SEAT Workshop Service and Repair Manuals

Removing gearbox, Alhambra 2011 ► with 1.4 litre petrol engine Brief description The gearbox is removed downwards separately. »From above« Remove battery, air filter and starter. The coolant hoses must be clamped off. Left subframe mounting is removed, engine and gearbox supported. »From below«:

Remove -subframe- together with -pendulum support-, -steering box- and -both suspension links-.

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-

t	Spring retainer -T10358-

Removing: –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Shift selector lever into position »P«. –  Remove cover for 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. It is advisable to remove the »lower« bolt first. –  Unbolt earth strap from bracket.

–  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 upper engine/gearbox connecting bolts.

These tools are appropriate for this:

A bolt is located in the starter motor hole -arrow-. –  Remove noise insulation and front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Remove coolant circulation pump -V50--arrow 1-; do not open coolant lines → Rep. gr.19.

–  Unclip line to Lambda probe. –  Remove connecting hose between charge air cooler and charge air pipe. –  Unbolt bottom of charge air pipe from engine and swing forwards → Rep. gr.21.

–  Unbolt wiring retainer from front of »black« gearbox cover -arrows- (2 nuts M6). Tightening torque: 10 Nm

–  Unbolt both drive shafts from gearbox and secure to suspension strut using securing straps -T10038- → Rep. gr.40. The surface protection of the shafts must not be damaged.

Then remove the -subframe- together with the -pendulum support-, the -two suspension links- and the -steering- → Running gear, axles, steering; Rep. gr.40.

–  Disconnect front exhaust pipe from catalytic converter so that lower engine/gearbox connecting bolts -arrows- can be removed → Rep. gr.26. Set up support device.

–  Remove the plenum chamber cover → Rep. gr.50 –  Unscrew the securing bolt for gearbox and bolt bracket -T10358- on as shown in the figure. –  Connect the hook attachment -U-30025F- to the bracket -T10358- as shown in the figure. –  Turn the spindle until the hooks are slightly tensioned.

–  Release the hook -1- from the eye ring and move the spindle to the left hand side of the mounting hook -U-30025F-. –  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-.

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. –  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.