Service SERI

auto emoci6n

Workshop Manual
C6rdoba 1999
C6rdoba Vario 1999
lbiza 1999
IRunning gear. axles. steering I
Edition 04.2006

Service Department. Techni cal lnformation

 Service
SERT
autoemoc:iOn

List of Workshop Manual Repair Groups

Repa ir Gr oup
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tyres , vehicle geometry
48 - Steering

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 normai 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 S01DBXX8920

 C6rdoba 1999 >- , C6rdoba Vario 1999 >- , lbiza 1999 SEFIT
> auto emociòn
Running gear, axles, steering - Edition
04.2006

Contents

00 - Technical data...............................................................................................................1
1 Technical data.............................................................................................................................. 1
1.1 Running gear...........................................................................................................................1
1.2 Steering...................................................................................................................................1
1.3 Wheel rims, tyres.......................................................................................................................... 1
1.4 Codes........................................................................................................................................... 1
1.5 Load index tables.......................................................................................................................... 1
1.6 Models.......................................................................................................................................... 2

40 - Front suspension............................................................................................................4
1 Front wheel suspension......................................................................................................................4
1.1
Front axle: overview............................................................................................................................4
1.2
I- Subframe, stabiliser bar, swinging arm overview....................................................................5
1.3
Swinging arm ball jo int: verification....................................................................................................6
1.4
Swinging arm ball jo int: removing and fitting.....................................................................................7
1.5
Swinging arm: removing and fitting..............................................................................................8
1.6
Swinging arm bonded rubber bearing: replacement.........................................................................9
1.7
Subframe: dismantling and fitting............................................................................................... 11
1.8
Bearing cap bolt on the longitudinal member: verification...........................................................15
1.9
Il - Wheel attachment , shock absorber , half shaft...............................................................16
1.1O Wheel bearing housing: removing and fitting..............................................................................19
1.11
Wheel bearing: repairs................................................................................................................ 21
1.12
Suspension strut: disassembly and assembly............................................................................22
1.13
Generai overview: telescopie arm: repairs.................................................................................23
1.14
Telescopie arm: repairs.............................................................................................................. 25
2 Articulated half shafts................................................................................................................. 27
2.1
Articulated half-shafts: repairs.................................................................................................... 27
2.2
Drive shaft with constant velocity jo int: repairs..........................................................................29
2.3
lnner constant velocity joint: verification.....................................................................................33
2.4
Exterior constant velocity joi nt: verification..........................................................................................35
2.5
Tripod joint: disassembly, repairs and assembly........................................................................36
2.6
Complete half shaft with tripod type joint: repairs............................................................................38

42 - Rear suspension.........................................................................................................42
1 Generai overview, wheel bearing: repairs..................................................................................42
1.1 Wheel bearing assembly: repairs............................................................................................... 43
1.2 Wheel bearing assembly: repairs, vehicles with brake drums....................................................43
1.3 Wheel bearing assembly: repairs, vehicles with brake disks......................................................45
1.4 Generai overview: rear axle body.............................................................................................. 47
1.5 Rear axle disassembly and assembly........................................................................................49
1.6 Bonded rubber bearing: removing and fitting.............................................................................52
1.7 Suspension strut: disassembly and assembly...........................................................................54
1.8 Suspension strut: removing and fitting.......................................................................................56

44 - Wheels, tyres, vehicle geometry.................................................................................59

1 Wheel alignment......................................................................................................................... 59
1.1 Generai aspects......................................................................................................................... 59
1.2 Test requirements...................................................................................................................... 59
1.3 Wheel alignment......................................................................................................................... 60
1.4 "Zero" vehicle inclination............................................................................................................ 62
1.5 Adjust the camber of the front wheels........................................................................................ 63
1.6 Front axle convergence: verification...........................................................................................63
1.7 Steering wheel rotation left and right limits: test ing...................................................................64
Contents I
 SEFIT
auto
emociOn
C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition
04.2006

1.8 Calculation of the track drift........................................................................................................ 65

