S04BHXV8S20-Automated Manual Gearbox 02E For Front-Wheel Drive

Service
Workshop Manual
Altea 2004 ➤ , Altea 2009 ➤ ,
Altea XL 2007 ➤ , Altea XL 2009 ➤ ,
Altea XL Freetrack 2008 ➤ ,
Altea XL Freetrack 2009 ➤ ,
León 2006 ➤ , León 2009 ➤ ,
Toledo 2005 ➤
Automated manual gearbox 02E for front-wheel drive
Edition 08.2011
Protected by copyright. Copying for private or commercial purposes, in 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
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 S04BHXV8S20

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Automated manual gearbox 02E for front-wheel drive - Edition 08.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox codes: Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Code letters, group numbers, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Calculating overall gear ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 General overview: Automated manual gearbox 02E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Safety functions of the gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Added information concerning the semi-automatic gearbox 02E . . . . . . . . . . . . . . . . . . . . 18
7 Instructions for tow starts and when towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9 Cleaning norms when working in the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Notes on clutch* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Clutch: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Removing clutch cover (end cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Installing clutch cover (end cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Removing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Preparing installation of multi-clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5 Installing and adjusting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 ...................................................................... 42
1.1 Mechatronic unit for the semi-automatic gearbox J743 : Removing and installing (with
gearbox installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Mechatronic unit for the semi-automatic gearbox J743 : Removing and installing (with
gearbox removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3 Gearbox input speed sender G182 / oil temperature sender for multi-plate clutch G509
Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.4 Tiptronic switch F189 : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.5 Selector lever locking solenoid N110 : removing and assembling . . . . . . . . . . . . . . . . . . . . 61
2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3 Removing and installing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4 Gear oil pump: dismounting and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5 Replace the seal ring for lever of selector rod shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6 Emergency release of gear selection mechanism from position „P“ . . . . . . . . . . . . . . . . . . 74
7 Removing / fitting the gear lever
permitted knob
unless and by
authorised cover
SEAT S.A. . .SEAT
. . .S.A
. .does
. . .not. guarantee
. . . . . .or.accept
. . . .any. .liability
. . . with
..... 76
8 Gear selection mechanism, up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.1 Gear selection mechanism, up to 02.2009: Assembly overview . . . . . . . . . . . . . . . . . . . . 78
8.2 Gear selection mechanism, up to 02.2009: Removing and installing . . . . . . . . . . . . . . . . . . 80
8.3 Gear selection mechanism up to 02.2009: Removing and installing . . . . . . . . . . . . . . . . . . 82
8.4 Selector lever control cable: checking and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9 Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.1 Gear selection mechanism, from 03.2009: Assembly overview . . . . . . . . . . . . . . . . . . . . . . 89
9.2 Gear selection mechanism with cable, from 03.2009: Removing and installing . . . . . . . . 90
10 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11 Check the ignition key withdrawal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
12 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Contents i
12.1 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

12.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
12.3 Gearbox support: dismounting and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
12.4 Pendulum support: dismounting and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
12.5 Transporting and securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
13 Oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
13.1 Oil filter: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
13.2 Engine oil level: Checking and refill with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
13.3 change oil and replace filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1 At present no repairs are made to the pinions and shafts of this gearbox. . . . . . . . . . . . . 124
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3 Conversion table by relevance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.1 Graphical information on the use and VW units, Seat equivalents . . . . . . . . . . . . . . . . . . 132
ii Contents
00 – Technical data
1 Gearbox identification
The „6-speed automated manual gearbox 02E for front-wheel
drive vehicles“ are installed in the Altea 2004 ►, Toledo 2005►,
Leon 2006 ►, Altea XL 2007► und Altea XL Freetrack 2008►, Al‐
tea 2004 ►, Leon 2009 ►, Altea XL 2009► and Altea XL Free‐
track 2009► models. Allocation ⇒ page 4
The gearbox code letters can be found on the upper section of

the gearbox, next to the oil radiator.
Example for a gearbox:
♦ GKF = gearbox codes
♦ 10.05.2 = date of manufacture, 10 May 2002
The gearbox code is also recorded on the vehicle data sticker.
1. Gearbox identification 1
1.1 Gearbox codes: Display

On some gearboxes, the engine code is located on the upper part
near the gear selection lever control cable, or on the rim of the
joint between the two housings -arrows- .
– Remove engine cover ⇒ Maintenance ; Booklet 101 .
– Remove the air filter body, breather hose and air duct hoses
⇒ Rep. gr. 24 ; Air filter: disassembly and assembly and ⇒
Rep. gr. 23 ; Air filter: parts diagram .
Observe the codes when they are under the gearbox console
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
– Remove battery tray -arrows-.
– Position bracket -U-30025E- on bolted flange for wing panels.

– Next, separate the hoses and cables that may be in the area
of the engine where the rings that grip the support -U-30025E
- go.
– Place eyes onto spindle hooks.
– Slightly tension the engine assembly/gearbox via the spindles.
2 Rep. gr.00 - Technical data

– Unscrew the bolts -1- and -2- from the console -A- .
– Move the gearbox slightly downward by loosening the spindle
on the support -U-30025E- until the console can be removed
-arrow-
Installation is carried out in reverse order. The following must be
taken into account:
– Replace the bolts -1 and 2- of the ⇒ Rep. gr. 10 ; Subframe
1. Gearbox identification 3
2 Code letters, group numbers, ratios,

equipment
Engine codes Altea 2004 ⇒ page 4
Engine codes Altea 2009 ⇒ page 5
Engine codes Toledo 2005 ⇒ page 6
Engine codes Leon 2006 ⇒ page 7
Engine codes Leon 2009 ⇒ page 9
Engine codes Altea XL 2007 ⇒ page 10
Engine codes Altea XL 2009 ⇒ page 11
Engine codes Altea XL Freetrack 2008 ⇒ page 12
Engine codes Altea XL Freetrack 2009 ⇒ page 12
Engine codes Altea 2004
Manual 02E, front-wheel drive
gearbox
Engine GPU HFQ HJP, HXW, HQM, GPU HFQ HJP, HXU,
code HQM, JPP,KC HXT, HQM, JPL,
HXT, Z, KNC, JPK, JPK, KCW,
JPK, KPV, KCV KCV, KMZ,
KCV, LQZ KMY, KMY, KPQ,
KMY, KPT, KPT, LQS
KPT, LQW LQW
LQW
Allocation Mod‐ Altea Altea Altea Altea Altea Altea Altea Altea Altea
el 2004► 2004► 2004► 2004► 2004► 2004► 2004► 2004► 2004►
En‐ 2.0l TDI 100 kW 4V 2.0l FSI 2.0L TDI 2.0l TDI 103 kW 4V 1.9 TDI
gine 147 kW 103kW 77kW
Protected by copyright. Copying for private or commercial purposes, in part2V
or in/whole,
DPFis not DPF
Gear ra‐ respect
Final to69the :correctness
17 = 70 :17 = 69
of information : 17
in this = 69 Copyright
document. : 17 = by69SEAT
: 17 = 69 : 17 = 70 :17 = 69 : 17 =
S.A. 70 : 16 =
tios: drive 4,059 4,118 4,059 4,059 4,059 4,059 4,118 4,059 4,375
I for
1st to
4th
gear
Z2 : Z1 Final 69 : 22 = 70 : 23 = 69 : 22 = 69 : 22 = 69 : 22 = 69 : 22 = 70 : 23 = 69 : 22 = 70 : 21 =
drive 3,136 3,043 3,136 3,136 3,136 3,136 3,043 3,136 3,333
II for
5th /
6th
gear
and
re‐
verse
gear
1. 45 :13 = 45 : 13 = 45 :13 = 45 :13 = 45 :13 = 45 :13 = 45 : 13 = 45 : 13 = 45 : 13 =
gear 3,462 3,462 3,462 3,462 3,462 3,462 3,462 3,462 3,462
2. 41 : 20 = 41 : 20 = 41 : 20 = 43 : 20 = 41 : 20 = 41 : 20 = 41 : 20 = 41 : 20 = 41 : 20 =
gear 2,050 2,050 2,050 2,150 2,050 2,050 2,050 2,050 2,050
3. 39 : 30 = 39 : 30 = 39 : 30 = 41 : 28 = 39 : 30 = 39 : 30 = 39 : 30 = 39 : 30 = 39 : 30 =
gear 1,300 1,300 1,300 1,464 1,300 1,300 1,300 1,300 1,300
4. 37 : 42 = 37 : 41= 37 : 41= 41 : 38 = 37 : 41 = 37 : 42 = 37 : 41= 37 : 41= 37 : 41 =
gear 0,880 0,902 0,902 1,079 0,902 0,880 0,902 0,902 0,902
5. 32 : 35 = 32 : 35= 32 : 35= 35 : 32 = 32 : 35 = 32 : 35 = 32 : 35= 32 : 35= 32 : 35 =
gear 0,914 0,914 0,914 1,094 0,914 0,914 0,914 0,914 0,914
6. 31 : 42 = 31 : 41= 31 : 41= 35 : 38 = 31 : 41 = 31 : 42 = 31 : 41= 31 : 41= 31 : 41 =
gear 0,738 0,756 0,756 0,921 0,756 0,738 0,756 0,756 0,756


gearbox
JPK, KPV, KCV KCV, KMZ,
KCV, LQZ KMY, KMY, KPQ,
KMY, KPT, KPT, LQS
KPT, LQW LQW
LQW
Re‐ 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x
verse 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 =
3,989 3,989 3,989 3,989 3,989 3,989 3,989 3,989 3,989
Spee - - - - 69 : 22 = - - - 69 : 22 =
do‐ 3,136 3,136
me‐
ter
total in top gear 2,995 3,113 3,068 3,738 3,068 2,995 3,113 3,068 3,307
I
Engine codes Altea 2009

Manual gear‐ 02E, front-wheel drive
box
Engine code LQS, MKJ, LQW LTG, MLX, LTG, MLX MFL, MSV, NJK
MLW MSW
Allocation Mod Altea 2009►
el
En‐ 1.9 TDI 77kW 2.0L TDI 100kW 2.0L TDI 103kW 2.0L TDI 103kW 2.0L TDI 103kW
gine DPF 4V -2.0L TDI 4V - 2.0L TDI 4V CR 4V CR
103kW 4V - 2.0L 103kW 2V DPF
TDI 103kW 2V
DPF
Gear ratios: Fi‐ 70 : 16 = 4,375 69 : 17 = 4,059 69 : 17 = 4,059 69 : 17 = 4,059 70 : 17 = 4,117
nal
driv
eI
for
1st
to
4th
gea
r
Z2 : Z1 Fi‐ 70 : 21 = 3,333 69 : 22 = 3,136 69 : 22 = 3,136 69 : 22 = 3,136 70 : 23 = 3,043
nal
driv
e II
for
5th /
6th
gea
r
and
re‐
vers
e
gea
r
1. 45 : 13 = 3,462 45 :13 = 3,462 45 :13 = 3,462 45 :13 = 3,462 45 :13 = 3,462
gea
r
2. Code letters, group numbers, ratios, equipment 5


box
MLW MSW
2. 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050
gea
r
3. 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300
gea
r
4. 37 : 41 = 0,902 37 : 41 = 0,902 37 : 41 = 0,902 37 : 41 = 0,902 37 : 41 = 0,902
gea
r
5. 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914
gea
r
6. 31 : 41 = 0,756 31 : 41 = 0,756 31 : 41 = 0,756 31 : 41 = 0,756 31 : 41 = 0,756
gea
r Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Re‐ 22 : 14 X 33 : 13 33 :respect
13 x to22
the:correctness
14 33 :of13 x 22 :in14 33 : 13Copyright
x 22 : by
14SEAT
33S.A.
: 13 x 22 : 14
information this document.
vers = 3,989 = 3,989 = 3,989 = 3,989 = 3,989
e
Spe - - - - -
ed‐
ome
ter
I
total in top gear 3,307 3,068 3,068 3,068 3,113
Engine codes Toledo 2005

gearbox
JPK, KPV, KCV, KCV, KMZ,
KCV, LQZ KMY, KPT, KPQ,
KMY, KPT, LQW LQS
KPT, LQW
LQW
Allocation Mod‐ Tole‐ Tole‐ Tole‐ Tole‐ Tole‐ Tole‐ Tole‐ Tole‐ Tole‐
el do 2005 do 2005 do 2005 do 2005 do 2005 do 2005 do 2005 do 2005 do 2005
► ► ► ► ► ► ► ► ►
En‐ 2.0l TDI 100 kW 4V 2.0l FSI 2.0L TDI 2.0l TDI 103 kW 4V 1.9 TDI
gine 147 kW 103kW 77kW
2V / DPF DPF
Gear ra‐ Final 69 : 17 = 70 :17 = 69 : 17 = 69 : 17 = 69 : 17 = 69 : 17 = 70 :17 = 69 : 17 = 70 : 16 =
tios: drive 4,059 4,118 4,059 4,059 4,059 4,059 4,118 4,059 4,375
I for
1st to
4th
gear


gearbox
JPK, KPV, KCV, KCV, KMZ,
KCV, LQZ KMY, KPT, KPQ,
KMY, KPT, LQW LQS
KPT, LQW
LQW
Z2 : Z1 Final 69 : 22 = 70 : 23 = 69 : 22 = 69 : 22 = 69 : 22 = 69 : 22 = 70 : 23 = 69 : 22 = 70 : 21 =
drive 3,136 3,043 3,136 3,136 3,136 3,136 3,043 3,136 3,333
II for
5th /
6th
gear
and Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
re‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
verse respect to the correctness of information in this document. Copyright by SEAT S.A.
gear
1. 45 :13 = 45 : 13 = 45 :13 = 45 :13 = 45 :13 = 45 :13 = 45 : 13 = 45 : 13 = 45 : 13 =
gear 3,462 3,462 3,462 3,462 3,462 3,462 3,462 3,462 3,462
2. 41 : 20 = 41 : 20 = 41 : 20 = 43 : 20 = 41 : 20 = 41 : 20 = 41 : 20 = 41 : 20 = 41 : 20 =
gear 2,050 2,050 2,050 2,150 2,050 2,050 2,050 2,050 2,050
3. 39 : 30 = 39 : 30 = 39 : 30 = 41 : 28 = 39 : 30 = 39 : 30 = 39 : 30 = 39 : 30 = 39 : 30 =
gear 1,300 1,300 1,300 1,464 1,300 1,300 1,300 1,300 1,300
4. 37 : 42 = 37 : 41= 37 : 41= 41 : 38 = 37 : 41 = 37 : 42 = 37 : 41= 37 : 41= 37 : 41 =
gear 0,880 0,902 0,902 1,079 0,902 0,880 0,902 0,902 0,902
5. 32 : 35 = 32 : 35= 32 : 35= 35 : 32 = 32 : 35 = 32 : 35 = 32 : 35= 32 : 35= 32 : 35 =
gear 0,914 0,914 0,914 1,094 0,914 0,914 0,914 0,914 0,914
6. 31 : 42 = 31 : 41= 31 : 41= 35 : 38 = 31 : 41 = 31 : 42 = 31 : 41= 31 : 41= 31 : 41 =
gear 0,738 0,756 0,756 0,921 0,756 0,738 0,756 0,756 0,756
Re‐ 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x
verse 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 =
3,989 3,989 3,989 3,989 3,989 3,989 3,989 3,989 3,989
Spee - - - - 69 : 22 = - - - 69 : 22 =
do‐ 3,136 3,136
me‐
ter
total in top gear 2,995 3,113 3,068 3,738 3,068 2,995 3,113 3,068 3,307
I
Engine codes Leon 2006

