shown in the illustration.
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!

The spanner must be centred with the counterweight of the sta‐


biliser bar, and perpendicular to the stabiliser bar.

– Tighten the fixing bolt -2- of the counterweight Tightening tor‐


que: 100 Nm + 1/4 turn (90°)

Note!

The fixing bolt is an expansion bolt and must always be replaced.

– Install the chain tensioner Tightening torque: 9 Nm


– Clean the chain with a cloth that does not shed fibres.

– Check that the mark -arrow- on the crankshaft pinion is at the


top.

– Fit the chain on the pinion/crankshaft, pinion/oil pump and the


pinion/stabiliser bar. The marks on the pinion/crankshaft and
the pinion/stabiliser bar must coincide with the coloured links
of the chain -arrows- .

Note!

The coloured links are also marked with a groove.

– Fit the pinion/return pulley on the chain and bolt the pinion/
return pulley to the axle support. Tightening torque: 20 Nm
– Remove pin -T10060- from the chain tensioner.

26 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Check that the marks on the pinion/crankshaft and the pinion/


stabiliser bar coincide with coloured links -arrows- .

Note!

The coloured links are also marked with a groove.

– Install the sealing flange of the pulley side ⇒ page 18 .


– Fit the cover on the stabiliser bar Tightening torque: 5 Nm

Note!

♦ Before fitting the cover, oil to O-ring of the oil pump and the
flange inside the cover.
♦ Check that the gasket is well seated in the cover.
♦ Check that the cover fits well on the axle support.

– Install the oil sump ⇒ page 71 .


– Toothed belt, install, tighten ⇒ page 38 .
– Install the Poly-V belt ⇒ page 13 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Stabiliser bar and axle support: removing and installing 27


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

4 Crankshaft: removing and installing

Note!

♦ Before removing the crankshaft, prepare an adequate base so that the sender rotor
( ⇒ Item 5 (page 28) ) does not support weight or get damaged.
♦ Before installation work, oil the support and slide surfaces.

1 - Half-bearings 1, 2 and 4
❑ For caps, without lubri‐
cation slot
❑ For engine block, with
lubrication slot
❑ Do not swap the used
half-bearings (mark
them)
2 - 65 Nm + 1/4 turn (90°)
❑ Replace
❑ To measure the radial
play, tighten to a torque
of 65 Nm, but do not re-
tighten
3 - Caps
❑ Cap 1: Pulley side
❑ The tabs of the engine
block half-bearings and
of the caps must coin‐
cide
4 - Half-bearing 3
❑ For cap, without lubrica‐
tion slot
❑ For engine block, with
lubrication slot
5 - Sender rotor
❑ For revs sender
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❑ Replace if worn permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
6 - 10 Nm + 1/4 turn (90°)
❑ Replace
7 - Pin
❑ Measure projection of
the pin above the crankshaft ⇒ page 31
8 - Crankshaft
❑ Before removing it, check the note ⇒ page 28
❑ Axial play, new: 0.07...0.17 mm Wear limit: 0.37 mm
❑ Measure the radial play with Plastigage New: 0.03...0.08 mm Wear limit: 0.17 mm
❑ When measuring the radial play, do not turn the crankshaft
❑ Crankshaft dimensions ⇒ page 29
9 - Drive washer
❑ For engine block, bearing 3

28 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Measure projection of the pin above the crankshaft

Special tools and workshop equipment required


♦ Depth calliper
Test process
– With depth callipers measure the projection -a- of the pin with
the sender rotor -1- removed.
1 - Sender rotor
2 - Bolt
3 - Projection pin -3- of the crankshaft
a = 2.5...3.0 mm

4.1 Crankshaft dimensions


(Dimensions in mm)
Re-cutting di‐ ∅ mounting ∅ mounting
mension bearing bearing
journals journals
Basic - 0.022 54.00 - 0.022 47.80
dimension - 0.042 - 0.042
Stage I - 0.022 53.75 - 0.022 47.55
- 0.042 - 0.042
Stage II - 0.022 53.50 - 0.022 47.30
- 0.042 - 0.042
Stage III - 0.022 53.25 - 0.022 47.05
- 0.042 - 0.042

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Crankshaft: removing and installing 29


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

5 Piston and connecting rod: disassembly and assembly

Note!

Before installation work, oil the support and slide surfaces.

1 - Piston ring
❑ Stagger the cuts in 120°
❑ Remove and install with
piston ring pliers
❑ The mark “TOP” must
point towards the piston
head
❑ Measure the play be‐
tween the edges of the
rings ⇒ page 31
❑ Measure the coupling
play between the rings
and the slots of the pis‐
ton ⇒ page 32
2 - Piston
❑ With combustion cham‐
ber
❑ Mark the installation po‐
sition and the corre‐
spondence to the re‐
spective cylinder
❑ Installation position and
piston/cylinder corre‐
spondence
⇒ page 33 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ The arrow on the respect


pistonto the correctness of information in this document. Copyright by SEAT S.A.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

head must point to‐


wards the pulley
❑ Install with ring fitting
sleeve
❑ If the piston rod is
cracked, replace the
piston
❑ Test the position of the
piston at TDC

30 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

⇒ page 33
3 - Piston rod
❑ If movement is difficult, heat the piston to 60 °C
❑ Remove and install with -T20019-
4 - Lock washer
5 - Connecting rod
❑ Replace only the unit
❑ Mark the correspondence to the cylinder -A-
❑ Installation position: the marks -B- must point towards the pulley
6 - Half-bearing
❑ Check the installation position
❑ Bear in mind the version: Upper half-bearing (towards the piston) of wear-resistant material Mark: Black
strip on the slide surface, in the area of separation
❑ Do not swap the used half-bearings
❑ Fit and centre the half-bearings
❑ Outer edge half-bearing to outer edge connecting rod/connecting rod cap 2.5 mm, measured on one side
❑ Check for firm seating
❑ Axial play Wear limit: 0.37 mm
❑ Measure the radial play with Plastigage: Wear limit: 0.08 mm When measuring the radial play do not turn
the crankshaft
7 - Engine block
❑ Measure the bore of the cylinders ⇒ page 32
❑ Dimensions of pistons and cylinders ⇒ page 34
8 - Connecting rod caps
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❑ unless
permitted Check the installation
authorised by SEAT S.A. SEATposition
S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
9 - Oil injector
❑ For cooling the pistons
❑ Check the installation position: Turn the oil injector counter-clockwise until it touches the engine block
and tighten it in this position
10 - 25 Nm
❑ Fit without sealant
11 - Connecting rod bolt, 30 Nm + 1/4 turn (90°)
❑ Replace
❑ Lubricate the thread and the support surface
❑ Tighten uniformly to a torque of 5 Nm
❑ Use the old bolt to measure the radial play

Edges of the piston rings: testing play


– Fit the ring from above so that it is at a right angle to the lower
opening of the cylinder, with a separation of approx. 15 mm
from the edge of the cylinder.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.25...0.40 1.0
2nd compression ring 0.20...0.40 1.0
Oil scrapper ring 0.25...0.50 1.0

5. Piston and connecting rod: disassembly and assembly 31


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Test the coupling play between the rings and the slots of the pis‐
ton
First clean the piston housing slots.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.06...0.09 0.25
2nd compression ring 0.05...0.08 0.25
Oil scrapper ring 0.03...0.06 0.15

Measure the bore of the cylinders

Special tools and workshop equipment required


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♦ Interior permitted
callipers 50...100
unless authorisedmm
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Measure across three different points crosswise -A- and
lengthwise -B- . Difference over the nominal dimension 0.10
mm max.

32 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

Do not measure of the bore of the cylinders when the engine block
is fixed to the installation trestle with engine support -Ar-2204 A- :
doing so could result in erroneous measurements.

Installation position of pistons and piston/cylinder correspond‐


ence
Pistons in cylinders 1 and 2:
Large hole for intake valve towards the flywheel side -arrows- .
Pistons in cylinders 3:
Large hole for intake valve towards the pulley side -arrows- .

Note!

♦ The new pistons have the numbering of the corresponding


cylinders in colour on the piston head.
♦ Pistons for cylinders 1 and 2: Numbering 1/2
♦ Pistons for cylinder 3: Numbering 3

5.1 Position of the piston at TDC: testing


Special tools and workshop equipment required
♦ -T20026-
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

5.1.1 Test process


When installing new pistons or a stripped engine, test the position
of the piston at TDC. Depending on the measurement of piston
projection, install the corresponding cylinderhead gasket, accord‐
ing to the following table:

Note!

To measure the position of the piston at TDC, turn the engine over
clockwise.

Piston projection Identification


notches/holes
0.91 mm ... 1.00 mm 1
1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3

5. Piston and connecting rod: disassembly and assembly 33


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

5.1.2 Identification of the cylinderhead gasket


♦ Part number = arrow -1-
♦ Processing code = arrow -2- (ignore!)
♦ Holes = arrow -3-

Note!

If divergent values are obtained in the measurement of the di‐


mension of piston projection, use the maximum dimension to
select the correct gasket.

5.2 Dimensions of pistons and cylinders


Re-cutting ∅ piston ∅ cylinder
dimension bore
Basic dimension mm 79.47 79.51
I re-cut mm 79.97 80.01

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

34 Rep. Gr. 13 - Crankshaft group


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

15 – Cylinder head, Valve gear


1 Cylinderhead: removing and instal‐
ling
Test the compression ⇒ page 44

Note!

♦ When installing a replacement cylinderhead with the camshaft


installed, oil the contact surfaces between the plungers and
the cam slide tracks before installing the cylinderhead cover.
♦ Oil the support and slide surfaces before installing.
♦ Do not remove the plastic bases included for the protection of
the open valves until just before fitting the cylinderhead.
♦ Change all the coolant after replacing the cylinderhead.

1 - Upper toothed belt shield


2 - Toothed belt
❑ Before removing, mark
the direction of rotation
❑ Check for wear
❑ Do not fold
❑ Remove and install,
tighten ⇒ page 38
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - 10 Nm permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
4 - 25 Nm
5 - 100 Nm
6 - Camshaft pinion
7 - Hub
❑ With sender rotor
❑ For loosening and tight‐
ening use countersup‐
port -T10051-
❑ For removing, use ex‐
tractor -T10052-
❑ Remove and install
⇒ page 55 , Camshaft:
removing and installing
8 - Inner toothed belt shield
9 - Sealing plug
❑ Replace if worn
10 - Hall sender -G40-
❑ For the camshaft posi‐
tion
❑ For removing, remove
the sealing plug

1. Cylinderhead: removing and installing 35


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

⇒ Item 9 (page 35) of the


inner toothed belt shield
❑ Test: ⇒ page 119
11 - Cylinderhead bolt
❑ Replace
❑ Follow the installation order when loosening and tightening ⇒ page 42 , Cylinderhead: removing and
installing
❑ Before installation, fit the washers on the cylinderhead ⇒ Item 4 (page 53) , Valve control: repairing
12 - Bolt, 10 Nm
❑ For the engine cover
13 - Cylinderhead cover
❑ With oil filler hole
❑ If the cylinderhead cover is worn, the oil filler hole must also be replaced
❑ Before fitting it, carefully clean the sealing surface of the cylinderhead with a clean cloth
14 - To turbocompressor
15 - 10 Nm
❑ First tighten all the bolts by hand
❑ Next, first tighten the two bolts of the upper part and then the other bolts in a crossing pattern working
inside out to the correct tightening torque
16 - Pressure regulator valve
❑ To the engine block vent
17 - Oil filler hole
❑ Replace
18 - Plug
❑ Replace the gasket if worn
19 - Ring gasket
❑ Replace if worn
20 - Support
❑ With fuel lines
21 - Cylinderhead cover gasket
❑ Replace if worn
22 - 20 Nm
23 - Ring
24 - Pump injector
❑ Remove and install ⇒ page 119
25 - Middle connector
❑ For pump injector
26 - From the brake servo
27 - Tandem pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ For the fuel supply and the vacuum respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Remove and install ⇒ page 102


❑ Test ⇒ page 100
28 - Supply hose
❑ From the fuel filter ⇒ page 89
❑ White or white mark
❑ Check for firm seating
❑ Immobilise with elastic strip clamps

36 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

29 - Return hose
❑ Towards the fuel filter ⇒ page 89
❑ Blue or blue mark
❑ Check for firm seating
❑ Immobilise with elastic strip clamps
30 - Gasket
❑ Replace
31 - Support
32 - Hexagonal conical nut
33 - Cylinderhead
❑ Remove and install ⇒ page 60
❑ After replacing it, change all the coolant
34 - Cylinderhead gasket
❑ Replace
❑ Check the identification ⇒ page 37
❑ After replacing it, change all the coolant
35 - Glowplug
❑ 15 Nm
❑ Test ⇒ page 170
36 - Tensioning roller
37 - 20 Nm + 45° (1/8 turn)

Check the cylinderhead for deformations


Maximum admissible deformation: 0.1 mm

Note!

Diesel cylinderheads cannot be re-cut.

Identification of the cylinderhead gasket


♦ Part number = arrow -1-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Processing code =byarrow
permitted unless authorised -2-SEAT
SEAT S.A. (ignore!)
S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Holes = arrow -3-

Note!

Depending on the dimension of piston projection, cylinderhead


gaskets of different thicknesses are fitted. When replacing the
gasket, replace it with one with the same identification.

1. Cylinderhead: removing and installing 37


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.1 Toothed belt: removing and installing

Special tools and workshop


equipment required
♦ Camshaft locking tool -
T20102-
♦ Distribution belt tensioning
tool -U-30009A-
♦ Distribution retaining ten‐
sioner tool -T10008-
♦ Crankshaft sprocket lock‐
ing tool -T10050-
♦ Torque spanner -SAT
8010-
♦ Engine and gearbox sup‐
port cross member -
U-30025-
♦ 4 mm ∅ bit

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.1.1 Removing

Note!

Adjustment of the toothed belt must only be done with the engine
cold.

– Remove ribbed belt ⇒ page 13


– Remove tensioning element for ribbed belt.
– Unbolt pendulum support from gearbox.
– Remove upper toothed belt guard.

38 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Fit the engine cross member -U-30025- as shown and receive


engine in assembly position.

– Remove bolts from engine unit supports, engine -arrows- and


completely remove from the unit support.
– Remove engine block support.
– Remove central toothed belt guard.
– Carefully lower the engine until the vibration damper/belt pul‐
ley can be removed.
– Remove lower toothed belt guard.
– Position crankshaft at TDC cylinder 1.

Note!Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Turn crankshaft until the mark on the crankshaft toothed belt
wheel is up and the arrow on the toothed belt coincides with the
lugs of the hub sender wheel -arrows- .

– Immobilise the hub with the locking pin -T20102- . This can be
done by moving the pin through the left-hand hole up to the
cylinder head hole.
– Secure crankshaft toothed belt sprocket by locking with lock‐
ing tool -T10050- . This can be done by moving the crankshaft
locking tool from the front of the toothed belt sprocket to the
sprocket teeth.

Note!

The marks of the wheel of the toothed belt of the crankshaft and
the crankshaft immobiliser have to align. The crankshaft locking
tool stub must fit into the hole in the sealing flange.

– Mark D.O.R. of toothed belt.

1. Cylinderhead: removing and installing 39


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Fully introduce an Allen key in the eccentric of the tensioning


roller and press the tensioning roller in the direction of the
-arrow- until the tensioning device of the toothed belt with the
locking plate -T10008- can be immobilised.

Note!

If the Allen key is not inserted enough the internal hexagonal may
break.

– Loosen fixing nut on tensioning roller.

– Remove securing bolts -1- of the toothed belt tensioner and


remove tensioner.
– Remove toothed belt.

1.1.2 Installation

Note!

Adjustment of the toothed belt must only be done with the engine
cold.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove the securing bolts -1- from the camshaft wheel until
the camshaft wheel can be turned
– Turn the camshaft wheel clockwise in its elongated holes
-arrow- up to the limit.

– Carefully turn the excentric clockwise with tool -U-30009A-


until the excentric is just reaching the stop -B- .
– Fit the toothed belt on the camshaft wheel, the tensioning roll‐
er, the crankshaft sprocket and finally on the coolant pump
wheel.
– Fit the toothed wheel tensioner.

40 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Turn the excentric anti-clockwise with tool -U-30009A- (the


excentric lug moves towards stop -A- ) until the locking plate -
T10008- can be removed freely.
– Release tensioner clockwise (excentric lug moves towards
stop -B- ) until the dimension -a- is attained. Specification di‐
mension -a- : 4 ±1 mm.

Note!

♦ The dimension -a- lessens while tightening the fixing bolts of


the tension roller. Thus adjust generously with the 4 mm di‐
ameter drill.
♦ Dimension -a- can decrease up to 1 mm when the engine is
hot.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Keep the tensioner


respect toroller in thisofposition and tighten Copyright
the ten‐
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the correctness information in this document. by SEAT S.A.
sioner nut to torque 20 Nm + 45° (1/8 turn)

– Tighten the camshaft wheel bolts -1- to a torque of de 25 Nm.


– Remove locking tool -T20102- and crankshaft immobiliser -
T10050- .
– Continue turning crankshaft two turns in the direction of engine
rotation and re-set at TDC cylinder 1.

Note!

♦ The crankshaft locking tool stub must fit into the hole in the
sealing flange while turning.
♦ If the crankshaft is turned beyond Cyl. 1 TDC and the crank‐
shaft immobiliser could not be completely inserted into the
sealing flange, turn crankshaft 1/4 turn backwards to return it
to Cyl. 1 TDC. The immobiliser insertion position cannot be
corrected by turning the crankshaft contrary to engine rotation.

– After introducing the crankshaft immobiliser -T10050- , check


that: 1) dimension -a- is attained and 2) the hub can be im‐
mobilised with the locking tool -T20102-
If dimension -a- is not attained:
– Re-tension the tensioning roller. For this, secure the tension‐
ing roller with the wrench -U-30009A- , unscrew the bolt and
relax the contrary force of the tensioner until dimension -a- is
reached Specification dimension -a- : 4 ± mm
Re-tighten the fixing bolt torque 20 Nm + 45° (1/8 turn)
If the camshaft wheel can not be immobilised
– Remove the stub of the crankshaft immobiliser from the hole
in the sealing flange and turn the crankshaft until the hub can
be locked with the pin.

1. Cylinderhead: removing and installing 41


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Loosen bolts -1- on the camshaft wheel.

– Turn crankshaft in the opposite direction of engine rotation


until the crankshaft immobiliser stub is just opposite the seal‐
ing flange hole -arrow- .
– Turn crankshaft in the engine rotation direction until the crank‐
shaft immobiliser stub can be inserted into the sealing flange
when moving.
– Tighten the camshaft wheel bolts to a torque of de 25 Nm
– Turn the crankshaft two turns in the direction of engine rotation
until cylinder 1 TDC is again reached.

Note!

♦ The crankshaft locking tool stub must fit into the hole in the
sealing flange while turning.
♦ If the crankshaft is turned beyond Cyl. 1 TDC and the crank‐
shaft immobiliser could not be completely inserted into the
sealing flange, turn Protected
crankshaft 1/4 turn
by copyright. backwards
Copying to return
for private or commercial it
purposes, in part or in whole, is not
to Cyl. 1 TDC. Thepermitted
immobiliser insertion
unless authorised position
by SEAT S.A. SEATcannot beguarantee or accept any liability with
S.A does not
corrected by turning the crankshaft contrary to engine rotation.
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Repeat the check.