48 - Steering.......................................................................................................................66
1 Steering...................................................................................................................................... 66
1.1 Steering wheel without airbag, steering column.........................................................................66
1.2 Steering wheel with airbag, steering column..............................................................................67
1.3 Airbag unit, driver's side: removing and fitting............................................................................67
1.4 Steering wheel with airbag: removing and fitting........................................................................69
1.5 Coil connector with slip ring: removing and installing.................................................................70
1.6 Steering mount and steering column: removing and fitting.........................................................71
1.7 Multiple cog adaptor tor the steering column: disassembly and assembly.................................73
1.8 Steering column, steering mount: assembly overview................................................................75
1.9 Steering column, steering mount: assembly overview................................................................78
1.1O Steering mount and steering column: disassembly and assembly.............................................80
2 Power steering: repairs.............................................................................................................. 86
2.1 Verificat ion of the hydraulic pump feed pressure.......................................................................86
2.2 Steering box: removing and fitting.............................................................................................. 87
2.3 Power steering box: generai overview........................................................................................ 92
2.4 Power steering box: adjust when fitted.......................................................................................94
2.5 Steering rad: removing and fitting (power steering box).............................................................95
2.6 Left steering rad: verification and adjustment of the length........................................................96
2.7 Fitting the dust cover.................................................................................................................. 96
2.8 Play, attachment and dust guard hoods on the steering heads: verification...............................97
2.9 Generai overview: Hydraulic pump, reservoir, hydraulic lines....................................................97
2.1O Power steering hydraulic pump: removing and fitting.................................................................99
2.11 Removing and fitting the Poly-V belt........................................................................................ 100
Il Contents
 C6rdoba 1999 >- , C6rdoba Vario 1999 >- , lbiza 1999 >- s -r
Running gear, axles, steering - Edition 04.2006 autoemock'.>n

00 - Technical data
1 Technical data

11 Runnmg gear
lI
Model lbiza 1999 •
Wheelbase mm 2440
I 1429 front , wheel rim ET 38
Track gauge empty vehicles mm
1394 rear, wheel rim ET 38
Diameter of turning angle m approx. 10,9

1.2 Steering
Model lbiza 1999 •
Steering box Mechanical Steering Power Steering
Number of steering wheel turns from limit to limit 3,827 3,2
Tota! steering ratio 19,19 16,04

1.3 Wheel rims, tyres

Tyre description (eg. 155 I 80 R13 79T)
155 Section of tread
80 Pratile (relation between tread and tyre wall expressed as a percentage)
R Type of structure (R I radiai, D I diagonal) 13" diameter of rim
13
"
79 Load index (maximum weight per tyre)
T Maximum speed code

1.4 Codes
Speed code
M 130 Km I
N 140 hKm I
p 150 hKm I
h h
Q 160 Km I
R 170 hKm I
s 180 hKm I
h
T 190 Km I
H 210 hKm I
V (R) + 210h Km I
V 240 Km I
w 270 hKm I
y h Ih
300 Km

1.5 Load index tables

Code kg Code kg Code kg Code kg Code kg
62 265 70 335 78 425 86 530 94 670
63 272 71 345 79 437 87 545 95 690
64 280 72 355 80 450 88 560 96 710

1. Technical data
 s -r C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
outo emoc;0n Running gear, axles,steering - Edition

Code kg Code kg Code kg Code kg Code kg

65 290 73 365 81 462 89 580 97 730
66 300 74 375 82 475 90 600 98 750
67 307 75 378 83 487 91 615 99 775
68 315 76 400 84 500 92 630 100 800
69 325 77 412 85 515 93 650

1.6 Models
Model lbiza 1999 •
Steel rims Tyre 1> Tyre 1> Tyre 1> Tyre 1> Tyre 1>
3 3
Alloy rims 2> Rim > Rim > Rim 3> Rim 3> Rim 3>
Engine capacity 155 I 80 R13 79 175 I 70 R13 82 185/ 60 R1482 185/55 R15 195 / 45R16 80
Power kW/bhp T T T 81V V
5J x 13 ( ET38 ) 51/2 J X 13 6J x 14 ( ET38 ) 6J X 15 2) 6J X 16 2)
( ET38 ) ( ET38 ) ( ET38 )
1.0 ltr 37 I 50 Select Stella Signa 1

1.0 ltr 16V 51 I70 Stella Signa I

1.4 ltr MPI 44 I 60 Select Stella Signa /
1.4 ltr 16V 55 I 75 Stella Signa
1.4 ltr 16V 74 I 100 Stella I Signa Sport
1.6 ltr MPI 55 I 75 I Stella Signa
1.6 ltr Simos 74 I 100 - - Stella I Signa Sport
1.6 ltr AG4 74 I 100 Stella I Signa
1.8 ltr 20VT 115 I 156 Cupra
1.9 ltr SDI 50 I 68 Select I Stella Signa
1.9 ltr TDI 66 I 90 Stella I Signa Sport
1.9 ltr TD I 11O I 81 Signa I Sport

1) Tyre pressures instruction manual and adhesive sticker on vehicle

2) Alloy Rim

3) Rim inset depth

Type Cordoba 1999 •

4 4
Steel rims Tyre ) Tyre > Tyre 4) Tyre 4) Tyre 4)
Alloy rims 5> Rim 7l Rim 7l Rim 7l Rim 7l Rim 7l
Engine 155I 80 R13 175 I 70 R13 185I 60 R14 185/55 R15 155 I
capacity 79 T 82 T 82 81V 80R1379 T
Power kW/bhp 5J x 13 ( ET38 51/2 J x 13 T 6J X 15 5) 6J X 16 5)
) ( ET38 6J x 14 ( ET38 ( ET38 ) ( ET38 )
) )
1.0 ltr 37 I 50 Stella Signa
1,0 ltr 16V 51 Stella Signa
I70
1,4 ltr MPI 44 I Stella Signa
60
1.4 ltr 16V 55 I Stella Stella6>/ Signa
75 ltr 16V 74 I 100
1.4 Stella I Signa Sport
1.6 ltr MPI 55 I Stella Stella6> 11
75 Signa
1.6 ltr Simos 74 I Stella I Signa Sport I Sport6>
100
1.6 ltr AG4 74 I 100 Stella I Signa
1.8 ltr 20VT 115 I Cupra6)
156