Man‐ 02E, front-wheel drive
ual
gear‐
box
En‐ HQM, HFQ HQM, HFQ HQM, HXU, HXW,
gine HXT, HXT, HXT, JPL, JPP,
code JPK, JPK, JPK, KCW, KCZ,
KCV, KCV, KCV, KMZ, KNC,
KMY, KMY, KMY, KPQ, KPV,
KPT, KPT, KPT, LQS LQZ
LQW LQW LQW
Allo‐ Mo Leon Leon Leon Leon Leon Leon Leon
cation del 2006 2006 2006 2006 2006 2006 2006
► ► ► ► ► ► ►


ual
gear‐
box
LQW LQW LQW
En‐ 2.0l TDI 100 2.0L 2.0l TDI 103 1.9 2.0l
gin kW 4V TDI kW 4V TDI FSI
e 103k 77kW 147
W 2V DPF kW
DPF
Gear Fi‐ 69 : 70 : 69 : 70 : 69 : 70 : 69 :
ratios: nal 17 = 17 = 17 = 17 = 17 = 16 = 17 =
driv 4,059 4,118 4,059 4,118 4,059 4,375 4,059
eI
for
1st
to
4th
gea
r
Z2 : Fi‐ 69 : 70 : 69 : 70 : 69 : 70 : 69 :
Z1 nal 22 = 23 = 22 = 23 = 22 = 21 = 22 =
driv 3,136 3,043 3,136 3,043 3,136 3,333 3,136
e II
for
5th
/
6th
gea
r
and
re‐
ver
se
gea
r
1. 45 : 45 : 45 : 45 : 45 : 45 : 45 :
gea 13 = 13 = 13 = 13 = 13 = 13 = 13 =
r 3,462 3,462 3,462 3,462 3,462 3,462 3,462
2. 41 : 41 : 41 : 41 : 41 : 41 : 43 :
gea 20 = 20 = 20 = 20 = 20 = 20 = 20 =
r 2,050 2,050 2,050 2,050 2,050 2,050 2,150
3. 39 : 39 : 39 : 39 : 39 : 39 : 41 :
gea 30 = 30 = 30 = 30 = 30 = 30 = 28 =
r 1,300 1,300 1,300 1,300 1,300 1,300 1,464
4. 37 : 37 : 37 : 37 : 37 : 37 : 41 :
gea 41 = 41= 41 = 41= 41 = 41 = 38 =
r 0,902 0,902 0,902 0,902 0,902 0,902 1,079
5. 32 : 32 : 32 : 32 : 32 : 32 : 35 :
gea 35 = 35= 35 = 35= 35 = 35 = 32 =
r 0,914 0,914 0,914 0,914 0,914 0,914 1,094
6. 31 : 31 : 31 : 31 : 31 : 31 : 35 :
gea 41 = 41= 41by=copyright.
Protected 41=Copying
41for=private
41or=commercial
38 = purposes, in part or in whole, is not
r 0,756 0,756
permitted0,756 0,756by 0,756
unless authorised SEAT S.A.0,756
SEAT S.A 0,921
does not guarantee or accept any liability with


ual
gear‐
box
LQW LQW LQW
Re‐ 22 : 33 : 22 : 33 : 22 : 22 : 22 :
ver 14 X 13 x 14 X 13 x 14 X 14 X 14 X
se 33 : 22 : 33 : 22 : 33 : 33 : 33 :
13 = 14 = 13 = 14 = 13 = 13 = 13 =
3,989 3,989 3,989 3,989 3,989 3,989 3,989
Spe - - 69 : - - 69 : -
ed‐ 22 = 22 =
om 3,136 3,136
eter
I
total in
Protected top 3,068
by copyright. Copying3,113
for private3,068 3,113
or commercial 3,068
purposes, in part3,307 3,738
or in whole, is not
gear
Engine codes Leon 2009

gearbox
Engine LQS, LQW LTG, MLX LTG, MLX MFL, KPS, LQT, LQZ, LTL,
code MKJ, MSV, NJK LTD, MMA,
MLW MFM, MSY, NJL
MSU, NJJ
Allocation Model Leon 2009►
Engine 1.9 TDI 2.0L TDI 2.0L TDI 2.0L TDI 2.0L TDI 2.0L TDI 2.0 TFSI
77kW 100kW 4V 103kW 4V 103kW 4V 103kW 4V 125kW 4V 155kW 4V
DPF -2.0L TDI - 2.0L TDI CR CR CR
103kW 4V 103kW 2V
- 2.0L TDI DPF
103kW 2V
DPF
Gear ratios: Final 70 : 16 = 69 : 17 = 69 : 17 = 69 : 17 = 70 : 17 = 70 :17 = 69 : 17 =
drive I 4,375 4,059 4,059 4,059 4,117 4,118 4,059
for 1st to
4th gear
Z2 : Z1 Final 70 : 21 = 69 : 22 = 69 : 22 = 69 : 22 = 70 : 23 = 70 : 23 = 69 : 22 =
drive II 3,333 3,136 3,136 3,136 3,043 3,043 3,136
for 5th /
6th gear
and re‐
verse
gear
1. gear 45 : 13 = 45 :13 = 45 :13 = 45 :13 = 45 :13 = 45 : 13 = 45 :13 =
3,462 3,462 3,462 3,462 3,462 3,462 3,462
2. gear 41 : 20 = 41 : 20 = 41 : 20 = 41 : 20 = 41 : 20 = 41 : 20 = 43 : 20 =
2,050 2,050 2,050 2,050 2,050 2,050 2,150
3. gear 39 : 30 = 39 : 30 = 39 : 30 = 39 : 30 = 39 : 30 = 39 : 30 = 41 : 28 =
1,300 1,300 1,300 1,300 1,300 1,300 1,464
4. gear 37 : 41 = 37 : 41 = 37 : 41 = 37 : 41 = 37 : 41 = 37 : 41 = 41 : 38 =
0,902 0,902 0,902 0,902 0,902 0,902 1,079
5. gear 32 : 35 = 32 : 35 = 32 : 35 = 32 : 35 = 32 : 35 = 32 : 35 = 35 : 32 =
0,914 0,914 0,914 0,914 0,914 0,914 1,094
6. gear 31 : 41 = 31 : 41 = 31 : 41 = 31 : 41 = 31 : 41 = 31 : 41 = 35 : 38 =
0,756 0,756 0,756 0,756 0,756 0,756 0,921


gearbox
Engine LQS, LQW LTG, MLX LTG, MLX MFL, KPS, LQT, LQZ, LTL,
code MKJ, MSV, NJK LTD, MMA,
MLW MFM, MSY, NJL
MSU, NJJ
Reverse 22 : 14 X 22 : 14 X 22 : 14 X 33 : 13 x 33 : 13 x 33 : 13 x 33 : 13 x
33 : 13 = 33 : 13 = 33 : 13 = 22 : 14 = 22 : 14 = 22 : 14 = 22 : 14 =
3,989 3,989 3,989 3,989 3,989 3,989 3,989
Speed‐ - - - - - -
ometer
I
total in top gear 3,307 3,068 3,068 3,068 3,113 3,113 3,738
Engine codes Altea XL 2007

box
Engine code KCZ, KNC, KCV, KMY, KCW, KMZ,
KPV, LQZ KPT, LQW KPQ, LQS
Allocation Model Altea XL Altea XL Altea XL
2007► 2007► 2007►
Engine 2.0l FSI 147 2.0L TDI 1.9 TDI
kW 103kW respect
DPF to77kW DPFof information in this document. Copyright by SEAT S.A.
the correctness
Gear ratios: Final 69 : 17 = 69 : 17 = 70 : 16 =

drive I 4,059 4,059 4,375
for 1st
to 4th
gear
Z2 : Z1 Final 69 : 22 = 69 : 22 = 70 : 21 =
drive II 3,136 3,136 3,333
for 5th /
6th
gear
and re‐
verse
gear
1. gear 45 :13 = 45 :13 = 45 : 13 =
3,462 3,462 3,462
2. gear 43 : 20 = 41 : 20 = 41 : 20 =
2,150 2,050 2,050
3. gear 41 : 28 = 39 : 30 = 39 : 30 =
1,464 1,300 1,300
4. gear 41 : 38 = 37 : 41 = 37 : 41 =
1,079 0,902 0,902
5. gear 35 : 32 = 32 : 35 = 32 : 35 =
1,094 0,914 0,914
6. gear 35 : 38 = 31 : 41 = 31 : 41 =
0,921 0,756 0,756
Re‐ 22 : 14 X 22 : 14 X 33 : 22 : 14 X
verse 33 : 13 = 13 = 3,989 33 : 13 =
3,989 3,989
Speed‐ - 69 : 22 = 69 : 22 =
ometer 3,136 3,136
I
total in top gear 3,738 3,068 3,307

Engine codes Altea XL 2009

box
MLW MSW
Allocation Mod Altea XL 2009►
el
En‐ 1.9 TDI 77kW 2.0L TDI 100kW 2.0L TDI 103kW 2.0L TDI 103kW 2.0L TDI 103kW
gine DPF 4V - 2.0L TDI 4V - 2.0L TDI 4V CR 4V CR
103kW 4V - 2.0L 103kW 2V/Die‐
TDI 103kW 2V sel particle filter
DPF
Gear ratios: Fi‐ 70 : 16 = 4,375 69 : 17 = 4,059 69 : 17 = 4,059 69 : 17 = 4,059 70 : 17 = 4,117
nal
driv
eI
for
1st
to
4th
gea
r
Z2 : Z1 Fi‐ 70 : 21 = 3,333 69 : 22 = 3,136 69 : 22 = 3,136 69 : 22 = 3,136 70 : 23 = 3,043
nal
driv
e II
for Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
5th
permitted unless /
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to6th
the correctness of information in this document. Copyright by SEAT S.A.
gea
r
and
re‐
vers
e
gea
r
1. 45 : 13 = 3,462 45 :13 = 3,462 45 :13 = 3,462 45 :13 = 3,462 45 :13 = 3,462
gea
r
2. 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050
gea
r
3. 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300
gea
r
4. 37 : 41 = 0,902 37 : 41 = 0,902 37 : 41 = 0,902 37 : 41 = 0,902 37 : 41 = 0,902
gea
r
5. 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914
gea
r
6. 31 : 41 = 0,756 31 : 41 = 0,756 31 : 41 = 0,756 31 : 41 = 0,756 31 : 41 = 0,756
gea
r
Re‐ 22 : 14 X 33 : 13 33 : 13 x 22 : 14 33 : 13 x 22 : 14 33 : 13 x 22 : 14 33 : 13 x 22 : 14
vers = 3,989 = 3,989 = 3,989 = 3,989 = 3,989
e
Spe - - - - -
ed‐
ome
ter


box
MLW MSW
I
total in top gear 3,307 3,068 3,068 3,068 3,113
Engine codes Altea XL Freetrack 2008

Manual gearbox 02E, front-wheel drive
Engine code KCZ, KNC, KCV, KMY,
KPV, LQZ KPT, LQW
Allocation Model Altea XL Free‐ Altea XL Free‐
track 2008► track 2008►
Engine 2.0l FSI 147 2.0L TDI
kW 103kW DPF
Gear ratios: Final drive 69 : 17 = 4,059 69 : 17 = 4,059
I for 1st to
4th gear
Z2 : Z1 Final drive 69 : 22 = 3,136 69 : 22 = 3,136
II for 5th /
6th gear
and re‐
verse gear
1. gear 45 :13 = 3,462 45 :13 = 3,462
2. gear 43 : 20 = 2,150 41 : 20 = 2,050
3. gear 41 : 28 = 1,464 39 : 30 = 1,300
4. gear
permitted41 : 38
unless = 1,079
authorised 37S.A.
by SEAT : 41 = 0,902
SEAT S.A does not guarantee or accept any liability with
5. gear 35 : 32 = 1,094 32 : 35 = 0,914
6. gear 35 : 38 = 0,921 31 : 41 = 0,756
Reverse 22 : 14 X 33 : 22 : 14 X 33 : 13
13 = 3,989 = 3,989
Speedom‐ - 69 : 22 = 3,136
eter
I
total in top gear 3,738 3,068
Engine codes Altea XL Freetrack 2009

Engine code LQZ, LTL, MMA, MSY, NJL
Allocation Model Altea XL Freetrack 2009 ►
Engine 2.0 TFSI 155kW 4V
Gear ratios: Final drive I for 69 : 17 = 4,059
1st to 4th gear
Z2 : Z1 Final drive II for 69 : 22 = 3,136
5th / 6th gear
and reverse
gear
1. gear 45 :13 = 3,462
2. gear 43 : 20 = 2,150
3. gear 41 : 28 = 1,464
4. gear 41 : 38 = 1,079
5. gear 35 : 32 = 1,094
6. gear 35 : 38 = 0,921


Engine code LQZ, LTL, MMA, MSY, NJL
Reverse 33 : 13 x 22 : 14 = 3,989
Speedometer
I
total in top gear 3,738
2.1 Calculating overall gear ratio „i“

Example:
6. gear Final group
Input gear ZG1 = 42 ZA1 = 22
Driven pinion ZG2 = 31 ZA2 = 69
i = Z2 : Z1 1)
iG = Gear ratio = ZG 2 : ZG 1 = 31 : 42 = 0,738
iA = Final group gear ratio = ZA2 : ZA1 = 69 : 22 = 3,136
itotal. = Overall ratio = iG x iA = 0.738 x 3.6 = 2.315
1) Z1 = Number of teeth of drive pinion, Z2 = number of teeth of driven pinion

3 Capacity
WARNING
Only the recommended gear oil should be used for semi-au‐

tomatic gearbox 02E. Other oils may cause malfunctions or
damage in the gearbox.
Gearbox capacity
Capacity Dual clutch gearbox 02E
Initial filling in factory 6.9 l to 7.2 l
depending on vehicle and date of
gearbox construction
Change quantity about 5.2 l
Change quantity, mecha‐ 3 - 4 litres
tronics only: Removing and
installing (with gearbox in‐
stalled)
Lubricant Gearbox oil for dual clutch gear‐
box DSG®
Spare part number ⇒ Spare parts
catalogue
Only the recommended gear oil should be used for semi-auto‐
matic gearbox 02E. The use of other oil sorts may lead to func‐
tional interferences or damage in the gearbox.
When changing gear oil always renew the gear oil filter
⇒ page 120 .
Check and replace gear oil ⇒ page 116 .

4 General overview: Automated manual gearbox 02E
1 - Filter
❑ Comment for changing
the filter ⇒ page 19
❑ Replace ⇒ page 116
2 - Control screw
❑ Near to the pendulum
arm support
❑ Change oil ⇒ page 116
3 - Release bolt
❑ The screw is no longer
fitted in the second gen‐
eration of the automated
manual gearbox 02E.
The oil can be drained
via the inspection
screw.
❑ Change oil ⇒ page 116
4 - Gearbox oil cooler
⇒ page 66
5 - Mechatronic unit for dual
clutch gearbox -J743-
⇒ page 44
6 - Gearbox input speed send‐
er -G182- and clutch tempera‐
ture sender -G509-
⇒ page 60
7 - Oil pump ⇒ page 68
8 - End cap on the multiple
clutch
9 - Multiple clutch
⇒ page 26
4. General overview: Automated manual gearbox 02E 15

5 Safety precautions
If in the test drives it is necessary to use the tester units, take note
of the following:
WARNING
♦ The testing and measurement equipment must always be

fitted to the rear seat to be operated by a second person.
♦ If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci‐
dent, there is a possibility that the person sitting in this seat
may receive serious injuries when the airbag is triggered.
To avoid injury to individuals and/or the destruction of electric and

electronic components, the following should be observed:
♦ Disconnect and connect test and measurement equipment
only when the ignition is switched off.
WARNING
♦ Observe the necessary precautions when disconnecting

the battery ⇒ Electrical system; Rep. gr. 27 .
♦ Always switch off ignition before disconnecting or con‐
necting the battery to ensure gearbox control unit is not
damaged.
5.1 Safety functions of the gearbox control

unit
If one or more components or sensors stop working, the gearbox
control unit activates the corresponding replacement functions.
This ensures the continued working of the gearbox without risk of
damage, nor of repercussions to the working and quality of the
gear shifts.
The gearbox records 4 different fault responses.
♦ 1. The fault is stored and a replacement programme allows
continued running (with some restrictions). The driver is not
informed of the fault response, as it is not critical to either the
gearbox or to driving safety. The gear speed indicator on the
instrument panel displays the position of the selector lever at
all times normally. The driver may possibly realise that some‐
thing is wrong, from the behaviour of the vehicle when running,
and will automatically go to a Seat Dealer.
♦ 2.: Certain positions on the gear selection indicator in the in‐
strument cluster start to flash. This advises
Protected the driverCopying
by copyright. that this
for private or commercial purposes, in part or in whole, is not
gear may not be selected at the moment. This authorised
permitted unless occurs,byfor SEATex‐S.A. SEAT S.A does not guarantee or accept any liability with
ample, when „D“ is engaged while reversing (the selector lever
is in „R“ and the vehicle is still moving backwards). In this case,

position „D“ of the selector lever on the gear speed indicator
on the instrument panel will flash. The gearbox control unit
prevents the 1st gear from being engaged in order to avoid
damage to the gearbox. 1st gear will be engaged once the
vehicle has come to a standstill.
♦ 3.: The complete gear selection indicator in the instrument
cluster is lit up and flashing. It is possible to identify the actual
position of the selector lever on the instrument panel, e.g. „D“,
because it will be brighter. In this case the gearbox was over‐
loaded or the maximum gearbox temperature was exceeded