– Begin by installing lower part of toothed belt guard as well as
belt pulley/vibration damper.
– Fit central toothed belt guard.
– Fit engine mounting to cylinder block. Tightening torques:
⇒ page 6
– Fit upper toothed belt guard.
– Install ribbed belt ⇒ page 13
– Fit the air filter/turbo compressor and intercooler/breather tube
connecting hoses.

1.1.3 Remove
– Drain the coolant ⇒ page 80 .
– Remove the toothed belt ⇒ page 38 .

Note!

Both rings for the lift hook are located on the cylinderhead; thus,
it is necessary to fix an additional support to hold the engine by
the block and thus be able to remove the cylinderhead.

42 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Fit crossbeam -U-30025- as shown and hold the engine in in‐


stallation position.
– Carefully raise the engine slightly with the shaft -A- .

– Thread -as shown in the illustration- support -T10014- into the


threaded hole near the coolant pump in the block Tightening
torque: 20 Nm
– Raise the engine slightly with the shaft -B- , until the shaft
-A- has no load.
– Remove the shaft -A- .
– Before removing the cylinderhead, drain the fuel with vacuum
pump -SAT 1390- with purge tank -SAT 1390/1- in the tandem
pump ⇒ page 102 ; Tandem pump: removing and installing.

– Follow the order for loosening the cylinderhead bolts.

1.1.4 Install
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Note! respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Always replace the cylinderhead bolts.


♦ In the event of reparation, carefully eliminate the remains of
the gasket from the cylinderhead and from the engine block.
Do not scratch the surfaces. If using sandpaper, the grain must
be no less than 100.
♦ Carefully eliminate abrasive particles.
♦ Do not remove the new cylinderhead gasket from its packag‐
ing until just before fitting.
♦ Handle the gasket with extreme care. Damage to the silicone
coating or grooved area may cause leaks.

– Before fitting the cylinderhead, set the crankshaft at TDC.


– Turn the crankshaft against engine rotation until the pistons
are all roughly evenly below TDC.

1. Cylinderhead: removing and installing 43


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Position the cylinderhead gasket.


– Position the cylinderhead, fit the 8 cylinderhead bolts and
hand-tighten them.
– Tighten the cylinderhead in four stages in the tightening order
shown below:
1. Pretightening with torque spanner:
Stage I = 40 Nm
Stage II = 60 Nm
2. Retightening with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!

It is not necessary to retighten the cylinderhead bolts after repar‐


ations.

– The retightening of the bolts with rigid spanner can be meas‐


ured with the protractor -T20030- .
– After tightening the cylinderhead, turn the camshaft pinion so
that the cams of cylinder 1 point upwards uniformly. Before
fitting the toothed belt, turn the crankshaft in the direction of
engine rotation until TDC.
– After installing the cylinderhead drain the fuel with vacuum
pump -SAT 1390- with purge tank -SAT 1390/1- on the tandem
pump ⇒ page 102 ; Tandem pump: removing and installing.
– Road test the vehicle and consult the fault memory: ⇒ Vehicle
diagnosis, testing and information system VAS 5051

1.2 Toothed belt: removing, installing and tensioning


(Vehicle with tensioning system with internal friction damper)

44 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Torque spanners -SAT
8010-
♦ holding tool -T10050-
♦ holding tool -T10115-
♦ holding tool -T20102-
♦ Turning tool -U-30009A-
♦ support -U-30025E-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.2.1 Removal

Note!

Adjustment of the toothed belt should only be carried out when


the engine is cold, as the position of the tensioning indicator varies
according to the engine temperature.

– Remove the engine insulation cover, pulling upwards firmly


-arrows- .
– Remove connecting hose between intercooler and intake
hose.
– Remove ribbed belt ⇒ page 13 .
– Remove tensioning element for ribbed belt.
– Remove upper toothed belt guard.
– Remove the insulation tray: ⇒ General body repairs - instal‐
lation work, exterior; Rep. Gr. 50 ; Body front.
– Unbolt pendulum support from gearbox.

1. Cylinderhead: removing and installing 45


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Fit support -U-30025E- as shown in the illustration and main‐


tain the engine in assembly position.

– Remove bolts from engine unit supports, engine -arrows- and


completely remove from the unit support.
– Remove engine block support.
– Remove central toothed belt guard.
– Carefully lower the engine until the vibration damper/belt pul‐
ley can be removed.
– Remove lower toothed belt guard.
– Position crankshaft at TDC cylinder 1.

Note!

Turn crankshaft until the mark on the crankshaft toothed belt


sprocket is up and the arrow
Protected on Copying
by copyright. the toothed
for privatebelt coincides
or commercial with
purposes, in part or in whole, is not
the lugs of the hub sender
permitted wheel by
unless authorised -arrows-
SEAT S.A. .SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Immobilise the hub with the retention tool -T20102- . To do


this, move the tool through the left hole up to the cylinder head
hole.
– Immobilise the sprocket of the crankshaft toothed belt with re‐
tention tool -T10050- .

Note!

The crankshaft toothed belt sprocket marks and those on the


crankshaft retention tool must coincide. The crankshaft retention
tool stub must fit into the hole in the sealing flange.

– Mark D.O.R. of toothed belt.


– Loosen securing nut on tensioning roller.

46 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Loosen securing bolts -1- of the camshaft sprocket until it can


be turned in the slotted holes.

– Turn the excentric with tool -U-30009A- in the opposite direc‐


tion to the arrow -1- , until the tensioner roller can be locked
with retention tool -T10115- .
– Turn the tensioner roller with tool -U-30009A- to its limit in the
direction of the arrow -1- , and tighten the tensioner roller se‐
curing nut.
– First remove the toothed belt from the coolant pump and then
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

from the remaining sprockets.


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.2.2 Installation

Note!

♦ Adjustment of the toothed belt should only be carried out when


the engine is cold, as the position of the tensioning indicator
varies according to the engine temperature.
♦ The tensioning roller should be immobilised with retention tool
-T10115- and on the right stop.

– Fit bolts -1- and hand tighten.


– Turn the camshaft sprocket in its elongated holes in the direc‐
tion of the arrow to its limit.
– Fit the toothed belt onto the camshaft sprocket, the tensioning
roller, the crankshaft sprocket, and finally onto the coolant
pump wheel.

1. Cylinderhead: removing and installing 47


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

Make sure that the tensioner roller is correctly housed in the rear
toothed belt guard -arrow- .

– Loosen the locking nut on tensioning roller.

– Using tool -U-30009A- , loosen the tensioning roller in the op‐


posite direction to the arrow -1- , and remove with retention
tool -T10115- .

– With tool -U-30009A- , carefully turn the tensioner roller in the


direction of arrow -1- , until the indicator arm is in the central
position of the plate groove -arrow- .
– Keep the tensioner roller in this position and tighten the roller
nut to 20 Nm + 45° (1/8 turn).
– Tighten the camshaft sprocket securing bolts to a torque of de
25 Nm.
– Remove retention tools -T20102- and -T10050- .
– Turn crankshaft twice in the direction of engine rotation and
replace the distribution elements in the TDC cylinder 1.

– Insert crankshaft locking tool -T10050- into the sprocket, slid‐


ing it in until it enters the sealing flange.

Note!

♦ The crankshaft retention tool stub must fit into the hole in the
sealing flange while turning.
♦ The position for inserting the crankshaft retention tool cannot
be adjusted by turning the crankshaft back.permitted
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If the crankshaft has been turned beyond TDC for cyl. 1 and
respect to the correctness of information in this document. Copyright by SEAT S.A.

the crankshaft retention tool could not be fully inserted in the


sealing flange, turn the crankshaft 1/4 turn backwards and set
the crankshaft again in the engine rotation direction to TDC
cyl. 1.

48 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– After inserting crankshaft retention tool -T10050- , check that


the camshaft sprocket hub can be immobilised with tool -
T20102- .
If the hub is not immobilised:
– Remove the stub of the crankshaft retention tool from the hole
in the sealing flange and turn the crankshaft until the hub can
be locked with the tool -T20102- .

– Loosen bolts -1- on the camshaft sprocket.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Cylinderhead: removing and installing 49


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Turn crankshaft in the opposite direction of engine rotation


until the crankshaft retention tool -T10050- stub is just oppo‐
site the sealing flange hole -arrow- .
– Turn crankshaft in the direction of engine rotation until the
crankshaft retention tool stub is inserted into the sealing flange
by the movement of rotation.
– Tighten the camshaft sprocket bolts to a torque of 25 Nm.
– Remove retention tools -T20102- and -T10050- .
– Turn the crankshaft two turns in the direction of engine rotation
until cylinder 1 TDC is again reached.

Note!

♦ The crankshaft retention tool stub must fit into the hole in the
sealing flange while turning.
♦ If the crankshaft has been turned beyond TDC for cyl. 1 and
the crankshaft retention tool could not be fully inserted in the
sealing flange, turn the crankshaft 1/4 turn backwards and set
the crankshaft again in the engine rotation direction to TDC
cyl. 1.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Repeat theunless
permitted former check.
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Install lower toothed belt guard as well as belt pulley/vibration
damper.
– Install central toothed belt guard.
– Fit the engine support on the engine block and tighten the bolts
to 45 Nm.
– Install the engine supports, engine. Tightening torques
⇒ page 6 .
– Screw in pendulum support to gearbox. Tightening torque
⇒ page 6
– Fit the insulation tray: ⇒ General body repairs - installation
work, exterior; Rep. Gr. 50 ; Body front.
– Remove the engine and gearbox support -U-30025E- .
– Install upper toothed belt guard
– Install ribbed belt ⇒ page 13 .
– Fit the air filter/turbocompressor and intercooler/breather tube
connecting hoses.
– Fit the engine insulation cover.

1.3 Compression: testing

50 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Glowplug spanner -
U-40082-
♦ Torque spanners -SAT
8010-
♦ Adaptor -V.A.G. 1381/12-
♦ Compression gauge -
V.A.G. 1763-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.3.1 Test condition


• Temperature of the engine oil, at least 30 °C

1.3.2 Test process


– Remove the middle connector of the pump injectors.
– Remove the connectors from the glowplugs.
– Remove all the glowplugs with spanner -U-40082- .
– Thread adaptor -V.A.G. 1381/12- into glowplug holes.
– Test the compression with the compression gauge -V.A.G.
1763- .

Note!

Use of the tester ⇒ Instructions for use .

– Activate the starter motor until the tester no longer shows an


increase in pressure.

1. Cylinderhead: removing and installing 51


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.3.3 Compression values


New: 25...31 bar Wear limit: 19 bar
Admissible difference between all the cylinders: 5 bar
– Install the glowplugs with spanner -U-40082- . Tightening tor‐
que: 15 Nm
– Consult the fault memory: ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051

Note!

When removing the middle connector of the pump injectors, faults


are stored. Thus, consult the fault memory and clear if necessary.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

52 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2 Valve control: repairing

Note!

♦ The cylinderheads with cracks between the valve seats can still be used without decrease in their useful
life, so long as the cracks are no wider than 0.5 mm max.
♦ Before installation work, oil the support and slide surfaces.

1 - 20 Nm + 1/4 turn (90°)


❑ Replace
❑ Follow the installation
order when loosening
and tightening
⇒ page 55 , Camshaft:
removing and installing
2 - Rocker shaft
3 - Cylinderhead bolt
❑ Replace
❑ Follow the installation
order when loosening
and tightening
⇒ page 39 , Cylinder‐
head: removing and in‐
stalling
❑ Before installation, fit
the washers
⇒ Item 4 (page 53) in
the cylinderhead
4 - Washer
❑ For the cylinderhead
bolts
5 - Hydraulic plunger
❑ Before removing, re‐
move the half-bearings
of the camshaft
❑ Do not swap them
❑ With hydraulic compen‐
sation of valve play
❑ Place with the slide sur‐
face down
❑ Before installation test

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Valve control: repairing 53


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

the axial play of the


camshaft ⇒ page 55
❑ Lubricate the slide surface
6 - Half-cones
7 - Valve spring plate
8 - Valve spring, exterior
❑ Remove and install: Cylinderhead: removed: with -T20034/1- installed: ⇒ Item 14 (page 54) , replace
the valve stem seals
9 - Valve spring, interior
❑ Remove and install: Cylinderhead: removed: with -T20034/1- installed: ⇒ Item 14 (page 54) , replace
the valve stem seals
10 - Valve stem seal
❑ Replace ⇒ Item 14 (page 54)
11 - Valve guide
❑ Test ⇒ Item 3 (page 53)
❑ Replace ⇒ Item 6 (page 54)
❑ Repair guides, with collar
12 - Pump injector
❑ Remove and install ⇒ page 119
13 - Cylinderhead
❑ Bear in mind the note ⇒ page 46
❑ Re-cut the valve seats ⇒ page 52
14 - Seal
❑ Do not apply more oil or grease to the seal lip
❑ Before installation, clean excess oil from the camshaft journal with a clean cloth
❑ For installation, cover the slot in the camshaft cone (e.g. with tape)
❑ Remove and install ⇒ page 58
15 - Valves
❑ Valve dimensions ⇒ page 55
16 - Half-bearings
❑ Do not swap the used half-bearings (mark them)
❑ Check that the cylinderhead and the fixing flanges fit well in the caps
17 - Camshaft
❑ Test the axial play ⇒ page 55
❑ Remove and install ⇒ page 55
❑ Test the radial play with Plastigage Wear limit: 0.11 mm
❑ Eccentricity: max. 0.01 mm
❑ Identification and distribution timing ⇒ page 56
18 - Cap
❑ Installation order ⇒ page 55 , Camshaft: removing and installing
❑ Cap 4 is marked as cap 5
❑ For installation, seal the contact surfaces of caps 1 and 4 with -AMV 17400401- ⇒ page 55
19 - 20 Nm + 1/4 turn (90°) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Replace respect to the correctness of information in this document. Copyright by SEAT S.A.

54 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Measure the axial play of the camshaft

Special tools and workshop equipment required


♦ Support universal for gauge -T20020-
♦ Gauge
Measure with the cup plungers removed and the caps installed.
Wear limit: max. 0.15 mm
Seal the contact surfaces of caps 1 and 4 with -AMV 17400401-
Apply and thin, even coating of -sealant AMV 17400401- to the
surfaces -1- .

Note!

♦ Make sure that no sealant gets into the slots -arrows- .


♦ The cap 4 is marked asProtected
cap 5.by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Valve dimensions

Note!

The valves can not be re-cut, only seated.

Dimension Intake valve Exhaust valve


∅a mm 35.95 31.45
∅b mm 6.980 6.956
c mm 89.95 89.95
α ∠° 45 45

2. Valve control: repairing 55


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Identification of the camshaft, distribution timing


Identification
♦ Basic cam diameter: a = ∅ 52.8 mm
♦ Identification with numbers and letters stamped on the front of
the exhaust valve cam in the cylinder 3.
Cylinder 3 -arrow- 045 C
Distribution timing for 1 mm of valve stroke
Intake opens after TDC 15.8°
Intake closes after BDC 25.3°
Exhaust opens before BDC 28.2°
Exhaust closes before TDC 18.7°

2.1 Valve seats: re-cutting


Special tools and workshop equipment required
♦ Depth calliper
♦ Valve seat re-cutter

Note!

♦ When re-cutting engines with leaky valves, it is not enough to


re-cut or replace the valve seats and the valves. Especially for
engines with high mileage it is important to check for wear on
the valve control.
♦ Only re-cut the valve seats until an impeccable drive track is
achieved. Before re-cutting, calculate the maximum admissi‐
ble re-cutting dimension. If the re-cutting dimension is excee‐
ded the hydraulic valve play compensation is no longer
ensured and thus the cylinderhead must be replaced.

2.1.1 Calculate the maximum admissible re-


cutting dimension
– Introduce the valve and press it hard against the seat.

Note!

If the valve is changed during the reparation, use the new S.A.valve
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT SEAT S.A does not guarantee or accept any liability with
for the measurement. respect to the correctness of information in this document. Copyright by SEAT S.A.

– Measure the distance -a- between the end of the stem and the
upper edge of the cylinderhead.
– Calculate the maximum admissible re-cutting dimension start‐
ing with the distance measured -a- and the minimum dimen‐
sion.
Minimum dimensions:
Intake valve 43.4 mm
Exhaust valve 43.2 mm
Distance measured less the minimum dimension = maximum ad‐
missible recutting dimension.

56 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.1.2 Example:
- Distance measured 44.1 mm
Minimum dimension 43.4 mm
= Maximum admissible re-cutting dimen‐ 0.7 mm
sion

2.1.3 Intake valve seat: re-cutting


a = ∅ 35.7 mm
b = 1.6 mm
45° = Valve seat angle

Note!

The 30° backing-off of the valve seat is essential for avoiding tur‐
bulence in the intake channel.

2.1.4 Exhaust valve seat: re-cutting


a = ∅ 31.4 mm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
b = 2.7 mm permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
45° = Valve seat angle respect to the correctness of information in this document. Copyright by SEAT S.A.

2.2 Valve guides: testing


Special tools and workshop equipment required
♦ Universal support for gauge -T20020-

♦ Gauge

2. Valve control: repairing 57


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.2.1 Test process


– Fit the new valve in the guide. The end of the valve stem must
be flush with the guide. Due to different stem diameters always
fit the intake valves in intake guides and exhaust valves in ex‐
haust guides.
– Tilting play: max. 1.3 mm

2.3 Valve guides: replacing


Special tools and workshop equipment required
♦ Punch -T20035-

♦ Manual reamer -T20066- and water-soluble oil

2.3.1 Removing
– Clean and check the cylinderhead. Cylinderheads with the
valve seat rings that can no longer be re-cut or that have been
re-cut to the minimum dimension are not fit for replacing the
valve guides.
– Dislodge the worn valve guides with the -T20035- from the
camshaft side (valve guides with collar -for replacement only-
from the combustion chamber side).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

2.3.2 Installing
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Oil the new guides and, from the cylinderhead side, dislodge
them up to the collar with the -T20035- on the cold cylinder‐
head.

58 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

Once the collar of the guide is supported, do not increase the


fitting pressure by more than 1.0 t. Otherwise the collar may
break.

– Ream the guides with manual reamer -T20066- . Always use


water-soluble oil.
– Re-cut the valve seats ⇒ page 56 .

2.4 Valve stem seals: replacing

Special tools and workshop


equipment required
♦ Valve removal/fitting tool -
T20034B-
♦ Valve guide seal extractor -
T20058-
♦ Valve guide seal fitting tool
-T20039-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2.4.1 Removing
(With cylinderhead installed)
– Remove the camshaft ⇒ page 55 .
– Extract the plungers and place them with the cam slide surface
downwards. Do not swap them.
– Set the piston of the respective cylinder at TDC.

2. Valve control: repairing 59


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Use valve removal/fitting tool -T20034B- with pressure ele‐


ment -T20034B- /∅ 34.

Note!

The valves rest on the head of the piston.

– Remove the valve stem seals with the -T20058- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

2.4.2 Installing
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Fit the plastic sleeve -A- over the respective valve stem. In this
way damage to the new seal -B- is avoided.
– Fit the new valve stem seal with the -T20039- .
– Oil the lip of the valve stem seal and carefully slide the seal
over the valve guide.

2.5 Camshaft: removing and install-ing

60 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Countersupport -T10051-
♦ Extractor -T10052-
♦ Torque spanners -SAT
8010-
♦ Sealant -AMV 17400401-

2.5.1 Removing
– Remove the Poly-V belt ⇒ page 13
– Remove the toothed belt ⇒ page 38
– Remove the bolts -1- from the camshaft wheel.
– Remove the camshaft wheel from the hub.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Valve control: repairing 61


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Loosen the hub bolt -1- .