2 Rep. Gr.00 -
 C6rdoba 1999 >- , C6rdoba Vario 1999 >- , lbiza 1999 SEFIT
> auto emociòn

Running gear, axles, steering - Edition

04.2006

Type Cordoba 1999 •

1.9 ltr SDI 50 I 68 Stella Signa
1.9 ltr TDI 66 I 90 Stella I Signa Sport I Sport6>
1.9 ltr TDI 11O I 81 - Signa Sport I Sport6>

-------------=
4) Tyre pressures instruction manual and adhesive sticker on vehide
5) Alloy Rim

6) Two-door C6rdoba
7) Rim inset depth

Model Cordoba I Vario 1999

•
Steel rims Tyre 8> Tyre 8> Tyre Tyre 8> Tyre 8>
> Alloy rims 9> Rim 10> Rim >10 8
> Rim 10> Rim 10>
10
Engine capacity 155 I 80 R13 175 170 R13 185 Rim I 60 R14 185/55 R15 155 I
Power kW/bhp 79 T 82 T 82 T 81V 80R1379 T
5J x 13 ( 51/2 J X 6J x 14 ( ET38 6J X 15 9) 6J x 16 9>
ET38 ) 13 ( ET38 ) ( ET38 ) ( ET38 )
1.0 ltr 37 I 50 )
1,0 ltr 16V 51 I70
1,4 ltr MPI44 I 60 Stella Signa
1.4 ltr 16V 55 I 75 Stella Signa
1.4 ltr 16V 74 I 100
1.6 ltr MPI 55 I 75 Stella Signa
1.6 ltr Simos 74 I Stella I Signa Sport
100
1.6 ltr AG4 74 I
100
1.8 ltr 20VT 115 I
156
1.9 ltr SDI 50 I 68 Stella Signa
1.9 ltr TDI 66 I 90 Stella Signa Sport
1.9 ltr TDI 11O I 81 Signa I Sport

8) Tyre pressures instruction manual and adhesive sticker on vehide

9) Alloy Rim
1O) Rim inset depth

Model lbiza Cupra -R-

Alloy Rims Tyre 11>
Rim 12>
Engine capacity 250/45 ZR 16 81 V
Power kW/bhp 16 X 7 (ET 35)
1,8 ltr 132 I 180 Cupra -R-

11) Tyre pressures instruction manual and adhesive sticker onvehicle

12) Rim inset depth

1. Technical data
 s -r C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
outoemoc;0n Running gear, axles,steering - Edition

O- Front sus ension

1 Front wheel suspension

1.1 Front axle: overview

I- Subframe, stabiliser bar

and swinging arm:
disassembly and assembly =>
page 5
Il - Wheel attachment ,
shock absorber , half
shafts: remov ing and
fitting => page 1 6

J[

· · .-.-.....
.

E40-0033

4 Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

1.2 I - Subframe, stabiliser bar, swinging arm overview

rL,!f:1J Note

+ lf the vehicle has to be moved when the complete half-shaft has been removed, a CV exteriorjoint
must be fitted instead of the complete half-shaft and tightened to 50 Nm to avoid damage to the
wheel bearing.
+ No welding or straightening work can be done on the suppor! andguide elements of the suspension
system.
+ Always renew self locking nuts fol!owing their remava/.
+ A/ways renew corroded nuts and bolts
+ A/ways replace bolts with defined final torque.

1- Articulated
arm 2 - Plate
with nuts 3 - Ball
joi nt
O Verificat ion
page 6
O Before removing mark
the installation position.
O Fit the ball joint in the
centre of the arm '---20
holes.
O Verify convergence.
4 - Bolt, 8 X 24
O 20 Nm + 114 turn
(270°)
13- - --.,...--
O PJways replace
5 - Self locking nut 12 I

O 25 Nm ----....-- --+'. 22
I
O Replace 1 1 -----
6 - Washer
O The collar indicates the
10 ---
apposite direction of
the socket
7 - Bearings tor the link rod ·-l
O The conica! side points 9 J((/:. --+- -- 1
towards the swinging
arm ------- 2
8 - Bearing tor the link rod
------ 3
O Removing and
refitting page 10

