SEAT Workshop Service and Repair Manuals

removing and installation; vehicles without separated notched belt guard Removing → Anchor Fitting → Anchor Tightening torques → 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-type clips -VAS 6499- or Pliers -T20174-, see equivalent → Anchor

t  Tensing belt -T10038-   Caution If a mechanical fault is detected on the turbocharger, for example, a broken blade wheel, changing the turbocharger is not enough. To avoid subsequent damage, carry out the following operations: t  Ensure that the air filter housing, the cartridge and the vacuum hoses are not dirty. t  Ensure that there are no foreign bodies in the supercharger air circuit and the intercooler. If foreign bodies are found in the supercharger air system, the supercharger air circuit should be cleaned and, if necessary, the intercooler replaced.

Removing –  Remove the suction hose -1-. –  Disconnect hose from the attachment clamps -4-. –  Pull out the plug -2-. –  Remove the bolts -3-. –  Remove the engine cover, by pulling firmly upwards.

–  Remove the air duct -1 and 2- with the pliers for spring-type clips -V.A.G 1921-   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open cap on coolant expansion tank. –  Drain coolant → Chapter

–  Remove right-hand side noise insulation.

–  Disconnect the air duct -arrow- of the intercooler.

–  Loosen the bolts -arrows-, and remove the supercharger air pipe.

–  Disconnect the connectors -1 and 2-. Loosen the bolts -arrows-, and remove the turbocharger hose.

–  Disconnect the connector of the Lambda probe -G39--arrow-, and set the cable aside.

–  Disconnect the connectors -1- of the ignition coils, and leave the cable harness to aside.

–  Separate the coolant piping towards the coolant expansion tank -flecha-.

–  Disconnect the coolant hoses -1- and -2-. –  Loosen the coolant piping -3- .

–  Remove the top coolant hose towards the heat exchanger -arrow-.

–  Loosen the coolant piping protector plate -arrows-.

–  Loosen the engine block breather hose with heat shield from the turbocharger -1-. –  Release the engine block breather hose -2- from the cylinder head cover, and remove it. –  Release the activated carbon filter hose which leads to the turbocharger from the cylinder head cover -3-. –  Loosen the turbocharger oil supply piping -4-.   Note Lubricate the threads of the turbo/exhaust before loosening the bolts

–  Loosen the two top securing bolts of the primary exhaust pipe/turbocharger.

–  Unbolt heat shield for right drive shaft -arrows-. –  Uncouple the right-hand side drive shaft from the gearbox flange and remove it towards the vehicle rear.

–  Loosen the two bottom securing bolts of the primary exhaust pipe/turbocharger.

–  Unbolt exhaust system retainer -arrow-. –  Release the primary exhaust pipe from the turbocharger, and move it to one side.   Note It is not necessary to remove the catalytic converter completely nor disconnect the Lambda probe.   Note The figure shows a rear view of the removed engine.

–  Unscrew the turbocharger oil supply conduit -2-.

–  Unscrew the turbocharger coolant supply conduit -2-.

–  Unscrew the turbocharger oil return duct -arrows-.

–  Unscrew the bolts -1- and -2- and detach the bracket of the exhaust turbocharger.   Note The following operation is required to obtain a little more space between the cylinder head and the splash guard.

–  Unscrew bolts -2 and 3-.

–  Pull the engine backwards approx. 20 mm, using the tensing belt -T10038-.

–  Disconnect the coolant tube-arrow-.   Note t  The figure shows a rear view of the removed engine. t  The nuts on the moulding fastening the lower part do not have be undone. –  Loosen the nut -1- of the coolant pipe, and loosen the top nuts -arrows-.

–  Unscrew upper nuts -arrows-. –  Remove the intake manifold/turbocharger upwards. Fitting Installation is carried out in the reverse sequence; note the following: t  Always replace seals, gaskets and self-locking nuts. t  Fill the turbocharger at the coupling of the oil supply pipe with engine oil. t  After fitting the turbocharger, allow the engine to run at idle for 1 min to ensure turbocharger oil supply. t  The coolant return pipe → Item must be fitted together with the turbocharger. t  The couplings and air hoses of the supercharging system must be free from oil and grease before assembling. t  Secure the hose connections with original clamps. –  Install the exhaust system, and adjust it without tension → Chapter. –  Fit the charge air system lines, follow the instructions during this → Chapter. –  Fill up coolant → Chapter. –  Checking oil level .   Note After fitting the turbocharger, allow the engine to run at idle for about 1 minute, without accelerating; this will lubricate the turbocharger. Tightening torques .

Part		Nm
Exhaust manifold/turbocharger to cylinder head		20 → Note
Oil supply pipe to the turbocharger		30
Turbocharger bracket to engine block		30 → Note
Turbocharger bracket to turbocharger		30 → Note
Right hand side supercharger air tube to the oil sump		10

1)  Renew nuts. 2)  Locking fluid for hot working bolts → Parts catalogue