(overheating). This can happen e.g. in the suspension in case

of high drag loads.
♦ 4.: If the complete gear selection indicator in the instrument
cluster is lit up and flashing, this means that a serious fault in
the gearbox has been identified. It is no longer possible to de‐
termine the position of the selector lever from the instrument
panel indicator. This is a critical condition for driving safety or
for the gearbox. It may be that, in some cases, it is no longer
possible to engage any of the gears. The gear speed indicator
flashes to warn the driver that he should go directly to a Seat
Dealer.
5. Safety precautions 17
6 Added information concerning the

semi-automatic gearbox 02E
Gearbox:
The semi-automatic gearbox 02E is also known as the dual clutch
gearbox. Engine torque is transmitted to the gearbox through the
dual-mass flywheel. The gearbox has the same structure as a
manual 6-speed gearbox. The gearbox functions as an automatic
gearbox through the alternating hydraulic control of the wet multi-
disc clutches, that is, the gears engage automatically, or manually
in Tiptronic mode. There is no clutch pedal. For further information
the corresponding ⇒ auto-didactic programme should be con‐
sulted.
Safety functions of the gearbox control unit
If one ore more components or sensors malfunction, the gearbox
control unit activates the corresponding replacement functions or
emergency run programmes. That way the function of the gear‐
box is guaranteed with no damages, though there are restrictions
in functioning and quality of the gear switching processes. For
further information the corresponding ⇒ auto-didactic programme
should be consulted.
Gear selection mechanism
The position of the selector lever is no longer transmitted to the
gearbox mechanically through the selector lever cable and the
multifunction switch (gear speed sensor), as is the case with the
automatic gearbox. The positions of the selector lever or the gear
shifts are sent to the gearbox control unit using its own control
unit located in the gear selection mechanism, through the CAN
bus. That is, the gears are changed without using a lever cable.
Only when the selector lever is in „P“ does the parking block en‐
gage mechanically using the selector lever cable.
Gearbox oil
The levels of gear oil in the gearbox and in the front final group
are checked and topped up together ⇒ page 116 .
♦ Only the recommended gear oil should be used for semi-au‐
tomatic gearbox 02E. The use of other types of oil may cause
damage to the working of the gearbox, part no. ⇒ page 14 .
♦ Do not add additives or different oils to the oil
♦ The oil which is removed should not be reused.
♦ To maintain the oil performance capacity, the gearbox filter
should also be replaced whenever the oil is changed during a
maintenance service.

Function of the oil

♦ The oil is not used to lubricate the gearbox
♦ The oil transports the finest of wear particulates of the differ‐
ential to the filters, keeps the lubricating film on the tooth flanks
of the differential intact and is also used as a pressure media
for the correct operation of the gearing mechanism.
♦ Additionally, it also seals the slider and helps the synchronis‐
ing hub when changing gear. Next to the noise insulation, it is
used to store and transport heat. Thus, the oil takes over sev‐
eral versatile functions. The oil of the automated manual gear‐
box 02E fulfils the highest demands.
♦ To maintain this oil performance capacity, the gearbox filter
should also be replaced whenever the oil is changed during a
maintenance service.
Oil filter change
It is not always necessary to replace the oil filter.
Do not change the filter if:
♦ the gearbox oil radiator or its O-rings have been replaced or
no coolant has entered the oil.
♦ the seal of the selector lever has been replaced.
♦ the seal of the flanged shaft or the insertable shaft has been
replaced.
♦ a non leak proof cover of the mechatronic control unit, of the
multiple clutch or the oil pump has been replaced.
♦ the gearbox input speed sender -G182- has been replaced
with the clutch temperature sender -G509- .
The filter should be changed if:
♦ the vehicle has been driven for 60,000 kilometres (perform
maintenance service).
♦ If coolant has entered the oil.
♦ If swarf has been found in the oil.
♦ The clutch is burnt or has a mechanical fault.
Oil level check and troubleshooting

♦ ⇒ page 19 The versatile functions of the oil are described here.
Oil cannot disappear »without leaving traces«. Oil will only be
missing if there is a leak in the gearbox.
♦ If the gearbox is covered with oil, first the oil leak has to be
Protectedfound. The
by copyright. leakformust
Copying privatebe eliminated
or commercial before
purposes, in partchanging the oil
or in whole, is not
andauthorised
permitted unless restoring theS.A.
by SEAT correct
SEAT S.Afilling level
does not ⇒ page
guarantee 116
or accept any .liability with
♦ The leak can neither be identified nor eliminated by simply re‐
filling with oil. A wrong feeling of safety is conveyed.
6. Added information concerning the semi-automatic gearbox 02E 19

Oil drain and oil inspection screw -A-

♦ The 1st generation of the automated manual gearbox 02E had
2 screws.
♦ Resulting from the second screw not being needed, the oil
drainage as well as the oil level adjustment are only carried
out using screw -A-.
♦ The gearbox oil level is determined using an 8 mm hexagon
socket (tightening torque 3 Nm) across the length of the overfill
tube made from plastic.
Regulations for oil waste management
Used oils should be taken to an appropriate centre for their correct
disposal.
♦ Used oils pollute the environment when not correctly disposed
of.
♦ It is forbidden to mix this oil with solvents, brake or coolant
liquids.
♦ Always follow the instructions shown on the oil container.
Modifications in the shift points, up and down
When shifting up or down, the gearshifts are automatically selec‐
ted using the possible range of gear shifts according to the
position of the accelerator pedal and the speed of travel.
• The possible range of a gear change will be adapted for max‐
imum engine power during extreme ascents.
• The possible range of a gear change will be adapted for max‐
imum engine braking power
Protected during
by copyright. extreme
Copying descents
• The engine braking effect
respectmay be usedofby
to the correctness directly
information selecting
in this a
document. Copyright by SEAT S.A.
specific gear using the Tiptronic, for example, when driving
with a trailer on downhill slopes.

7 Instructions for tow starts and when

towing
WARNING
When towing the vehicle, the selector lever should be in N po‐

sition, and the vehicle should not be towed for more than 50km
nor at a speed of over 50 km/h, otherwise the gearbox will be
destroyed.
Note
It is not possible to start the engine by towing, for example, if the

battery is flat or if the starter motor does not work.
7. Instructions for tow starts and when towing 21

8 Repair instructions
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. Always observe the
basic safety rules when performing servicing procedures.
Here follows a series of general valid instructions for the different
repair processes, which are repeated in other areas of the repair
manual. They apply for this individual Workshop Manual.
Guided fault location, vehicle self-diagnosis and measurement
module
♦ Before commencing any repairs to the gearbox, the cause of
the fault must be determined as accurately as possible using
the central diagnosis -VAS 505X- in the operative modes „Gui‐
ded fault location“, „Vehicle self-diagnosis“ and „Measurement
module“.
Special instructions for fault finding

♦ Selector lever position indicator - without „R“: Simultaneous

illumination of all segments of the selector lever position indi‐
cator specifies an emergency run of the gearbox. The vehicle
cannot drive backwards any more.
♦ The Tiptronic does not work - Gear change not possible:
Check the locking disc of the support bracket for selector lever
cable in the top part of the gearbox
Note
If the »correct voltage« is no longer at hand, undo the locking

-B-. The -arrow- points in the direction of the adjustment screw of
the control cable.
♦ Insufficient »drive« - Possible oil deficiency: Only fill oil after

the ⇒ page 19 „Oil level check and troubleshooting“.
♦ No fault found. As a matter of experience, it is common that
the gearbox is made responsible for »faults« that are caused
by other components or units. There were some cases that a
faulty behaviour of the gearbox occurred that had been trig‐
gered by a defective air supply to the engine. Such mistakes
must be avoided at all costs. If this type of fault is already ex‐
empted, under certain circumstances work can be carried out
using the testing equipment from SEAT.
♦ Error at hand: First the meaning of the registered fault has to
be understood. The testing equipment of SEAT includes the
function Guided Fault Finding . When used correctly, the
Guided Fault Finding allows a large number of faults to be
detected.
♦ Presence of a fault »not caused on the gearbox side«: If, for
example, the gearbox registers a fault that the „ABS Signal
Missing“ and there may be another controller that specifies
that the „ABS Signal Missing“, one can assume that this can‐
not lead to the gearbox being »faulty«. This entry only means
that the gearbox (and possibly another controller)is waiting to
receive a signal via the data bus that, however, is not arriving.
In this case, it is more than likely that the controller for the ABS
is faulty. For this reason, the mechatronic control unit for the
DSG automaticrespectgearbox -J743- should notinbethisremoved without

to the correctness of information document. Copyright by SEAT S.A.
cause. In this example, the fault indicated a problem with the
ABS system.
Gearbox:
♦ If the oil sump has been removed or if gear oil is needed, do
not start the engine or tow the vehicle.
♦ After replacing the gearbox, verify the gearbox oil level
⇒ page 116 and complete if necessary. Level quantities and
specifications ⇒ page 14 .
♦ Thoroughly clean unions and adjacent areas before removing.
♦ When assembling check that fitting sleeves are correctly posi‐
tioned.
O-rings, seals, gaskets
♦ O-rings, flanges and gaskets should always be replaced.
♦ After removing gaskets, check the contact surfaces of the cas‐
ing and shaft for feathering or damage caused by the removal
process.
♦ Always replace paper gaskets, completely disposing of the
used gasket and thoroughly cleaning the contact surfaces.
8. Repair instructions 23
♦ In order to fit flanges apply gear oil around the outer edge and
on the sealing lip.
♦ Coat the O-rings with gear oil or Vaseline before fitting to avoid
crushing during assembly.
♦ Never use other lubricants in the gear oil area. Otherwise there
is a danger of operation faults in the hydraulic gear mecha‐
nism.
♦ The open side of the seals should face the liquid to be retained.
♦ Follow rules for cleanliness: ⇒ page 25 .
♦ After assembly, check the level of the gear oil and top up if
necessary: ⇒ page 116 .
Safety locks
♦ Do not over expand the securing rings; replace them if nec‐
essary.
♦ Securing rings must be well seated in the groove.
Bolts, nuts
♦ The bolts are removed in reverse order to the tightening se‐
quence.
♦ If no tightening sequence is specified, nuts and bolts used to
fix covers and casings should be tightened and loosened in
stages and in diagonal pairs.
♦ Renew self-locking nuts.
♦ The thread of bolts threaded with a fixing agent should be
cleaned using a wire brush. Next, position the bolts with AMV
185 101 A1.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
Electrical components
You are bound to have received an electric shock at some time

on touching metal objects, caused by the electrostatic charge of
the human body. This charge can cause malfunctions if you touch
the electric steering box components and the gear selection
mechanism.
– Before proceeding with work on electric components, you
should touch an object that has an earthing cable. Never touch
contacts nor electric components directly.

9 Cleaning norms when working in the

gearbox
♦ Thoroughly clean unions and adjacent areas before removing.
♦ Place removed parts on a clean surface and cover. Use foil or
paper. Use only lint-free cloths.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
♦ Only fit clean parts: only remove replacement parts from pack‐
aging immediately prior to installation.
♦ O-rings, flanges and gaskets should always be replaced.
♦ Always replace paper gaskets, completely disposing of the
used gasket and thoroughly cleaning the contact surfaces.
♦ The thread of bolts threaded with a fixing agent should be
cleaned using a wire brush. Next, position the bolts with AMV
185 101 A1.
9. Cleaning norms when working in the gearbox 25

30 – Clutch
1 Notes on clutch*
*
When carefully considered, the term »clutch« is not exactly cor‐
rect. The clutch of a DSG® comprises always of at least 2 clutch‐
es. So the term „multi-clutch“ is more appropriate. In this case,
the clutch has 2 sets of plates - making it a wet clutch. The outer,
larger set of plates is called „C 1“ (clutch 1). The „C 1“ selects
reverse gear and gears »1«, »3« and »5«. The smaller set of
plates (on the inside) is designated „K 2“ (clutch 2), and controls
the torque flow for gears »2«, »4« and »6«.
Any assembly work performed on the multiple clutch requires ex‐
tra care as all the components are calibrated and matched to‐
gether in production. If parts are rotated relative to each other
during assembly, imbalances develop which are detrimental to
ease of shifting and service life.
Therefore, genuine clutches are supplied with a built-in retaining
ring.
To avoid the risk of parts rotating relative to each other, the meth‐
od of assembling and installing the clutch in the gearbox housing
is shown here. Therefore, you should carefully refer to this de‐
scription ⇒ page 27 .
26 Rep. gr.30 - Clutch

2 Clutch: removing and installing

The cover over the clutch must be removed before the clutch can
be removed ⇒ page 27 .
2.1 Removing clutch cover (end cover)

Brief description
The cover closes the gearbox to the outside. It is retained in its
seating using a retaining ring. After the retaining ring has been
removed, the cover can be levered out of its seat. Cover and re‐
taining ring must always be renewed. Never install a new cover
with a hammer and never oil the centre seal or touch it with a
hand! However, if this should happen, the cover is certain to leak!
The gearbox must be removed for work on cover.
– Remove gearbox ⇒ page 97 .
– Mount gearbox on assembly stand ⇒ page 114 .
– Drain oil.
To gearbox manufacture date „20 September 2004“, gearboxes
were constructed with 2 plugs.
The second plug was then discontinued, and oil can only be
drained and the level checked with plug -A-.
There is a black plastic overflow tube in the hole (with an interior
8 mm nut, tightening torque: 3 Nm) is located behind the plug. Its
length determines the oil level in the gearbox.
– Remove this oil pipe.
– Drain oil.by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– Screwrespect
in overflow tubeofagain
to the correctness hand-tight,
information 3 Nm.
in this document. Copyright by SEAT S.A.
– Install drain plug -A- with new seal.

Tightening torque: 45 Nm
2. Clutch: removing and installing 27

– Remove filter if necessary.

Often, doubts arise as to whether the filter must be renewed or
not.
The notes on the oil filter change can help you in reaching this
decision ⇒ page 19 .
– Insert new filter with shoulder downwards and tighten cover to

20 Nm.
– Following repair work, it is not necessary to change filter again

when filling oil.
Remove cover.
– Remove retaining ring from cover.

Cover can be levered out with a screwdriver.
Install only a »new« cover ⇒ page 29 .

2.2 Installing clutch cover (end cover)

There are 2 types of cover.
♦ Covers supplied without a bush ⇒ page 29

♦ Covers supplied with a white bush ⇒ page 31
2.2.1 Covers supplied without a bush

Cover and retaining ring must always be renewed. Never install
a new cover with a hammer and never oil the centre seal or touch
it with a hand!
Caution
Do not grasp new cover in centre hole. The hole of the cover
must not be touched, oiled or brought into contact with other
materials. Leaks will result.
– Always handle cover only as shown -in this picture-!
Special tools and workshop equipment required

♦ Assembly sleeve -T10302- „Clean before using. Do not use a

scratched sleeve“.
New cover must be free of oil and dry around centre seal!
– If necessary, clean end of clutch shaft.
There must be no stickers on the inside of the cover.
– If any stickers are present, remove them carefully!
Moisten only the outer edge of the seal for the DSG® gearbox oil.
– Set sleeve on a flat surface.
The centre seal of the new cover must now be »preformed«:
– Guide cover horizontally and evenly over entire sleeve. This

will bring the sealing lip into installation position.
– Now remove sleeve upwards out of cover and set sleeve on
end of clutch shaft.
– Guide cover horizontally over assembly sleeve and press cov‐

er down evenly onto its seat.
Caution
Handle with care. Any sort of blow to the cover is certain to

cause leaks.

It is possible to lever cover carefully into its seat with a

-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.
2.2.2 Covers supplied with a bush

Cover and retaining ring must always be renewed. Never install
a new cover with a hammer and never oil the centre seal or touch
it with a hand!
Caution
Do not grasp new cover in centre hole. The hole of the cover
must not be touched, oiled or brought into contact with other
materials. Leaks will result.
Do not remove bush!
New cover must be free of oil and dry around centre seal!
– If necessary, clean end of clutch shaft.
There must be no stickers on the inside of the cover.
– If any stickers are present, remove them carefully!
Moisten only the outer edge of the seal for the DSG® gearbox oil.

– Insert cover with bush.
Caution
Handle with care. Any sort of blow to the cover is certain to

cause leaks.
It is possible to lever cover carefully into its seat with a

-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.
– Do not remove bush until retaining ring is installed.
2.3 Removing clutch

To remove or install clutch, gearbox must be securely attached
to an assembly stand in vertical position.
– Remove clutch cover (end cover) ⇒ page 27 .
– Remove retaining ring from clutch cover.
– Remove cover from clutch.

– Remove circlip -arrow-.

For your information: During assembly, the retaining ring must be
replaced with a new circlip of the correct thickness.
Caution
Carefully remove clutch. Ensure that end cover or other parts

of clutch do not fall out. Therefore, do not turn over clutch under
any circumstances!
But if this should happen ⇒ page 40 .
– Remove clutch.
– Remove pump shaft -A-.

– The pump shaft is not re-installed until after the new clutch has
been fitted. Set shaft aside until then.
2.4 Preparing installation of multi-clutch

Multi-clutch as Genuine part

1 - Multiple clutch
❑ The cover of a new
clutch is secured with a
retaining ring.
2 - 10 retaining rings
❑ Rings have different
thicknesses. They are
sized in 0.1 mm incre‐
ments.
❑ Refer to instructions in
⇒ page 35 .
3 - Cover (end cover)
❑ Ensure that inner seal‐
ing lip is not damaged
⇒ page 29 . Manufactur‐
er inserts a bush to pro‐
tect sealing lip. Please
leave this bush in cover.
4 - Circlip
❑ For cover.
– When removing clutch from packing, press on clutch cover.

This is to prevent the clutch cover and the plate carriers beneath
it from sliding out of the inner plates.

– Ensure that the 4 -piston rings- are properly seated.

Ring gaps should not be »over each other«.
– Turn rings once. They must move freely and must not bind.
Important: Position of clutch cover

– Please check whether there is a marking on clutch -arrow-.
– If there is no mark, make a coloured mark. Later the »lug« of
the cover must be placed at the marked spot.
Set down clutch so that it cannot tip over.
The clutch is now ready for installation ⇒ page 35 .
2.5 Installing and adjusting clutch
Caution
Avoid removing or lifting plate carrier. Not even a little bit! The
plates could turn.
Brief description
• Gearbox must be turned vertical in assembly bracket. Only this
way is it possible later to adjust axial play of the clutch without
error.
• It is essential that the gearbox be securely clamped in support
clamp -VW 313- or engine and gearbox support -VAS 6095-
⇒ page 114 . It must not be turned.
• Inside the clutch, the large plate carrier goes through all plates.
It must not slip out of the lowest plates.
• The oil pump shaft is removed.
• DoProtected
not install corrugated
by copyright. retaining
Copying for private rings purposes, in part or in whole, is not
or commercial

♦ Retaining pin -T10303-
– First set -retaining pin- on seat of cover.
– Then insert -clutch- without letting it fall in.

Do not mount on clutch. Clutch is inserted with cover as it was
when packaged.
– The -retaining pin- should be held by a second mechanic in

the process.
-Retaining pin- remains inserted until all further work has been
completed.
Do not remove the pin until instructed to do so. But not yet.

– Carefully remove clutch cover -arrow- from clutch and lay it to

side.
Caution
Avoid removing or lifting plate carrier. Not even a little bit! The
plates could turn.
– Select retaining ring with -2 millimetre diameter- from among

the rings supplied and install it temporarily.
Before this ring is removed again, 2 measurements must be
made.
First measurement:
• Retaining pin -T10303- remains in!
– Screw universal dial gauge -VW 387- to gearbox flange.
– Set -tip of dial gauge- on input shaft.

– Set -dial gauge- to 0 with preload.
– Raise clutch to stop and note result of measurement.
Second measurement:
• Retaining pinpermitted
-T10303- remains in!
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Set tip of dial gauge -on hub of large plate carrier-.

Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.
– Raise clutch to stop again and also note this result.
Now it can be determined which of the remaining 9 rings will ulti‐
mately be installed:
– Use this formula:
Second measurement - first measurement + 1.85 mm = thick‐
ness of ring to be installed
– Please note down this result.
The remaining 9 retaining rings are in increments of 0.1 millimetre.

– Measure all rings and determine which ring is closest to your
result.
– Remove 2 mm thick ring and install calculated ring.
– Dispose of all remaining rings and the 2 mm ring.
Retaining rings are only allowed to be installed once.
– Insert -pump shaft-.

– Install clutch cover so that lug aligns with marking.
– Then remove retaining pin -T10303- .

– Install cover (end cover) ⇒ page 29 .
This concludes the installation and the clutch is correctly adjusted.
After installing gearbox
– Conduct basic adjustment of mechatronic unit for dual clutch
gearbox -J743- .

Special care
Any assembly work performed on the multiple clutch requires ex‐
tra care as all the components are calibrated and matched to‐
gether in production. If parts are turned relative to each other,
imbalances result which reduce ease of shifting and service life.
If parts of clutch have slipped out or plate carriers have been lifted:
Then the large plate carrier and if necessary, also the small one
can be threaded into all inner plates with gentle turning move‐
ments.
Especially the clutchbycover should always
does not be installed inany
theliability
same
permitted unless authorised SEAT S.A. SEAT S.A guarantee or accept with
position as towas
respect the case
the correctness in the »delivery«
of information ofCopyright
in this document. the new clutch.
by SEAT S.A.
⇒ page 35

1 - Multiple clutch/clutch hous‐

ing
2 - Seal
❑ 4x
3 - Large plate carrier
❑ Do not remove
Caution
Avoid removing or lifting
plate carrier. Not even a
little bit! The plates could
turn.
4 - Outer plate
❑ 4x
5 - Inner plate
❑ 4x
6 - Thrust washer
7 - Circlip
❑ If retaining ring was re‐
moved to insert new
plates, it should be re‐
newed with
Protected by a new,
copyright. Copying for private or commercial purposes, in part or in whole, is not
equally thick ring

8 - Circlip
❑ This ring must be re‐
measured each time the
clutch is installed
9 - Clutch cover
10 - Circlip
❑ Always replace.
❑ Do not install corrugated retaining rings

34 – Controls, housing
1 Electric/electronic components and as‐
sembly positions
Diagnostics connection
Installation location: the diagnosis socket is located below the
footwell cover, driver's side ⇒ Bodywork, interior fitting work; Rep.
gr. 68 .
Selector lever locking solenoid -N110-

Installation location: the selector lever locking solenoid -1- is lo‐
cated in the gear selection mechanism.
The magnet is a fixed component of the gear selection mecha‐
nism, and can therefore not be replaced separately. It can only
be removed or fitted together with the gear selection mechanism.
⇒ page 80
Mecatronic unit for the semi-automatic gearbox -J743-

Installation location: the mechatronics unit for dual clutch gearbox
-J743- is screwed onto the front side of the gearbox and is cov‐
ered by the oil sump of the gearbox.
The control unit is integrated fixed in the mechatronics unit for
dual clutch gearbox - J743- .
♦ Verified by self-diagnosis
Removing and installing the Mechatronic unit for the semi-auto‐
matic gearbox -J743- with the gearbox fitted ⇒ page 44 .
Removing and installing the mechatronic unit for the semi-auto‐
matic gearbox -J743- with the gearbox removed.
42 Rep. gr.34 - Controls, housing

Tiptronic switch -F189-

Installation location: The Tiptronic switch -F189- is securely inte‐
grated on the printed circuit board -B- of the gearbox control.
The Tiptronic switch is a fixed component of the gear selection
mechanism, and can therefore not be replaced separately. It can
only be removed or fitted together with the gear selection mech‐
anism. ⇒ page 80
Gear selector position indicator -Y6-

Installation location: Integrated in dash panel insert.
Note
The selector lever position indicator can only be replaced together

with the dash panel.
If the selector lever position indicator is flashing or lit up, the gear‐
box control unit safety functions should be observed ⇒ page 16
♦ Removing and assembling the selector
Protected leverCopying
by copyright. position indicator
-Y6- ⇒ Electrical system; Rep. gr.unless
permitted 90authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Selector level locking switch in P -F319-

Installation location: the selector level locking switch in P -F319-
is an integral component of the printed circuit board -B- of the gear
selection mechanism.
It is necessary to replace the gear selection control in order to
change the switch ⇒ page 80
Gate selector lever -E313-

Installation location: the electrical component selector leveer -
E313- is an integral component of the printed circuit board -B- of
the gear selection control.
It is necessary to replace the gear selection control in order to
change the switch ⇒ page 80
Vehicles up to ►2009
1. 43
Brake light switch -F-

Installation location: the brake light switch -arrow- is located at
pedal cluster.
Vehicles from 2009►
Brake light switch -F-

Installation location: The brake light switch -arrow- is located on
the brake pump. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Removing and installing ⇒ brake system; Rep. gr. 46 .
Note
To ensure a good fit, the switch should only be mounted once.
Kick-down switch -F8-

Installation location:
♦ In vehicles with a petrol-fuelled engine a set value is stored by
the accelerator pedal position senders -G79/G185 - , in the
engine control unit.
♦ Checked by the self-diagnosis.
♦ Signal transmission from the engine control unit to that of the
gearbox by the CAN bus.
♦ Removing and installing accelerator pedal module ⇒ Rep. gr.
20
Printed circuit board for the selector lever
The printed circuit board for the selector lever is an integral part
of the selector lever handle and cover unit for the gear selection
mechanism, and can therefore not be replaced alone. If a re‐
placement is required, it is necessary to replace the entire selec‐
tor lever handle and cover for the gear selection mechanism
⇒ page 76 .
1.1 Mechatronic unit for the semi-automatic

gearbox - J743 - : Removing and instal‐
ling (with gearbox installed)
⇒ „1.2 Mechatronic unit for the semi-automatic gearbox J743 :
Removing and installing (with gearbox removed)“, page 54
Consult the equivalence table for tools and equipment according
to applicability among Seat / VW / Audi / Skoda ⇒ page 131 .

♦ Extractor -SAT 1100- , see equivalent ⇒ page 131
♦ Torque wrench kit -SAT 8010- , see equivalent ⇒ page 131
♦ Adapter for oil filling -VAS 6262 A-
♦ Assembly tool -T10465-
When the gearbox is »open«, extreme care must be taken to pre‐

vent dirt from enteringpermitted
into it.unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
In particular, dirt may enter when the mechatronic control unit for
the dual clutch automatic gearbox (DSG) -J743- or the oil pump
are open, causing damage to the gearbox.
1. 45
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 19 .
When the gearbox is very hot, the mechatronics on the dowel pins
may block. In this case, allow the gearbox to cool down.
1.1.1 Remove the mechatronic unit for dual

clutch gearbox -J743 -
– Raise the vehicle. In doing so, place the supports of the lifting
platform at the same height.
– Put the gear selector lever into position „P“.
– With ignition switched off, disconnect earth connection
-arrow- from the battery⇒ Electrical system; Rep. gr. 27 .
– Remove central soundproofing, bolts -1 ... 3-.
– If fitted, remove the hose joining the intercooler and the boos‐
ter air pipe ⇒ Intercooler system; Rep. gr. 21 .
Note
Parts may have to be removed that do not belong to the mecha‐

tronics. This is dependent on the vehicle equipment. In this way,
space is made in order to remove the mechatronics.

♦ Depending on the vehicle, these parts may include, for exam‐

ple,
♦ Radiator fan support
♦ Additional lines for air conditioner
♦ Charge air or air cooling pipes
– To unlock and remove the plug connection of the mechatron‐

ics -1-, turn the catch of the plug connection.
Note
Disregarding of -item A-.
– Unscrew the cable bracket from the gearbox cover (on the
front side).
– Tie the pipes in the area around the cover high up.
– Place the oil extractor -SAT 1100- below the gearbox.
Caution
Some oil will run out of the cover when the screws are removed.
The hot gearbox oil may cause burns.
– Loosen bolts -arrows- of cover diagonally and remove. Hold

the cover tight whilst doing this.
– Allow the oil to drain and then remove the cover with the seal.
About 3 litres of oil will drain.
Note
♦ The screws of the cover must be replaced.

♦ The seal of the cover must also be replaced.
1. 47
– Remove cover of the gear oil pump -A-.
– Screw out the bolts -2, 3- that fix the pendulum support to
gearbox ⇒ Rep. gr. 40 .
In this case, the gearbox can be pushed backwards slightly.
Before making contact with the mechatronics, first make contact

with an object that has an earth ⇒ page 24 .
– Release connector -1- of gearbox input speed sender -G182-

and oil temperature sender
Protected by copyright. in multi-plate
Copying clutchpurposes,
for private or commercial -G509-in using
part or in whole, is not
release permitted
tool -T10465- and pull connector off.

– First remove the cable from the lower fastener -arrow I-.
– Then remove it from upper clip -arrow II- and lay to side. Do
not bend the cable.
– Unscrew attachment bolts -1- to -10- in the order shown.
– Carefully remove the mechatronic control unit from the gear‐

box casing until the sensor arm -B- at the side is outside of the
casing.
When working with the mechatronic control unit, special care
should be taken with the »long« sensor arm.
– Carefully remove the mechatronic control unit -J743- by turn‐
ing it downwards.
1. 49
Deposit the mechatronic control unit correctly.
Caution
Never lift the mechatronic control unit by the »sensor arm« nor
lean the unit on the arm.
If the arm is damaged, the mechatronic control unit must be re‐

placed.
1.1.2 Mechatronic unit for the semi-automatic

gearbox -J743 - : Install
Before making contact with the mechatronics, first make contact
with an object that has an earth ⇒ page 24 .
Installation is carried out in the reverse order, noting the following:

– Place the mechatronic control unit -J743- on the gearbox cas‐

ing carefully.
Note
♦ The side cover was not dismantled during removal.

♦ For reasons of illustration, the cover on the side has been re‐
moved in the figure.
– Do not pinch wiring.

Take care not to trap the cable.
– The mechatronic unit must be carefully fitted onto the dowel
pins -arrow-. Make sure that the »sensor arm« is in
-its assembly position-.
– Check that mechatronic unit is mounted correctly.
– Hand tighten new bolts -1- to -10-.

– Tighten the bolts in the order shown, to 5 Nm + 90° (1/4 turn).
– First hook the cable -A- on the upper fastening tab and then
on the lower tab -arrows-.
– Plug in the connector and fit it in socket.
– Replace the two -O-rings- if the »old« mechatronic control unit

is to be reassembled.
– Lubricate the O-rings with gearbox oil for DSG dual clutch.
– Clean the seal of the cover and the seal surface on the gear‐
box.
– Make sure that the seal isProtected
correctly fitted. Copying for private or commercial purposes, in part or in whole, is not
by copyright.
– Put the cover on the mechatronics.
respect toDo not attach
the correctness any tubes
of information in thisin
document. Copyright by SEAT S.A.
doing so.
1. 51
– Thread on and tighten new screws -arrows- in diagonal pairs

and in stages to a torque of 10 Nm.
– Connect the connector of the mechatronic control unit of the
DSG automatic gearbox -J743- and then turn the lock to en‐
gage it.
– Fit new cover on the gearbox oil pump -A- and tighten the
screws -arrows- in diagonal pairs and in stages to a torque of
8 Nm.
– Fit the cable support on the cover and tighten the nuts to a
torque of 10 Nm.
– Connect the connector of the mechatronic control unit of the
DSG automatic gearbox -J743- and then turn the lock to en‐
gage it.
– If fitted, fit the hose joining the intercooler and the booster air
pipe ⇒ Rep. gr. 21 ; Intercooler system components: Remov‐
ing and installing .
– Reassemble all vehicle components which have been re‐
moved.
– Fit the cable support on the large cover and tighten the nuts
to a torque of 10 Nm.
– Reassemble all vehicle components which have been re‐
moved.
– Connect the battery earth strap ⇒ Electrical system; Rep. gr.
27
– Do not start the engine.

– The filter has to be replaced if the oil is dirty ⇒ page 116 .
– Connect ⇒unless
permitted Vehicle diagnostic,
authorised by SEAT S.A.testing
SEAT S.Aand information
does not system
guarantee or accept any liability with
VAS 5051. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Fit the oil tray -SAT 1100- under the drain plug of the gearbox.

– Undo the drain plug -arrow- located near to the pendulum

support.
– Before screwing adapter for oil filling -VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a- and
shorten ⇒ page 116 .
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
counting glass) of the adapter for oil filling -VAS 6262 A- .
– Screw the adapter for filling -VAS 6262 A- hand tight into the
inspection hole.
1. 53
– Shake the bottles before opening them.

– Top up with 3 litres of oil.
– To change the bottle, the valve must be closed or the adapter
for the oil filling -VAS 6262 A- must be held above the gearbox.
Then start the engine, check the oil and top up with oil when re‐
quired. The adapter for the oil filling -VAS 6262 A- must remain
installed.
– Check the oil level and top-up if necessary ⇒ page 117 .
– Install the noise insulation ⇒ Exterior body installation work;
Rep. gr. 50 ; Noise insulation; Noise insulation: assembly
overview .
– Make the basic adjustment using the central diagnosis -VAS
505X- .
1.2 Mechatronic unit for the semi-automatic

gearbox - J743 - : Removing and instal‐
ling (with gearbox removed)
⇒ „1.1 Mechatronic unit for the semi-automatic gearbox J743 :
Removing and installing (with gearbox installed)“, page 44
Always make sure that no dirt can enter an »open« gearbox.
In particular, dirt entering an exposed mechatronic unit for dual
clutch gearbox -J743- and / or oil pump can lead to gearbox fail‐
ure.
Please also refer to the
permitted notes
unless on by
authorised the oilS.A.
SEAT filter change
SEAT regarding
S.A does not guarantee or accept any liability with
»dirty oil« ⇒ page 19 . to the correctness of information in this document. Copyright by SEAT S.A.
respect
1.2.1 Remove the mechatronic unit for dual

clutch gearbox -J743 -
– Undo the bolt -A- which is near the pendulum support.
Note
Some gearboxes, depending upon versions, may have two dif‐

ferent screws

Approximately 5.0 litres of oil should drain out. The oil extractor -
SAT 1100- should remain under the gearbox.
– Thread overflow pipe back on, 3 Nm.

– Remove the filter, where necessary.

For further information, we recommend reading the notes on
changing the oil filter ⇒ page 19 .
– Place the new filter with the collar facing down, and tighten the
case to a torque of 20Nm.
– After repair, it is not necessary to replace the filter again when
adding oil.
– Remove both -covers-.

Always replace the »small« cover on the oil pump and the bolts
on the »large« cover.
Likewise, seal of »large« cover must be renewed.
Before touching mechatronic
respect tounit, touch an
the correctness earthed
of information object
in this document. Copyright by SEAT S.A.
⇒ page 24 .
1. 55
– Release connector -1- of gearbox input speed sender -G182-

and oil temperature sender in multi-plate clutch -G509- using
release tool -T10465- and pull connector off.
– First remove the cable from the lower fastener -arrow I-.
– Then remove from the second fastener -arrow II- and place to
one side. Do not bend the cable.
– Unscrew the -fastening bolts- in diagonal pairs. Start with bolt

-1-.
The 10 -fastening bolts- should be replaced.

– Remove the mechatronic control unit -J743- .

When working with the mechatronic control unit, special care
should be taken with the »long« sensor arm.
Caution
Never lift the mechatronic control unit by the sensor arm nor

placed.
– Deposit the mechatronic control unit correctly.
Deposit the mechatronic control unit correctly.
1.2.2 Mechatronic unit for the semi-automatic

gearbox -J743 - : Install
Caution
Never lift the mechatronic control unit by the sensor arm nor
1. 57

placed.
– Before assembly make sure that the gearbox input speed

sender -G182- and the clutch temperature sender -G509 - are
mounted.
– Replace the two -O-rings- of the connection if the mechatronic

control unit is to be reassembled.
– Lubricate the O-rings with gearbox oil for DSG dual clutch.

– Carefully place the mechatronic control unit on the pins

-arrow-. Make sure that the »sensor arm« is in
-its assembly position-.
– Do not pinch wiring.
Take care not to trap the cable.
The 10 -fastening bolts- should be replaced.

– First tighten all the -fastening bolts- »by hand«.
– Then tighten the 10 -bolts- in diagonal pairs to a torque of 5
Nm and retighten 90° in the same order. Start with bolt -1-.
– First insert the cable of the gearbox intake speed sender -

G182- and the clutch temperature sender -G509- in fastener
-II-. Then in fastener -I-.
– Insert connector in the mechatronic control unit.
Always replace the »small« cover on the oil pump and the bolts
on the »large« cover.
1. 59
Likewise, -seal- of »large« -cover- must be renewed.

– Tighten the screws cross-wise to 10 Nm.
After installing gearbox
– Fill with gear oil without replacing the filter ⇒ page 116 .
– Make the basic adjustment using the central diagnosis -VAS
505X- .
1.3 Gearbox input speed sender -G182- / oil

temperature sender for multi-plate
clutch -G509 - Removing and installing
Brief description
Both sensors form one component and may be only be replaced
together. They are in an »oil bath« in the gearbox close to the
multiple clutch. Before removal, the mechatronic unit for dual
clutch gearbox -J743- must be removed.
The sensor cable is often damaged due to pulling on it. If the cable
is pulled, the sensor must be replaced
1.3.1 Detaching
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are »bathed in oil« in gearbox near
the multi-clutch. Before removal, the mechatronic unit for dual
clutch gearbox -J743- must be removed.
The sensor cable is often damaged due to pulling on it. Conse‐
quently, if the cable is pulled on, the sender must be renewed.
– Remove the mechatronic unit for dual clutch gearbox -J743-
⇒ page 44 .
Do not pull on the cable.

– Undo the bolt and remove the sender by carefully levering with
a screwdriver and/or pliers.
1.3.2 Installing
Only fit used senders if you are sure that:
• The sender is not defective.
• The cable was not pulled when removing it.
Otherwise, a new sender should be mounted.
– Fit the sender, lubricated with gear oil.
– Tighten bolt to 10 Nm.
– Fit the mechatronic control unit -J743- ⇒ page 44 .
Take special care not to trap the cable when fitting the mecha‐
tronic control unit.
1.4 Tiptronic switch -F189 - : removing and

fitting
The Tiptronic switch -F189- is a fixed component of the gear se‐
lection mechanism, and can therefore not be replaced separately.
It is necessary to replace
respect tothe gear selection
the correctness mechanism
of information inCopyright
in this document. order by SEAT S.A.
to change the switch ⇒ page 80 .
1.5 Selector lever locking solenoid -N110 - :

removing and assembling
The solenoid for the selector lever locking -N110- is a fixed com‐
ponent of the gear selection mechanism, and can therefore not
be replaced separately. It is necessary to replace the gear selec‐
tion mechanism in order to change the switch ⇒ page 80 .
1. 61
2 Removing and installing oil sump

♦ Torque wrench kit -SAT 8010-respect
, seetoequivalent ⇒information
the correctness of page 131 in this document. Copyright by SEAT S.A.
♦ Protective glasses
Removal:
• Engine switched off.
WARNING
If the oil sump has been removed or if gear oil is needed, do

Note
♦ Cleaning norms when working in the gearbox ⇒ page 25 .

♦ General repair instructions. ⇒ page 22
♦ Pay attention to the notes relative to the semi-automatic gear‐
box 02E ⇒ page 18 .
♦ Lubricate the o-rings and seals with gear oil. Other lubricants
can cause malfunctions in the hydraulic gear control.

WARNING
Take all the necessary precautionary measures when discon‐

necting the battery ⇒ Electrical system; Rep. gr. 27
– With ignition switched off, disconnect earth connection

-arrow- from the battery⇒ Electrical system; Rep. gr. 27 .

– Unbolt the two bolts holding the support onto the front section
of the gearbox oil sump.
Note
The threaded bolts are welded to the oil sump in the front section
of the gearbox.
– Press out the threaded bolt support from the gearbox oil sump
and place it above.
– If there is one, remove the protective plate located in the lower

section of the gearbox -arrows-.
– Fit the tray oil extractor -SAT 1100- beneath gearbox.
WARNING
Wear eye protection.
– Empty the gearbox oil ⇒ page 116 .
2. Removing and installing oil sump 63

– Release the bayonet lock -1- of the 20-contact connector from

the gearbox, by turning and disconnecting.
– Touch the vehicle earth with the hand (without gloves) to re‐
lease static energy.
WARNING
The person who is going to touch or remove the mechatronic

system for the automatic DSG gearbox - J743- should first re‐
lease static energy by touching an earthed object, e.g. the
vehicle earth.
The gearbox connector contacts should never be touched with
the hands, as this may damage the control unit and, therefore,
the Mecatronic as a result of a discharge of static energy
– Unscrew the 5 screws of the oil sump -arrows- diagonally.

– The bolts must be replaced.
Note
There is still gear oil in the sump as it is not possible for all the oil
to drain out.
– Remove the oil sump together with the oil sump gasket.
Installation
– Replace the O-rings -B- of the 20 contact connector of the
mecatronic system for the automatic DSG gearbox - J743- .
– Moisten the O-rings with gear oil.
– Clean the gasket and seal surfaces and remove all traces of
oil.
– Ensure that the sump gasket is correctly fitted.
– Check that no cable or tube is snagged when fitting the oil
sump.

– Tighten the 5 new bolts of the oil sump -arrows- in diagonal

pairs and in stages.
Component Nm
Oil sump to gearbox housing 10
5 bolts M6 (tighten in diagonal pairs and in
stages)
– Replace the seal of the drain plug.
– Undo the drain plug -A-.

Component Nm
Drain plug to gearbox, M24 45
– Fill with gear oil ⇒ page 116
Replace the check plug seal after checking gear oil.
– Connect battery ⇒ Electrical system; Rep. gr. 27 .
– Take all the necessary precautionary measures when con‐
Tightening torques
Component Nm
Drain plug to gearbox, M24 45
Check plug to gearbox, M24 45
Oil sump to gearbox housing 10
5 bolts M6 (tighten in diagonal pairs and in
stages)
2. Removing and installing oil sump 65

3 Removing and installing gearbox oil

cooler
♦ Hose clamp -U-30042 - , see equivalent ⇒ page 132
Removal:
– Switch ignition OFF.
– Clamp shut each of the transmission oil radiator hoses using
the pressure tool - U-30042- and dismount from the radiator.

– Undo the three bolts -A-.

– Remove the transmission oil radiator from the gearbox -B- with
the two O rings -C-.
WARNING
Coolant must not enter the gearbox!
Installation
taken into account:
– Replace radiator O-rings.
– Tighten the new bolts -A- with 20 Nm + 90° (1/4 turn).
– Check the coolant level in the cooling system ⇒ Rep. gr. 19 .

– Check the gear oil level and top up as necessary
⇒ page 116 .
3. Removing and installing gearbox oil cooler 67

4 Gear oil pump: dismounting and as‐

sembly
♦ Protective glasses
Conditions:
WARNING
If the oil sump has been removed or if gear oil is needed, do

Note

♦ The paper gasket between the gear oil pump and the gearbox
should always be replaced.
♦ The cover of the oil pump should always be replaced.

Removal:
Note
The oil pump can be replaced without removing the gearbox. To

do so, raise the vehicle and remove the covers on the lower front
section. It is not necessary to separate the swinging arm from the
telescopic arm. Nor is it necessary to remove the drive shaft. Nor
run „basic settings adjustment“. It is only necessary to change the
gear oil ⇒ page 116 and the pump cover.
WARNING
Wear eye protection.
– Dismounting the left-hand soundproofing -arrows-.

– Fit the tray oil extractor -SAT 1100- beneath gearbox.
– Undo the bolt -A- which is near the pendulum support.

Note
Some gearboxes, depending upon versions, may have two dif‐

ferent screws

– Drain oil.
For further information, we recommend reading the notes on
changing the oil filter ⇒ page 19 .
– Thread overflow pipe back on, 3 Nm.
4. Gear oil pump: dismounting and assembly 69

– Replace the seal -arrow- of the bolt.
– Take out the bolts -arrows- and remove the cover of the gear
oil pump -A-.
– Take out theto bolts
respect -arrows-
the correctness and liftin this
of information outdocument.
the oil Copyright
pump-1- for‐S.A.
by SEAT
wards.
Installation
taken into account:
– Insert the shaft -A- for the oil pump in the gearbox as far as
the stop mark; turn slightly if necessary.
The assembly spacing -a- of the shaft is approximately 23 mm
– In this case, carefully remove any metal shavings that may be
in the drive gear -B-, but do not demagnetise the gear.
– Remove the paper gasket that goes between the oil pump and
the gearbox.
– Remove the rest of the paper gasket and clean the inside of
the gearbox.
– Clean the seal surfaces of the oil pump and the gearbox.
– Insert a new paper gasket between the oil pump and the gear‐
box, attaching if necessary with gear oil.

– Insert the oil pump -1- on the shaft and place ready for as‐
sembly.
– Tighten the new bolts -arrows- in diagonal pairs with 5 Nm +
90° (1/4 turn).
– Replace the gear oil pump cover
– Place the new pump cover in position -A- and tighten the new
bolts -arrows- in diagonal pairs to 8 Nm.
– Fill with gear oil and replace the oil filter ⇒ page 116 .
4. Gear oil pump: dismounting and assembly 71

5 Replace the seal ring for lever of se‐

lector rod shaft
♦ Pipe section -VW 423- , see equivalency ⇒ page 131
♦ Extractor kit -T20143 - , see equivalent ⇒ page 131
Operation process
– Remove the selector lever mechanism ⇒ page 82
– Remove the bolt -arrow- and remove the articulated rod -A-
from the selector shaft by gently prying it apart.

– Remove the seal from the articulated rod in the selector shaft
with the extractor -T20143/1 - .
– Lightly lubricate outer edge of new seal.
– Refill space between sealing lip and dustcap halfway with
sealing grease ⇒ Spare parts catalogue .
– Fit the new seal until it reaches the limit without leaning it on
the tube element -VW 423- .
WARNING
The articulated rod for the shaft selector only fits into one po‐
sition on the perforation.
– Position the articulated rod and tighten the bolt with 20 Nm.
– Assemble the selection lever cable control in the gearbox and
adjust it ⇒ page 82 .
5. Replace the seal ring for lever of selector rod shaft 73

6 Emergency release of gear selection

mechanism from position „P“
♦ Lever -U 30800- , see equivalent ⇒ page 132
The Electro-magnet for locking the selector lever -N110- locks the
selector lever in the position „P“. The selection lever can only be
moved from the „P“ position if, while the ignition is on and/or the
engine is started, the brake pedal is held down and the button on
the handle of the selector lever is pressed in ⇒ page 93 .
If there are faults in the supply voltage of the solenoid for the se‐
lector lever locking (flat battery or defective fuse), or if the solenoid
is faulty, the selector lever can not be taken out of position „P“,
that is, the vehicle cannot be moved because the parking lock is
engaged.
In that case:
– Check fuses ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– check the battery voltage ⇒ Electrical system; Rep. gr. 27 .
If the selector lever can not be taken out of position „P“ in spite of
having carried out the fault location, it is possible to proceed to
the emergency solenoid release. However, if the selector lever
returns to the position „P“, it will be locked once again in position
„P“.
Carry out the emergency release:
– Clip out the trim -arrow- using the lever -U 30800- . Take care
not to scratch or damage trim.
– Lift the trim together with the gear lever boot in the direction
or the -arrows-.
Vehicles up to 02.2009:

– Release the selector lever locking solenoid -A- by pressing the

lever -B- inwards with a screwdriver -arrow- and hold in this
position.
Note
The screwdriver from the vehicle tool set may be used for this
operation.
Vehicles from 03.2009:
– Press against the yellow plastic part in the direction of the

-arrow-.
All vehicles (continued):
WARNING
The gear operation mechanism can only be replaced as a unit,

that is, it any of its components are damaged then the mech‐
anism must be replaced completely.
– With the lever released, now press the button on the handle
and take the selector lever out of position „P“.
Note
However, if the selector lever is moved back to position „P“, the

solenoid will, in turn, mechanically lock it in position „P“ again, and
it will be necessary to unlock it again.
6. Emergency release of gear selection mechanism from position „P“ 75

7 Removing / fitting the gear lever knob

and cover
♦ Lever -U 30800- , see equivalent ⇒ page 132
Removal:
– switch ignition on.
– Move the selector lever to position „D“.
– Carefully lift button -1- away from the selector lever handle
-2- just enough to allow the insertion of a cable clamp between
the button and the selector lever handle.
Note
Do not in any event extract the button, as this will damage the
selector lever handle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Secure the button in the raised position using the cable har‐
ness -arrow-, as shown in the diagram.
– Remove the cover -arrows - using the lever -U-30800 - .
– Disconnect the connector -A- for the printed circuit board in

the cover.
– Remove the whole handle by pulling upwards from the plastic
sleeve-arrow-.
Installation
– Move the selector lever to position „D“.