9 - Bolt, M 12 X 1,5 X 78
r:-r .,
11- Bolt, M 12 X 1,5 X 82
----- 4

O 70 Nm + 1/4 turn O 70 Nm + 1/4 turn (270°) O Replace

(270°) O Replace
1O - Bolt,M 12 X 1,5 X 65
O 70 Nm + 1/4 turn
(270°) O Replace

1.Front wheel suspension

s -r C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
outoemoc;0n Running gear, axles,steering - Edition
8 7 6 5

6 Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

12 - Subframe
O Removing and installing page 11
13 - Self locking nut
O 90 Nm
O Replace
14 - 25 Nm
O Far attachment of the stabiliser bar.
15 - Damper
O lnstallation position: Fit so that the side furthest from the forward facing holes, towards the front of the
vehicle.
16 - Traverse bolt
17 - Stabiliser bar clamp
18 - Rubber bearing
19 - Hood nut
O Check this on the longitudinal member page
15 20 - Stabilizer bar
21 - 65 Nm
22 - Track rad
23 - Rear socket far the swinging
arm O Releasing page 11
O Insertion page 11

1.3 Swinging arm ball joint: verification

Check axial play
- Pull forcefully on the swinging arm downwards and then press
upwards.

[i J Note

+ During both checks there must be no discernible or visible

"play'.
+ Observe the bai/ joint during the checking.
+ Play in the wheelbearings or "play "in the upper telescopie arm
bearing must be taken into consideration.
+ Check the rubber bel/ows tor damage; if necessary
replace bal/ joint.
+ Always replace se/f locking nuts following their remava/.
+ Always replace nuts/bolts with defined final torque.

Check radiai play

1.Front wheel suspension

SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

- Move the lower part of the wheel in and out forcefully.

1.4 Swinging arm ball joint: removing

and fitting
Special tools and workshop equipment required
+ Torque wrench -SAT 8010-
SAT 8010

20...100 Nm

5...25Nm

I W00·2760 I

1.4.1 Removing
- Lift the vehicle untiI the front axle is free of weight.
- Extract the bolt -1- securing the ball joint to the bearing
hous- ing.

[i J Note

+ Mark the position of the bolts -2- before !oosening tor

posterior fitting.
+ Always rep/ace the bo/ts securing the swinging arm bai/ joint.

- Extract the bolts -2- securing the ball joint to the swinging arm.

- Push the wheel and the ball joint outwards and support.
- Move the swinging arm downwards and extract the ball joi nt.

[i J Note
+ Always rep/ace se/f !ocking nuts fol!owing their remava/.
+ Ensure that the hood of the bai/ joint is fitted without
twisting and that it is not damaged.
+ Check the convergence every time that the bai/ joint has been
removed.

8 Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

1.4.2 Fitting
- Fit the ball joint and secure with the bolt -1- to the
bearing housing.
- Fit the bolts -2- securing the ball joi nt assembly to the
swinging arm on the marks made before removal.

Tightening torques:
Swinging arm ball joi nt 20 Nm + 1/4
attachment Use new bolts turn
Bali joi nt attachment to the bearing (90°)
housing Use a new bolt 50 Nm

1.5 Swinging arm: removing and fitting

Special tools and workshop equipment required
+ Torque wrench -SAT 8010-
SAT 8010

5.. 25
Nrn

I W00·2760 I

1.5.1 Removing
- Lift the vehicle untiI the front axle is free of weight.
- Remove wheel.
- Remove the sound proofing element when fitted.
- Extract the bolt -1- securing the ball joint to the bearing
hous- ing.
- Extract the nut -2- jo ining the rad from the stabiliser bar to
the subframe.
- Extract the swinging arm along with the ball joint from the
bearing housing.

I E40.10022 I

1.Front wheel suspension

SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

- Extract the bolts -1- and -2- and separate the swinging
arm from the subframe along with the ball joint.
- Separate the ball joint from the swinging arm.

1.5.2 Fitting
The assembly operations are carried out in the reverse arder of
the disassembly with some exceptions.

[i ) Note

The bai/ joint is fitted centred on the swinging arm e!ongated

ho/es.

Tightening torques:
Swinging arm to ball joi nt attachment
20 Nm + 114
Use new bolts
turn
Front bolt of the swinging arm (90°)
Rear bolt of the swinging arm
Use new bolts 70 Nm + 114
Ball joi nt attachment to the bearing turn
housing Use a new nut (90°)
From link rad to the stabiliser bar
Use a new bolt 50 Nm
Attaching the wheel
30 Nm

110 Nm

1.6 Swinging arm bonded rubber bearing: replacement

10 Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

Special tools and workshop

equipment required
SAT 8010
+ Torque wrench -SAT 8010-
+ Clamping tool -T20002- (UlI(lUl(l!
OlfJ•===::=::=;;=;;a•;JJiiloo...300 ,..
+ Clamping tool -U-40452A
+ Lubrication oil (ie -G :z:ti '20...100 Nrn
294 421 A1- )

L40- 10014 I

- Remove the swinging arm page 8

Front socket far the swinging arm: release
- Release the front socket of the swinging arm using the instal
lation tool -T20002- .
Front socket far the swinging arm: engaging
T20002

[i J Note

App/y /ubrication oi! (ie -G 294 421 A1- ) on the contact

surface before fitting.

