SEAT Workshop Service and Repair Manuals

Removing and installing the cooler for exhaust gas recirculation (Altea - Altea XL - Leon) t  Removing → Anchor t  Installing → Anchor Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter

Special tools and workshop equipment required

t	Hose clamp -3094-, see equivalent → Anchor

t	Collecting tray -VAS 6208-, see equivalent → Anchor

t	Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor

t  Wrench kit 17 mm -T10395-, see equivalent → Anchor

t  Torque wrench -VAG 1331-, see equivalent → Anchor. t  Wrench kit -3337-, see equivalent → Anchor

Removing –  Loosen the engine cover at the locations -arrows- and remove.

–  Remove crankcase breather hose -1-, press release buttons for this. –  Leave the vacuum hoses -arrows- loose. –  Release the hose clamp -3- and remove the air conduit from the air filter housing. –  Unscrew bolt -2-, swing intake hose and intake unions to rear and pull off of turbocharger.

–  Remove bolts -arrows-. –  Loosen hose clip -1- and remove pulsation damper -2-. Loosen particulate filter.

–  Disconnect connector for Lambda probe -G39--3- and connector for exhaust gas temperature sender 4 -G648--1-.

–  Disconnect connector for exhaust temperature sender 3 -G495--1- (secured behind bracket). –  Pull connector out of retainers and guide wiring out of retainers on plenum chamber bulkhead -2- and on turbocharger.

–  Unplug connector from pressure differential sender -G505--2-. –  Unscrew the screws -3, 4 -.

–  Release the pressure differential sender -G505- with bracket -1- from the toothed belt cover top section. –  Lay pressure differential sender -G505- down on particulate filter.

–  Unscrew the bolt -1-.

–  Turn out the fixing bracket -2- between the particle filter and the exhaust gas turbocharger.   Note Disregard: -Items 1, 3-.

–  Remove the screws -1- and take off the heat shield for drive shaft on the right side. –  Detach right drive shaft from gearbox flange.

–  Unscrew securing nuts -2- for particulate filter bracket on crankcase.

–  Remove bolts -arrows-.

–  Slacken the fastening nuts -arrows- of the clamping sleeve and then lower the exhaust pipe to the rear.

–  Remove the particulate filter -1- and fix accordingly on the steering box -2- in order not to damage it.

–  Remove connection pipe -2- leading to cooler for exhaust gas recirculation. –  Unscrew connecting pipe -1- only at exhaust gas recirculation cooler -arrows-.

–  Unscrew the bolts -1, 2- and the hollow bolts -4, 5-; remove the exhaust gas turbocharger bracket together with the oil return hose.   Note Ignore -item 3-. –  Place the drip tray -VAS 6208- under the engine.

–  Clamp off the coolant hoses -1, 3- with hose clamps -3094- and detach hoses from the exhaust gas recirculation radiator. For this purpose loosen the hose clamp. –  Disconnect connector -2-. –  Disconnect vacuum hose -4- from the vacuum switch and move clear. –  Remove bolts -arrows- and detach the radiator for the exhaust gas recirculation. Installing Installation is carried out in reverse order, noting the following: l  Tightening torques → Chapter   Note t  Replace the seals, gaskets and self-locking nuts → Electronic parts catalogue. t  Checking engine oil level → Chapter. t  Fill up with coolant → Chapter. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  After removing and installing the particulate filter or the pressure differential sender -G505-, the pressure differential sender -G505- must be adapted using the → Vehicle diagnostic tester in all cases. Guided functions; pressure differential sender -G505-: adapting. –  Fit the combined flange (oil supply and oil return lines) to the exhaust gas turbocharger and cylinder block together with the support of the exhaust gas turbocharger. –  Fit oil supply line onto turbocharger and crankcase.

–  First bring the bolts -1- and the hollow bolt -4- of the exhaust gas turbocharger to the engine block by hand. –  Fix the screw -2- to the exhaust turbocharger. –  Then move the hollow bolt -5- and the combined flange -3- for the oil supply line to the engine block. –  Then tighten the turbocharger support bolts in several steps up to the specified torque alternating between the crankcase → Item and turbocharger → Item. –  Finally tighten bolt -3- on the oil supply line / turbocharger support clamp to specified torque. Tightening torques → Chapter –  Mount the intake hose on the vibration damper → Chapter. –  Mount the particle filter → Chapter. –  Checking engine oil level → Chapter. –  Check the coolant level.