SEAT Workshop Service and Repair Manuals

Charge air cooler: Removing and installing t  Charge air cooler: Removing → Anchor t  Charge air cooler: 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  Pliers for spring-loaded band-type clamps -VAS 6340-, see equivalent → Anchor

t  Tension belt -T10038-, see equivalent → Anchor   Note When removing the intercooler, it is not necessary to drain the coolant nor remove the upper and lower coolant hoses.

Removing . –  Remove the engine cover upwards -arrows-.

–  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.

–  Unplug electrical connector -2- at air mass meter -G70-. –  Disconnect the breather hose -1- and the air conduit hoses -3- and -5-. –  Unscrew bolt -4- and remove air filter housing.

–  Remove the bottom left air hose from charge air cooler. For this purpose undo hose clamps -1-.

–  Remove the bottom right air hose from charge air cooler. For this purpose undo hose clamps -1- and -2-.   WARNING Risk of injury caused by refrigerant. The air conditioner refrigerant circuit must not be opened.   Note To prevent damage to the alternator and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

–  Unscrew the bolts -2- and -3- in the bracket for the refrigerant tubes.   Note Item -1- can be disregarded.   Caution Danger of damage to condenser, refrigerant lines and hoses. Do not expand, kink or bend the refrigerant lines and hoses excessively. –  Bring lock plate carrier into service position: → Bodywork, exterior fitting work; Rep. gr.50.

–  Remove the bolts -arrows- from the cowling. –  Disconnect the connection -1- from the radiator fan -V7-.

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

–  Unscrew the fixing bolts -1- that fasten the intercooler to the lock carrier plate.   Note Item -2- can be disregarded.

–  Lift the assembly comprising condenser / intercooler and remove the existing sleeves -1- in the lock carrier plate. –  Incline the intercooler to the engine -direction of the arrow-.

–  Unscrew the fixing bolts -2- of the condenser on the intercooler.   Note Item -1- can be disregarded.

–  Unscrew the condenser bracket bolt -arrow-. –  Insert the condenser in the mount of the lock carrier plate. –  Remove the intercooler, taking care not to cause damage and imperfections in the system. Fitting . 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 hose clips corresponding to original equipment → Electronic parts catalogue. –  Mount air charged air hoses with screw clamps → Chapter. –  Install the coolant radiator → Chapter.

–  Fix the brackets -2- and -3- for the coolant lines.   Note Item -1- can be disregarded. –  Install the air conduit with the fans → Chapter. –  Insert the lock carrier → Bodywork, exterior fitting work ; Rep. gr.50.