1O Rep. Gr.40 - Front suspension

1.Front wheel suspension
SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

- lnsert the front socket of the swinging arm using the

installation tool -T20002- .
- Fit the swinging arm page 8
T20002
Rear socket far the swinging arm: release
- Remove the swinging arm page 8 .

- Release the rear bearing with the calliper tool -U-40452A-

.

[i J Note
lf the silentbloc bearing is extremely hard due to corrosion, U-40452A
cut the rubber. Saw the metal covering and release the
bearing.

lnstallation position of the rear bearing

- One of the -arrows- stamped on the bearing should be facing IE40-0142 I
the rebate on the swinging arm.

- The rise -arrow- should always point towards the outside of

the vehicle.
Rear socket far the swinging arm: release

[i J Note
Apply lubrication oil (ie -G 294 421 A1- ) on the contaci
surface before fitting.
I N40-0042 I

- lnsert the bearing using the installation tool -U-40452A- .

- Fit the swinging arm page 8

U-40452A

IE40·0143 I

1.7 Subframe: dismantling and fitting.

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

Special tools and workshop

equipment required
+ Hydraulic column jack - SAT 1040 SAT 8010
SAT 1040-
;:;;;;;;;;;;; ;;i:;:s
• Torque wrench -SAT 8010- 60. 300 Nm

+ Base -T20145-
+ Counterhold -T20161- 20... 100 Nm

+ Centre guide -T20163A

+ Bracket -U-30025E-

T20163A

L40-0054

1.7.1 Removing
- Remove the air filter Rep. Gr. 24 ; Fuel preparation .
- Fit the support stand -U-30025E- .

[i ] Note

Before fitting the reception hooks of the tool, the hose

connections and cab/es in the area of the lifting eyes of the
engine tackle must be removed so as not to damage them.

- Put some torce on the drive train using the spindles.

12 Rep. Gr.40 - Front suspension 1. Front wheel suspension

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

- Extract the bolt -1- from the right hand side of the engine
con sole to the subframe if there is one, the reception plate
far the cable connector should be removed first -A-.
- Unscrew the bolt securing the gearbox to the left hand side
of the subframe.

- Raise the vehicle.

- Extract the bolt -1- securing the balljoi nt to the bearing

housing on both sides.
- Extract the swinging arm along with the ball joint from
the bearing housing.

- Push the wheel and the ball joint outwards and support.

- Release the bolts -1- securing the steering housing to the

sub frame and attach it to the body of the car.
- Release the subframe, the gearbox bracket, the power
steer ing intake and pressure pipes.
- Extract the bolts -2- on the side of the swinging arm rear
si lentbloc, securing the subframe to the bodywork.

1. Front wheel suspension 13

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

- Fit the guides -T20163A- in the bolt positions.

T20163A

IE40-0189 I

- Fit the hydraulic jack -SAT 1040- under the subframe with
the base -T20145- and the support -T20161- .

- Extract the bolts -2- and -3- securing the subframe to the
bodywork.

[i J Note

Attention: the steering gear wi// be re/eased downwards from

the subframe.

- Lower the subframe with the hydraulic jack -SAT 1040-

with the base -T20145- and the support -T20161- .

T20161

1.7.2 Fitting
The assembly operations are carried out in the reverse arder of
the disassembly with some exceptions.

14 Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

[i J Note
Before partial/y screwing the subframe screws on the vehic!e
body, put the steering casing into position.

Before removing the centre guides, secure the subframe

using the bolts -2- and -3-.

- Extract the centre guides -T20163A- and finish fitting the

sub- frame.
Fit the drive train brackets free of tension Rep. Gr. 1O ;
Engine: removing and fitting .
- Following the assembly of the subframe, verify the steering
wheel position and the vehicle alignment.

T20163A

IE40-0189 I

Tightening torques:

Ball joi nt attachment to the bearing 50 Nm

housing Use a new nut
Attachment screw for steering box -1- 30 Nm
Front bolt of the swinging arm-2- 70 Nm + 1/4
Rear bolt of the swinging arm-2- turn (90°)
Use new bolts
Bolt -3- 65 Nm

1.8 Bearing cap bolt on the longitudinal

member: verification

1.8.1 Removing
- Suspend the engine/gearbox assembly with the
tool - U-30025E- .
- Remove the sub-frame page 11 .
lf the hood screw thread on the longitudinal member is
damaged , it must be reworked or the bolt on the hood must
be perforateci.
lf it is to be perforateci proceed as follows.
- Pierce the damaged bearing cap nut on the longitudinal
mem ber by drilling upwards using a drill bit of 0 10.2 mm.

1. Front wheel suspension 15

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

WARN ING

# Wear protective glasses.

# Do not tilt the drill while piercing.

- Tap the new thread M 12 x 1,5 in the bearing cap nut.

- AJways use new collar bolts page 1 6 .

1.8.2 Bolts with celiar for subframe

Anchor point Thread Bolt Part No.
Front subframe M12 X 1.5 M12 X 1.5 X 95 10.9 N 101 612.0113>
Rear subframe M12 X 1.5 M12 X 1.5 X 95 10.9 N 101 612.01
Subframe ear M10 M10 X 38 10.9 N 019 541.1
13) These bolts do not appear in the parts catalogue. They must be ordered specially. The tightening torque does not change.

1 - Bolt
2 - Hood nut
3 - Longitudinal member
4 - Subframe
5 - Metal/rubber bearing

1.9 Il - Wheel attachment, shock absorber, half shaft

l,fl Note

+ lf the vehicle has to be moved when the complete half-shaft has been removed, an exterior joint
must be fitted instead of the complete half-shaft and tightened to 50 Nm to avoid damage to the
wheel bearing.
+ No welding or straightening work can be done on the support andguide elements of the suspension
system.
+ Always replace se/f locking nuts following their remova/.
+ Always replace corroded bolts/nuts.
+ Always replace nuts/bolts with defined final torque.

16 Rep. Gr.40 - Front

 C6rdoba 1999 >- , C6rdoba Vario 1999 >- , lbiza 1999 >- s -r
Running gear, axles, steering - Edition 04.2006 autoemock'.>n

1- Bolt
O 15 Nm + 1/2 turn
(180°) O Replace
2 - Suspension strut
O Removing and installing
page 23
3 - Bracket
2
O Only vehicles with ABS.
4 - Self locking
nut O 95 Nm 6
O Replace
5 - Bolt with interior 21
multiple cog
O 45 Nm
6 - Complete half-shaft
O Repairing page 29
7 - Steering bar 20
O Removing and installing
page 95
8 - Self locking
nut O 50 Nm
O Replace
9 - Wheel bearing
O Releasing page 22
O Replace, this is dam
aged during removal.
O lnsertion page 22
1O - Securing ring
26 25 E40-0031
O Ensure that it is correct
ly seated.
11- Splash plate
O Far brake clip VW Il.
12 - 10 Nm
13 - Rotor far revolution sensor
O Vehicles equipped with ABS.
14 - Wheel hub
O Releasing page 21
O lnsertion page 22
O Release the interior bearing ring page 21 .
15 - Star-head
screw O 4 Nm
16 - Twelve-sided self-locking
nut O Tighten page 29
O Before fitting clean the remains of paint and/or corrosion on the screw thread of the exterior jo int.
O Replace
17 - Self locking
nut O 32 Nm

1. Front wheel suspension 17

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition
O Replace
18 - Wheel bearing housing
O Far brake clip VW Il.
19 - Bolt
20 - Revolution sensor
21 - lnterior hexagonal nut
O 10 Nm
22 - Bolt
O Adjust the camber page 63 .
O Before loosening mark the installation position.
23 - 10 Nm
24- Bracket
25 - Splash plate
O Far Lucas brake clips
26- Wheel bearing housing
O Far Lucas brake clips

18 Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

1.1O Wheel bearing housing: removing and fitting

Special tools and workshop

equipment required
SAT 8010
+ Torque wrench -SAT 8010-
+ Extractor -T20001- DC'. Dl!lU!Jll!il!:
(J}=====;•i:l:iieo ..300 ""'

+ KIT -T20022-
+ Measuring tool -T20030- 20...100 Nm

+ Extractor -T20147-
5...25Nm

+ KIT -U-40450A-

T20030

L40-10015 I

1.10.1 Removing
- Partially loosen the dodecagonal nut of the half shaft.
- Lift the vehicle untiI the front axle is free of weight.
- Remove wheel.
- Far vehicles fitted with ABS ,disconnect the revolution sensor.
- Remove the brake carrier along with the calipers, secure the
calipers to the bodywork so that the brake hose is not dam
aged or under pressure :::} Rep. Gr. 46 ; Front wheel brake:
repairs .
- Extraet the self locking nut securing the ball joi nt of the
steering bar to the bearing housing.

1. Front wheel suspension 19

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

- Use the extractor -T20147- to take out the steering rad ball
joi nt from the wheel bearing housing.

- Pull out the half shaft using the extractor T20001 -T20001- .

[i J Note

+ The ha/f shaH shou/d never be /efl suspended, because the

internaljoint wou/d be damaged by bending.
+ Ensure that there is enough space avai/ab/e tor the
extraction of the ha/f shaH without damaging it.
+ Mark the fitting position of the attachment bo/ts between the
shock absorber and the whee/ bearing housing before /oos
ening. I E40-000 1 I

- Remove the bolt -1- securing the ball joi nt to the bearing
hous ing.
- Extract the swinging arm along with the ball joint from the
bearing housing.