Note
♦ To fit the selector lever handle -2-, button -1- must be raised
to the maximum, secured with a cable clamp -arrow- or an
assembly tool supplied with the new handle by the manufac‐
turers.
♦ If, by accident, the button was not secured, it must not be re‐
moved from the selector lever handle using auxiliary mechan‐
ical tools. Place a compressed air gun underneath the handle
and make the button come out using compressed air.
– Insert the complete selector lever handle -2- on to the selector

lever; the button -1- must face in the direction of the driver. The
handle should be set onto the selector lever housing.
– Remove the cable harness -arrow- or the assembly aid; the
button mechanism is now inserted into the vertical groove of
the selector lever. If necessary, use pressure to insert the but‐
ton into the selector lever handle.
– Jam the selector lever by pushing the plastic sleeve down in

the opposite direction to that indicated by the -arrows-.
– Measures to be followed after connecting the battery ⇒ Elec‐
trical system; Rep. gr. 27 .
7. Removing / fitting the gear lever knob and cover 77

8 Gear selection mechanism, up to

02.2009
WARNING
Before any repair work with the engine running, put the gear
selector lever into the „P“ position and apply the handbrake.
⇒ „9 Selector mechanism from 03.2009 onwards“, page 89
8.1 Gear selection mechanism, up to 02.2009: Assembly overview
Note
Lubricate the support points and contact surfaces with polycarbamide grease ⇒ Spare parts catalogue .
The ignition key withdrawal lock is not mechanical, with cable, but
electrical.
1 - Selector lever
❑ removing and fitting
⇒ page 76
❑ With handle locking
sleeve, preventing its
extraction
2 - Cover for actioning mecha‐
nism
❑ With selector range and
Tiptronic mode
❑ Forms a unit with the se‐
lector lever handle
❑ With symbols template
and printed circuit board
❑ The printed circuit board
may be checked in the
„Guided fault location“
with the central diagno‐
sis -VAS 505X-
3 - Rubber stop for the selector
lever
❑ Tightly inserted into the
gear selection mecha‐
nism
4 - Gear selection mechanism
(bracket) respect to the correctness of information in this document. Copyright by SEAT S.A.

⇒ page 80
❑ With printed circuit
board for integrated
gear selection mecha‐
nism, do not touch
❑ With integrated Tiptron‐
ic switch -F189- and sol‐
enoid for the selector

lever lock -N110- ; these may be checked using the „Fault location guide“ with the central diagnosis -
VAS 505X-
❑ The Tiptronic switch -F189- can only be replaced by a new gear operation mechanism ⇒ page 61
❑ The Selection lever locking magnet -N110- can only be replaced by a new gear operation mechanism
⇒ page 61
5 - Insertion spring
6 - Bolt, 3.5 Nm
7 - Insertion plate
8 - Bolt, 3.5 Nm
❑ 4x
❑ To attach the insertion plate to the gear selection mechanism
9 - Bearing pin
❑ To attach the selector lever cable to the gear selection mechanism
10 - Locking plate
❑ For selector lever cable to bracket
❑ Always replace.
11 - Panel
❑ For the gear selection mechanism.
❑ With gasket attached Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - Self-locking nut: 9 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ To attach the cover to the gear selection mechanism

❑ 4x
❑ Always replace.
13 - Selector lever cable
❑ Do not bend or kink
❑ Replace the gear selection cable if the protective sheath is damaged
❑ verification and adjustment ⇒ page 86
❑ removing and fitting ⇒ page 82
❑ Do not grease the shaft ring or ball socket
14 - Nut, 13 Nm
❑ for fixing the bracket ⇒ Item 15 (page 79) to the gearbox
❑ 2 off
15 - Spring retainer
❑ For the selector lever cable
16 - Bolt, 23 Nm
❑ To fix the counter support to the gearbox
❑ 2 off
17 - Counter support
❑ For the selector lever cable in the gearbox
18 - Nut, 10 Nm
❑ 4x
❑ For the gear selection mechanism attached to the bodywork
8. Gear selection mechanism, up to 02.2009 79

8.2 Gear selection mechanism, up to

02.2009: Removing and installing
Removal:
– Remove selector lever knob ⇒ page 76 .
– Removing central console ⇒ Bodywork, interior fitting work;
Rep. gr. 68 .
– Disconnect connector -A- from the gear selection mechanism
towards the vehicle set of cables.
– Remove plate safety clip -C-.

– Press the safety washer -A- upwards and remove by turning
clockwise.
– Disengage the selector lever cable from the selector rod shaft,
following the direction indicated by the arrow and place above.
– Do not loosen the bolt -B-.
– Do not bend or twist the selector lever cable.
– Raise the vehicle.


– Dismount primary exhaust pipes with the catalyser and pri‐
mary silencer ⇒ Rep. gr. 26 .
– Remove the attachments -arrows- and extract the heat shield

towards the rear.
Note
To remove the gear selection mechanism, the help of a second

mechanic is required from underneath the vehicle.

– Unscrew the bolts (from above) -arrows-.

– Remove the gear selection mechanism and the selector lever
cable by pulling downwards.
The gear selection mechanism may also be replaced without the
selector cable; To do so, it is necessary to separate the selector
lever cable from the gear selection mechanism and detach the
cable ⇒ page 82 .
Installation
taken into account:
For information about tightening torques of nuts and bolts and
whether it is necessary to replace them, see the chapter, Gear
selection mechanism: disassembling and assembling - Compo‐
nents overview ⇒ page 78 .
– Fit the heat shield and the trimmings from the vehicle under‐
body.
– Install and adjust the exhaust system free of stress ⇒ Rep.
gr. 26. .
– Fit the gear selection mechanism cover and the selector lever
handle ⇒ page 76 .
– Check operation of ignition key withdrawal lock ⇒ page 95 .
– Adjust selector lever cable ⇒ page 86 .
– Check the gear selection mechanism ⇒ page 93 .
8.3 Gear selection mechanism up to

02.2009: Removing and installing
Removing ⇒ page 82
Install ⇒ page 84 .
Removing
– Put the respect
gear toselector lever into position „S“.

– Remove plate safety clip -C-.
clockwise.


– Take off clips -arrows- and remove heat shield.
– Remove the lower cover of the gear selection mechanism

-arrows-.
– Slide the cover and the protective sheath over the selector
lever cable
Protected forward.
by copyright. The
Copying for protective sheath
private or commercial must
purposes, notorbe
in part dam‐
in whole, is not
aged.

– Unscrew bolts -arrows-.
WARNING
The printed circuit board -B- of the gear selection mechanism

should not in any case be touched with fingers, as the electrical
components of the circuit may be damaged beyond repair due
to static discharge.
The printed circuit board may only be replaced with the gear
– Remove the insertion plate -A- from the gear selection mech‐
anism.
Note
The insertion plate is held in place on the left and right with clips.
– Pull retaining clip downwards -1- from selector lever control

cable in the gear selection mechanism.
– Pull the plastic safety spring -2- slightly forwards and press the
bolt -3- upwards only if necessary -arrow-.
Note
♦ This operation may only be carried out when the selector lever
is in position „S“.
♦ Make sure the bolt does not come out completely.
– Remove the selector lever cable -4- from the gear selection
mechanism.
Note
Do not bend or twist the selector lever cable.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried out in reverse order.
respect to the The
correctness following
of information must
in this be Copyright by SEAT S.A.
document.
taken into account:
Note
♦ Ensure that the protection sheath of the gear selection lever

is not damaged; this may only be changed along with the cable
itself.
♦ Ensure that the cover is correctly attached and is not twisted.
Tightening torques: ⇒ page 78 .

– Insert the selector lever cable together with the protective
sheath into the cover . Be careful not to damage the protective
sheath in the process.

– Insert the end of the selector lever cable -4- into the joint of the
selector lever.
– Press the bolt -3- downwards -arrow-.
– Check whether the plastic safety spring -2- has engaged the
bolt.
– Position a new safety fastener -1- for the selector lever cable
in the gear selection mechanism.
Fitting position:
The bent end of the retaining clip faces inwards towards the gear
– Fit the insertion plate -A-.
Note
The insertion plate is held in place on the left and right with clips.
– Mount bolts-arrows-.
WARNING
The printed circuit board -B- of the gear selection mechanism

should not in any case be touched with fingers, as the electrical
components of the circuit may be damaged beyond repair due
to static discharge.
The printed circuit board may only be replaced with the gear
– Screw down the cover, with the gasket stuck on, to the support
bracket -arrows- by hand. While doing this, ensure the gasket
stays in place correctly.
– Fit the protective sheath of the selector lever cable on the cov‐
er.
– Carefully insert the selector lever cable into the selector rod
shaft, -in the opposite direction to that shown by the arrow-.
– Fit the safety washer -A- and lock downwards.
– Mount the plate safety clip -C-.
– Change the gear selector lever from position „S“ to „P“.
• The gear
permitted actioning
unless mechanism
authorised by SEAT S.A. SEATand thenotselector
S.A does lever
guarantee or acceptcable
any liability with
shouldrespect
move freely;
to the if necessary,
correctness of information in replace theCopyright
this document. selector lever
by SEAT S.A.
cable or repair the gearbox actioning mechanism.


– Bolt the lower cover of the gear selection mechanism

-arrows-.
– Assemble the heat shield -arrows-.

– Align the exhaust system so it is free of stress ⇒ Rep. gr. 26 .
– Adjust selector lever cable ⇒ page 86 .
8.4 Selector lever control cable: checking

and adjusting
check


clockwise.
– Position the selector lever cable so that the end may be freely
moved.
♦ Do not bend or twist the selector lever cable.
– Shift the selector lever from „P“ to „S“.
– Check the protective cover for damage, on the front section of
the selector lever cable, replacing the cable if necessary.
• The gear selection mechanism and the selector lever cable
should not be hard when changing gear; if necessary, replace
the selector lever cable or repair the gear selector mechanism
⇒ page 82 .
shaft, -in the opposite direction to that shown by the arrow-.

8.4.1 Selector lever control cable: and adjust‐

ing
– Loosen the bolt -B-.
– Move the gearbox selector lever to position „P“.
– Make both front wheels turn, e.g. by moving the vehicle for‐
wards, until the gearbox lever engages in the parking block
gear and the wheels are locked (they can no longer be turned
simultaneously in the same direction).
Note
When the fastening bolt -B- is loosened, the selector lever should
be kept in „P“, otherwise the adjustment will not be correct.
– Carefully move the selector lever forwards and backwards

slightly without engaging another gear.
– Tighten bolt -B- without jerking (tightening torque: 13 Nm) is
located behind the plug.

Note
On tightening the bolt -B- ensure that the selector lever cable does
not move.
8.4.2 Adjusting selector lever cable: verifica‐

tion
– From position „P“ and with the button pressed in, pull the se‐
lector lever back approximately 5 mm and hold in this position,
without engaging „R“.
– Release the selector lever.
The selector lever should return on its own to position „P“.
– If so, adjust the selector lever ⇒ page 87 .
– Place the selector lever in position „N“.
– From position „N“ and with the button pressed in, pull the se‐
lector lever back approximately 5 mm and hold in this position,
without engaging „D“.
The selector lever should return on its own to position „N“.
– From position „N“ and with the button pressed in, push the
selector lever forwards approximately 5 mm and hold in this
position, without engaging „R“.
The selector lever should return on its own to position „N“.

9 Selector mechanism from 03.2009

onwards
WARNING
Before any repair work with the engine running, put the gear
selector lever into the „P“ position and apply the handbrake.
⇒ „8 Gear selection mechanism, up to 02.2009“, page 78
9.1 Gear selection mechanism, from 03.2009: Assembly overview
1 - Selector lever
removing and fitting
⇒ page 76
2 - Selector lever and gear se‐

lection mechanism with gear
selector cable
❑ Operate manual release
mechanism ⇒ page 74
⇒ page 90
❑ Check and adjust the
gear selector cable
⇒ page 86 .
❑ Do not lubricate the gear
selector cable
❑ With integrated printed
circuit for selector
mechanism ( selector
lever - E313 - ), do not
touch
❑ Incorporates Tiptronic
switch -F189- and se‐
lector lever lock sole‐
noid -N110 - . These
components can be tes‐
ted in the „Guided Fault
Finding“ mode ⇒ Vehi‐
cle diagnostic, testing
and information system
VAS 5051.
❑ The Tiptronic switch -
F189- and selector lever
lock solenoid -N110-
can only be renewed to‐
gether with the com‐
plete selector
permitted unless authorised by SEAT S.A.mecha‐
SEAT S.A does not guarantee or accept any liability with
nism
respect to the unit of information in this document. Copyright by SEAT S.A.
correctness
3 - Bolt.
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ 4x
9. Selector mechanism from 03.2009 onwards 89

5 - Lever protection box

6 - Locking plate
❑ Replace after each removal
7 - Locking plate
❑ Replace after each removal
9.2 Gear selection mechanism with cable,

from 03.2009: Removing and installing
Note
♦ The gear selection mechanism and the selector lever cable

cannot be separated from each other. They can only be re‐
moved together. When fitting, it may be necessary to make
more space in the engine compartment. The air cleaner must
be removed regularly.
♦ The ventral console may have to be removed from the interior.
♦ After fitting, check that the cable works smoothly and adjust it.
Removal:
– Remove selector lever knob ⇒ page 76 .
– Removing central console ⇒ Bodywork, interior fitting work;
Rep. gr. 68 .
– Unscrew the 4 fixing bolts.



– Remove the attachments -arrows- and extract the heat shield

towards the rear.
– Remove the air filter housing ⇒ Rep. gr. 24 and ⇒ Rep. gr.
23 .
– Remove lock washers -A- and -B-. The lock washers must be
replaced later when adjusting the control cable.
Loosen the adjusting screw -arrow-.
– Before refitting the selector lever cable, the selector lever in
the vehicle must be moved to the „P“ position.
– Remove the gear selection mechanism -arrow-.

Installation
Installation is carried out in reverse order.
– Check the cable ⇒ page 86 before inserting in the gearbox.
– Fit the components of the ⇒ Rep. gr. 26 .
– Install heat shield ⇒ Rep. gr. 66 .
9. Selector mechanism from 03.2009 onwards 91

– Insert the 4 securing bolts and tighten to 8 Nm.

– After installation, the selector lever cable must be adapted
⇒ page 86 .

10 Checking selector mechanism

♦ If the selector lever is in position„S“, „D“ or „R“ or even in Tip‐
tronic mode, the starter motor should not be turned on
♦ At speeds above 5 km/h, when the selector lever is in the po‐
sition „N“, the selector lever locking electro-magnet should not
engage. The selector lever may be displaced to another gear
♦ When travelling at speeds below 5 km/h (almost stopped) and
shifting into selector lever position „N“, solenoid for selector
lever lock must not engage until after approx. 1 sec. Selector
lever cannot be shifted out of„N“ position until brake pedal is
depressed.
Selector lever in „P“, selector lever button pressed and ignition is
on:
• Brake in rest position:
If the button is kept pressed in, the selector lever remains locked
and can not be taken out of position „P“. The selector lever locking
solenoid locks the lever.
• Brake pedal depressed:
The selector lever locking solenoid releases the lever.Copyright
It is pos‐
respect to the correctness of information in this document. by SEAT S.A.
sible to select a gear. Starting from position„P“ positions„R, N, D,
S“ should now be engaged slowly and consecutively, checking
during the operation whether the position shown on the instru‐
ment panel coincides with the position of the selector lever.
Selector lever in „N“, selector lever button pressed and ignition is
on:
• Brake in rest position:
The gear selection lever is secured and cannot move from „N“
position. The selector lever locking solenoid locks the lever.
• Brake pedal depressed:
The selector lever locking solenoid releases the lever. It is pos‐
sible to select a gear.
Note
When the brake pedal is depressed it is also possible to shift from

„N“ to „D“ without pressing the selector lever button. However to
shift from „N“ to „R“ it is also necessary to press the selector lever
button.
Selector lever in „D“ and ignition on:

The selector lever is locked and it is not possible to shift from „D“
to „S“.
• Press the selector lever button:
The selector lever is released and it is possible to shift from „D“
to „S“.
Selector lever in position „D“, ignition and lights switched on:
• Shift selector lever into Tiptronic gate.
The symbol„D“ should go out on the selector lever indicator and
the symbols „+“ and „-“ should light up.
The gear selector lever position indication on the instrument panel
should go from „PRNDS“ to „654321“, when the gear selector
lever is placed in the Tiptronic mode.
10. Checking selector mechanism 93

• In Tiptronic mode, press the selector lever towards „+“ and

towards „-“:
The „PRNDS“ indicator on the instrument panel should display a
higher or lower gear accordingly when the selector lever is moved
towards „+“ or towards „-“.
– Selector lever cable: check and adjust ⇒ page 86 .
– Check the ignition key withdrawal lock ⇒ page 95 .
Ignition and lights switched on:
The corresponding symbol lights up on the cover of the gear se‐
lection mechanism.
Gear selector position indicator:
Simultaneous illumination of all segments of the selector lever
position indicator specifies an emergency run of the gearbox.

11 Check the ignition key withdrawal lock
Start
↓
↓ ← ← ← ← ← ← ← ← ← ← ↑
↓ ↑
– Put the gear selector lev‐ Faulty gear selection mecha‐
er into position „P“. nism or steering lock.
– Read the fault memory us‐
– Switch ignition OFF. ing the diagnosis centre -
VAS 505X- .
– Take out the ignition key.
– Replace the faulty parts
↓ ↑
↓ no
↓ ↑
Can the gear selector → Yes → Fault in lock lever? → Y → – Correct the ad‐
lever be moved from po‐ e justment
sition „P“ when the but‐ permitted unless authorised by SEAT S.A. SEAT S.A s
does not guarantee or accept any liability with
ton is pressed? respect to the correctness of information in this document. Copyright by SEAT S.A.
↓ ↑
no ↑
↓ ↑
Correct function‐ ↑
ing
↓ ↑
↓ ↑
– Insert the ignition key ↑
↑
– Depress brake ↑
↑
– switch ignition on.
↓ ↑
Can the gear selector → no → → → → → ↑
lever be moved from po‐ ↑
sition „P“ when the but‐ ↑
ton is pressed?
↓ ↑
↓ ↑
Yes ↑
↓ ↑
– The selector lever must be free ↑
to move to the positions „R, N, D ↑
or even S“
↓ ↑
Can the ignition key be removed? → → Y → → ↑ ← ← ← ← no
e
s
↓ ↑
no → → → – Depress brake → The ignition key can be re‐
moved and the selector lever
– Put the gear selector lever is locked in „P“.
into position „P“.
↓
Yes
11. Check the ignition key withdrawal lock 95

↓
The withdrawal lock is in or‐
der.

12 Gearbox : removing and fitting

Special tools and workshop

equipment required
♦ Kit (case) -T20017A - , see
equivalent ⇒ page 131
♦ Base -T20029 - , see equiv‐
alent ⇒ page 131
♦ counterhold -T20111 - , see
♦ Socket -U-30025E - , see
♦ Hose clamp -U-30042 - ,
see equivalent
⇒ page 132
12. Gearbox : removing and fitting 97

♦ Hydraulic jack -SAT 1040- ,

see equivalent
⇒ page 131
♦ counterhold -T20138C - ,
see equivalent
⇒ page 131
♦ base -T20145 - , see equiv‐
alent ⇒ page 131
♦ Adapter for the hydraulic
engine and gearbox jack -
SAT 1001/1-
Note

♦ Pay attention to the notes relative to the semi-automatic gear‐
box 02E ⇒ page 18 .
Removal:
Note
All cable clamps that become loose or cut when removing must
be re-installed in the same place when installing.


WARNING

necting the battery ⇒ Electrical system; Rep. gr. 27.
– Remove cover -1- above the battery. To do this press the re‐
lease tab -arrow-.
– Disconnect battery earth strap-arrow-with the ignition switch‐

ed off.


clockwise.
– Remove bolts -1-.
– Removing the starter motor⇒ Electrical system; Rep. gr. 27 .

– Unscrew the earth cable -4-.
– Touch the vehicle earth with the hand (without gloves) to re‐
lease static energy.
– Release the bayonet lock -5- of the 20-contact connector from
the gearbox, by turning and disconnecting.
WARNING
The gearbox connector contacts should never be touched with

the hands, as this may damage the control unit and, therefore,
the Mecatronic as a result of a discharge of static energy
– Unscrew the cable bracket from the gearbox cover (on the
front side).
– Clamp shut each of the transmission oil radiator hoses using

the pressure tool - U-30042- and remove from the radiator
-A-.
– Plug the radiator using clean plugs from the kit -T20017A - .

– Unbolt all the bolts joining the engine and the gearbox which
are accessible from above.

- go.
– Pretension the engine with both spindles equally, do not lift.

– Remove left and right-side soundproofing, bolts -1 ... 3-.

– Detach electrical connector -2- at charge air pressure sender

-G31 - .
– Unscrew the bolt -4-.
– Remove the front air duct along with the corresponding hose;
to do this, lift the retaining clips slightly -1- and -3-.
– Remove the right hand side air hose; to do this, lift the retaining
clips slightly -arrows-.
– Remove both front wheels.
– If there is one, remove the protective plate located in the lower

section of the gearbox -arrows-.
– Unbolt the two bolts holding the support onto the front section
Note
of the gearbox.
– Separate the support with the threaded bolts from the oil sump,
by pressing, and place it above, to ensure it does not get
caught up when lowering the gearbox.
– Remove front crosspiece from vehicle underbody -arrows-.
Note
The connecting elements of the front exhaust pipe must not be

bent more than 10º. Risk of damage!
– Remove the exhaust system by the surrounding hose -1-.

– Unbolt the exhaust system bracket -arrows-.
– Unbolt the exhaust system bracket -arrows-.
– Open the clamp -arrow- and detach front exhaust pipe from
turbocharger.
WARNING
Close over the opening in the turbocharger using a clean cloth

of spongy material so that coolant and other elements do not
enter.
– Extract bolts -1... 3- and remove the pendulum support.

– Remove articulated shaft ⇒ Running gear, shafts, steering;
Rep. gr. 40 .
From above:

– Unscrew bolts -1- and -2- and detach gearbox console -.-
– Lower the engine/gearbox using the spindle of the support -

U-30025E - ....
– ... until the spacing -a- between the gearbox housing and the
gearbox support = 100 ... 110 mm.
– Unbolt the heat shield for the power steering control unit -
J500- from the subframe -arrows-.

– Connect the support -T20185- onto the subframe in the place

of the power steering control unit heat shield and operate the
support -T20111- on the engine block.
– Push the engine forwards using the spindle on the support
tool. Pay special attention to the following points:
• The alternator should not rub more than lightly on the refrig‐
erant tubes.
• The air conditioning compressor should not rub more than
lightly on the refrigerant tube connections.
– Place support tool -T20138C- on the base - T20145- , and fit
to the hydraulic jack -SAT 1040- using the adapter for the hy‐
draulic engine and gearbox jack -SAT 1001/1- .
– Secure the support tool -T20138C- to the gearbox.
– Remove gearbox lower securing bolts, disengage gearbox

from guide sleeves.
– Regulate counterhold -T20138C- so that gearbox moves with‐
out force, at the same time separating gearbox from engine.
– Carefully remove the gearbox.
12.1 Installing gearbox

Installation is carried out in the reverse order. When installing,
note the following:
Note
♦ Always replace self-locking nuts and bolts during assembly.

♦ Replace bolts that are submitted to goniometric tightening,
along with seals and gaskets.
♦ Secure hose unions with hose clamps the same as those of
the series ⇒permitted
Current
Protected bySpare
copyright.parts
Copyingcatalogue .
♦ All cable clamps that become loose or cut when removing the
gearbox must be re-installed in the same place when instal‐

ling.

– Before continuing with the assembly, ensure that the dowel

sleeves -A- are correctly fitted onto the engine block.
A: Dowel sleeves for centring
– Before assembling the gearbox check the needle bearing that
goes in the crankshaft ⇒ Rep. gr. 13 .
Vehicles with intermediate shaft
– Replace the seal -1- in the gearbox, if not fitting a new gearbox.
Continued for all vehicles
– Place support tool -T20138C- and the base - T20145- on the
gearbox.
– Fit the previous assembly onto the hydraulic jack -SAT 1040-
and place it in installation position.
– Position the gearbox, checking that no cables or pipes are
trapped.
Vehicles with intermediatepermitted
shaft unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– The intermediate axle of the right-hand articulated shaft must
be correctly fitted in the gearbox axle tooth ⇒ Running gear,
shafts, direction; Rep. gr. 40 .
Continued for all vehicles
– Screw in all the bolts that hold the engine to the gearbox. Use
new bolts, check tightening torques ⇒ page 109 .
– Fit the subframe as follows:

– Place the gearbox console -A- between the gearbox and the
gearbox support.

Fix the gearbox console -A- to the gearbox:

– Renew bolts
Bolts -1- 50 Nm + 90° (1/4 turn)
– Pull the gearbox upwards, towards the leg of the support, with
the help of the securing tool.
WARNING
Before screwing the screws to fix the gearbox console to the

gearbox support it is necessary for the gearbox support and
the console to be aligned totally parallel to each other; other‐
wise the thread may be damaged. If necessary push the rear
part of the gearbox upwards with the aid of a trolley jack.
Fix the gearbox console to the gearbox support -arrows-:

– Renew bolts
– At the start only hand tighten bolts.
WARNING
Do not remove support -U-30025E- until all the bolts on the

mechanical assemblies mounting have been tightened to cor‐
responding torque and the subframe has been mounted.
shaft (in the opposite direction to that shown by the arrow).
– Screw the counter support-D- to the gearbox with the selector

lever cable:
– Replace bolts -1-.
2 bolts -1-, M8 20 Nm + 90° (1/4 turn)

– Screw the pendulum again with new screws on the gearbox

-item 2- and -item 3-.
– Assemble the exhaust system ⇒ Rep. gr. 26 .
– Mount the protector for the right-hand articulated shaft (25
Nm).
– Fit the complete half-shafts ⇒ Running gear, axles, steering;
Rep. gr. 40 .
Fix the gearbox console to the gearbox support -arrows-:

– Tighten bolts to the corresponding torque to fix gearbox con‐
sole to gearbox support -arrows-.
Bolts -arrows- 100 Nm
– Fit the cable support on the large cover and tighten the nuts
to a torque of 10 Nm.
– Place the support onto the threaded bolts of the gearbox oil
sump.
Note
of the gearbox.
– Tighten the two bolts holding the support onto the front section
– Attach the cooling pipes to the transmission oil radiator -A-

using the pliers -T20029- and then remove each hose clamp
-U-30042 - .

– Mount battery support -arrows-.

– Fit the battery ⇒ Electrical system; Rep. gr. 27 .
– With ignition switched off, connect earth connection-arrow-to

battery.
WARNING
Take all the necessary precautionary measures when con‐

– Then check the gear oil level and top up if necessary

⇒ page 116 .
– Check the selector lever cable adjustment; adjusting if neces‐
sary. ⇒ page 86
– Check the coolant level in the cooling system ⇒ Rep. gr. 19 .
12.2 Tightening torques
Note
♦ The tightening torques listed on this page apply only to lightly

greased, oiled, phosphated, or black-finished nuts and bolts.
♦ Additional lubricants may be used, for example engine
permitted unless or gear
oils, but they should never contain graphite. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Use is never to be made of degreased parts.
♦ Tolerance for specified torques is ± 15%.

Gearbox to engine attachments

– Use new bolts.
Item Bolt. Nm
1 M12 x 55 80
2 M 10 x 45 40
– only attaches the starter motor
to the gearbox
3 M12 x 55 80
4 M 10 x 40 40
– with threaded pin M8
– only attaches the starter motor
to the gearbox
5 M12 x 70 80
6 M10 x 50 40
7 M10 x 50 40
8 M10 x 50 40
10 M12 x 55 80
Engine to gearbox
– Use new bolts to attach.
Item Bolt. Nm
9 M12 x 70 80
All remaining bolted unions:
Component Nm
Bolts/nuts M6 10
M8 20
M10: 45
M12 65
12.3 Gearbox support: dismounting and as‐

sembly
♦ Socket -U-30025E - , see equivalent ⇒ page 132

Removal:
WARNING

– Remove cover -1- above the battery. To do this press the re‐
lease tab -arrow-.
– Disconnect battery earth strap-arrow-with the ignition switch‐

ed off.


- go.
– Slightly tension the engine assembly/gearbox via the spindles.
– Unbolt bolts -arrows- to release the gearbox support console.

– Carefully lower the engine/gearbox assembly via the spindles.
– Dismount all the necessary pieces to obtain access to the bolts

-1-.
– Remove bolts -1-.
– Remove the gearbox support -A-.
Installation permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
taken into account:
– Assembling the gearbox support -A-.

– The bolts -1- must be replaced.
Component Nm
Always replace the bolts -1-, 40 Nm + 90° (1/4 turn)
M10 x 55
– Pull the gearbox upwards, towards the leg of the support, with
the help of the support -U-30025E - .
WARNING
Before screwing the screws to fix the gearbox console to the

gearbox support it is necessary for the gearbox support and
the console to be aligned totally parallel to each other; other‐
wise the thread may be damaged. If necessary push the rear
part of the gearbox upwards with the aid of a trolley jack.

– Bolt the gearbox support to the console using bolts -arrow-.

– Renew bolts
Denomination Torque
Bolts -arrow- 100 Nm
WARNING
Before removing the support -U-30025E- the bolts of the me‐

chanical assemblies mounting must have been tightened to
corresponding torque.
12.4 Pendulum support: dismounting and as‐

sembly
Removal:
– Remove the central soundproofing, bolts -1 ... 3-.
– Extract bolts -1... 3- and remove the pendulum support.

Installation
Installation is carried out in the reverse order. When installing,
note the following:
Fit the pendulum
Protected by arm support
copyright. Copying .for private or commercial purposes, in part or in whole, is not
– Fit the pendulum
respect to thesupport
correctnessfirst to the ingearbox
of information and
this document. then by
Copyright toSEAT
the S.A.
assembly mounting bridge.
– Renew bolts
Component Nm
Pendulum support to subframe -A- 100 + 90° (1/4
Replace bolts turn)
gearbox arrows 40 + 90° (1/4
-B- and -C- turn)
Replace bolts

12.5 Transporting and securing gearbox to assembly stand


equipment required
♦ base -T20172/1 - , see
♦ Tower -T20172/2 - , see
♦ Gearbox support -
T20172/4A - , see equiva‐
lent ⇒ page 131
Operation process
– Fit the base -T20172/1- with the tower -T20172/2- and the
gearbox support -T20172/4A - .
– Fit counterhold -T20186- on gearbox in order to transport it.
Protected WARNING
by copyright. Copying for private or commercial purposes, in part or in whole, is not
When transporting, take care not to damage the transmission
oil radiator.

– Fit the gearbox to the gearbox support -T20172/4A- as shown

in the figure.
Note
If the full gearbox revolves on the installation stand with the oil
sump facing upwards, the breather pipes of the gearbox casing
should be closed.

13 Oil and oil filter
Note

♦ See information relative to semi-automatic gearbox 02E, reg‐
ulations for oil waste management ⇒ page 18
♦ Breather pipe of adapter for oil filling -VAS 6262 A- may need
to be shortened.
Shortening breather pipe of adapter for oil filling -VAS 6262 A- :

– In order to ensure that the breather pipe of the adapter for oil
filling -VAS 6262 A- does not contact the bottom of some oil
bottles, the pipe must be shortened to the length -a-.
Note
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter -VAS 6056/2- .
13.1 Oil filter: replace
Note
♦ It is not always necessary to replace the oil filter.

♦ When the oil filter has to be changed ⇒ page 19 .
Removal: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Put the gear selector lever into position »P«.

– Remove the air filter ⇒ Rep. gr. 24 ; Air filter: Removing and
installing .
– Remove the battery together with the battery tray ⇒ Rep. gr.
27 ; Battery; Battery: Removing and installing .