– Use countersupport -T10051- .
– Loosen the hub bolt about two turns.

– Fit extractor -T10052- and align it with the holes in the hub.
– Screw the fixing bolts -1- into the hub.
– Pull on the hub by uniformly tightening the centre bolt -2- until
the hub comes loose from the camshaft cone.

Note!

During this process, hold the extractor with a spanner e/c 30.

– Remove the hub from the camshaft cone.


– Remove the cylinderhead cover.
– Remove the rocker shaft ⇒ page 119 .

Note!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
First loosen the outer bolts and
respectthen
to the the two inner
correctness onesincrosswise.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
of information this document. Copyright by SEAT S.A.

– Remove the tandem pump ⇒ page 102 .


– First remove caps 2 and 3. Loosen caps 1 and 4 alternately
and crosswise.

Note!

Cap 4 is marked as cap 5.

2.5.2 Installing

Note!

♦ When fitting the camshaft, the cylinder 1 cams must point up‐
wards.
♦ Do not swap the worn half bearings (mark them).
♦ When fitting the camshaft, check that the mounting flanges of
the half bearings seat correctly in the caps and the cylinder‐
head.
♦ Before installing the cap, check that the cylinderhead washers
are fitted on the cylinderhead.

– Lubricate the slide surfaces of the half bearings.


– Replace the cap bolts.

62 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Tighten caps 2 and 3 alternately and crosswise to a torque of


8 Nm + 1/4 turn (90°)
– Fit caps 1 and 4 and tighten them to a torque of 8 Nm + 1/4
turn (90°) too.

Note!

♦ Cap 4 is marked as cap 5.


♦ Seal the contact surfaces of caps 1 and 4 with -AMV
17400401- ⇒ page 55 .
♦ Cap 4 must be flush with outer edge of the cylinderhead: oth‐
erwise the tandem pump may leak.

– Fit the camshaft seal ⇒ page 58 .


– Replace the rocker shaft bolts.
– Fit the rocker shaft tighten the two inner bolts first and then the
outer ones, uniformly and crosswise, until there is no play in
the housing. Tightening torque 20 Nm + 1/4 turn (90°)
– Fit the hub on the camshaft.
– Tighten the hub bolt -1- . Tightening torque 100 Nm
– Use the countersupport -T100051- .

– Slip the camshaft wheel over the hub.

Note!

The toothed section -arrow- of the camshaft wheel must be up‐


wards.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Align the camshaft
respect to thewheel at ofthe
correctness centre
information position
in this inCopyright
document. the elliptical
by SEAT S.A.
holes.
– Hand-tighten the bolts -1- into the camshaft until they have no
play.
– Immobilise the hub with lock pin -T20102- .
– Toothed belt: fit, tighten ⇒ page 38 .
– Poly-V belt: fit ⇒ page 13 .
– Fit the tandem pump ⇒ page 102 .

Note!

After fitting new plungers do not start the engine for approx. 30
minutes. The hydraulic compensation components must seat (the
valves may rest on the piston).

2. Valve control: repairing 63


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.6 Camshaft seal: removing and installing

Special tools and workshop


equipment required
♦ Seal extractor -T20031B-
♦ Plungers for fitting seals -
T20081B-
♦ Torque spanners -SAT
8010-
♦ Screwdriver M12X65

2.6.1 Removing
– Remove the Poly-V belt ⇒ page 13 .
– Remove the toothed belt ⇒ page 38 .
– Remove the camshaft wheel and the hub ⇒ page 53 , Cam‐
shaft: removing and installing.
– Oil the threaded head of extractor -T20031B- /∅ 32, position
it and, pressing hard, thread it into the seal as far as possible.
– Turn the centre bolt of the extractor against the camshaft until
the seal comes free.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

64 Rep. Gr. 15 - Cylinder head, Valve gear


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.6.2 Installing

Note!

Do not apply more oil or grease to the sealing side of the seal.

– Eliminate excess oil from the camshaft journal with a clean


cloth.
– Fit the seal over the -T20081B/3- and introduce the unit into
the cam-shaft. Also add the -T20081B/5- .
– Press on the seal with pressure part of the -T20081B/1- and
bolt M12X65 as far as it will go.
– Toothed belt: fit, tighten ⇒ page 38 .
– Fit the Poly-V belt ⇒ page 13 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Valve control: repairing 65


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

17 – Lubrication
1 Lubrication system components: re‐
moving and installing

Note!

♦ When repairing the engine, if significant quantities of metal


shavings and particles due to wear or abrasion, e.g. damage
to the mount or connecting rod bearings are found in the oil,
in order to avoid further damage, not only must the oil lines be
cleaned carefully but the oil radiator must also be replaced.
♦ The oil level must not exceed the max. mark; danger of dam‐
aging the catalyst!

Test the oil pressure ⇒ page 72


Oil capacity:
With oil filter 4.2 l
Specification of the engine oil:
Use only VW 50501 standard engine oils.
Part I
Part II, Oil filter support: disassembly ⇒ page 69

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

66 Rep. Gr. 17 - Lubrication


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - 15 Nm
2 - Sealing flange
❑ With seal
❑ Must fit in alignment
sleeves
❑ Removing and installing
⇒ page 18
❑ Install with silicone-
base sealant -D 176 404
A2- ⇒ page 18
❑ Do not apply more oil or
grease to the seal lip
❑ Before installing, clean
excess oil on the crank‐
shaft journal with a
clean cloth
❑ Replace the seal for
crankshaft - pulley side
⇒ page 17
3 - Engine block
4 - Gasket
❑ Replace
5 - Oil filter support
❑ Disassembly and as‐
sembly ⇒ page 69
6 - 15 Nm + 1/4 turn (90°)
❑ Replace
❑ First fit the upper left and
lower right bolts and
then tighten the four
bolts in a crossing pat‐

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Lubrication system components: removing and installing 67


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

tern
7 - Oil dipstick
❑ The oil level must not exceed the max. mark!
❑ Marks ⇒ page 70
8 - Filler funnel
❑ Remove in case of draining of the oil by absorption
9 - 5 Nm
10 - Guide sleeve
11 - 10 Nm
12 - O-ring
❑ Replace
❑ Check for firm seating
❑ Oil lightly for installation
13 - Cover
❑ With gasket
❑ Clean the filter if dirty
14 - 15 Nm
15 - Oil pump
❑ With discharge valve 11.5 bar
❑ Before installing, check for the two alignment sleeves for the centring
16 - Alignment sleeve
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17 - 25 Nm permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
18 - Axle support
❑ Before installing check for the alignment sleeve for the centring of the engine block and that it is fitted on
the axle support
❑ Removing and installing ⇒ page 24
19 - Oil injector
❑ For cooling the pistons
❑ Check the installation position: Turn the oil injector counter-clockwise to the stop of the engine block and
tighten at this position
20 - O-ring
❑ Replace
21 - Oil sump
❑ Before installing, clean the sealing surface
❑ Install with silicone-base sealant -D 176 404 A2- ⇒ page 70
❑ To remove the oil sump, the gearbox must be removed ⇒ 5-speed manual gearbox 02J; Rep. Gr. 34 ;
Gearbox: removing and installing
22 - Support
❑ For connection line/intercooler
23 - 15 Nm
❑ To remove the sump bolts (gearbox side), the gearbox must be removed ⇒ 5-speed manual gearbox
02J; Rep. Gr. 34 ; Gearbox: removing and installing
24 - Seal
❑ Replace
25 - Oil purge bolt, 30 Nm

68 Rep. Gr. 17 - Lubrication


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

26 - Chain wheel
❑ For oil pump
❑ Installation is only possible in one position
27 - 20 Nm + 1/4 turn (90°)
28 - Chain
❑ Check the installation position ⇒ page 24 . Stabiliser bar: removing and installing
29 - Chain wheel
❑ For stabiliser bar
❑ Installation is only possible in one position
30 - 100 Nm + 1/4 turn (90°)
❑ Replace
❑ The retightening can be done in several phases
❑ Use the -T10061- for loosening and tightening
31 - Counterweight
❑ Installation is only possible in one position
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

32 - 20 Nm
respect to the correctness of information in this document. Copyright by SEAT S.A.

33 - Pinion/return roller
34 - 9 Nm
35 - Chain tensioner with slide rail
❑ For the removal, immobilise with -T10060-
❑ Removing and installing ⇒ page 24

Part II

1. Lubrication system components: removing and installing 69


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - Gasket
❑ Replace
2 - 25 Nm + 1/4 turn (90°)
❑ Replace
❑ First fit the upper left and
lower right bolts and
then tighten the four
bolts in a crossing pat‐
tern
3 - Oil filter support
4 - Seal
❑ Replace
5 - Connecting sleeve
❑ For oil feed line towards
the turbocompressor
6 - Oil feed line, 22 Nm
❑ Towards the turbocom‐
pressor
7 - 0.7 bar oil pressure switch -
F1- , 20 Nm
❑ Test ⇒ page 72
8 - Plug
9 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Replace respect to the correctness of information in this document. Copyright by SEAT S.A.

10 - Oil filter element


11 - Lock bolt, 10 Nm
12 - Gasket
❑ Replace
❑ Fix with the tabs on the
oil radiator
13 - Oil radiator
❑ Check the installation position
❑ Check the note ⇒ page 66
14 - Gasket
❑ Replace
15 - Lock bolt, 25 Nm

Marks on the oil dipstick


1 - Max. mark
2 - Min. mark
a - Area between the upper edge of the marked area and the max.
mark: do not add oil
b - The level is within the marked area: oil may be added
c - Area between the min. mark and the lower edge of the marked
area: add maximum 0.5 l of oil

70 Rep. Gr. 17 - Lubrication


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.1 Oil sump: removing and installing


Special tools and workshop equipment required
♦ Hand drill with plastic brush
♦ Silicone-base sealant -D 176 404 A2-
♦ Flat scrapper

1.1.1 Removal
– Remove the soundproofing sump: ⇒ Bodywork-exterior fitting
work; Rep. Gr. 50 ; Bodywork, front Fitting chart
– Drain the engine oil.
– Remove the intercooler/turbocompressor connecting line from
the sump.
– Remove the gearbox: ⇒ 5-speed manual gearbox 02J; Rep.
Gr. 34 ; Gearbox: removing and installing
– Unbolt the oil sump.
– If necessary loosen the oil sump tapping it lightly with a rubber
hammer.
– Eliminate the sealant residues from the engine block with a flat
scraper.
– Eliminate the sealant residues from the oil sump with a rotating
brush, e.g. a hand drill with a plastic brush (use shop goggles).
– Clean the contact surfaces of oil and grease.

1.1.2 Install Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!

♦ Check the use-by date of the sealant.


♦ The oil sump must be installed within 5 minutes of applying the
siliconebase sealant.

– Cut the nozzle of the tube at the front mark (diameter of the
nozzle: approx. 3 mm).
– Apply the silicone-base sealant to the clean contact surface of
the oil sump, as shown in the illustration.
The bead must:

1. Lubrication system components: removing and installing 71


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ be 2...3 mm thick
♦ pass next to the bolts, along the inside -arrow-

Note!

The sealant bead must be no thicker; otherwise excess sealant


could get into the oil sump and obstruct the filter of the oil pump
breather pipe.

– The location of the sealant bead on the engine block can be


seen in the illustration.
– Fit the oil sump immediately and tighten all the fixing bolts
slightly.

Note!

The oil sump should be flush


Protected with Copying
by copyright. the engine
for privateblock.
or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Tighten the oil sump bolts to a torque of 15 Nm
– Install the gearbox: ⇒ 5-speed manual gearbox 02J; Rep. Gr.
34 ; Gearbox: removing and installing
– Tighten the oil sump/gearbox bolts to a torque of 45 Nm.

Note!

After installing the oil sump, allow the sealant to dry for approx.
30 minutes, after which oil may be added.

Continue the installation in the reverse order of removal.

1.2 Oil pressure and oil pressure switch: testing

72 Rep. Gr. 17 - Lubrication


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Oil pressure gauge -V.A.G.
1342-
♦ Diode lamp tester -V.A.G.
1527 B-
♦ Auxiliary measurement set
-V.A.G. 1594 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Note! respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Testing and reparation of optical and acoustic oil pressure in‐


dicators:
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations

1. Lubrication system components: removing and installing 73


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.2.1 Test process


– Remove the oil pressure switch -F1- and thread it into oil pres‐
sure gauge -V.A.G. 1342- .
– Thread the oil pressure gauge into the oil filter support in the
place of the oil pressure switch.
– Connect the brown wire of the oil pressure gauge to earth (-).
– Attach diode lamp -V.A.G. 1527 B- with auxiliary leads of the
-V.A.G. 1594 A- to battery positive (+) and to the oil pressure
switch.
– Start the engine and slowly increase the revs.
Between:
0.55...0.85 bar of pressure
The diode should light up; if not, replace the oil pressure switch.
– Continue raising the revs.
At 2,000 rpm and with the oil at a temperature of 80 °C, the oil
pressure should be 2.0 bar, minimum.
At higher revs, the oil pressure should not exceed 7.0 bar. If nec‐
essary, replace the oil pump cover with the discharge valve.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

74 Rep. Gr. 17 - Lubrication


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

19 – Cooling system
1 Cooling system components: remov‐
ing and installing

Note!

♦ The cooling system is under pressure when the engine is hot.


This pressure must be reduced before repairing.
♦ The hose connections are fixed with strip clamps. In case of
reparation, use only strip clamps.
♦ For installing the strip clamps, pliers -T20029- are recommen‐
ded.

Test the cooling system for leaks with tester -SAT 1274- and
adaptors -V.A.G. 1274/3- and -V.A.G. 1274/4- .
Cooling system components, bodywork ⇒ page 75 .
Cooling system components, engine ⇒ page 77 .
Coolant hose connection diagrams ⇒ page 79 .
Drainbyand
Protected fill coolant
copyright. Copying for ⇒ page
private 80 . purposes, in part or in whole, is not
or commercial
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Instructions for the ofcoolant
respect to the correctness informationmixture ⇒ page
in this document. 80 by
Copyright . Coolant:
SEAT S.A. drain‐
ing and filling.

1.1 Cooling system components, bodywork side

1. Cooling system components: removing and installing 75


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - Radiator
❑ Removing and installing
⇒ page 82
❑ After replacing, change
all the coolant
2 - Lockholder plate
3 - Intercooler
4 - Fan screen
5 - 10 Nm
6 - Radiator fan
7 - Lower coolant hose
❑ Coolant hose connec‐
tion diagrams
⇒ page 79
8 - 10 Nm
9 - Connector
10 - Heat switch -F18- , 35 Nm
❑ For electric fan
❑ Switching tempera‐
tures: 1st gear on:
92...97 °C off: 84...91 °C
2nd gear on: 99...105 °C
off: 91...98 °C
11 - Upper coolant hose
❑ Coolant hose connec‐
tion diagram
⇒ page 79 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
12 - Expansion tank respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Test the cooling system


for leakage with tester -
SAT 1274- and adaptor
-V.A.G. 1274/3-
13 - O-ring
❑ Replace if faulty
14 - Plug
❑ Test with tester -SAT 1274- and adaptor -V.A.G. 1274/4-
❑ Test pressure 1.4...1.6 bar
15 - Cover

76 Rep. Gr. 19 - Cooling system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.2 Cooling system components, engine side

1 - Hose
❑ Towards the heat ex‐
changer
❑ Coolant hose connec‐
tion diagram
⇒ page 79
2 - Connecting sleeve
3 - 10 Nm
4 - Hose
❑ From the heat exchang‐
er
❑ Coolant hose connec‐
tion diagram
⇒ page 79
5 - 25 Nm
6 - Hose
❑ Towards the lower part
of the expansion tank
❑ Coolant hose connec‐
tion diagram
⇒ page 79
7 - Mounting bracket
8 - Coolant line
❑ Coolant hose connec‐
tion diagram
⇒ page 79 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
9 - O-ring respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Replace
10 - Hose
❑ Towards the upper part

1. Cooling system components: removing and installing 77


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

of the expansion tank


❑ Coolant hose connection diagram ⇒ page 79
11 - Hose
❑ Towards the radiator, upper part
❑ Coolant hose connection diagram ⇒ page 79
12 - Hose
❑ Towards the radiator, lower part
❑ Coolant hose connection diagram ⇒ page 79
13 - Connecting sleeve
❑ For coolant thermostat
14 - 15 Nm
15 - Coolant thermostat
❑ Removing and installing ⇒ page 84
❑ Check the installation position ⇒ page 84 ; Coolant thermostat: removing and installing
❑ Test: heat the thermostat in water
❑ Commencement of opening approx. 85 °C
❑ End approx. 105 °C
❑ Opening stroke at least 7 mm
16 - Coolant pump
❑ Check that it rotates freely
❑ Check the installation position
❑ Removing and installing ⇒ page 83
17 - O-ring
❑ Check for firm seating
❑ Replace
18 - Securing clip
❑ Check for firm seating
19 - Coolant temperature sender -G62-
❑ Test: ⇒ Vehicle diagnosis, testing and information system VAS 5051
❑ With coolant temperature gauge sender -G2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

78 Rep. Gr. 19 - Cooling system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.3 Coolant hose connection diagram

1 - Intake manifold
2 - Expansion tank
3 - Heat exchanger for the
heating
4 - Coolant line
5 - Oil radiator
6 - Upper coolant hose
7 - Radiator
8 - Lower coolant hose
9 - Coolant pump/coolant ther‐
mostat
10 - Engine block

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Tightening order of the bolts fixing the compact support to engine


block
– Position the compact support on the engine block (check the
alignment sleeve between the compact support and the en‐
gine block).
– First, hand-tighten all the fixing bolts, taking up all play.
– Tighten the compact support bolts to a torque of 45 Nm, in the
following order: 1 - bolt -A- . 2 - bolt -B- . 3 - bolt -C- . 4 - bolt
-D- . 5 - bolt -E- . 6 - bolt -F- .

1. Cooling system components: removing and installing 79


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.4 Coolant: draining and filling

Special tools and workshop


equipment required
♦ Antifreeze tester -T10007-
♦ Strip clamp pliers -T20029-
♦ Tray -V.A.G. 1306-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.4.1 Drain
– Open the plug of the coolant expansion tank.
– Remove the soundproofing sump:
⇒ Bodywork-exterior fitting work; Rep. Gr. 50 ; Bodywork, front
Fitting chart
– Remove the lower radiator hose and let the coolant drain.

80 Rep. Gr. 19 - Cooling system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– For draining coolant from the engine, the coolant hoses must
also be detached from the oil radiator -arrow- .

Note!

Observe waste disposal rules!

1.4.2 Fill

Note!

♦ Only use antifreeze additive G 12 according to specification


TL VW 774 F. Identification: purple colour.
♦ The purple G 12 (TL VW 774 F standard) may be mixed with
the previously used red G 12 antifreeze additive.
♦ On no account must G 12 be mixed with other anti-freeze ad‐
ditives.
♦ If the fluid in expansion tank is brown, G 12 has been mixed
with other anti-freeze additives. In this case the coolant must
be changed.
♦ G 12 and anti-freeze additives marked “In accordance with TL
VW 774 F” prevent frostProtected
and corrosion damage, scaling and
also raise the boiling point of coolant. For bythis reason,
S.A. SEATthe
S.A sys‐
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised SEAT does not guarantee or accept any liability with
tem must be filled all year round with
respect to recommended
the correctness anti-
of information in this document. Copyright by SEAT S.A.
freeze and anti-corrosive additives.
♦ Because of its high boiling point, coolant improves engine re‐
liability under heavy work loads, particularly in countries with
tropical climates.
♦ Anti-freeze protection should be guaranteed to approx. -25 °
C (in countries with arctic weather up to approx. -35 °C).
♦ Coolant concentration must not be reduced by adding water,
even in warmer seasons or in warmer countries. The anti-
freeze additive ratio must be at least 40 %.

Recommended mixes:
Antifreeze pro‐ Proportion anti‐ -G12- 4) Water4)
tection to freeze
-25 °C 40 % 2.0 l 3.0 l
-35 °C 50 % 2.5 l 2.5 l
4) The quantity of coolant may vary according to the equipment on each vehicle.

– Fix the lower coolant hose to the radiator.


– Attach the coolant hoses to the oil radiator.

1. Cooling system components: removing and installing 81


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Install the soundproofing sump: ⇒ Bodywork-exterior fitting


work; Rep. Gr. 50 ; Bodywork, front Fitting chart
– Fill with coolant up to the max. mark of the expansion tank.
– Close the expansion tank.
– Switch off the heating.
– Start the engine and hold engine revs at approx. 2,000 rpm for
about 3 minutes.
– Run the engine until the fan starts up.
– Check the coolant level and, if necessary, top up. With the
engine warm the coolant level must be at the max. mark, and
with the engine cold, between the min. and max. marks.

1.5 Radiator: removing and install-ing

Special tools and workshop


equipment required
♦ Antifreeze tester -T10007-
♦ Strip clamp pliers -T20029-
♦ Tray -V.A.G. 1306-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Torque spanners respect
-SATto the correctness of information in this document. Copyright by SEAT S.A.
8010-

1.5.1 Remove
– Remove the front bumper: ⇒ Bodywork-exterior fitting work;
Rep. Gr. 63 ; Front bumper: removing and installing
– Drain the coolant ⇒ page 80 .

82 Rep. Gr. 19 - Cooling system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Remove the coolant hoses from the radiator.


– Detach the terminal connector from the heat switch.
– Remove the radiator bolts and remove the radiator down‐
wards.

1.5.2 Vehicles with air conditioning


– Remove the bolts fixing the condenser to the radiator.
– Remove the power steering reserve tank and the condenser
lines from their mounts.
– Separate the condenser as far as possible - without bending
or damaging the lines - to remove the radiator.

1.5.3 Install
Install in the reverse order, bearing in mend the following:
– Fill coolant ⇒ page 80 .

1.6 Coolant pump: removing and installing

Special tools and workshop


equipment required
♦ Antifreeze tester -T10007-
♦ Strip clamps pliers -
T20029-
♦ Tray -V.A.G. 1306-
♦ Torque spanners -SAT
8010-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Cooling system components: removing and installing 83


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.6.1 Remove

Note!

Always replace the gaskets and the ring gaskets.

– Drain the coolant ⇒ page 80 .


– Remove the Poly-V belt ⇒ page 13 .
– Remove the toothed belt ⇒ page 38 .
– Remove the bolts -1- from the coolant pump -2- and carefully
remove the coolant pump.

1.6.2 Install
Install in the reverse order, bearing in mend the following:
– Install the new O-ring -3- covered with coolant.
– Fit the coolant pump -2- on the engine block and tighten the
fixing bolts -1- . Tightening torque: 15 Nm

Note!

The sealing plug for the coolant pump points downwards.

– Toothed belt, install, tighten ⇒ page 38 .


– Install the Poly-V belt ⇒ page 13 .
– Fill coolant ⇒ page 80 .

1.7 Coolant thermostat:


Protected removing
by copyright. Copying and installing
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

84 Rep. Gr. 19 - Cooling system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Antifreeze tester -T10007-
♦ Strip clamp pliers -T20029-
♦ Tray -V.A.G. 1306-
♦ Torque spanners -SAT
8010-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

1.7.1 Remove
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note!

Always replace the gaskets and the ring gaskets.

– Drain the coolant ⇒ page 80 .


– Remove the alternator: ⇒ Electrical system; Rep. Gr. 27 ;
Alternator with Poly-V belt: removing and installing
– Detach the coolant hose from the connecting sleeve.

1. Cooling system components: removing and installing 85


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Remove the fixing bolts -1- from the connecting sleeve -2- and
remove the connecting sleeve -2- with the coolant thermostat
-4- .
– Turn the coolant thermostat -4- 1/4 turn (90°) to the left and
remove it from the connecting sleeve -2- .

1.7.2 Install
Install in the reverse order, bearing in mend the following:
– Wet the new O-ring -3- with coolant.
– Fit the coolant thermostat -4- in the connecting sleeve -2- and
turn 1/4 turn (90°) to the right.

Note!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
The thermostat braces should be almost vertical.
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Fit the connecting sleeve -2- with the coolant thermostat -4-
on the engine block.
– Tighten the fixing bolts -1- . Tightening torque: 15 Nm
– Fill coolant ⇒ page 80 .

86 Rep. Gr. 19 - Cooling system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

20 – Fuel supply system


1 Fuel supply system components: re‐
moving and installing

Note!

♦ The hose connections are fixed with tightening or screw


clamps.
♦ Always replace the tightening clamps with strip or screw
clamps.

Repair the fuel filter ⇒ page 89 .


Check the safety measures ⇒ page 90 .
Follow the cleaning rules ⇒ page 90 .
Repair the accelerator control cable ⇒ page 93 .

1.1 Fuel tank and accessory parts: removing and installing

1 - Plug
❑ Replace the gasket if
worn
2 - Fixing bolt
3 - Tank cover unit
❑ With dustboot
4 - Gravity/safety valve
❑ To remove, extract it
from the filler hole, up‐
wards
❑ Test the continuity of
flow from valve Perpen‐
dicular valve: open
Valve inclined 455:
closed
5 - O-ring
❑ Replace
6 - Earth connection
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Check for firm seating permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
7 - Connector
8 - Plug nut
❑ Remove and install with
-U-40055A-
9 - Fuel level gauge sender
❑ Check the installation
position on the fuel tank
⇒ page 88
10 - Ring gasket
❑ Replace if worn
❑ For installing wet with

1. Fuel supply system components: removing and installing 87


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

fuel
11 - Spacer bushing
12 - 15 Nm
13 - Fuel tank
❑ When removing, hold it with the engine/gearbox lift -SAT 1001-
❑ Removing and installing ⇒ page 91
14 - 25 Nm
15 - Holding strap
❑ Check the different lengths
16 - Supply line
❑ Towards the fuel filter ⇒ page 89
❑ Clipped to the fuel tank
❑ Check for firm seating
❑ Black
❑ To free from the flange, press the lock on the connecting part
17 - Return line
❑ Of the fuel radiator ⇒ page 91
❑ Blue or blue mark
❑ Clipped to the fuel tank
❑ Check for firm seating
❑ To free from the flange, press the lock on the connecting part
18 - Breather valve
❑ To remove it, extract laterally from the filler hole
❑ Before installing, remove the plug ⇒ Item 1 (page 87)
❑ Test ⇒ page 88 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Installation position of the fuel level gauge sender


The marks on the sender and on the fuel tank must coincide.
The connections for return line blue -1- and supply line black -2-
are marked with arrows on the cover of the fuel level gauge
sender.

Note!

Once installed the fuel level gauge sender, check that the supply
and return lines are still fixed to the fuel tank.

Test the breather valve


Lever at rest position: closed.
Lever set at position of the arrow: open.

Note!

Before installing the breather valve, remove the plug from the fuel
tank.

88 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.2 Fuel filter: repairing

1 - Return line
❑ Towards the fuel radia‐
tor ⇒ page 91
❑ Blue or blue mark
❑ Check for firm seating
2 - Supply line
❑ Of the fuel tank
⇒ Item 13 (page 88)
❑ White or white mark
❑ Check for firm seating
3 - Fixing clip
4 - Control valve
❑ Installation position: ar‐
row points towards the
fuel tank
❑ To change the filter, re‐
move the fixing clip and
remove the control
valve with the fuel lines
connected
❑ At less than +15 °C:
FlowCopying
Protected by copyright. towards the orfilter,
for private commercial purposes, in part or in whole, is not
open
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ At more than +31 °C:
Flow towards the filter,
closed
5 - O-ring
❑ Replace
6 - Return line
❑ Of the tandem pump

1. Fuel supply system components: removing and installing 89


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

⇒ Item 13 (page 11)


❑ Blue or blue mark
❑ Check for firm seating
7 - Fuel line
8 - Fuel temperature sender -G81-
❑ Test ⇒ page 119
9 - Retaining valve
❑ Installation position: Arrow points towards the tandem pump
10 - Supply line
❑ Towards the tandem pump ⇒ Item 13 (page 11)
❑ White or white mark
❑ Check for firm seating
11 - Fuel filter
❑ Fill with diesel fuel before installing
❑ The direction of flow is marked with arrows
❑ Do not swap the connections
❑ Replace if worn
12 - Gasket
❑ Replace if worn
13 - Water purge bolt
❑ To ventilate, remove the fixing clip of the control valve and remove the valve with the fuel lines connected
❑ Loosen and allow about 100 cm³ of liquid to escape

1.3 Safety measures for work on the fuel


supply system
When removing or installing the fuel level gauge sender from full
or partially full fuel tanks, bear in mind the following:
♦ Before beginning work, the vacuum tube of a working extractor
must be close at hand, near the fuel tank assembly opening,
to absorb the gases given off by the fuel. If an extractor is not
available, a radial fan can be used (the engine must be kept
out of the flow of air) with an air flow above 15 m³/h.
♦ Avoid contact between skin and fuel. Use fuel-resistant
gloves!

1.4 Cleaning rules


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
For work on the fuel supply/injection system, carefully follow the
“6 rules” of cleaning:
♦ Carefully clean the connections and the area around them be‐
fore detaching them.
♦ Place the removed parts on a clean surface and cover them.
Do not use cloths that shed fibres!
♦ If the repair work is not carried out immediately, the open com‐
ponents should be covered or carefully stored.
♦ Only install clean components: Remove the replacement parts
from their wrapping right before carrying out assembly. Do not
install components that have been stored without wrapping
(e.g. in the toolbox, etc.).
♦ As the system is open, avoid the use of compressed air when
possible. Do not move the vehicle if possible.

90 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Also make sure not to spill diesel fuel on the coolant hose. If
necessary, immediately clean the hoses. Replace affected
hoses.

1.5 Fuel radiator: removing and installing


Special tools and workshop equipment required
♦ Torque spanners -SAT 8010-

1.5.1 Remove
Follow the cleaning rules ⇒ page 90 .

Note!

The fuel radiator is on the return line to the tank. It is fitted on the
underside of the vehicle.

– Detach the fuel lines on the fuel radiator.


– Remove the nuts -arrows- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.5.2 Install
Install in the reverse order, bearing mind the following:
– Tighten the nuts of the fuel radiator to a torque of 15 Nm.

1.6 Fuel tank: removing and installing


Special tools and workshop equipment required

1. Fuel supply system components: removing and installing 91


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Engine/gearbox lift -SAT 1001-

♦ Torque spanners -SAT 8010-

1.6.1 Remove
– Check the safety measures before starting removal work
⇒ page 90 .
– First check whether the vehicle has a coded radio; if so consult
the antitheft code.
– With the ignition off, disconnect the battery earth strap.
– Remove the rear axle: ⇒ Running gear; Rep. Gr. 42 ; Rear
axle: repairing Rear axle: removing and installing
– Remove the right rear mudguard: ⇒ Bodywork-fitting work;
Rep. Gr. 66 ; Wheel arch: removing and installing
– Open the tank cap.
– Empty the fuel tank and clean around the fuel filler hole.
– Remove the fixing bolt and remove the tank cap unit with the
dustboot.
– Remove the filler hole bolts.
– Fold the rear seat forward.
– Remove the cover from the fuel level gauge sender.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

92 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Detach the fuel return line -1- (blue) and the fuel supply line
-2- from the flange.

Note!

To do so, press the lock buttons on the hose connections


-arrows- .

– Remove the connector -3- .


– Remove the holding straps on the fuel tank with engine/gear‐
box lift -SAT 1001- .
– Lower the fuel tank.

1.6.2 Install
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Install in the reverse
permitted unlessorder, bearing
authorised mind
by SEAT S.A. SEATthe
S.A following:
does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Fit the breather hoses without bends.
♦ Do not swap the supply and return lines (return line blue or
with blue mark, supply line, black).
♦ Clip the supply and return lines to the fuel tank.
The connections for return line blue -1- and supply line black -2-
are marked with arrows on the cover of the fuel level gauge
sender.

1.7 Accelerator control: repairing


Left-hand drive vehicles
Right-hand drive vehicles ⇒ page 94

1. Fuel supply system components: removing and installing 93


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - Support
❑ Removing and installing
⇒ Brake system; Rep.
Gr. 46 ; Brake, Brake
pedal, General installa‐
tion chart
2 - Connector
❑ Black, 6 contacts
3 - Accelerator pedal position
sender -G79-
❑ Cannot be adjusted
❑ The accelerator pedal
position sender trans‐
mits driver intentions to
the engine control unit
❑ To remove the sender,
remove the cover on the
footrest area
❑ Test ⇒ page 96
4 - 10 Nm

Right-hand drive vehicles

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

94 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - 10 Nm
2 - Accelerator pedal position
sender -G79-
❑ Test ⇒ page 96
❑ Adjust ⇒ page 100
3 - Pulley for cable
4 - Washer
5 - 10 Nm
6 - Threaded cage
7 - Support
❑ Removing and installing
⇒ Brake system; Rep.
Gr. 46 ; Brake, Brake
pedal, General installa‐
tion chart

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Fuel supply system components: removing and installing 95


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.8 Accelerator pedal position sender: test

Special tools and workshop


equipment required
♦ Fault reader -V.A.G. 1551-
or vehicle systems checker
-V.A.G. 1552- with lead -
V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -
V.A.G. 1526 A- or multime‐
ter -V.A.G. 1715-
♦ Auxiliary measurement set
-V.A.G. 1594 A- or -V.A.G.
1594 C-
♦ Wiring diagram

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.8.1 Left-hand drive vehicles


Right-hand drive vehicles ⇒ page 98

1.8.2 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with the cor‐
responding “address code” 01, select the engine electronics
control unit. When doing so, the ignition must be on. ⇒ Vehicle
diagnosis, testing and information system VAS 5051
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and press Q to confirm the entry.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 2 for the “Display group number 2” and press


Q to confirm the entry.

96 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Read measured value block 2 →


0/min 0.0 % 0 1 0 18.4 °C

– Check the reading for accelerator pedal position in field 2,


without depressing the pedal. Target value: 0.0 %
– Also check the reading for the idle switch in field 3. The middle
digit should be 1. Reading: 0 1 0
Read measured value block 2 →
0/min 100.0 % 0 0 0 18.4 °C

– Depress the accelerator pedal slowly all the way, watching


display fields 2 and 3.
♦ Display field 2: the accelerator pedal position value should rise
continuously. Target value at full gas: 100.0 %
♦ Display field 3: the middle digit should change to 0. Reading:
000
If the final target value is not reached:
– Press → .
– Press 0 and 6 for the function “End data transmission” and
press Q to confirm the entry.
– Switch off the ignition.
– Replace the accelerator pedal position sender -G79-
⇒ Item 3 (page 94)
– Consult the fault memory: ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051
If the reading does not change or only changes irregularly:
– Test the wiring of the accelerator pedal position sender as fol‐
lows:
– Remove the wiper arms and the air deflector: ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wipers Windscreen wipers:
removing and installing
– Attach test box -V.A.G. 1598/31- to the wiring harness of the
control unit without connecting the engine control unit.
– Remove the cover from the footrest area (driver side).
– Detach the 6-contact connector for the accelerator pedal po‐
sition sender.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Fuel supply system components: removing and installing 97


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram.
Contact 1 + female contact 63
Contact 2 + female contact 12
Contact 3 + female contact 50
Contact 4 + female contact 69
Contact 5 + female contact 70
Contact 6 + female contact 51
Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires, to vehicle
earth and to battery positive. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the accelerator pedal position sender -G79- .
⇒ Item 3 (page 94)
– Consult the fault memory: ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

1.8.3 Right-hand drive vehicles


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with the cor‐
responding “address code” 01, select the engine electronics
control unit. When doing so, the ignition must be on. ⇒ Vehicle
diagnosis, testing and information system VAS 5051
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and press Q to confirm the entry.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 2 for the “Display group number 2” and press


Q to confirm the entry.

Read measured value block 2 →


0/min 0.0 % 0 1 0 18.4 °C

– Check the reading for the accelerator pedal position in field 2,


without depressing the pedal. Target value: 0.0 %
– Also check the reading for the idle switch in field 3. The middle
digit should be 1. Reading: 0 1 0
Read measured value block 2 →
0/min 100.0 % 0 0 0 18.4 °C

– Depress the accelerator pedal slowly all the way, watching


display fields 2 and 3.
♦ Display field 2: the accelerator pedal position value should rise
continuously. Target value at full gas: 100.0 %
♦ Display field 3: the middle digit should change to 0. Reading:
000
If the final target value is not reached:
– Press → .
– Press 0 and 6 for the function “End data transmission” and
press Q to confirm the entry.

98 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Switch off the ignition.


– Adjust the accelerator pedal position sender -G79-
⇒ page 100
If the reading does not change or only changes irregularly:
– Test the accelerator pedal position sender as follows:
– Press → .
– Press 0 and 6 for the function “End data transmission” and
press Q to confirm the entry.
– Switch off the ignition.
– Remove the cover from the footrest area (driver side).
– Detach the 6-contact connector for the accelerator pedal po‐
sition sender.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– permitted
Measure the resistance of the sender between contacts 1 + 3
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

of the connector. Target value Accelerator pedal at idling po‐


respect to the correctness of information in this document. Copyright by SEAT S.A.

sition: 0.8 ... 1.4 kΩ


– Test the idle switch -F60- on the accelerator pedal position
sender. To do so, measure the resistance between contacts
4 + 6 of the connector.
Target value
Accelerator pedal at idling position: 0.8 ... 1.2 kΩ
Accelerator pedal depressed: ∞ Ω
– Measure the resistance of the sender between contacts 1 + 3
of the connector.
Target value
Accelerator pedal at idling position: ∞ Ω
Accelerator pedal depressed: 0.8 ... 1.2 kΩ
If target values are not reached:
– Replace the accelerator pedal position sender -G79-
⇒ Item 2 (page 95)
– Consult the fault memory:
⇒ Vehicle diagnosis, testing and information system VAS 5051
If the target values are reached:
– Remove the wiper arms and the air deflector: ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wipers Windscreen wipers:
removing and installing

– Attach test box -V.A.G. 1598/31- to the wiring harness of the


control unit without connecting the engine control unit.
– Remove the cover from the footrest area (driver side).
– Detach the 6-contact connector for the accelerator pedal po‐
sition sender.