- Extract the bolts -1- securing the shock absorber to the

wheel bearing housing.

IE40-0046 I

1.10.2 Fitting
The assembly operations are carried out in the reverse arder of
the disassembly with some exceptions.

2O Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

[i J Note
+ Oil the contaci surface tor the dodecagonal nut
+ The camber must be checked or adjusted.
+ To tighten the dodecagonal nut, use the retightening
angle measurement too/ -T20030- .

- Fit the dodecagonal nut page 29 .

Tightening torques:
Steering rad ball joi nt attachment 32 Nm
Use a new bolt
Ball joi nt attachment to the bearing 50 Nm
housing Use a new nut
Telescopie arm attachment bolt 115 Nm
Use new nuts
Attaching the wheel 110 Nm

1.11 Wheel bearing: repairs

1.11.1 Removing
- Remove the wheel bearing housing page 19 .
Release the wheel hub from the wheel bearing housing
Use the KIT -U-40450A-

lnner bearing ring: release from the wheel hub

Use the KIT -T20022-

- Remove the wheel rotation rotor if the vehicle is fitted with
ABS.
Vehicles with ABS

IE40.()()()9 I

1. Front wheel suspension

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

Wheel bearing: release from the wheel bearing housing

- First remove the retention ring.
Use the KIT -U-40450A- .

[i J Note

App/y grease to the surface of the ho/e in the wheel bearing

hous ing using the Mo/ygote grease -ND52 723 DO- , use a
grease bag from the repair kit.
IE40-0137 I

lnsert the wheel bearing into the housing

Use the KIT -U-40450A- .
- Fit the securing rings. [ U-40450A/1O
- Fit the rotor far revolution sensor. Star-head screw
I tem 15 (page 1-==='""1

17) . All vehicles

(continued)

Wheel hub: insert the wheel bearing

IE40-0050 I

1.12 Suspension strut: disassembly and as

sembly
1.12.1 Removing
- Raise the vehicle.
- Remove wheel.
- Release the revolution sensor from the telescopie arm far
those vehicles fitted with ABS.

22 Rep. Gr.40 - Front

 G6rdoba 1999 >- , G6rdoba Vario 1999 >- , lbiza 1999 SEFI
>

- Extract the bolts -1- securing the shock absorber to the

wheel bearing housing.

IE40-0046 I

- Extract the bolts -1- far the shock absorber to bodywork

upper attachment.

1.12.2 Fitting
The assembly operations are carried out in the reverse arder of
the disassembly with some exceptions.
- After fitting the telescopie arm, verify the wheel alignment.

Tightening torques:
Upper shock absorber 15 Nm + 112
attachment Use new nuts turn
Telescopie arm attachment bolt (180°)
Use new nuts 115 Nm
Attaching the wheel
110 Nm

1.13 Generai overview: telescopie arm: repairs

[i ) Note

+ lf the vehic!e has to be moved when the complete half-shaft has been removed, a CV exteriorjoint
must be fitted instead of the complete ha/f-shaft and tightened to 50 Nm to avoid damage to the
wheel bearing.
+ No welding or straightening work can be done on the suppor! andguide elements of the suspension
system.
+ A/ways renew se!f !ocking nuts fol!owing their remava/.
+ A/ways renew corroded nuts and bolts

1. Front wheel suspension

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

1- Shock absorber
O Can be replaced sepa
rately.
O Ensure that the shock
absorber does not have
any leaks or produce
noise.
O After replacement ad 7
just camber and I .
conver gence. . I

2 - Elastic limit 6
3 - Protective cover
4 - Suspension spring ----- 5
O Removal and fitting
page 25
O Note the identification
using colours.
O The surface of the
spring coil must not be
damaged.
5 - Telescopie arm bearing
6 - 60 Nm
O Loosening and tighten
ing page 26
O Always replace
7 - Bolt
O 15 Nm + 1/4 turn (90°)
O Always replace

E40-0052

24 Rep. Gr.40 - Front

 C6rdoba 1999 >- , C6rdoba Vario 1999 >- , lbiza 1999
SEFIT
> auto emociòn
Running gear, axles, steering - Edition
04.2006

1.14 Telescopie arm: repairs

Special tools and workshop

equipment required
SAT 8010
+ Torque wrench -SAT 8010-
+ Compression tool - U-
10081-
lllltuOD
cra
60...300Nm

+ Wrench -U40003-
20...100Nm
+ lnterior hexagon wrench,
socket size 7 (commerciai CimilI:J=;ç;
5...25 Nm
wrench)

U-40003

l40-0012

Removing and fitting the spring with the compression tool - U-

10081-

-- U-10081

I E40-0053 I

1. Front wheel suspension

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

Unscrew and screw the nut for the upper spring plate - +--- U-10081
& WARN ING
- =...====-= 1

