SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger t  Removing → Anchor t  Fitting → 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  Plug set for engine -VAS 6122-, see equivalent → Anchor   Caution If the turbocharger has suffered mechanical damage (e.g. damaged compressor wheel), it is not sufficient merely to fit a new turbocharger. To avoid any subsequent damage, the following work must be carried out: t  Check the air filter housing, the filter element and the air intake hose for dirt. t  Check the complete process of the charge air circuit and the charge air cooler for foreign particles. t  If foreign objects are discovered in the charge air system, clean the charge air path and, if necessary, renew the charge air cooler.

Removing –  Remove engine cover panel -arrows-. –  Remove air cleaner housing → Chapter.

–  Press release tabs, disconnect crankcase breather hose -2- and move clear. –  Remove air intake hose. To do this, loosen hose clip -1-.

–  Release the quick fasteners -1... 3- and remove the noise insulation in the front and back.

–  Disconnect exhaust system at clamp -arrow-.

–  Unscrew bolt -1- from front exhaust pipe   Note Ignore -item 2-.

–  Disconnect air intake hose from turbocharger -arrow-.

–  Loosen the bolts -1- and -2-, and remove the turbocharger bracket.

–  Remove bolts -1-. –  Detach electrical connector -3- for exhaust gas temperature sender 1 -G235- from bracket, unplug connector and move electrical wiring clear.   Note Ignore -item 2-.

–  The exhaust gas temperature sender 4 -G648--Pos. 1-.

–  Unplug electrical connectors -3 and 4-, and move wiring clear. –  Screw out the Lambda probe -G39--1- using the wrench -3337/1-. –  Unscrew the exhaust gas temperature sender 3 -G495--2- using the 17 mm wrench -T10395/6-. –  Unscrew the line -3- of the pressure differential sender -G505- in front of the particle filter using a 17 mm socket wrench -T10395/5-.

–  Remove nuts -arrows- and move particulate filter to rear.

–  Remove union nut -2-.   Note Ignore -item 1-.

–  Unplug electrical connector -1-. –  Pull off vacuum hose -2-. –  Remove nuts -arrows- and detach turbocharger.   Caution Risk of damage to oil supply line. Do not attempt to bend oil supply line to a different shape. –  Close open line and connection by positioning clean covers included in set of engine lock covers -VAS 6122-.   Note t  Danger of damaging oil return line t  After removing the turbocharger, do not put it down so it rests on the top section of the oil return line – this could cause damage. Installing Reassembly is carried out in the reverse order; note the following: l  → Chapter „Turbocharger - exploded view“. l  → Chapter „Exhaust system“   Note t  Always replace gaskets, O-rings and self-locking nuts. t  Fill turbocharger with engine oil at oil supply line connection. t  The supercharger air system should not leak t  Hose connections and hoses for charge air system must be free from oil and grease before fitting. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Observe the correct installation position of the hose connections of the charged-air system in order to enable the markings to be aligned correctly. t  To ensure that the charge air hoses can be connected securely, you must spray the screws on used screw-type clips with rust remover prior to installation. t  After installing exhaust turbocharger, allow engine to idle for approx. 1 minute to ensure that the turbocharger is lubricated. –  Install particulate filter → Chapter. –  Align exhaust system without tension → Chapter –  Install the air cleaner housing → Chapter –  Check oil level → Chapter.