1. Fuel supply system components: removing and installing 99


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram.
Contact 1 + female contact 69
Contact 2 + female contact 12
Contact 3 + female contact 50
Contact 4 + female contact 70
Contact 5 + female contact 63
Contact 6 + female contact 51
Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires, to vehicle
earth and to battery positive. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the control unit of the direct diesel injection system -
J248- ⇒ page 157

1.9 Accelerator pedal position sender: ad‐


justing

1.9.1 Only right-hand drive vehicles


Work sequence
Adjust the pulley:
– Install the pulley in the position shown in the illustration.
– Bolt the accelerator pedal position sender with the pulley fitted
to the support.
– Attach the 6-contact connector of the sender.
Precision adjustment of the fitted sender:
– With your hand depress the accelerator pedal all the way.
If the accelerator pedal limit is not reached:
Turn the sender in the connection holes of the support.
– Once adjusted, test the sender with fault reader -V.A.G. 1551-
or vehicle systems checker -V.A.G. 1552- ⇒ page 96 , Accel‐
erator pedal position sender: test.

1.10 Tandem pump: test


Special tools and workshop equipment required
♦ Pressure gauge -VAS 5187-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

100 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Torque spanners -SAT 8010-

♦ Fault reader -V.A.G. 1551- or vehicle systems checker -V.A.G.


1552- with lead -V.A.G. 1551/3B-

1.10.1 Test conditions


• Coolant temperature, 85 °C minimum
• Pump injectors, OK
• The fuel filter and the fuel lines must not be clogged
• The retaining valve on the fuel supply line must be OK
• The fuel sender must be OK

1.10.2 Work sequences


– Remove the lock bolt -arrow- .

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Fuel supply system components: removing and installing 101


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Attach pressure gauge -VAS 5187- as shown in the illustration.


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with the cor‐
responding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be idling. ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051
Reading on the display:
Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and press Q to confirm the entry.
Reading on the display:
Read measured value block
Enter value group number XXX

– Press 0 , 0 and 2 for the “Display group number 2” and press


Q to confirm the entry.

Reading on the display: (1 ... 4 = display fields)


Read measured value block 2 →

– Read the idling revs displayed in field 1.


– Increase the revs to 1,500 rpm.
– Check the pressure reading on the pressure gauge. Target
value: min. 3.5 bar
If the target value is not reached:
– Replace the tandem pump ⇒ page 102 , Tandem pump: re‐
moving and installing.

Note!

After removing the pressure gauge tighten the lock bolt to a torque
of 25 Nm. Replace the seal.

1.11 Tandem pump:Protected


removing and installing
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

102 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Torque spanners -SAT
8010-
♦ Vacuum pump -SAT 1390-
♦ Purge tank -SAT 1390/1-
♦ Strip clamp pliers -T20029-

1.11.1 Remove
– Detach the supply line -1- (white mark) and the return line
-2- (blue mark) from the fuel filter.
– Attach hand vacuumpermitted
pump -SAT 1390-bywith
authorised purge
SEAT S.A. SEATtank -SAT
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless S.A does not guarantee or accept any liability with
1390/1- to the return line.respect to the correctness of information in this document. Copyright by SEAT S.A.
– Operate the hand vacuum pump until no fuel come out of the
return line. Check that fuel is not absorbed inside the vacuum
pump.
– Detach the middle connector for the pump injectors.

1. Fuel supply system components: removing and installing 103


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Detach the vacuum hose -1- of the power brake from the tan‐
dem pump -4- .
– Detach the supply line -2- (white mark) from the tandem pump
-4- .
– Remove the bolts -arrows- .
– Remove the tandem pump -4- from the cylinderhead.

– Raise the tandem pump -4- slightly, detach the return line -3-
(blue mark) and remove the tandem pump -4- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.11.2 Install
Install in the reverse order, bearing in mend the following:

Note!

♦ Check that the coupling of the tandem pump seats well on the
camshaft.
♦ Replace the gaskets of the tandem pump.

– Attach the return line -3- (blue mark) to the return connection
of the tandem pump.
– Install the tandem pump and tighten the uppers bolts to a tor‐
que of 20 Nm.
– Tighten the lower bolts to a torque of 10 Nm.
– Attach the supply line -2- (white mark) to the supply connection
and the power brake vacuum hose -1- to the tandem pump
-4- .
– Connect the middle connector of the pump injectors.

104 Rep. Gr. 20 - Fuel supply system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Attach the supply line -1- (white mark) to the fuel filter.
– Attach hand vacuum pump -SAT 1390- with purge tank -SAT
1390/1- to the return line -2- (blue mark) of the fuel filter.
– Operate the vacuum pump until fuel comes out of the return
line. Check that fuel is not absorbed inside the vacuum pump.
– Attach the return line -2- (blue mark) to the fuel filter.
– Consult the fault memory: ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051

Note!

When the middle connector is detached from the pump injectors,


faults are stored. Thus consult the fault memory and, if necessary,
clear.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Fuel supply system components: removing and installing 105


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

21 – Charging
1 Supercharging system with exhaust
gas turbocompressor

1.1 Exhaust gas turbocompressor with at‐


tachments: removing and installing
Observe rules for cleanliness ⇒ page 110

Note!

♦ All hose connections are secured with spring-type clips. When


repairing, only use spring-type clips.
♦ For the removing and installing spring-type clips use pliers -
T20029- .
♦ The supercharging system must be free of leaks.
♦ Renew self-locking nuts.
♦ Fill the turbocompressor with engine oil through the oil supply
pipe connection before fitting the oil supply tube.
♦ After installing the turbocompressor, run the engine and let it
run at idling speed for approximately one minute, without ac‐
celerating immediately. This will guarantee the correct lubri‐
cation of the compressor.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

106 Rep. Gr. 21 - Charging


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - Exhaust manifold
2 - 30 Nm
❑ Replace
❑ Apply -G 000 500- to the
thread and to the sup‐
port surface of the head
3 - Intake manifold
4 - Of the intercooler
5 - Gasket
❑ Replace
❑ Lining (edge) towards
the intake manifold
6 - 25 Nm
7 - Gasket
❑ Check the installation
position
8 - Support
❑ For shield
⇒ Item 10 (page 107)
9 - Washer
10 - Shield
❑ Fit in support
⇒ Item 8 (page 107)
11 - 10 Nm
12 - Lock washer
13 - Pressure unit
❑ For supercharging pres‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Supercharging system with exhaust gas turbocompressor 107


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

sure control valve


❑ Test ⇒ page 112
❑ Removing and installing ⇒ page 112
14 - Activating lever
15 - 10 Nm
❑ Fit with -D6-
16 - Support
17 - Comes from the air filter
18 - Hollow bolt, 15 Nm
19 - Seal
20 - Hose
❑ At the supercharging pressure control solenoid
Protected valve
by copyright. -N75-
Copying ⇒ or
for private page 110 purposes,
commercial , exhaust turbocompressor
in part or in whole, is not hose
connections permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
21 - Oil return line
❑ To the engine block
22 - 15 Nm
23 - Gasket
❑ Replace
24 - Exhaust pipe, front
25 - 25 Nm
❑ Replace
26 - Exhaust turbocompressor
❑ For removal, first remove the turbocompressor/air mass meter connection line and intake manifold/in‐
tercooler connection line and the right cover of the articulated half-shaft
❑ Test the supercharging pressure control ⇒ page 113
27 - Connection
28 - Oil feed line
❑ Of the oil filter support ⇒ Item 6 (page 70)
29 - Support

108 Rep. Gr. 21 - Charging


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.2 Intercooler system components: removing and installing

Note!

♦ All the hoses are fixed with clamps.


♦ The supercharging system must be airtight.
♦ For removing and installing the strip clamps use the -T20029- .

1 - Intercooler
2 - Connection hose
3 - 10 Nm
4 - Support
❑ For connection line Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Bolted to the oil sump respect to the correctness of information in this document. Copyright by SEAT S.A.

5 - Connection line
6 - Connection hose
❑ Connection line/turbo‐
compressor
7 - Connection hose
❑ Connection line/intake
hose
8 - Intake manifold tempera‐
ture sender -G72-
❑ Test ⇒ page 119
9 - 3 Nm
10 - O-ring
❑ Replace if worn
11 - Connecting sleeve

1. Supercharging system with exhaust gas turbocompressor 109


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.3 Supercharging pressure control hose connection diagram

1 - Intake manifold flap switch‐


ing valve -N239-
❑ Test ⇒ page 119
2 - Exhaust recirculation valve
-N18-
❑ Test ⇒ page 164
3 - Supercharging pressure
control sol-enoid valve -N75-
❑ Test the supercharging
pressure control
⇒ page 113
4 - Connecting part
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
5 - Towards the power brake
6 - Retaining valve
7 - Pressure unit
❑ For supercharging pres‐
sure control
8 - Exhaust turbocompressor
9 - Intercooler
10 - Intake manifold
11 - Tandem pump
❑ For the fuel supply and
the vacuum
12 - Cylinderhead
13 - Vacuum unit for intake
manifold switching
14 - Exhaust recirculation
valve
❑ Is an integral part of the
intake hole
❑ Can only be replaced along with the intake hole
15 - Air filter

1.4 Cleaning rules


For work on the turbocompressor, carefully follow the following “5
rules” for cleaning:
♦ Carefully clean the connections and the area around them be‐
fore detaching them.
♦ Place the removed parts on a clean surface and cover them.
Do not use cloths that shed fibres!
♦ If the repair work is not carried out immediately, the open com‐
ponents should be covered or carefully stored.
♦ Only install clean components: Remove the replacement parts
from their wrapping right before carrying out assembly. Do not
install components that have been stored without wrapping
(e.g. in the toolbox, etc.).

110 Rep. Gr. 21 - Charging


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ As the system is open, avoid the use of compressed air when


possible. Do not move the vehicle if possible.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Supercharging system with exhaust gas turbocompressor 111


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2 Supercharging system: test

2.1 Pressure unit for supercharging pres‐


sure control valve: test

2.1.1 Test condition


• Engine oil temperature, 80 °C minimum.

2.1.2 Test process


– Remove the connector -2- from the supercharging pressure
control solenoid valve -N75- -1- .

– Start the engine and give a throttle burst to maximum revs.


The control rod -2- for the supercharging pressure control
valve should move.
If the control rod does not move:
– Check that lever for the supercharging pressure control valve
-1- works smoothly. If not, replace the turbocompressor.
If the control rod does not move although the lever works smooth‐
ly:
– Replace the pressure unit for the supercharging pressure con‐
trol valve -3- .

2.2 Pressure unit for supercharging pres‐


sure control valve: removing and instal‐
ling
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools
permitted and
unless workshop
authorised equipment
by SEAT required
S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Torque spanners -SAT 8010-

112 Rep. Gr. 21 - Charging


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.2.1 Removal
– Remove the exhaust turbocompressor.
– Unclip the safety -4- .
– Remove the fixing nuts -1- .
– Remove the pressure unit -6- .

2.2.2 Installation
– Install the pressure unit -6- on the turbocompressor and tight‐
en the fixing nuts -1- to a torque of 10 Nm.
– Loosen the counternut -2- of the control rod -3- .
– Move the lever for supercharging pressure control valve -5- to
the stop in direction of the pressure unit and hold it.
– Adjust the length of the control rod -3- so that the hole fits
easily over the pin
Protected on theCopying
by copyright. leverfor-5- (lever
private at stop,
or commercial with play).
purposes, in part or in whole, is not

– From this position,


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect tothread on the
the correctness controlinrod
of information 8 turns.Copyright
this document. (reducing
by SEAT S.A.
the length)
– Tighten the counternut -2- .
– Attach the control rod over the lever and fit the safety -4- .
– Install the exhaust turbocompressor.

2.3 Supercharging pressure control: testing

2. Supercharging system: test 113


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Hand vacuum pump -SAT
1390-
♦ Hand-held multimeter -
V.A.G. 1526 A-
♦ Auxiliary measurement set
-V.A.G. 1594 A- or -V.A.G.
1594 C-
♦ Test box -V.A.G. 1598/31-
♦ Fault reader -V.A.G. 1551-
or vehicle systems checker
-V.A.G. 1552- with lead -
V.A.G. 1551/3B-
♦ Electrical diagram

2.3.1 Test conditions


• No faults stored in the fault memory. ⇒ Vehicle diagnosis,
testing and information system VAS 5051
• There must be no leaks at either the intake or exhaust side.
• Control line to the supercharging pressure control valve not
clogged, loose or leaky.
• No faults in the engine/injection system.
• Engine oil temperature, 80 °C minimum. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
2.3.2 Test process respect to the correctness of information in this document. Copyright by SEAT S.A.

If test and measurement apparatuses are needed during a road


test, take into account the following:
♦ The test and measurement apparatuses must be installed in
the rear seat and operated by a second mechanic.
If the test and measurement apparatuses are operated from the
front passenger seat, in the event of an accident the person oc‐
cupying that seat could be injured by the airbag.
– The supercharging pressure is measured with fault reader -
V.A.G. 1551- during a road test.

114 Rep. Gr. 21 - Charging


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

To test the functioning of the supercharging pressure control, it is


first necessary to determine the supercharging pressure without
pressure control.

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Supercharging system: test 115


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Remove the connector -2- from the supercharging pressure


control solenoid valve -N75- -1- .
– Attach the -V.A.G. 1551- ( -V.A.G.1552- ) and, with the corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be idling: ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051
Reading on the display:
Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and press Q to confirm the entry.
Reading on the display:
Read measured value block
Enter value group number XXX

– Press 0 , 1 and 1 for the “display group number 11”S.A.and press


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT SEAT S.A does not guarantee or accept any liability with
Q to confirm the entry. respect to the correctness of information in this document. Copyright by SEAT S.A.

Reading on the display:


Read measured value block 11 →
900 rpm 1020 mbar 1020 mbar 64 %

– Vehicle in 3rd gear and accelerate to full gas from approx.


1,500 rpm.
– At approx. 3,000 rpm press PRINT on the -V.A.G. 1551- .
Target value in display field 3: 1375...1625 mbar
Read measured value block 11 →
3090 rpm 1866 mbar 1650 mbar 62 %

If the supercharging pressure is not reached:


– Test the pressure unit for the supercharging pressure control
valve, and replace if necessary.
– Test the vacuum hoses ⇒ page 110 .
– Retest the supercharging pressure.
If the supercharging pressure is still not reached:
– Replace the exhaust turbocompressor.
If the supercharging pressure is exceeded:
– Test the supercharging pressure control solenoid valve -N75-
(continuity of flow: hose of the turbocompressor, valve, and
until the pressure unit, with the connector detached).
– Test the vacuum hoses ⇒ page 110 .
– Test the pressure unit for supercharging pressure control
valve and the control rod, and replace if necessary.
– Check that the shaft works smoothly in its housing at the su‐
percharging pressure control valve on the turbocompressor. If
not, replace the turbocompressor.
– If the measured supercharging pressure is OK, retest the su‐
percharging pressure with supercharging pressure control
functioning:
– Connector attached to the supercharging pressure control sol‐
enoid valve -N75- .

116 Rep. Gr. 21 - Charging


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

When the connector on the supercharging pressure control sol‐


enoid valve -N75- is detached faults are stored. Thus, consult the
fault memory and clear.

– Consult the fault memory: ⇒ Vehicle diagnosis, testing and in‐


formation system VAS 5051
– Attach the -V.A.G. 1551- ( -V.A.G.1552- ) and, with the corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be idling: ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051
Reading on the display:
Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and press Q tobyconfirm
Protected the entry.
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Reading on the display:
respect to the correctness of information in this document. Copyright by SEAT S.A.

Read measured value block


Enter value group number XXX

– Press 0 , 1 and 1 for the “display group number 11” and press
Q to confirm the entry.

Reading on the display:


Read measured value block 11 →
840 rpm 938 mbar 978 mbar 92 %

– Vehicle in 3rd gear and accelerate to full gas from approx.


1,500/min.
– At approx. 3,000 rpm press PRINT on the -V.A.G. 1551- .
Target value on the -V.A.G. 1551- : 1800...2200 mbar (in display
field 3).
Read measured value block 11 →
3090 rpm 1866 mbar 1917 mbar 62 %

If the target value is not reached:


– Test the supercharging pressure control solenoid valve -N75-
⇒ page 117 .
– Test the vacuum hoses ⇒ page 110 .

2.3.3 Test the supercharging pressure control


solenoid valve -N75-
– Switch off the ignition.

2. Supercharging system: test 117


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Remove the connector -2- from the supercharging pressure


control solenoid valve -N75- -1- .
– Measure the resistance between the valve contacts. Target
value: 25...45 Ω
If the target value is not reached:
– Replace the supercharging pressure control solenoid valve -
N75- .
If the target value is reached:
– Switch on the ignition.

– Test the voltage supply of the valve at the contact -1- of the
connector and earth engine. Target value: approx. battery
voltage
If the target value is not reached:
– Switch off the ignition.
– Remove the wiper arms and the air deflector: ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wipers Windscreen wipers:
removing and installing

– Attach test box -V.A.G. 1598/31- to the wiring harness of the


control unit without connecting the engine control unit.
– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram.
Contact 1 + female contacts 1 and 2
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Contact 3 + female contact 62
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires, to vehicle
earth and to battery positive.
Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the control unit of the direct diesel injection system -
J248- ⇒ page 157

118 Rep. Gr. 21 - Charging


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

23 – Mixture preparation, Injection


1 Direct diesel injection system: repair‐
ing
The direct diesel injection system control unit has a fault memory.
Before repairing or adjusting, and for the fault finding, consult the
fault memory and carry out the final control diagnosis ⇒ Vehicle
diagnosis, testing and information system VAS 5051 .

Note!

♦ When carrying out test and adjustment work, the control unit
can detect and store faults.
♦ Therefore, once all test and adjustment is finished, clear the
fault memory ⇒ Vehicle diagnosis, testing and information
system VAS 5051 .

1.1 Safety measures


If testing and measurement apparatusesby SEAT are to beS.Aused during aor accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised S.A. SEAT does not guarantee
road test, the followingrespect
must becorrectness
to the taken into account:
of information in this document. Copyright by SEAT S.A.

♦ Always install test and measurement equipment in the rear


seat to be operated from there by a second mechanic.
If test or measurement equipment is operated from the front pas‐
senger seat, the operator could be injured by the airbag in the
event of an accident.

Caution

The fault reader must be installed in the rear seat and operated
from there.

In order to avoid injury to persons and/or the damage to the pre-


heating and injection system the following rules must be ob‐
served:
♦ Detach and connect the wires of the pre-heating and injection
system, including the leads of the measurement equipment,
only with the ignition off.
♦ If the engine must be turned over at start-up revs without start‐
ing it, for example: to test the compression, remove the injec‐
tor-pump unit connector from the cylinder head.
♦ In the case of a radio with anti-theft coding, consult the code
before disconnecting the battery.
♦ The battery may only be disconnected or connected with the
ignition off; otherwise, the direct diesel injection system control
unit may be damaged.

1.2 Cleaning rules


For work on the fuel supply/injection system, the following “Clean‐
ing rules” must be rigorously observed:
♦ Thoroughly clean the connections and surrounding area be‐
fore loosening them.
♦ Place the parts removed on a clean surface and cover them.
Do not use cloths that shed fibres!

1. Direct diesel injection system: repairing 119


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ If repairs are not done immediately, the open components


must be covered and stored with great care.
♦ Only install clean components: Remove the replacement parts
from their packaging just before assembly. Do not install com‐
ponents that have been stored without packaging (e.g. in the
toolbox, etc.).
♦ When the system is open: If possible, avoid using compressed
air. If possible, do not move the vehicle.
♦ Avoid spilling diesel fuel on the coolant hoses. If necessary,
clean the hoses immediately. The affected hoses must be re‐
placed.

1.3 Location of components


The components from A to D do not appear in the exploded view.

