SEAT Workshop Service and Repair Manuals

Removing and installing exhaust gas recirculation cooler (Ibiza) 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	Hose clamp -3094-, see equivalent → Anchor

t	Collecting tray -VAS 6208-, see equivalent → Anchor

t	Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor

t  Wrench kit 17 mm -T10395-, see equivalent → Anchor

t  Torque wrench -VAG 1331-, see equivalent → Anchor. t  Wrench kit -3337-, see equivalent → Anchor

Removing

–  Loosen the engine cover at the locations -arrows- and remove. –  Version for cold climate zones: Unplug electrical connector -2-. –  Press release tabs and detach crankcase breather hose -1-. –  Disconnect vacuum hose -arrow-. –  Unscrew the screw -3-, swing air pipe with intake hose to the rear and pull off from the turbocharger.

–  Unscrew the union nut of the oil supply line using the socket wrench insert -T40055-, the square ratchet of the torque wrench -VAG 1331--1- and a 13 mm spanner.

–  Remove bolts -arrows-. –  Loosen hose clip -1- and remove pulsation damper -2-. Loosen particulate filter. t  -1- Separate exhaust gas temperature sender 1 -G235- connector t  Detach the connector -2- of the exhaust gas temperature sender 3 -G495-. t  Detach the connector -3- of the exhaust gas pressure sensor 4 -G648-.

t  Detach the connector -4- of the Lambda probe -G39-.

–  Unplug connector from pressure differential sender -G505--3-. –  Unscrew bolt -2-, remove pressure differential sender -G505-, free hoses -1-. –  Pull lines out of retainers on engine and remove heat shield from particulate filter; if necessary remove cable ties.

–  Unscrew the bolt -1- from the centre support of the particle filter mount. –  Remove securing clamp -2- between particulate filter and turbocharger.

–  Remove the screws -1- and take off the heat shield for drive shaft on the right side. –  Detach right drive shaft from gearbox flange.   Note The flexible joint in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

–  Fix the transport lock -T10403--arrow- on the decoupling element in the front exhaust pipe.

–  Unscrew bolts -1- and then nuts -2-.

–  Pull the particulate filter from its brackets in the mountings -arrows-.

–  Slacken the fastening nuts -arrows- of the clamping sleeve and then lower the exhaust pipe to the rear.

–  Remove the particulate filter -1- and fix accordingly on the steering box -2- in order not to damage it.

–  Remove connection pipe -2- leading to cooler for exhaust gas recirculation. –  Unscrew connecting pipe -1- only at exhaust gas recirculation cooler -arrows-.

–  Unscrew the bolts -1, 5- and the hollow bolts -9, 10-; remove the exhaust gas turbocharger bracket together with the oil return hose.

–  Clamp off the coolant hoses -2, 3- with hose clamps -3094- and detach hoses from the exhaust gas recirculation radiator. For this purpose loosen the hose clamp. –  Disconnect connector -1-. –  Disconnect vacuum hose -4- from the vacuum switch and move clear. –  Remove bolts -arrows- and detach the radiator for the exhaust gas recirculation. Installing Installation is carried out in reverse order, noting the following: l  Tightening torques → Chapter   Note t  Replace the seals, gaskets and self-locking nuts → Electronic parts catalogue. t  Checking engine oil level → Chapter. t  Fill up with coolant → Chapter. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  After removing and installing the particulate filter or the pressure differential sender -G505-, the pressure differential sender -G505- must be adapted using the → Vehicle diagnostic tester in all cases. Guided functions; pressure differential sender -G505-: adapting. l  The work procedure must be followed to ensure that the oil supply/return lines together with the turbocharger support are installed tension-free. l  Furthermore this ensures that the turbocharger support is installed tension-free between crankcase and turbocharger. –  Position oil return line on turbocharger together with turbocharger support on turbocharger and crankcase. –  Fit oil supply line onto turbocharger and crankcase.

–  First bring the bolts -1- and the hollow bolt -9- of the exhaust gas turbocharger to the engine block by hand. –  Fix the screw -5- to the exhaust turbocharger. –  Then move the banjo bolt -10- and the union nut -2- for the oil supply line. –  Move the bolt of the combined flange -7- for the oil supply line to the engine block. –  Finally tighten the bolts -1- and banjo bolt -9- to the engine block and the support of the exhaust gas turbocharger -5- one after another and in several stages to the specified tightening torque → Item. → Item. –  Tighten banjo bolt of the oil supply line -10- → Item to the specified tightening torque.

–  Then tighten the union nut of the oil supply line using the socket wrench insert -T40055-, the square ratchet of the torque wrench -VAG 1331--1- and a 13 mm open-ended spanner -SAT 8010/13A-. –  Finally tighten bolt -7- of the oil supply line / turbocharger support clamp to specified torque. Tightening torques → Chapter –  Mount the intake hose on the vibration damper → Chapter. –  Mount the particle filter → Chapter. –  Checking engine oil level → Chapter. –  Check the coolant level.