Firstly, put tension on the spring so that the upper piate of the SAT 8010
spring is discharged. _fe -U-40003

26 Rep. Gr.40 - Front

 C6rdoba 1999 >- , C6rdoba Vario 1999 >- , lbiza 1999 >- s -r
Running gear, axles, steering - Edition 04.2006 autoemock'.>n

2 Articulated half shafts

2.1 Articulated half-shafts: repairs

Special tools and workshop

equipment required
A-81124
+ Pliers -A-81 124-
+ Extractor -T20001-
+ Plunger -T20027-
+ Pliers -T20072-
+ Clamping tool -U-40061/ 1-
+ KIT -U-40450A-

T20072

U-40061/1

L40-10016 I

2.1.1 Removing

SAT 8010

20...100 Nm

s...25Nm

I W00-2760 I

2.Articulated half shafts

 SEFI C6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
1999 ,.... Running gear, axles,steering - Edition

+ Torque wrench -SAT 8010-

T20030
+ Measuring tool -T20030-

[i J Note

+ Thebearings will be damaged, the weight of the vehic/e is

ex cessive and wil/ reduce the usefu/ /ife as a consequence.
+ Oil the contact surface tor the dodecagonal nut
+ The complete ha/f shaft cannot be separated from the
wheel hub without using the extractor - T20001- . I W00.2310 I
+ Ensure that there is enough space avai/ab/e tor the
extraction of the complete ha/f shaft without damaging it.
+ The ha/f shaft shou/d never be /eft suspended, because the
internaljoint wou/d be damaged by bending.
+ lf the vehic/e has to be moved when the ha/f shaft has
been removed, an exteriorjoint must be fitted instead of
the ha/f shaft and tightened to 50 Nm to avoid damage to
the whee/ bearing.

- Partially loosen the dodecagonal nut of the articulated half

shaft.
- Lift the vehicle untiI the front axle is free of weight.
- Remove wheel.
- Far vehicles fitted with ABS, disconnect the revolution
sensor.
- Remove the sound proofing element when fitted.
- Release the complete half-shaft from the flanged shaft of the
gearbox.
- Finish removing the dodecagonal nut from the complete half
shaft.

[i J Note

While the complete ha/f shaft is being pushed out, take

special care that there is a/ways enough space.

- Pull out the articulated half shaft using the extractor

T20001 - T20001- .

I E40-0001 I

2.1.2 Fitting
The assembly operations are carried out in the reverse arder of
the disassembly with some exceptions.
Before fitting clean the remains of paint and/or corrosion on the
screw thread of the exterior joint.

28 Rep. Gr.40 - Front

 C6rdoba 1999 >- , C6rdoba Vario 1999 >- , lbiza 1999
SEFIT
> auto emociòn
Running gear, axles, steering - Edition
04.2006

The points of the cogs -arrow- are slightly flattened. This is to

®
avoid the existence of play between the flanks of the exterior joi
nt cogs and the hub.
Fit the dodecagonal nut

[i J Note
+ To tighten the dodecagonal nut, use the retightening
angle measurement too/ -T20030- .
+ lf the too/ is not avai/ab/e, the dodecagonal nut can be tight
ened using the tol!owing method.

- Oil the contact surface of the dodecagonal nut and tighten as

much as possible.
- Lower the vehicle unti! the wheels partially touch the ground.
- Tighten the dodecagonal nut using a torque of 200 Nm and
loosen by one turn.
- Turn the nut to a torque of 50 Nm to begin.

- Mark the head of the nut with a line -Arrow A-.

- Mark a second line -arrow 8- on the edge of the wheel hub,
aver the following notch.
- Continue to turn the dodecagonal nut unti! the marks coincide.

Tightening torques:
CV joint to gearbox attachment. 45 Nm
Tripod joint housing to gearbox 40 Nm
Self-locking dodecagonal nut 50 Nm +
Use a new nut 1
/a
Attaching the wheel turn (45°)
110 Nm
Grease the joi nts

[i J Note

+ Quantity otgrease: tor the constant ve/ocityjoint exterior

and interior, app/y 90 grams ot -G 000 603- to each one.
+ Grease distribution tor the exterior constant ve/ocityjoint:
in troduce ha/f ot the grease into thejoint,·the other ha/f
should be distributed even/y over the dust guard.
+ When rep/acing the dust guard, itnecessary, grease thejoint.
+ Removing and fitting the articu/ated ha/f shafts page 27.

2.2 Drive shaft with constant velocity joint: repairs

rL :
Note
;!-

J1

2.Articulated half shafts

 lf ba/ance weights have been fitted, after repair work, they shou/d be p!aced in the positions in which
SEFI theyC6rdoba 1999 ,.... , C6rdoba Vario 1999 ,.... , lbiza
were betore.
1999 ,.... Running gear, axles,steering - Edition

30 Rep. Gr.40 - Front