SEAT Workshop Service and Repair Manuals

Gearbox: removing, Altea 2009 ►, Altea XL 2009 ►, Leon 2009 ► Transporting gearbox and securing to assembly stand → Chapter. Install gearbox → Chapter. Tightening torques to attach the gearbox to the engine and information on the gearbox mounting → Chapter Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Hydraulic jack -SAT 1040-, see equivalent → Anchor

t	Gearbox support -T20138C -, see equivalent → Anchor

t	base -T20145-, see equivalent → Anchor

t	Engine bracket -U30025F-, see equivalent → Anchor

t	Torque wrench -VAG 1331-, see equivalent → Anchor.

t	Torque wrench -VAG 1332-, see equivalent → Anchor.

t  Adapter for the hydraulic engine and gearbox jack -SAT 1001/1- Operation process   Note t  Observe rules for cleanliness when working on gearbox → Chapter. t  Refer to general repair instructions → Chapter. t  All cable ties which are released or cut open when removing the gearbox must be refitted in the same position when installing the gearbox. –  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 battery earth strap. –  Remove complete air filter housing → 4 cylinder Engine with direct petrol injection 1.8 Turbo 4V; Rep. gr.24 –  Remove battery → Electrical system; Rep. gr.27.

–  Remove battery tray -arrows-. –  Remove starter → Electrical system; Rep. gr.27.

–  Hang-out the selector lever control cable -2- from the lever of the selection shaft. –  Pull off securing clip -1- for selector lever cable.   Note t  A lock washer, which was removed, never insert again. It could be damaged if it no longer has the necessary inner tension. t  This is why a new circlip must always be used when assembling. –  Remove the control cable from the counter bearing on the gearbox with great care. Do not bend it. You can push the control cable a little out of the counter bearing to the back and remove it later when lowering the gearbox. In this case, you have to take care when lowering using the control cable.

–  To unlock and remove the plug connection on the catch draw out the plug connection of mechatronics. –  Then unscrew all upper securing bolts between engine and gearbox.

One screw is located in the opening of the starter. The socket -T10061 - can be used instead of the 18 mm socket. –  Remove the central sound insulation → Bodywork, exterior fitting work; Rep. gr.50. –  Remove the left and right wheel box cover → Exterior body installation work; Rep. gr.66

The number of electrical connectors on the bracket described below may vary depending on the engine model. –  Remove all brackets in front of the plug connection of the gearbox.

–  Removing pendulum support:

–  Press »engine and gearbox« forwards and secure in position with an appropriate piece of wood -A-. –  Pay special attention to the following points: l  The alternator should not rub more than lightly on the refrigerant tubes. l  The air conditioning compressor should not rub more than lightly on the refrigerant tube connections.

–  Remove the heat shield (when fitted) of the right hand side wheel drive shaft -arrows-. –  Remove articulated shaft from the flange shaft of the gearbox → Running gear, shafts, steering; Rep. gr.40.

–  Unbolt the exhaust system bracket -arrows-. –  If necessary, the engine cover may have to be removed depending on the engine version. –  Separate the hoses and cables in the engine compartment near to the retainers that hang in the engine support -U30025F-.

–  Fit the engine support -U30025F- on wing panel flanges. –  Place eyes onto spindle hooks.   Note t  Fit the supporting equipment so that it is seated correctly on the hardest parts of the wing water drains and will not cause any damage. t  Ensure that the pipe connections and the cables in the area where the engine is suspended do not suffer any damage while fitting the hooks of the support equipment. –  Slightly tense the engine assembly/gearbox via the spindles.

Unscrew all bolts -1- and -2- from the console. –  Then lower the engine / gearbox unit a little using the spindle of the engine mount -U30025F- in order to remove the console.

–  Attach the support tool -T20138C- on the base - T20145-, and move these onto the engine and gearbox jack -SAT 1040- using the adapter for the hydraulic engine and gearbox jack -SAT 1001/1-. –  Unscrew the remaining lower securing bolts between engine and gearbox. –  Release the gear box from the centring cases and turn toward subframes, move the spindles of the gear box carrier -T20138C - There are brackets on the front side of the gearbox with certain versions.   Note Lower the gearbox very carefully.

–  When fitting a new gearbox, remove this bracket as it is no longer required.

–  Renew the needle bearing of the crankshaft → Rep. gr.13.