SEAT Workshop Service and Repair Manuals

Exhaust gas recirculation radiator: Installing and removing: t  Engine codes ASZ, ATD, BPX, BLT, BUK and AXR → Anchor t  Engine code BMT → Anchor Engine codes ASZ, ATD, BPX, BLT, BUK and AXR t  Removing → Anchor t  Installing → Anchor. Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Recipient tray -T20173-, see equivalent → Anchor

t	Pliers -T20174- or pliers -T20029-, see equivalent → Anchor

t	Counterhold -U 30042-, see equivalent → Anchor

Removing

–  Remove the engine sound proofing cover, pulling upwards forcefully (-arrows A-) and remove forwards, from the rear attachment (-arrow B-).

–  Remove supercharging tube -1- with connecting hose -2-, releasing the flanges -arrows- in doing so.

–  Disconnect the hose -5- to the air filter housing. –  Separate the ventilation tube -6- from the air conduction pipe. –  If the engine is equipped, disconnect the connector -3- for the heating rheostat (crankshaft sump breather) -N79-. –  Leave the hoses for low pressure loose. –  Remove the bolts -1- and -2-.

–  Remove noise insulation: → Bodywork, exterior fitting work; Rep. Gr.50.

–  Loosen the spring-type clamp -arrow- with pliers -T20174- and remove the pipe from the turbocharger.

–  Extract air hose -4-.

–  Close the flexible coolant hoses with the pressure tool -U-30042-. –  Separate the flexible hoses exhaust gas recirculation radiator using the counterhold -T20174-.   Note In vehicles with engine identification letters BPX and BUK, the coolant hose must be separated from the expansion drum using the counterhold -T20174-.

–  Unscrew the bolts -1-and the nuts -2- and remove the union hose -3- from the exhaust gas recirculation radiator. –  Extract the bolts -4-. –  Remove the bolts -5- which join the exhaust gas recirculation radiator to the intake manifold. –  Remove the exhaust gas recirculation radiator. Installing . Installation is carried out in the reverse order of removal while noting the following:   WARNING When assembling the supercharger air pipes, do not use an oil-based lubricant.   Note t  Apply the correct tightening torques. t  Always replace gaskets and self-locking nuts. t  The sleeves for the hoses and the supercharger air flow tubes should be free of oil and grease before fitting. t  Secure all of the flexible tube connections using clips specially designed, corresponding to the series: t  Fit the supercharger air system hoses and observe the assembly instructions → Chapter. Engine code BMT t  Removing → Anchor t  Installing → Anchor. Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Recipient tray -T20173-, see equivalent → Anchor

t	Pliers -T20174- or pliers -T20029-, see equivalent → Anchor

t	Counterhold -U 30042-, see equivalent → Anchor

t	Socket wrench e/c 22 -T20202A-, see equivalent → Anchor

t	Socket wrench e/c 17 -T20211-, see equivalent → Anchor

t	Articulated wrench e/c 17 -T20212-, see equivalent → Anchor

t	"Ratchet 1/2"" x 9-12" -VAG 1331/1-, see equivalent → Anchor

Removing   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open the cap of the coolant expansion tank.

–  Remove the central soundproofing → Bodywork, exterior installation work; Rep. Gr.50 –  Drain coolant → Chapter

–  Unscrew the bolts -arrows- and remove the heat protecting plate. –  Dismount the right articulated shaft → . Removing and fitting ; Rep. Gr.40. –  Remove right wheel housing moulding → Bodywork, exterior fitting work; Rep. Gr.63

–  Unbolt the pressure pipe -2- using the articulated wrench E/C 17 -T20212-. –  Unbolt the temperature sender after the particulate filter -G527--1- using the articulated wrench E/C 17 -T20212-.

–  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards.

–  Remove supercharging tube -2- with connecting hose -3-, releasing the flanges -arrows- in doing so. –  Disconnect connector -1- from intake manifold pressure sensor -G71-.

–  Detach electrical connector -1- of the engine intake manifold flap -V157-. –  Unscrew the bolts -arrows- and remove the intake manifold flap motor -V157-.   Note For improved understanding, it is shown from the rear in the illustration with engine removed.

–  Disconnect the electrical connector -1- on the exhaust gas recirculation valve -N18- with the potentiometer for regulating exhaust gases -G212-. –  Remove the electrical harness from the brackets and move to one side. –  Undo both bolts -arrows-. –  Remove the exhaust gas recirculation valve -N18- of the intake manifold.

–  Disconnect the connectors -1-, -2-, -3- and -4- and remove them from their housings.

–  Undo the pressure pipe -3- of the particulate filter using the socket wrench E/C 17 -T20211-. –  Undo the lambda probe -G39--1- using the socket wrench E/C 22 -T20202A- and the "ratchet 1/2"" x 9-12" -VAG 1331/1-. –  Unscrew the bolts -arrows- and free heatproof plate of the particulate filter -4- without removing it.

–  Undo the exhaust gas temperature sender 2, bench 1 -G448--2- using the socket wrench E/C 17 -T20211- and the "ratchet 1/2"" x 9-12" -VAG 1331/1-.

–  Disconnect the connector -arrow- for exhaust gas pressure sender 1 -G450-. –  Unbolt the exhaust gas pressure sensor sensor 1 -G450- and remove together with the pressure pipes. –  Remove the heatproof plate of the particulate filter.   Note If it is not possible to remove the heatproof plate, place it to one side and then lower it together with the particulate filter.

–  Unscrew the brackets -5- of the particle filter.

–  Remove the bolts -arrows- and remove the upper support of the particulate filter.

–  Unscrew the nuts on the double clamp -1-. In that case it is not necessary to unscrew nuts -arrows-.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

–  Remove the securing bolts of the particulate filter and the engine block, and remove the support. –  Remove the front part of the exhaust pipe with the particulate filter and place it on the power steering.   Note t  The silencer in the front section of the exhaust pipe with particle filter should not be bent by more than 10º otherwise there is a risk of damage.. t  Be careful not to damage the electrical connections and cable routing.

–  Push the coolant hoses -1- using the pressure tool -U 30042- and remove them with the counterhold -T20174- or pliers -T20029-. –  Remove the heat shield of the vacuum actuator. –  Detach connection hose -2-. –  Detach the vacuum line.

–  Unscrew the nuts -arrows- and take connecting pipe for exhaust gas recirculation off.

–  Remove the oil return pipe by removing bolts -1-, -2- and the hollow bolt -3-.

–  Unbolt the support -2- for the fuel filter. –  Remove the bolts -arrows- and remove the exhaust gas recirculation radiator. –  Remove the exhaust gas recirculation radiator through the right hand side wheel housing cavity. Installing Continue the installation in the reverse order of removal sequence, observing the following:   Note t  Replace seals, gaskets and self-locking nuts. t  The sleeves for the hoses and the supercharger air flow tubes should be free of oil and grease before fitting. t  Secure all hose connections with the correct hose clips (same as original equipment) → Spare parts catalogue. –  Check the coolant level. –  Check the engine oil level