Note
♦ There are still oil remnants in the filter. This oil escapes when
unscrewing the filter.
♦ Before unscrewing the oil filter, cover the area around the filter
with a few cloths.
– First release the filter housing -arrows- by 7 turns.

– Wait about 10 seconds.
This allows the oil to return to the gearbox from the filter casing.
– Now remove the filter housing and oil filter.
Installation
taken into account:
– Thoroughly clean the area around the gearbox that has been
soiled with oil.
– Install the oil filter with collar -arrow- facing downwards.

– Screw in and tighten the oil filter to 20 Nm.
The remaining installation steps are carried out in the reverse se‐
quence.
– Check the oil level and top-up if necessary ⇒ page 117 .
13.2 Engine oil level: Checking and refill with
oil
If DSG gearbox oil has to be filled, only use oil that is supplied as
a spare part ⇒ Electronic spare parts catalogue „ETKA“ .
13. Oil and oil filter 117

♦ Diagnosis tester -VAS 505X- , see equivalent ⇒ page 132

♦ Oil tester w/auto -VAS 6262 A- , see equivalent ⇒ page 132
Conditions
♦ Vehicle on a level, all lifting platform housings at the same
height.
♦ Noise insulation removed
♦ Diagnosis tester -VAS 505X- connected
♦ The oil temperature must not be higher than 50° Celsius at the
beginning of the work.
♦ Test temperature: 35 - 45 ℃
Checking
– Connect Diagnosis tester -VAS 505X- and identify vehicle via
the Guided functions .
– Select dual clutch gearbox .
– Select Check fluid level .

Note
If the oil temperature is more than 45°C, allow the gearbox to cool
down first.
The engine must run idle and the selector lever must be in the „P“
position.
– Undo the oil drain plug.
Gearboxes manufactured until „20th September 2004“ have 2
different screws.
It is important that these bolts are not interchanged. Only undo
the screw -arrow- located near to the pendulum support.
Gearboxes manufactured after the 20th September 2004, thus
the »newer« gearboxes have only screw -A-.
– Always renew the seal -arrow- of the screw.
Note
Even when the gearbox oil level is very low, a small quantity will
initially come out of the overspill pipe, which fills when the engine
is running.
– Allow the remaining oil to drain.

– As soon as the oil has drained (itpermitted
startsunless
to drip), the screw must
be inserted using a new seal. respect to the correctness of information in this document. Copyright by SEAT S.A.
– If no more oil runs out, this then has to be topped up.

Filling
Note

inspection hole.
– Top up with 1.0 litres of oil.
Shake the bottles before opening them.
– Remove the oil tester w/auto -VAS 6262 A- at the rapid con‐
nection and check the following visually:
whether the oil is coming out through the hole of the adapter:
no need to add oil.
– Allow the remaining oil to drain.
– As soon as the oil has drained (it starts to drip), the adapter
for the oil filling -VAS 6262 A- must be unscrewed and the
screw inserted using a new seal.
If no oil drips out of the opening:
– Another litre of oil must be added ⇒ page 117 .
WARNING
The function of the gearbox will be influenced with an oil level

that is too low as well as too high.
Oil drain screw, tightening torque: 45 Nm

13.3 change oil and replace filter.

When the oil filter has to be changed ⇒ page 19
If DSG gearbox oil has to be filled, only use oil that is supplied as
a spare part ⇒ Electronic spare parts catalogue „ETKA“ .
Brief description
First check the oil temperature. If it is above 50 °C, let the gearbox
cool off.
With engine stopped, unscrew and remove overflow pipe and let
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
box with oil.
Then start engine and drain excess oil until oil level attains level
of overflow pipe.
♦ Diagnosis tester -VAS 505X- , see equivalent ⇒ page 132

♦ Oil tester w/auto -VAS 6262 A- , see equivalent ⇒ page 132

DSG oil is available as a spare part ⇒ Spare parts catalogue .
Conditions
• Vehicle on a level, all lifting platform housings at the same
height.
• Soundproofing sump removed, where applicable.
• Selector lever must be in position „P“.
• Diagnosis tester -VAS 505X- connected
• The oil temperature must not be higher than 45 ℃ at the be‐
ginning of the work.
Operation process
– Comply with rules for cleanliness when working on gearbox.
– Only gear oil available as spare part is allowed to be used for
dual clutch gearbox. Other types of lubricant cause malfunc‐
tions and/or failure of the gearbox.
WARNING
Hot gearbox oil can cause burns.
– Connect vehicle diagnosis, testing and information system -

VAS 5051B- and identify the vehicle in Guided functions .
– Select dual clutch gearbox .
– Select Check fluid level .

Note
If oil temperature is above 45 °C, let the gearbox cool off.
WARNING
Do not start engine if there is no oil in gearbox.
– Engine off - Do not start engine!

– Remove oil drain plug close to pendulum support -arrow-.
A black plastic »overflow tube« (with 8 mm hexagon socket head
bolt) is located in this hole. Its length determines the oil level in
the gearbox.
– Remove oil level pipe -arrow- and allow oil to run out.
Approximately 5 litres of oil should drain out.
– Screw oil level pipe back in to stop and tighten to 3 Nm.
Note

inspection hole.
Shake the oil cans before opening.
– Pour in 5.5 litres of DSG oil.

When changing bottles the valve could be closed, or the oil tester
automatic gearbox -VAS 6262 A- could be held higher than the
gearbox.
– Tighten oil drain plug -A- only until finger tight.

– Start engine.
– Depress brake pedal, select each selector lever position for
Protected byabout 3 Copying
copyright. seconds andorthen
for private move
commercial leverinback
purposes, towhole,
part or in »P«. is not
– Switch
respect off theofengine.
to the correctness information in this document. Copyright by SEAT S.A.
– Then check the oil level and top-up if necessary ⇒ page 117 .

35 – Gears, shafts
1 At present no repairs are made to the
pinions and shafts of this gearbox.
124 Rep. gr.35 - Gears, shafts

39 – Final drive - differential

1 Renewing oil seal for left flange shaft

equipment required
♦ Torque wrench kit -SAT
8010- , see equivalent
⇒ page 131
♦ Tappet -T10088 - , see
♦ Spanner -T20203 - , see
♦ Extractor -T20143 - , see
♦ Tray -T20173 - , see equiv‐
alent ⇒ page 131
Removal:
The seals may be changed while the gear box is mounted.
Note
♦ Cleaning norms when working on automatic gearbox.

⇒ page 25
– Remove left-hand articulated shaft: ⇒ Running gear, shafts,

steering; Rep. gr. 40 .
– Fit tray -T20173- beneath gearbox.
1. Renewing oil seal for left flange shaft 125

– Unscrew the attachment bolt from the left flange shaft using
the wrench -T20203 - . To do this, loosen two bolts on the
clamp and use a lever to immobilize the shaft.
– The bolt must be replaced.
– Remove flanged shaft together with compression spring.
– Remove sealing ring with pliers -T20143/2 - .

Installation
taken into account:
– Lightly lubricate outerProtected
edge byofcopyright.
new seal. Copying for private or commercial purposes, in part or in whole, is not
– Fit new seal as far as it will go using tappet -T10088 - .
– Fill space between sealing lip and dustcap -arrow-, halfway,

with sealing grease ⇒ Spare parts catalogue .
– Insert the flanged shaft pushing against the spring and fix with
a new bolt.
– Mount left-hand articulated shaft: ⇒ Running gear, shafts,
Check the gear oil ⇒ page 116
Tightening torques
Component Nm
Flanged shaft to gearbox 30
Replacing bolts
126 Rep. gr.39 - Final drive - differential

2 Renewing seal for right flange shaft


equipment required
♦ Torque wrench kit -SAT
8010- , see equivalent
⇒ page 131
♦ Tappet -T10089 - , see
♦ Spanner -T20203 - , see
♦ Extractor -T20143 - , see
♦ Tray -T20173 - , see equiv‐
alent ⇒ page 131
Removal:
The seals may be changed while the gear box is mounted.
Note
♦ Cleaning norms when working on automatic gearbox.

⇒ page 25
Vehicles with intermediate shaft

– Remove right-hand articulated shaft: ⇒ Running gear, shafts,
2. Renewing seal for right flange shaft 127

– Unscrew the intermediate shaft -B- from the support frame,

-arrows-, and take it out of the insert shaft of the gearbox.
– Release the dust protection hood -arrow- with the screwdriver.
– Unscrew the attachment bolt -arrow- from the right hand side
insert shaft using the wrench -T20203 - .
– Pull out the insert shaft.
– Extract the insert shaft seal using the adapter -T20143/2 - .


the tube element -T10089- .

Rest of installation is carried out in the reverse sequence, ob‐
serving the following:
– Mount right-hand articulated shaft: ⇒ Running gear, shafts,
Check the gear oil ⇒ page 116
Tightening torques
Component Nm
Replacing bolts
Vehicles with flanged shaft
– Remove right-hand articulated
permitted shaft:by⇒
unless authorised Running
SEAT S.A. SEAT gear,
S.A doesshafts,
not guarantee or accept any liability with
steering; Rep. gr. 40 .respect to the correctness of information in this document. Copyright by SEAT S.A.
– Unscrew the attachment bolt from the left flange shaft using
the wrench -T20203 - . To do this, loosen two bolts on the
clamp and use a lever to immobilize the shaft.
– Remove flanged shaft together with compression spring.
– Remove sealing ring with pliers -T20143/2 - .

2. Renewing seal for right flange shaft 129

the tube element -T10089- .

Rest of installation is carried out in the reverse sequence, ob‐
serving the following:
– Insert the flanged shaft pushing against the spring and fix with
a new bolt.
– Mount right-hand articulated shaft: ⇒ Running gear, shafts,
Check the gear oilProtected
⇒ page 116 Copying for private or commercial purposes, in part or in whole, is not
by copyright.
Tightening torques respect to the correctness of information in this document. Copyright by SEAT S.A.
Component Nm
Replacing bolts

3 Conversion table by relevance

SEAT tool VW / AUDI tool
Engine and gearbox jack -SAT Hydraulic jack - V.A.G 1383
1040- A- See image of the tool or
equipment ⇒ page 138
Oil extractor -SAT 1100- Oil extraction equipment -
V.A.G 1782- . See image of
the tool or equipment
⇒ page 132
Torque wrench kit -SAT 8010- Torque wrench -V.A.G
1331- . See image of the tool
or equipment ⇒ page 132
Tappet -T10088- Push rod -3305- See image of
⇒ page 137
Tappet -T10089- Push rod -3158- See image of
⇒ page 137
Slider -T10302- No equivalent
Support equipment -T10303- No equivalent
Kit (case) -T20017A- No equivalent
Spring retainer -T20020- Universal measurement
clock holder - VW 387- See
image of the tool or equip‐
ment ⇒ page 138
Pliers -T20029- Hose clamp fitting tool -VAG
1921- . See image of the tool
Support equipment -T20138C- Gearbox support assembly
-3282- See image of the tool
Extractor -T20143- No equivalent
Base -T20145- No equivalent
Clamping tool -T20153 - . See Tube element -VW
respect to the 423-of information in this document. Copyright by SEAT S.A.
correctness
image of the tool or equipment
⇒ page 139
Base -T20172/1- Engine and gearbox holder -
VAS 6095- , holding plate -
VW 309- see image of the
tool or equipment
⇒ page 133
Tower -T20172/2- Engine and gearbox holder -
VAS 6095- , holding plate -
VW 309- see image of the
tool or equipment
⇒ page 133
Gearbox support -T20172/4A- Gearbox support assembly -
VW 353- See image of the
tool or equipment
⇒ page 134
Tray -T20173- Drip tray -VAS 6208- See im‐
age of the tool or equipment
⇒ page 137
3. Conversion table by relevance 131

SEAT tool VW / AUDI tool

Support equipment -T20186- Suspension -2024 A- see im‐
age of tool or equipment
⇒ page 134 , shackle -10 -
222 A /12- , gearbox, suspen‐
sion tool - 3336- .. See image
of the tool or equipment
⇒ page 135
Spanner -T20203- Socket -T10072 - See image
of the tool or equipment
⇒ page 140
Spring retainer -U-30025E- Shock tool -10-222A - See
image of the tool or equip‐
ment ⇒ page 136
Thrust piece -U-30042- Tube braces -3093 / 3094-
See image of the tool or
equipment ⇒ page 136
Lever -U 30800- Lever -3409- See image of
⇒ page 139
Diagnosis tester -VAS 505X- No equivalent
Oil tester w/auto -VAS 6262- No equivalent
3.1 Graphical information onrespect

the touse and
VW units, Seat equivalents

3.1.1 Torque wrench -V.A.G 1331-
3.1.2 Used oil collection and extraction unit -

V.A.G 1782-

3.1.3 Retaining plate -VW 309-
Application
3.1.4 Engine and gearbox support -VAS

6095-
Application

3.1.5 Gearbox support assembly -VW 353-
Application
3.1.6 Coupling tool -2024 A-
Application

3.1.7 Gearbox suspension tool -3336-
Application
3.1.8 Gearbox support assembly -3282-
Application

3.1.9 Hose clamps -3093 / 3094-
Application
3.1.10 Support. -10-222A-
Application

3.1.11 Tray -VAS 6208-
3.1.12 Thrust piece -3305-
Application respect to the correctness of information in this document. Copyright by SEAT S.A.
3.1.13 Press tool -3158-

Application
3.1.14 Engine/gearbox jack -V.A.G 1383 A-
3.1.15 Hose clip pliers -VAG 1921-
3.1.16 Universal bracket for gauge -VW 387-


Application
3.1.17 Tappet -T20153-
Application
3.1.18 Lever -3409-

3.1.19 Multi-point socket screwdriver -T10072-

S04BHXV8S20-Automated Manual Gearbox 02E For Front-Wheel Drive

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S04BHXV8S20-Automated Manual Gearbox 02E For Front-Wheel Drive

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Service

Service Department. Technical Information

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Copyright © 2015 Seat S.A S04BHXV8S20

12.1 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

The gearbox code letters can be found on the upper section of

1.1 Gearbox codes: Display

– Remove battery tray -arrows-.

– Position bracket -U-30025E- on bolted flange for wing panels.

2 Rep. gr.00 - Technical data

– Replace the bolts -1 and 2- of the ⇒ Rep. gr. 10 ; Subframe

2 Code letters, group numbers, ratios,

4 Rep. gr.00 - Technical data

Manual 02E, front-wheel drive

Engine codes Altea 2009

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

Manual gear‐ 02E, front-wheel drive

Engine codes Toledo 2005

6 Rep. gr.00 - Technical data

Manual 02E, front-wheel drive

Engine codes Leon 2006

2. Code letters, group numbers, ratios, equipment 7

Man‐ 02E, front-wheel drive

8 Rep. gr.00 - Technical data

Man‐ 02E, front-wheel drive

Engine codes Leon 2009

2. Code letters, group numbers, ratios, equipment 9

Manual 02E, front-wheel drive

Engine codes Altea XL 2007

Gear ratios: Final 69 : 17 = 69 : 17 = 70 : 16 =

10 Rep. gr.00 - Technical data

Engine codes Altea XL 2009

2. Code letters, group numbers, ratios, equipment 11

Manual gear‐ 02E, front-wheel drive

Engine codes Altea XL Freetrack 2008

Engine codes Altea XL Freetrack 2009

12 Rep. gr.00 - Technical data

Manual gearbox 02E, front-wheel drive

2.1 Calculating overall gear ratio „i“

1) Z1 = Number of teeth of drive pinion, Z2 = number of teeth of driven pinion

2. Code letters, group numbers, ratios, equipment 13

Only the recommended gear oil should be used for semi-au‐

14 Rep. gr.00 - Technical data

4 General overview: Automated manual gearbox 02E

4. General overview: Automated manual gearbox 02E 15

♦ The testing and measurement equipment must always be

To avoid injury to individuals and/or the destruction of electric and

♦ Observe the necessary precautions when disconnecting

5.1 Safety functions of the gearbox control

is in „R“ and the vehicle is still moving backwards). In this case,

16 Rep. gr.00 - Technical data

(overheating). This can happen e.g. in the suspension in case

6 Added information concerning the

18 Rep. gr.00 - Technical data

Function of the oil

Oil level check and troubleshooting

6. Added information concerning the semi-automatic gearbox 02E 19