A - Brake pedal switch -F47-


♦ In foot rest area, brake ped‐
al
B - Brake light switch -F-
♦ In foot rest area, brake ped‐
al
C - Accelerator pedal position
sender -G79-
♦ In foot rest area, accelera‐
tor pedal ⇒ page 87
D - Clutch pedal switch -F36-
♦ In foot rest area, clutch ped‐
al
1 - Fuel filter
2 - Air mass meter -G70- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
3 - Mechanical exhaust recir‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
culation valve
❑ With intake manifold
flap
4 - Direct diesel injection sys‐
tem control unit -J248-
❑ With altimetric sender -

120 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

F96-
❑ Replace ⇒ page 126
5 - Intake manifold flap switch-over valve -N239-
6 - Exhaust recirculation valve -N18-
7 - Turbocharging pressure limitation solenoid valve -N75-
8 - Coolant temperature sender -G62-
9 - Fuel temperature sender -G81-
10 - Connector
❑ For injector-pump unit -N240- ...243)
11 - Engine revs sender -G28-
12 - Connector
❑ For Hall sender -G40- , for camshaft position
13 - Connector
❑ For engine revs sender -G28-
14 - Hall sender -G40-
❑ For camshaft position
15 - Intake manifold pressure sender -G71- with temperature sender at the intake manifold -G72-

1.4 Intake manifold flap: repairing


The intake manifold flap closes for roughly 3 seconds during the
engine cut-out cycle and then opens again. In this way engine

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Direct diesel injection system: repairing 121


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

run-on is avoided. Test the switching of the intake manifold flap


⇒ page 126

1 - Intake manifold
2 - O-ring
❑ Replace
3 - Exhaust recirculation valve
4 - Air intake hole
❑ With exhaust recircula‐
tion valve and intake
manifold flap
5 - 10 Nm
6 - From the intercooler
7 - Gasket
❑ Replace
8 - Connecting line
❑ To the intake manifold
9 - 25 Nm
10 - 10 Nm
11 - Support
12 - Vacuum activator
13 - Intake manifold flap
switch-over valve
❑ Test ⇒ page 131
14 - Vacuum supply
❑ From the vacuum pump

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

122 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.5 Injector-pump unit: repairing

1 - 20 Nm and retighten 1/4


turn (90°)
2 - Rocker shaft
❑ With rockers
❑ Remove and install
⇒ page 125 , Injector-
pump unit: disassembly
and assembly
3 - Lock nut
4 - Adjustment bolt
❑ Replace in case of in‐
stalling a new injector-
pump unit, or if worn
❑ Apply -G 000 100- to the
contact surface with the
round-headed pin of the
injectorpump unit
5 - Injector-pump unit
❑ Check the round-head‐
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ed pin for wear; replace respect to the correctness of information in this document. Copyright by SEAT S.A.
it if necessary
❑ Apply -G 000 100- to the
contact surface with the
adjustment bolt
❑ Remove and install
⇒ page 125
6 - O-ring
❑ Replace ⇒ page 124
7 - O-ring
❑ Replace ⇒ page 124
8 - O-ring
❑ Replace ⇒ page 124
9 - Heat shield seal
❑ Replace
10 - Safety washer
11 - Cylinder head
12 - Fixing block
13 - 12 Nm + 3/4 turn (270°)
❑ Replace

1.6 O-rings for injector-pump unit: disas‐


sembly and assembly
Special tools and workshop equipment required

1. Direct diesel injection system: repairing 123


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Assembly sleeves -T10056-

1.6.1 Remove
– Remove used O-rings from the injector-pump unit very care‐
fully.
– Make sure not to create any burrs in the O-ring seats.

1.6.2 Assembly

Note!

♦ Always use the sleeves for fitting the O-rings. If they are not
used, the Orings may be damaged.
♦ Make sure that the O-rings are seated in the injector-pump unit
without twisting.

– Remove the heat shield seal along with the safety washer.
– Carefully clean the O-rings support surfaces in the injector-
pump unit.
– Fit assembly sleeve -T10056/1- all the way over the injector-
pump unit.
– Carefully slide the upper O-ring over the assembly sleeve and
into its seating on the injector-pump unit.
– Remove the assembly sleeve. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Fit assembly sleeve -T10056/2- all the way over the injector-
pump unit.
– Carefully slide the middle O-ring over the assembly sleeve and
into its seating on the injector-pump unit.
– Remove the assembly sleeve.

124 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Fit the assembly sleeve -T10056/3- all way over the injector-
pump unit.
– Carefully slide the lower O-ring over the assembly sleeve and
into its seating on the injector-pump unit.
– Remove the assembly sleeve.
– Fit a new heat shield sleeve along with the safety washer.

1.6.3 Installation
The already established work is carried out as follows:

Note!

Progressive introduction of O-rings without colour code. They


must be fitted in the correct order, following the grooves: the
thickness of the rings decreases the nearer they are to the injec‐
tor.

1.7 Pump-injector set: removing and installing

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Direct diesel injection system: repairing 125


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Universal dial gauge brack‐
et -T20020-
♦ Set of spanners -U-40020-
♦ Extractor -T10055-
♦ Torque spanner -SAT
8010-
♦ Straight edge positioner for
injector - pump -T20110A-

Note!

Due to the extension of the service intervals, the adjusting screws


have been modified -1- as well as the round head pin -2- of the
pumpinjector. In older engines that do not have these extended
service intervals, a mixed assembly is permitted in pre-modified
versions.

Note!
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Progressive introduction of pump-injector units with modified sol‐
respect to the correctness of information in this document. Copyright by SEAT S.A.
enoid valve nut. Mixed assembly of both nuts is permitted.

126 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.7.1 Pump-injector set with pre solenoid


valve nut
– Pump-injector set with pre solenoid nut
Place the pump-injector independently of the solenoid valve nut
model so that it is perpendicular to the camshaft seatings, to do
this continue as follows:
– To install the pump-injector including both models of the sol‐
enoid valve nut , place rule -T20110- so that the corresponding
centering projection can go no further into the cylinder head
(see figure).

– Fit centraliser -T20110A/3- by the widest end and move the


pump-injector until the cylindrical part of the injector nut can
go no further into the centraliser.
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.7.2 Pump-injector unit with new solenoid


valve nut
– Pump-injector unit with new solenoid valve nut
Place the pump-injector independently of the solenoid valve nut
model so that it is perpendicular to the camshaft seatings, to do
this continue as follows:
– To install the pump-injector including both models of the sol‐
enoid valve nut , place rule -T20110- so that the corresponding
centering projection can go no further into the cylinder head
(see figure).

– Fit centraliser -T20110A/3- by the thinnest end and move the


pump-injector until the cylindrical part of the injector nut can
go no further into the centraliser.

1. Direct diesel injection system: repairing 127


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.7.3 Continue for both models of pump-injec‐


tor unit
– If necessary, re-adjust the pump-injector and tighten the fixing
screw as follows: 12 Nm and 270° (3/4 turn) (the tightening
process can be carried out in various stages)
– Fit the rocker arm shaft and tighten the fixing screws as fol‐
lows.
– Uniformally tighten the internal, then the external screws, by
hand. Next, and in the same order, tighten to 20 Nm and ¼
turn (90°).

1.7.4 Remove
– Remove the upper toothed belt shield and the cylinder head
cover.
– Turn the crankshaft over until the pair of injector-pump unit
cams to be removed and fitted points uniformly upwards.
– Loosen the lock nuts on the adjustment bolts -1- and unscrew
the adjustment bolts until the respective rocker rests on the
push spring of the injector-pump unit.
– With corresponding box spanner from spanner set -U-40020- ,
loosen the bolts -2- that hold the rocker shaft, beginning with
the outer ones and working inwards, and remove the rocker
shaft.
– With corresponding box spanner from spanner set -U-40020- ,
loosen the bolt -3- holding the fixing block, and remove the
block.
– Lever out the injector-pump unit connector with a screwdriver.
To avoid bending it, support the opposite side of the connector
with your finger.
– Check that each cylinder has its corresponding injector-pump
unit.

– Instead of the fixing block, fit extractor -T10055- into the side
slot of the injector-pump unit.
– Carefully remove the injector-pump unit from its seating in the
cylinder head (upwards) with soft taps.

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respect to the correctness of information in this document. Copyright by SEAT S.A.

128 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.7.5 Assembly

Note!

♦ If fitting a new injector-pump unit, the corresponding adjust‐


ment bolt on the rocker must also be replaced.
♦ Any time work requiring adjustment of the injector-pump unit
is carried out, clean the adjustment bolt on the rocker and the
round-headed pin on the injector-pump unit, also checking for
wear. If worn, the round-headed pin and the adjustment bolt
must be replaced.
♦ Apply -G 000 100- to the contact surfaces between the round-
headed pin and the adjustment bolt.
♦ New injector-pump units are supplied with their own O-rings
and heat shield seal.

– If the used injector-pump unit is refitted, replace the O-rings


and the heat shield seal ⇒ page 123 .
– Before assembly of the injector-pump unit, check the three
seals, the heat shield seal and the safety washer for correct
seating.

Note!

The seals must not be bent.


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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Oil the seals and fit the injector-pump unit very
respect to the correctness carefully
of information in document.
in this its Copyright by SEAT S.A.
seating in the cylinder head.
– Pressing uniformly, seat the injector-pump unit all the way on
to the cylinder head.
– Fit the fixing block in the side slot of the injector-pump unit.

Note!

If the injector-pump unit is not perpendicular to the fixing block,


the fixing bolt may come loose, and this could result in damage
to the injector-pump unit or the cylinder head.

– Therefore, the injector-pump unit must be fitted as follows.


– Screw the new bolt into the fixing block until the injector-pump
unit can still be turned slightly.
– Fit a dial gauge over the injector-pump unit cam as shown in
the illustration.
– Turn the crankshaft in direct of engine turn-over until the rocker
roller is at the point of the activator cam. Side of the roller
-arrow A- is at the highest point. Dial gauge -arrow B- is at the
lowest point.
– Remove the dial gauge.
– Screw the adjustment bolt into the rocker until you feel clear
resistance (injector-pump component is at stop).

1. Direct diesel injection system: repairing 129


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Unscrew the adjustment bolt. 225° from the stop.


– Hold the adjustment bolt in this position and tighten the lock
nut to a torque of 30 Nm.
– Attach the connector of the injector-pump unit and fit the cyl‐
inder head cover and the toothed belt shield.

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

130 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2 Components and functions: testing

2.1 Voltage supply of the direct diesel injec‐


tion system: testing
Special tools and workshop equipment required
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.1.1 Test condition


• Battery voltage, OK (at least 11.5 V).

2.1.2 Test process


– Switch off the ignition.
– Attach the test box -V.A.G. 1598/31- to the wiring harness and
to the control unit.
– Measure the voltage between the followings female contacts:
1/2 and 4/5 37 and 4/5 Target value: approx. 0 V
– Switch on the ignition.
– Measure the voltage between the female contacts again: 1/2
and 4/5 37 and 4/5 Target value: approx. battery voltage
If the target values are not reached:
– Test the voltage supply relay terminal 30 -J317- .
– Test the wiring for open circuits, short circuits and pitch resis‐
tances at the contact points, following the wiring diagram.
If no faults are found in the wiring or in the relay:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126
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2.2 Engine revs sender: testing


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

The engine revs sender depends on revolutions and the reference


mark. The engine cuts out in the event of a fault in the sender.
Special tools and workshop equipment required
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.2.1 Test process


– Switch off the ignition.

2. Components and functions: testing 131


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Detach the grey connector from the engine revs sender -1- .

– Attach the hand-held multimeter -V.A.G. 1526- (measurement


of resistance) at contacts 1 and 2 of the engine revs sender
connector, using the test lead of the -V.A.G. 1594 A- or -V.A.G.
1594 C- . Target value: approx. 450...550 Ω
If the target value is not reached:
– Replace the engine revs sender -G28- . ⇒ page 8
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

If the target value is reached:


– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the control unit.

– Test for open circuits in the wiring between the test box and
the triple connector, following the wiring diagram. Contact 1 +
female contact 110 Contact 2 + female contact 102 Contact 3
+ female contact 102 Wiring resistance: 1.5 Ω max.
– Test for short circuit in the wiring of the triple connector, fol‐
lowing the wiring diagram. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

2.3 Intake manifold pressure sender and al‐


timetric sender: testing
The altimetric sender is housed in the direct diesel injection sys‐
tem control unit. The intake manifold pressure sender is a sepa‐
rate component. This sender and the intake manifold temperature
sender are found together in a housing at the intake manifold.
Special tools and workshop equipment required

132 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.


1552- with lead -V.A.G. 1551/3B-
♦ Turbocompressor tester -V.A.G. 1397 A-

♦ Test box -V.A.G. 1598/31-


♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.3.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with the cor‐
responding “address code” 01, select the engine electronics
control unit. When doing so, the ignition must be on. (Fault
reader: connecting and selecting the engine electronics con‐
trol unit ⇒ Vehicle diagnosis, testing and information system
VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 1 and 0 for “Display group number 10” and confirm


the entry with the Q button.
Read measured value block 10 →
0 mg/stroke 1027 mbar 1013 mbar 0.0 %

– Test the values shown in fields 2 (altimetric sender -F96- ) and


3 ( intake manifold pressure sender -G71- ) and in the turbo‐
compressor tester -V.A.G. 1397/A- Target value: the pres‐
sures must coincide (tolerance of ± 30 mbar)

Note!

The turbocompressor tester is needed for obtaining an independ‐


ent comparative value. The turbocompressor tester must be set
to measurement range I (absolute pressure). In its place a bar‐
ometer may also be used.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The value displayed in field 2 differs: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.

2. Components and functions: testing 133


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Switch off the ignition.


– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .
If the value displayed in field 3 differs:
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Start the engine and select again the function 08 “Read meas‐
ured value block” .
– Press 0 , 1 and 0 for “Display group number 10” and confirm
the entry with the Q button.
– Detach the connector from the intake manifold pressure send‐
er ⇒ page 120
– Check the value in display field 3 (intake manifold pressure
sender).
Read measured value block 10 →
515 mg/stroke1,009 mbar 1,009 mbar 0.0 %

– It should descend continually and then adopt the value of the


altimetric sender (display field 2).
If the target value is reached:
– Replace the intake manifold pressure sender with the temper‐
ature sender on the intake manifold.
If the target value is not reached:
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Switch off the ignition.
– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the control unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram. Contact 3 + fe‐
male contact 31 Contact 4 + female contact 71 Wiring resist‐
ance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

134 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.4 Coolant temperature sender: testing


Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.4.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 7 for the “Display group number 7” and con‐


firm the entry with the Q button.
Reading on the display: Read measured value block 7 →
15.4 °C 0% 15.9 °C 16.7 °C

– Watch the coolant temperature value in display field 4. The


value should rise uniformly without interruption.
– In the event of a fault, as supplementary values either the fuel
temperature or the value of -5.4 °C is displayed.
– If no realistic reading is displayed in field 4 or if the fuel tem‐
perature or -5.4 °C is displayed as a supplementary value, test
the coolant temperature sender and the wiring to the sender,
as follows:
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Switch off the ignition.
– Remove the connector from the sender Location of compo‐
nents, ⇒ page 120

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Components and functions: testing 135


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Measure the resistance between contacts 1 + 3 on the sender.

Target value: see diagram


Zone A indicates the resistance values for the temperature range
0...50 °C, and zone B the values for the temperature range
50...100 °C.
Examples:
♦ 30 °C corresponds to a resistance of 1,500...2,000 Ω
♦ 80 °C corresponds to a resistance of 275...375 Ω
If the target value is not reached:
– Replace the coolant temperature sender -G62- .
If the target value is reached:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Attach the test box -V.A.G. 1598/31- to the wiring harness
respect to theof
correctness of information in this document. Copyright by SEAT S.A.
the control unit.

– Test for open circuits in the wiring between the test box and
the 4-contact connector, following the wiring diagram. Contact
3 + female contact 112 Contact 4 + female contact 104 Wiring
resistance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

2.5 Brake light and brake pedal switches:


testing
As the injection system works with a accelerator pedal sender
(potentiometer), which can be faulty, for safety reasons, engine
supply is cut off when the brakes are applied. For this reason, the
control unit needs both the signal from the brake light switch and
the signal from the brake pedal switch. This means that if the

136 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

brakes are applied while depressing the accelerator, the engine


supply is immediately cut to idling revs. If the switches are mal‐
adjusted involuntary supply cuts may occur.
Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.5.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, via the corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the ignition must be on. (Fault
reader: connecting and selecting the engine electronics con‐
trol unit ⇒ Vehicle diagnosis, testing and information system
VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 6 for “Display group number 06” and confirm


the entry with the Q button.
Read measured value block 6 →
0 km/h 0 0 0 0.0 % 255

– Watch the value displayed in field 2. Target value: 0 0 0


– Slowly apply the brakes.
Target value: 0 1 1 The two digits should change simultaneously Read measured value block 6 →
from 0 to 1. 0 km/h 0 1 1 0.0 % 255

♦ middle value = brake pedal switch


♦ right-hand value = brake light switch
– Slowly release pressure on brake pedal.
Both digits should change back from 1 to 0. Read measured value block 6 →
0 km/h 0 0 0 0.0 % 255

If one or both digits do not change:


– Test the switches or the wiring to the switches: ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations

2.6 Clutch pedal switch: testing


The clutch
Protected pedalCopying
by copyright. switch for informs the control
private or commercial unit
purposes, of or
in part the clutch
in whole, is notsit‐
uation.unless
permitted When the by
authorised clutch is depressed
SEAT S.A. SEAT S.A does not injection flow
guarantee or isany
accept briefly
liability with
reduced.
respect This avoids rough
to the correctness engine
of information performance.
in this document. Copyright by SEAT S.A.

Special tools and workshop equipment required


♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-

2. Components and functions: testing 137


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Test box -V.A.G. 1598/31-


♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.6.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with the cor‐
responding “address code” 01, select the engine electronics
control unit. When doing so, the ignition must be on. (Fault
reader: connecting and selecting the engine electronics con‐
trol unit ⇒ Vehicle diagnosis, testing and information system
VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 Protected


for thebyfunction “Readformeasured
copyright. Copying valuepurposes,
private or commercial block”in part or in whole, is not
and confirm the entryunless
permitted the Q bybutton.
withauthorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 6 for “Display group number 6” and confirm


the entry with the Q button.
Read measured value block 6 →
0 km/h 0 0 0 0.0 % 255

– Watch the value displayed in field 2. Target value: 0 0 0


Read measured value block 6 →
0 km/h 1 0 0 0.0 % 255

– Depress the clutch pedal. The left-hand digit should change to


1. Target value: 1 0 0
If the target values are not reached:
– Press → .
– Press 0 and 6 for the function “End data transmission” and
confirm the entry with the Q button.
– Switch off the ignition.
– Remove the clutch pedal switch connector Location of com‐
ponents, ⇒ page 120 .
– Measure the resistance at the switch contacts. Target value
Clutch without depressing: 10 Ω max. Clutch depressed: ∞ Ω
If the target values are not reached:
– Replace the clutch pedal switch -F36- .
If the target values are reached:

138 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Attach the test box -V.A.G. 1598/31- to the wiring harness of


the control unit.

– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram. Contact 1 + fe‐
male contact 1 Contact 1 + female contact 2 Contact 2 +
female contact 66 Wiring resistance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

2.7 Intake manifold temperature sender:


testing
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.7.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 7 for the “Display group number 7” and con‐


firm the entry with the Q button.
Reading on the display: Read measured value block 7 →
15.4 °C 0 % 15.9 °C 16,7 °C

2. Components and functions: testing 139


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– If no realistic reading or a supplementary temperature of 135.9


°C is shown in field 3, test the intake manifold temperature
sender and the wiring to the sender, as follows:
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Switch off the ignition.
– Remove the connector from the sender Location of compo‐
nents, ⇒ page 120
– Measure the resistance between sender contacts 1 + 2.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Target value: see diagram


Zone A indicates the resistance values for the temperature range
0...50 °C, and zone B the values for the temperature range
50...100 °C.
Examples:
♦ 30 °C corresponds to a resistance of 1500...2000 Ω
♦ 80 °C corresponds to a resistance of 275...375 Ω
If the target value is not reached:
– Replace the intake manifold temperature sender -G72- .
If the target value is reached:

– Attach the test box -V.A.G. 1598/31- to the wiring harness of


the control unit.

140 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram. Contact 1 + fe‐
male contact 52 Contact 2 + female contact 73 Wiring resist‐
ance: 1.5 Ω max.
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

2.8 Temperature sender fuel: testing


Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Fault reader -V.A.G. 1551- or vehicle systems tester
respect -V.A.G. of information in this document. Copyright by SEAT S.A.
to the correctness
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.8.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 7 for the “Display group number 7” and con‐


firm the entry with the Q button.
Reading on the display: Read measured value block 7 →
15.4 °C 15.9 °C 16,7 °C

– If no realistic reading or a supplementary temperature of -5.4


°C is displayed in field 1, test the fuel temperature sender and
the wiring to the sender, as follows:
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Switch off the ignition.
– Remove the connector from the fuel temperature sender Lo‐
cation of components, ⇒ page 120
– Measure the resistance between sender contacts 1 + 2.

2. Components and functions: testing 141


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Target value: see diagram


Zone A indicates the resistance values for the temperature range
0...65 °C, and zone B the values for the temperature range
65...100 °C.
Examples:
♦ 30 °C corresponds to a resistance of 3,790...4,270 Ω
♦ 80 °C corresponds to a resistance of 600...660 Ω
If the target value is not reached:
– Replace the fuel temperature sender.
If the target value is reached:

– Attach the test box -V.A.G. 1598/31- to the wiring harness of


the control unit.
– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram. Contact 1 + fe‐
male contact 103 Contact 2 + female contact 111 Wiring
resistance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

2.9 Air mass meter: testing


The control unit needs the signal from the air mass meter to cal‐
culate the admissible injection flow and to regulate exhaust recir‐
culation. The lower the signal from the air mass meter, the lower
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
the quantity of fuel injected.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.9.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)

142 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Caution

The fault reader must be installed in the rear seat and operated
from there.

Reading on the display: Rapid data transmission HELP


Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 1 and 0 for “Display group number 10” and confirm


the entry with the Q button.
Read measured value block 10 →
209 mg/stroke 1027 mbar 1011 mbar 0.0 %

– Watch the reading in field 1.


Target value: 200...320 mg/stroke
If the target value is not reached:
– Test the exhaust recirculation: ⇒ page 160
If the target value is reached:
– Accelerate the vehicle to full gas from approx. 1,500/min
– At approx. 3,000/min press PRINT on the -V.A.G. 1551- . The
accelerator pedal should be floored at this point.
Read measured value block 10 →
830 mg/stroke 1027 mbar 1850 mbar 100 %

– Target value in display field 4: 100 % (accelerator position).


If the target value is not reached:
– Repeat the test and accelerate the vehicle to full gas.
Read measured value block 10 →
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is830
not mg/stroke 1027 mbar 1850 mbar 100 %
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Target value in display field 1 (intake air mass): over 700 mg/
respect to the correctness of information in this document. Copyright by SEAT S.A.

stroke.
If the target value is not reached:
– Replace the air mass meter.
If a constant value of 539 mg/stroke (fixed supplementary value)
is shown in display field 1:
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Switch off the ignition.
– Detach the air mass meter connector Location of components,
⇒ page 120
– Switch on the ignition.

2. Components and functions: testing 143


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Measure the voltage supply of the air mass meter between the
following connector contacts:
Connector in - Target value
G70- Contact
2 + earth approx. battery
voltage
2+3 approx. battery
voltage
4 + earth approx. 5 V
4+3 approx. 5 V
If the target value is not reached:
– Switch off the ignition.

– Attach the test box -V.A.G. 1598/31- to the wiring harness of


the control unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram. Contact 2 + fe‐
male contacts 1 and 2 Contact 3 + female contact 49 Contact
4 + female contact 30 Contact 5 + female contact 68 Wiring
resistance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

2.10 Intake manifold flap switch-over: testing


Special tools and workshop equipment required
♦ Manual vacuum pump -SAT 1390-
♦ Test box -V.A.G. 1598/31-

144 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.


1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.10.1 Test the functioning


– Start the engine and run it at idling revs.
– Switch off the ignition.
– Watch the control lever on the intake manifold flap (a second
person is needed).
– The intake manifold flap should close when the ignition is
switched off and open again after roughly 3 seconds.
If switch-over does not occur, check the following:
– Check that the intake manifold flap switch-over mechanism
works smoothly, operating the linkage by hand.
– Test the functioning of the vacuum activator with manual vac‐
uum pump -SAT 1390- .
– Test that the vacuum lines are correctly connected.
If no fault is found in the components mechanics:
– Test the intake manifold flap switch-over valve.

2.10.2 Test process


– Remove the connector from the intake manifold flap switch-
over valve -N239- Location of components, ⇒ page 120
– Measure the resistance between the contacts of the switch-
over valve: Target value: 25...45 Ω
If the target value is not reached:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Replace the intake manifold flap switch-over valve.
respect to the correctness of information in this document. Copyright by SEAT S.A.

If the target value is reached:

– Change the multimeter to voltage measurement and connect


it at contacts 1 + 2 of the detached connector of the intake
manifold flap switch-over valve.
– Start the engine and run it at idling revs. Target value: battery
voltage
– Switch off the ignition.
– After roughly three seconds the voltage value should fall to 0
V.
If the voltage value does not vary as described:

2. Components and functions: testing 145


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Attach the test box -V.A.G. 1598/31- to the wiring harness of


the control unit.

– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram. Contact 1 + fe‐
male contacts 1 and 2 Contact 2 + female contact 81 Wiring
resistance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
If no fault is found in the wiring:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

2.11 Injector-pump unit valves: testing


Special tools and workshop equipment requiredProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
respect to the correctness of information in this document. Copyright by SEAT S.A.

1552- with lead -V.A.G. 1551/3B-


♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.11.1 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, via the corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)

Note!

If the engine will not start, test the resistances of the injector-pump
valves ⇒ page 126 .

Reading on the display: Rapid data transmission HELP


Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

146 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Press 0 , 1 and 8 for “Display group number 18” and confirm


the entry with the Q button.
Reading on the display: Read measured value block 18
0 0 0

– “0” (regulation OK) should appear in the 3 display fields.


If another number appears instead of 0:
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Switch off the ignition.
– Test the resistances of the injector-pump valves ⇒ page 126 .

2.11.2 Test the resistances of the injector-


pump valves
– Detach the connector from the injector-pump
Protected unitforatprivate
by copyright. Copying the cylin‐
or commercial purposes, in part or in whole, is not
der head side Location of components, ⇒ page 120
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Test the resistance of the injector-pump valves between the


connector contacts cyl. 1: contact 6 + 3 cyl. 2: contact 6 +5 cyl.
3: contact 6 + 2 Target value: approx. 0.5 Ω
– Also test the wiring for short circuits between wires or vehicle
earth. Target value: ∞ Ω
If the target value is reached:
– Following the wiring diagram, test the wiring to the control unit
⇒ page 146 .
If the target value is not reached:
– Remove the upper toothed belt shield and the cylinder head
cover.
– Lever the connectors out from the 3 injector-pump units with
a screwdriver. To avoid bending, support the opposite side of
the connector with your finger.
– Test the resistance of the injector-pump valves between the
injector-pump valve contacts Target value: approx. 0.5 Ω
If the target value is not reached:
– Replace the faulty injector-pump unit ⇒ page 125
If the target value is reached:

– Test for open circuits in the wiring from the injector-pump unit
connector to the 3 connectors (contact 2). cyl. 1: contact 2
(grey) + contact 3 cyl. 2: contact 2 (red) + contact 5 cyl. 3:
contact 2 (yellow) + contact 2 Wiring resistance: 1.5 Ω max.
– Test for open circuits in the wiring from the injector-pump unit
connector to the 3 connectors (contact 1). Contact 1 (brown)
+ contact 6 Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires. Target
value: ∞ Ω

2. Components and functions: testing 147


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

2.11.3 Test the wiring to the control unit


– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the control unit.

– Following the wiring diagram, test the wiring between the test
box and the connector for open circuits. Contact 6 + female
contact 114 Contact 3 + female contact 116 Contact 5 + female
contact 118 Contact 2 + female contact 121 Wiring resistance:
1.5 Ω max.
– Also, test the wiring for short circuits between wires, to vehicle
earth and to positive battery.
ProtectedTarget value:
by copyright. ∞ for
Copying Ωprivate or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
If no fault is found in the wiring:
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Replace the direct diesel injection system control unit -J248-


⇒ page 126 .

2.12 Hall camshaft position sender: testing


Special tools and workshop equipment required
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

2.12.1 Test condition


• Fuses 23 and 37, OK

2.12.2 Test process


– Remove the 3-contact connector from the Hall sender Loca‐
tion of components, ⇒ page 120
– Set the multimeter for voltage measurement and connect it to
contacts 1 (positive) and 3 (earth) of the Hall sender connec‐
tor, using the auxiliary leads of the -V.A.G. 1594 A- or -V.A.G.
1594 C- .
– Switch on the ignition. Target value: battery voltage
– Switch off the ignition.
If there is no voltage:

148 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Attach the test box -V.A.G. 1598/31- to the wiring harness of


the control unit.

– Test for open circuits in the wiring between the test box and
the triple connector, following the wiring diagram. Contact 1 +
female contacts 1 and 2 Contact 2 + female contact 109 Con‐
tact 3 + female contact 101 Wiring resistance: 1.5 Ω max.
– Also test for short circuits between wires, to vehicle earth and
to positive battery. Target value: ∞ Ω
If no fault is found in the wiring and there was voltage between
contacts 1 + 3:
– Replace the Hall sender -G40- ⇒ page 35
If no fault is found in the wiring and there was no voltage between
contacts 1 + 3:
– Replace the direct diesel injection system control unit -J248-
⇒ page 126 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Components and functions: testing 149


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

3 Supplementary signals: testing

3.1 Speed signal: testing


Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Diode test lamp -V.A.G. 1527-
♦ Wiring diagram

3.1.1 Test condition


• Speedometer OK, test: ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051

Note!

To test the speed signal, the vehicle must be moving and the help
of another person is required.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Caution

The fault reader must be installed in the rear seat and operated
from there.

3.1.2 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.
Reading on the display: Read measured value block
Enter value group number XXX

– Press 0 , 0 and 6 for “Display group number” and confirm the


entry with the Q button.
– Do a road test, and compare the reading on the display (a
second person is needed) with the reading on the speedom‐
eter.
Target value, display field 1: approx. running speed. Read measured value block 6 →
55 km/h 0 0 0 60.5 % 255

– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.

150 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

If no speed is indicated:
– Switch off the ignition.
– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the control unit.
– To measure the voltage attach the multimeter between female
contacts 4/5 + 20 of the test box.
– Switch on the ignition.
– Raise the vehicle at the left front.
– Turn the front wheel and watch the voltage reading. Target
value: oscillating between 0 and at least 10 volts
– If the value displayed does not oscillate:
– Test for open circuits or short circuits in the wiring from contact
20 of the engine control unit connector, to the instrument pan‐
el. ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations

3.2 Signals from/to air conditioning: testing


Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C-
♦ Wiring diagram

3.2.1 Test conditions


• Functioning of the air conditioning, OK.
• The fault memory must be cleared of all faults ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051 , Fault
memory: consulting
• The vehicle must be at ambient temperature (over + 15 °C).
• Air conditioning on.

3.2.2 Test air conditioning compressor cut-out


Via the AC ready signal, the engine control unit receives the in‐
formation that the air conditioning compressor will soon be acti‐
vated.
Via another wired connection, the engine control unit can cut out
the air conditioning compressor under various operating condi‐
tions:
♦ Hard acceleration at low speeds
♦ In the emergency programme (emergency running mode)
♦ If the coolant temperature is over +120 °C
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ During roughly 6s after each start-up respect to the correctness of information in this document. Copyright by SEAT S.A.

3.2.3 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at

3. Supplementary signals: testing 151


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

idling revs. (Fault reader: connecting and selecting the engine


electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 3 for the function “Final control diagnosis” .


Reading on the display: Rapid data transmission Q
03 - Final control diagnosis

– Confirm the entry with the Q button.


Reading on the display: Final control component diagnosis →
Exhaust recirculation valve -N18

– Press → .
Reading on the display: Final control component diagnosis →
Air conditioning compressor, ready

Air conditioning compressor cut-out is tested.


The air conditioning compressor should cut out within 5 s (visual
check), and then start up every 5 s and cut out again.
If the air conditioning compressor does not cut out:
– Continue the final control diagnosis to the end.
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach the test box -V.A.G. 1598/31- topermitted
the respect
wiring harness of
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

the control unit.


to the correctness of information in this document. Copyright by SEAT S.A.

– Test for open circuits in the wiring between test box female
contact 29 and the air conditioning, following the wiring dia‐
gram. Wiring resistance: 1.5 Ω max. ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations

3.2.4 Test the signal from the air conditioning


for the adaptation of engine revs
The signal makes the engine control unit hold idling revs constant,
even when the air conditioning system demands a power supply
of a different magnitude.

3.2.5 Test process


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be running at
idling revs. (Fault reader: connecting and selecting the engine
electronics control unit ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .)
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 8 for the function “Read measured value block”


and confirm the entry with the Q button.

152 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Reading on the display: Read measured value block


Enter value group number XXX

– Press 0 , 0 and 2 for “Display group number 2” and confirm


the entry with the Q button.
Reading on the display: (1...4 = display fields) Read measured value block 2 →
1 2 3 4

– Watch the value in the field 3. The air conditioning should not
be on.
Target value: 0 X 0 (air conditioning signal) Read measured value block 2 →
1 2 010 4

– Switch on the air conditioning. According to the air conditioning


version, the “AC” must be pressed in the case of a manual
climate system or the “Auto” button in the case of automatic
climate control (Climatronic).
– Select the lowest temperature and the highest blower speed.
The compressor should come on.
– Watch the value in field 3.
Target value: X X 1 (air conditioning signal) Read measured value block 2 →
1 2 111 4

Target value: 1 X X (high idling revs)


Meaning if digits = 1
X X X Engine load
state
1 Air condition‐
ing compres‐
sor, on
1 Idle switch, off
1 Idling revs high
due to activa‐
tion of the air
conditioning
If the target values are not reached:
– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the control unit.
– Test for open circuits in the wiring between test box female
contact 34 and the air conditioning, following the wiring dia‐
gram. Wiring resistance: 1.5 Ω max. ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

3.3 Rev signal: testing


permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

The signal generated by the engine revs sender cannot be ana‐


lysed in its original form, and the engine control unit must adapt
it for posterior applications. The signal is needed for, for example,
the automatic gearbox control unit to calculate when to shift
gears, and the rev counter in the instrument panel.
Special tools and workshop equipment required
♦ Test box -V.A.G. 1598/31-

3. Supplementary signals: testing 153


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594


C-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Wiring diagram

3.3.1 Test process


– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the control unit.
– Following the wiring diagram, test the wiring from contact 27
of the test box to the instrument panel for open circuits. ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations

3.4 Data bus: testing

3.4.1 Functioning
The engine control unit communicates with the ABS control unit
via a data bus CAN.
These control units, designed for data bus, are interconnected by
means of two data bus wires twisted round each other (CAN_High
and CAN_Low) and interchange information (messages). The
lack of information in the data bus is interpreted as a fault by the
engine control unit and by the ABS control unit, interconnected
via the data bus CAN.
In order to function without static problems, the data bus CAN
needs the control units in front of the bus CAN controller to have
a matching resistor of 120 Ω each. These matching resistors are
found at the control units of the engine and of the ABS.
Special tools and workshop equipment required
♦ Test box -V.A.G. 1598/21-
♦ Test box -V.A.G. 1598/31-
♦ Hand-held multimeter -V.A.G. 1526- or multimeter -V.A.G.
1715-
♦ Auxiliary measurement set -V.A.G. 1594 A- or -V.A.G. 1594
C- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Wiring diagram respect to the correctness of information in this document. Copyright by SEAT S.A.

3.4.2 Test conditions


• Consult the fault memory before starting the test. Automatic
test cycle ⇒ Vehicle diagnosis, testing and information system
VAS 5051 .
• A fault has been found in the data bus CAN by means of self-
diagnosis.
• ABS control unit coded to function with data bus.

154 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

3.4.3 Test process


– Switch off the ignition.
– Remove the wiper arms and the air deflector: ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wipers; Windscreen wipers:
disassembly and assembly
– Free the connectors of the engine control unit and remove
them.
– Attach the test box -V.A.G. 1598/31- to the wiring harness of
the engine control unit.
– Test the data bus CAN wiring with the matching resistor in‐
corporated in the ABS control unit.
– To do so, measure the resistance between female contacts 6
+ 7 of the test box: Target value: 2.2...2.8 KΩ
If the resistance value is within the tolerance range ⇒ page 154

3.4.4 If the resistance value is outside the tol‐


erance range:
– Free the terminal connector (arrow -1- ) of the ABS control unit
and remove it (arrow -2- ).

Note!

The ABS control unit is located in the hydraulic unit, in the engine
compartment.

– Test the data bus CAN wiring for short circuits between wires:
– To do so, re-measure the resistance between female contacts
6 + 7 of the test box Target value: ∞ Ω
If the target value is not reached (the wiring has a short circuit
between wired):
– Eliminate the wiring fault following the wiring diagram: ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
If the target value is reached (theunless
wiring has bynoSEAT
shortS.A. circuit
SEAT S.Abe‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised does not guarantee or accept any liability with
tween wires): respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Supplementary signals: testing 155


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Attach test box -V.A.G. 1598/21- to the wiring harness of the


ABS control unit.
– Following the wiring diagram, test the data bus CAN wiring
between the female contacts of test box -V.A.G. 1598/21- and
-V.A.G. 1598/31- for open circuits:
-V.A.G. -V.A.G.
1598/21- 1598/31-
female contact female contact
10 female con‐ 6 female con‐
tact 11 tact 7
Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits to positive, battery and
earth.
If no fault is found in the wiring:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Replace the ABS control unit:
respect⇒ Brake
to the systems;
correctness Rep.in this
of information Gr.document.
45 ; Copyright by SEAT S.A.
Control unit and hydraulic unit: disassembly and assembly

3.4.5 If the resistance is within the tolerance


range:
– Free the terminal connector (arrow -1- ) of the ABS control unit
and remove it (arrow -2- ).

Note!

The ABS control unit is located in the hydraulic unit, in the engine
compartment.

