SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger 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  Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor

t  Base -VAS 6340-, see equivalent → Anchor

Removing –  Pull off engine cover panel -arrows-. –  Drain coolant → Chapter.

–  Loosen the bracket -1-, disconnect the air hose and place to the side. –  Disconnect the connector -2- from the air mass meter -G70-. –  Unclip cable harness from air cleaner housing and lay down to side. –  Loosen expansion clip -3- and separate air cleaner housing. –  Pull upward to loosen lower mounts and to remove air cleaner housing.

–  Disconnect coolant hose -arrow-.   Note The installation position is shown in the following illustrations with the engine removed.

–  Remove heat shield -arrows-.

–  Remove bolts -arrows- and detach crankcase breather system from turbocharger. –  Disconnect hose -1- from turbocharger.

–  Unscrew bolts -1 and 2- and move the fuel supply line clear to one side. –  Unscrew bolt -3- and move coolant pipe clear to one side.

–  Open hose clip -arrow-, detach the air hose and swivel to the side.

–  Unplug electrical connectors -1 and 2- and move wiring clear.

–  Remove bolts -arrows- and detach support for turbocharger.

–  Remove bolts -arrows- at oil return pipe.   Caution Risk of damage to flexible joints in front silencer. Do NOT bend the flexible joints in the front silencer more than 10°.

–  Loosen bolted connections -arrows- and push clamp towards rear.

–  Lower front silencer slightly and tie up to cross piece -arrow-.

–  Unscrew nuts -arrows- and press catalytic converter towards rear. –  Remove engine mounting (right-side).

–  Unbolt electrical wire -1- from engine support (right-side). –  Remove engine support (right-side) -arrows-.

–  Remove nuts -arrows-. –  Pull out the turbocharger upwards with the exhaust manifold. Installing Installation is carried out in the reverse sequence; note the following: l  Tightening torques → Chapter   Note t  Replace the seals, the gaskets, O-rings and the self-locking nuts. t  Charge the turbocharger with engine oil using the connection sleeve of the oil supply pipe. t  The brackets for the hoses and the supercharger air system tubes must be free from oil and grease for fitting. t  Secure hose unions with hose clamps the same as those of the series → Electronic parts catalogue. –  Install engine mounting (right-side). –  Install catalytic converter → Chapter. –  Align exhaust system without tension → Chapter –  Install air pipes/hoses with plug-in connectors → Chapter. –  Fill up with coolant → Anchor. –  Check oil level → Booklet301.   Note After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil.