SEAT Workshop Service and Repair Manuals

Removing and installing charge air cooler Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required

t  counterhold -T10038-, see equivalent → Anchor

t  Base -VAS 6340-, see equivalent → Anchor t  Centre guide -T10093-, see equivalent → Anchor   Note When removing the intercooler, it is not necessary to drain the coolant nor remove the upper and lower coolant hoses. Removal: –  Dismount the air filter housing together with the air mass meter and the connecting pipe → Chapter.

–  Loosen the bolt by one turn -1-. –  Remove bolt -2- and nut -3-. –  Leave the fuel filter to one side with the flexible hoses coupled.

–  Remove connecting hose on »hot side« from charge air pipe. To do this, detach hose clips -1-.

–  Remove connecting hose on »cold side« from charge air pipe. Release hose clips -1- and -2- for this.   WARNING Risk of injury due to refrigerant. The air conditioning refrigerant circuit must not be opened.   Caution Danger of damage to condenser, refrigerant lines and hoses. Do not stretch, kink or bend refrigerant pipes and hoses.

–  Unscrew the bolts -2- and -3- in the bracket for the refrigerant tubes.   Note Disregard item -1-. –  Bring lock carrier into service position: → General body repairs, exterior; Rep. gr.50.

–  Remove the bolts -arrows- from the cowling. –  Pull connector -1- off thermo-switch and radiator fan.

–  Unscrew bolts -arrows- of the radiator fan. –  Disconnect the radiator fan together with the hoses on the engine side and attach to a fixed point using the tensioning belt -T10038-.

–  Undo the bolts -1- from the lock carrier plate to the intercooler.   Note Disregard item -2-.

–  Lift the assembly comprising condenser and supercharger, remove the existing sleeves in the lock carrier plate -1- and slide in the -direction of the arrow-. –  Swing charge air cooler backwards slightly.

–  Unscrew the bolts -2- that fixes the condenser to the charge air cooler.   Note Disregard item -1-.

–  Unscrew the condenser bracket bolt -arrow-. –  Support the condenser in the recess of the lock carrier. –  Remove the intercooler upwards, being careful to not damage and cause imperfections in the system. Installation Installation is carried out in reverse order, noting the following: l  Tightening torques → Chapter Installation is carried out in reverse order, noting the following:   Note t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. –  Install the lock carrier → Bodywork, exterior fitting work ; Rep. gr.50. –  Fit the pipe of the charged air system . –  Installing radiator → Chapter.