– Test the wiring between the control units of the engine and of
the ABS for short circuits to earth and short circuits to positive.
If no fault is found in the wiring:
– Re-attach the connectors in the engine control unit.
– Attach test box -V.A.G. 1598/21- to the wiring harness of the
ABS control unit.
– Test the matching resistor incorporated in the engine control
unit:
– To do so, measure the resistance between female contacts 10
+ 11 of the test box: Target value: 60...72 Ω
If the resistance value is not within the tolerance range:
– Replace the engine control unit ⇒ page 126

156 Rep. Gr. 23 - Mixture preparation, Injection


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

4 Engine control unit: replacing, encod‐


ing and adapting

4.1 Engine control unit: replacing


Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- with lead -V.A.G. 1551/3B-

4.1.1 Operation sequences


– First, print out the control unit identification and, with it, the
code for the previous control unit, as follows:
– Attach fault reader -V.A.G. 1551- ( -V.A.G. 1552- ) and, via the
corresponding “address code” 01, select the engine electron‐
ics control unit. (Fault reader: connecting and selecting the
engine electronics control unit ⇒ Vehicle diagnosis, testing
and information system VAS 5051 .)
The control unit encoding is shown on the display of fault reader 045906019M 1.4l R3 EDC 0000SG 1043 →
-V.A.G. 1551- , for example: Encode 00002 WSC XXXXX

– Print out the control unit identification pressing Print on the


fault reader.
– Press → .
– Press 0 and 6 for the function “End transmission” and confirm
the entry with the Q button.
– Switch off the ignition.
– Remove the wiper arms and the air deflector: ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wipers Windscreen wipers:
disassembly
Protected and assembly
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Free the connectors from the
respect to the correctness control inunit
of information and remove
this document. Copyrightthem.
by SEAT S.A.

– Remove the control unit from its support -arrows- .


– Install the new control unit.
– Check the previous code and encode the new control unit
⇒ page 126 .
– Adapt the engine control unit to the electronic immobiliser
⇒ page 126 .
– Finally, consult the fault memory of the new engine control unit
and, if necessary, clear the fault memory ⇒ Vehicle diagnosis,
testing and information system VAS 5051 .

4.2 Engine control unit: encoding


If the code corresponding to the vehicle is not displayed, and after
replacing a control unit, encode the control unit as follows:
Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-

4.2.1 Operation sequences


– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, via the corre‐
sponding “address code” 01, select the engine electronics
control unit. When doing so, the ignition must be on. (Fault
reader: connecting and selecting the engine electronics con‐

4. Engine control unit: replacing, encoding and adapting 157


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

trol unit ⇒ Vehicle diagnosis, testing and information system


VAS 5051 .)
– Press → .
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 7 for the function “Encode the control unit” and
confirm the entry with the Q button.
Reading on the display: Encode the control unit Q
Enter code XXXXX (0-32000)

– Enter the code corresponding to the vehicle and confirm the


entry with the Q button.

Code Vehicles with


00001 Automatic
gearbox
00002 Manual gear‐
box
00003 Cycle foreseen
in event of col‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
lision and data respect to the correctness of information in this document. Copyright by SEAT S.A.
bus CAN Man‐
ual gearbox
and ABS
00005 Without data
bus CAN
The control unit encoding is shown on the display of fault reader 045906019M 1.4l R3 EDC 0000SG 1043 →
-V.A.G. 1551- , for example: Encode 00002 WSC XXXXX

– Switch off the ignition and switch it on again.

Note!

In switching the ignition off and on again, the encoding entered is


activated. If the ignition is not switched off and on after entering
the valid code, the fault “control unit, Incorrect encoding” cannot
be cleared.

Adapt the engine control unit to the electronic immobiliser


⇒ page 126 .
– Clear the fault memory ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051 .

4.3 Engine control unit: adapting to the elec‐


tronic immobiliser
Special tools and workshop equipment required
♦ Fault reader -V.A.G. 1551- or vehicle systems tester -V.A.G.
1552- with lead -V.A.G. 1551/3B-

4.3.1 Test condition


• An authorised key is needed

4.3.2 Operation sequences


– Attach fault reader -V.A.G. 1551- or systems tester -V.A.G.
1552- using lead -V.A.G. 1551/3B- .
– Switch on the ignition.

158 Rep. Gr. 23 - Mixture preparation, Injection


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3-cyl. diesel engine, mechanics - Edition 01.03

– Operate the fault reader or vehicle systems tester taking into


account the message on the display:
– Press 1 for “Rapid data transmission” .
– Press 2 and 5 for the address code “Immobiliser” and confirm
the entry with the Q button. ⇒ Vehicle diagnosis, testing and
information system VAS 5051
– Press → .
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 1 and 0 for function “Adaptation” and confirm the entry


with the Q button.
Reading on the display: Adaptation
Enter channel number XX

– Press 0 twice for “Channel number 0” and confirm the entry


with the Q button.
Reading on the display: Adaptation Q
Clear learning values?

– Confirm the entry with the Q button.


The display reads: Adaptation →
Learning values cleared

– End the adaptation by pressing → .


– Press 0 and 6 for function “End transmission” and confirm the
entry with the Q button.
– Switch off the ignition.

Note!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
When the ignition is switched
permitted on again,
unless authorised theS.A.
by SEAT identification
SEAT S.A does notofguarantee
the or accept any liability with
engine control unit is entered
respect to in
the the immobiliser
correctness control
of information unit. Copyright by SEAT S.A.
in this document.

4. Engine control unit: replacing, encoding and adapting 159


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

26 – Exhaust system
1 Exhaust system components: remov‐
ing and installing

Note!

♦ Exhaust manifold: removing and installing ⇒ page 106 , Ex‐


haust turbocompressor with accessory parts: removing and
installing.
♦ After doing assembly work on the exhaust system, pay special
attention to avoiding stresses and that there is sufficient clear‐
ance between exhaust pipes and the bodywork. If necessary,
loosen the double and tightening clamps and the silencer and
the exhaust pipe such that it is far enough from the bodywork
and that the mounts are uniformly placed.
♦ Replace the self-locking nuts.

1.1 Exhaust pipe front with catalyst and accessory parts

1 - Of the turbocompressor
2 - Gasket
❑ Replace
3 - 25 Nm
4 - Fixing ring
❑ Replace if worn
5 - Front exhaust pipe with cat‐
alyst
6 - Towards the presilencer

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

160 Rep. Gr. 26 - Exhaust system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.2 Silencer with holders

1 - Front exhaust pipe with cat‐


alyst
2 - Mark
3 - Double clamp
4 - Dimension -a- = approx. 5
mm
5 - 40 Nm
6 - Middle silencer
7 - Fixing ring
❑ Replace if worn
❑ Check the installation
position ⇒ page 162
8 - Union brace
9 - 15 Nm
10 - Hanger
❑ With fixing ring
❑ Replace if worn
11 - 20 Nm + 1/4 turn (90°)
❑ Replace
12 - Rear silencer
13 - Mark
❑ For double repair clamp,
⇒ Item 15 (page 161)
14 - Cutting point
❑ In the event of repara‐
tion
❑ Marked with three
marks stamped on the
circumference of the ex‐
haust pipe
❑Protected
The by middle
copyright.silencer
Copying forand
privatethe rear silencer
or commercial purposes,come
in part oras a unit.
in whole, is notFor repairs the middle silencer and the rear
silencer
permitted are supplied
unless authorised separately,
by SEAT S.A. SEAT S.A doeswith a double
not guarantee clamp
or accept to hold
any liability with them together.
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Cut the exhaust pipe perpendicularly along the marked area with the -U-40075- .

15 - Double repair clamp


❑ Should fit up to the marks, ⇒ Item 13 (page 161)

1. Exhaust system components: removing and installing 161


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Align the exhaust system


• The engine must be cold
– Align the exhaust system bearing in mind the dimension -a-
on the fixing ring, ⇒ Item 7 (page 161) .
The arrow points forward.
Dimension -a- = 5 ± 2 mm

1.3 Exhaust recirculation system


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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Note!

♦ The exhaust recirculation system is activated by the control


unit of the direct diesel injection system -J248- via the exhaust
recirculation valve -N18- , until the mechanical exhaust recir‐
culation valve.
♦ The mechanical exhaust recirculation valve with conical plung‐
er permits different openings via different valve strokes.
♦ The cadenced activation permits any valve position.
♦ Replace the self-locking nuts.

1.4 Exhaust recirculation system components: removing and installing

162 Rep. Gr. 26 - Exhaust system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1 - Intake manifold
2 - O-ring
❑ Replace
3 - Intake hole
❑ With exhaust recircula‐
tion valve and intake
manifold flap
4 - Mechanical exhaust recir‐
culation valve
❑ Is an integral part of the
intake hole
❑ Can only be replaced
along with the intake
hole
❑ Test ⇒ page 164
❑ Test the activation ⇒ Ve‐
hicle by
Protected diagnosis, testing
copyright. Copying for private or commercial purposes, in part or in whole, is not
and information system
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
VAS 5051
5 - 10 Nm
6 - From the intercooler
7 - Gasket
❑ Replace
8 - 25 Nm
9 - Exhaust manifold
10 - Connection line

1. Exhaust system components: removing and installing 163


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

1.5 Vacuum hose connection diagram

1 - Intake manifold flap switch‐


ing valve -N239-
❑ Test ⇒ page 119
2 - Exhaust recirculation valve
-N18-
❑ Test ⇒ page 164
3 - Supercharging pressure
control sol-enoid valve -N75-
❑ Test the supercharging
pressure control
⇒ page 113
4 - Connecting part
5 - Towards the power brake
6 - Retaining valve
7 - Pressure unit
❑ For supercharging pres‐
sure control
8 - Exhaust turbocompressor
9 - Intercooler
10 - Intake manifold Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
11 - Tandem pump respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ For the fuel supply and


the vacuum
12 - Cylinderhead
13 - Vacuum unit for intake
manifold switching
14 - Mechanical exhaust recir‐
culation valve
❑ Is an integral part of the
intake hole
❑ Can only be replaced along with the intake hole
❑ Test ⇒ page 164
❑ Test the activation ⇒ Vehicle diagnosis, testing and information system VAS 5051
15 - Air filter

1.6 Mechanical exhaust recirculation valve:


test
Special tools and workshop equipment required

164 Rep. Gr. 26 - Exhaust system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

♦ Hand vacuum pump -SAT 1390-

1.6.1 Test process


– Remove the soundproofing cover of the engine.
– Remove the connection hose, supercharging air line/intake
line.
– Remove
Protected theCopying
by copyright. vacuum hose
for private from the
or commercial exhaust
purposes, in partrecirculation
or in whole, is not
permittedvalve.
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Attach hand vacuum pump -SAT 1390- to the valve.
– Operate the vacuum pump and check the membrane rod. The
membrane rod should move in the direction of the arrow.
– Remove the vacuum pump hose from the exhaust recircula‐
tion valve.
The membrane rod return to its original position (moving in the
opposite direction of the arrow).

1.7 Exhaust recirculation: testing

1. Exhaust system components: removing and installing 165


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Special tools and workshop


equipment required
♦ Hand-held multimeter -
V.A.G. 1526 A- or multime‐
ter -V.A.G. 1715-
♦ Auxiliary measurement set
-V.A.G. 1594 A- or -V.A.G.
1594 C-
♦ Test box -V.A.G. 1598/31-
♦ Fault reader -V.A.G. 1551-
or vehicle systems checker
-V.A.G. 1552- with lead -
V.A.G. 1551/3B-
♦ Wiring diagrams
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.7.1 Test process


The functioning the exhaust recirculation is tested with function
04 (basic settings). In this procedure, every 10 seconds the ex‐
haust recirculation valve is timed, such that in the measured value
block 003 the extreme values for exhaust recirculation (air mass
meter) can be read, with the reading in field 3.
– Attach the -V.A.G. 1551- ( -V.A.G. 1552- ) and, with the cor‐
responding “address code” 01, select the engine electronics
control unit. When doing so, the engine must be idling: ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051
Reading on the display: Rapid data transmission HELP
Select function XX

– Press 0 and 4 for the function “Start basic settings” and press
Q to confirm the entry.

Reading on the display: Start basic settings


Enter value group number XXX

– Press 0 , 0 and 3 for the “Display group number 3” and press


Q to confirm the entry.

166 Rep. Gr. 26 - Exhaust system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

After selection display group number 3 and confirming with the


Q button, the engine control unit increases the idling revs in dis‐
play field 1 to 1350...1450 rpm.

Reading on the display: (1...4 = Display fields) System in basic settings 3 →


1400 rpm EGR inact 500 mg/H 20 %

The message in field 2 should oscillate every 10 s between EGR


activ. and EGR inact.
The values in display fields 3 and 4 should oscillate within the
following control range:

Note!

♦ If a constant value of 539 mg/H appears in display field 3, test


the air mass meter
♦ ⇒ page 119

EGR inact.
– Target value display field 3 420...600 mg/H (stroke)
– Target value display field 4 20 %
EGR activ.
– Target value display field 3 160...310 mg/H (stroke)
– Target value display field 4 65 %
If target values are not reached:
– Test the mechanical exhaust recirculation valve ⇒ page 164
– Test the vacuum hoses ⇒ page 164
– Test the exhaust recirculation valve -N18- as follows:
– Press → . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Press 0 and 6 for the function “End data transmission” and
respect to the correctness of information in this document. Copyright by SEAT S.A.

press Q to confirm the entry.


– Switch off the ignition.
– Remove the connector from the exhaust recirculation valve.
– Measure the resistance at the valve Target value: 14...20 Ω
If the target value is not reached:
– Replace the exhaust recirculation valve -N18- .

Note!

At ambient temperature, the resistance is within the lower toler‐


ance range; with the engine at running temperature, in upper
tolerance range.

If the target value is reached:


– Switch on the ignition.

1. Exhaust system components: removing and installing 167


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Test the voltage supply of the valve at contact 1 of the con‐


nector and earth engine. Target value: approx. battery voltage
If the target value is not reached:
– Switch off the ignition.
– Remove the wiper arms and the air deflector: ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wipers Windscreen wipers:
removing and installing

– Attach the test box -V.A.G. 1598/31- to the wiring harness of


the control unit.
– Test for open circuits in the wiring between the test box and
the connector, following the wiring diagram.
Contact 1 + female contacts 1 and 2
Contact 2 + female contact 61
Wiring resistance: 1.5 Ω max.
– Also test the wiring for short circuits between wires, to vehicle
earth and to battery positive.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Targetpermitted
value: ∞ Ωauthorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless
respect to the correctness of information in this document. Copyright by SEAT S.A.
If no fault is found in the wiring:
– Replace the control unit of the direct diesel injection system -
J248- ⇒ page 119

168 Rep. Gr. 26 - Exhaust system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

28 – Glow plug system


1 Pre-heating system: testing
Special tools and workshop equipment required
♦ Hand-held multimeter -V.A.G. 1526-

♦ Auxiliary measurement set -V.A.G. 1594-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Test conditions
• Battery voltage, 11.5 V minimum
• Ignition off
• Direct diesel injection system control unit -J248- , OK
• Glowplug fuse -S163- , OK
Test process
– Remove the connector from the coolant temperature sender
⇒ page 120 , Location of components

1. Pre-heating system: testing 169


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

Note!

When the connector is removed from the sender, “engine cold” is


simulated. When the ignition is switched on, the corresponding
pre-heating process is carried out.

– Remove the connectors from the glow plugs.


– To measure the voltage, attach the multimeter between one
glow plug connector and vehicle earth.
– Switch on the ignition. During roughly 20 seconds approx. bat‐
tery voltage should be displayed.
– If there is no voltage: ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations

1.1 Glowplugs: testing


Special tools and workshop equipment required
♦ Auxiliary measurement set -V.A.G. 1594 A-

♦ Glowplug spanner -U-40082-

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Torque spanner -SAT 8010- (5...50 Nm)


♦ Diode test lamp -V.A.G. 1527-

1.1.1 Test conditions


• Battery voltage, 11.5 V minimum
• Ignition off

1.1.2 Test process


– Remove the connectors from the glow plugs.

170 Rep. Gr. 28 - Glow plug system


Arosa 1997 ➤
3-cyl. diesel engine, mechanics - Edition 01.03

– Connect the diode lamp wire to l battery positive battery (+)


with auxiliary clamps of the auxiliary measurement set.
– Apply the diode lamp test point to each glow plug successively.
The diode lights up: glow plug OK The diode does not light up:
replace the glow plug
– Remove and install the glow plugs with the tool -U-40082-
Tightening torque: 15 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Pre-heating system: testing 171


Service

Workshop Manual
Arosa 1997 ➤
4 cyl. injection motor (push rods), mechanics
Engine ID AHT

Edition 10.99

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
24 - Fuel preparation, injection
26 - Exhaust system
28 - Ignition system

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2015 Seat S.A S01AAHT8620


Arosa 1997 ➤
4 cyl. injection motor (push rods), mechanics - Edition 10.99

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


1 Engine: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Fitting: details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Drivetrain supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Vehicles with air conditioner: additional indications and fitting work . . . . . . . . . . . . . . . . . . 8

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Engine: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Poly-V belt: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Poly-V belt routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Engine block, crankshaft, and flywheel: removing and installing . . . . . . . . . . . . . . . . . . . . 13
3 Crankshaft retainer -pulley side-: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Piston, connecting rod, and casing: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . 18

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22


1 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.1 Cylinder head: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Valve guides: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Valve seats: re-cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Basic adjustment of hydraulic valve play compensation . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Compression: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Valve control unit: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Hydraulic tappets: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Lubrication system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.1 Oil pressure and
permitted unless oil pressure
authorised switch:
by SEAT S.A. SEAT S.A test . .guarantee
does not . . . . . or. accept
. . . .any
. . liability
. . . .with
.................... 40
respect to the correctness of information in this document. Copyright by SEAT S.A.

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Cooling system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Cooling system components, bodywork side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Cooling system components, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Cooling system components, coolant pump side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.4 Coolant liquid: bleed and fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.5 Radiator: removing and install - ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.6 Coolant pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54


1 Fuel supply system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Fuel tank with accessory parts and fuel filter: removing and installing . . . . . . . . . . . . . . . . 54
1.2 Safety measures for working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.3 Rules for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.4 Fuel supply unit: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.5 Fuel tank: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.6 Fuel pump: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Contents i
Arosa 1997 ➤
4 cyl. injection motor (push rods), mechanics - Edition 10.99

2 Accelerator control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67


2.1 Accelerator control unit: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Accelerator control cable: adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Components of the activated carbon filter system: removing and installing . . . . . . . . . . . . 68
2.4 Deaeration of fuel tank: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

24 - Fuel preparation, injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71


1 Injection system: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 General indications relating to injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Injection system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.3 Intake manifold: disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.4 Fuel distributor: disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.5 Air filter: disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.6 Air filter: installing and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.7 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.8 Rules for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2 Testing of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Lambda probe heating: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Throttle control unit: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.3 Coolant temperature pressure transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.4 Intake manifold pressure transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.5 Intake air temperature transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.6 Engine speed transmitter: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.7 Injectors: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.8 Fuel and retention pressure regulator: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.9 Intake system: check the airtightness (undue air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.10 Intake air preheating: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.11 Test of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.12 Lambda regulation: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.13 Engine load states: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.14 Dynamic behaviour after a cold start: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.1 Control unit voltage supply: test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Engine control unit: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5 Control unit: encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
115
5.1 Engine control respectunit: adapt toofthe
to the correctness throttle
information in thiscontrol
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Copyright . . .S.A.
....................... 116
5.2 Engine control unit: adapt to the electronic immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6 Supplementary signals: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.1 Signal to/from the air conditioner: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2 Speed signal: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.3 Engine speed signal: check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124


1 Exhaust system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126


1 Ignition system: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 General indications relative to the ignition sy