SEAT Workshop Service and Repair Manuals

Removing gearbox, Alhambra 2011 ► with 2.0 litre - 100, 103 and 125 kW - diesel engine. Brief description The gearbox is removed downwards separately. »From above« Remove battery with battery tray, air filter and starter. The coolant hoses must be clamped off. The engine and gearbox must be supported before the left subframe mounting is unbolted. »From below«: Remove → pendulum support. The subframe remains in the vehicle.

Special tools and workshop equipment required

t	Engine and gearbox jack -SAT 1040-

t	Torque wrench kit -SAT 8010-

t	Gearbox support -T20138C-

t	Rack -T20145-

t	Engine support -U30025F-

t	Thrust piece -U30042-

t	Tensioning tool -T10038-

t	Socket and key -T10107A-

t	Engine sealing plug set -VAS 6122-

t	Spanner -T10179-

Removing: –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Shift selector lever into position »P«.   Note Do not place the vehicle on the ground once the centre bolt has been removed.

–  Press the brakes, unscrew the left bolt of the drive shaft -arrow- (second mechanic). –  Remove cover for engine.

–  Then pull off grommet -arrow- so that it is not damaged when supporting engine. –  Remove complete air filter housing → Rep. gr.24. –  Remove battery and battery tray → Rep. gr.27.

–  Release mechatronic unit connector -1- by turning and pull off connector. –  Remove starter -A- → Electrical system; Rep. gr.27.

–  Remove selector lever cable from gearbox. Use pliers to remove the securing clip on the cable support bracket. Do not use a sharp-edged lever, as the rubber grommet on the cable could be damaged.

Both securing clips must be later renewed when cable is adjusted. During later installation, do not clip »small« securing clips on until cable has been checked and adjusted. –  Remove cable with great care from cable support bracket on gearbox. Do not bend cable. Cable can also be removed later on when gearbox is being lowered. Then observe cable whilst lowering gearbox.

–  Clamp shut each of the transmission oil radiator hoses using the pressure tool -U30042- and remove from the radiator -A-. –  Seal the radiator with clean plugs from engine sealing plug set -VAS 6122-. –  Remove charge air line → Rep. gr.21.

–  Remove upper engine/gearbox connecting bolts.

These tools are appropriate for this:

A bolt is located in the starter motor hole -arrow-. It is advisable to now do all the work which must be done »beneath« the car. This will avoid having the weight of the engine carried by the support bar and, consequently, by the body, for »a long time«. –  Remove noise insulation and front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Remove left coupling rod from suspension link and lay to side. –  Remove left drive shaft → Rep. gr.40.

–  If present, remove heat shield above right drive shaft. Tightening torque → Rep. gr.40

–  Screw out the right drive shaft from the gearbox and fix to the suspension strut using the tensioning belt -T10038- → Rep. gr.40.

–  Remove → pendulum support. First remove bolt -1-, followed by bolts -2- and -3- → Rep. gr.40.

–  Unbolt wiring retainer from front of »black« gearbox cover -arrows- (2 nuts M6).

Set up support device. –  Remove the plenum chamber cover → Rep. gr.50 –  Fit the engine bracket -U30025F- with the necessary adapters and attach as shown in the figure, and catch the motor in its installation position.   Note

t  The gearbox support -U30025/5B- must be mounted with the rubber blocks in the direction of the wing. Front bearing point in the area of the screw of the fixing plate of the front side. t  The screws that secure the subframe support can only be undone when the engine is supported using the engine bracket -U30025F-. –  Lightly tension the subframe support using the spindle of the engine bracket -U30025F-.

–  Remove all bolts -1- and -2- for bracket -A-. –  Lower the engine and gearbox a little using the spindle of the engine bracket -U30025F- and remove the console.

At most, 5 turns are sufficient to remove bracket -arrow-. In many cases, the spindle does not need to be lowered further for the later removal of the gearbox.   Note Before removing flange shaft, check oil seal for leaks. If oil seal is leaking, it must be renewed before flange shaft is installed.

–  Remove the right flange shaft of the gearbox using the socket wrench -T10107A-. Bolt has a 6 mm hexagon socket. –  Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft. –  Remove flanged shaft together with compression spring. –  Close opening in drive shaft using a suitable plug. –  When flange shaft is reinstalled, compression spring prevents bolt engaging in thread. If necessary press flange shaft against gearbox with a lever and screw in bolt. Tightening torque: 30 Nm –  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-.

–  Fix the gearbox bracket -T20138C- to the gearbox casing. The gearbox is separated from the engine in this position. –  Remove remaining engine/gearbox connecting bolts. –  Separate the gearbox from the engine »observing selector lever cable in the process« and lower the gearbox. Transporting gearbox and securing to assembly stand → Chapter. Install gearbox → Chapter.