SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger t  Exhaust gas turbocharger : Removing → Anchor t  Exhaust gas turbocharger : 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  Socket wrench insert -T40055-, see equivalent → Anchor

t  Pliers for spring-loaded band-type clamps -VAS 6340-, see equivalent → Anchor t  Torque wrench (5 - 50 Nm) -V.A.G 1331-, see equivalent → Anchor Removing   Note When fitting the heat protection plate, fit to the same location. –  Observe rules for cleanliness → Chapter.   Caution If a mechanical fault is discovered on the turbocharger (e.g. a destroyed compressor impeller), it is not sufficient to just renew the turbocharger. To avoid any subsequent damage, the following work must be carried out: t  Check air filter housing, air filter element and air inlet hoses for contamination. t  Check the 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. –  Remove particulate filter → Chapter. –  Remove the air filter housing → Chapter.

–  Disconnect the crankcase breather hose -1- for the cylinder head cover. To do so, press the tabs. –  Free vacuum hoses -arrows- at air pipe. –  Unscrew bolt -2-, swing air pipe with inlet connection to rear and pull from turbocharger.

–  Remove heat insulation sleeve. –  Pull vacuum hose -2- from turbocharger vacuum unit. –  Separate vacuum hose -3-. –  Disconnect electrical connector -1- at position sender for charge pressure positioner -G581-.

–  Free electrical connector -3- for exhaust temperature sender 1 -G235- and electrical line.   Note Ignore positions -1- and -2-.

–  Remove bolts -arrows-. –  Release hose clip -1- and remove pulsation damper -2-.

–  Remove the connecting pipe -2- for the exhaust gas recirculation.

–  Unscrew bolts -1, 3-, union nut -2- and screw out together with the socket wrench insert -T40055- and banjo bolts -4, 5-, and remove turbocharger support with oil supply line.

–  Unscrew bolts -arrows- and remove heat shield.

–  Remove nuts -arrows-. –  Remove turbocharger with exhaust manifold from cylinder head, turning so that intake side points down. Remove turbocharger and exhaust manifold downwards. Installing l  Tightening torques → Chapter Installation is carried out in reverse sequence; note the following:   Note t  Renew seals, gaskets, O-rings and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply line. t  Hose connections and air pipes and hoses 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) → Electronic parts catalogue. t  After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. t  Reinstall heat insulation sleeves in the original positions when installing. l  The sequence of the actions must be maintained so that a tension-free assembly of the combined flange (oil supply and oil return lines) is guaranteed together with the support of the exhaust gas turbocharger. l  Furthermore this ensures that the turbocharger support is installed tension-free between crankcase and turbocharger. –  Fit the combined flange (oil supply and oil return lines) to the exhaust gas turbocharger and cylinder block together with the support of the exhaust gas turbocharger. –  Fit oil supply line onto turbocharger and crankcase.

–  First bring the bolts -1- and the hollow bolt -4- of the exhaust gas turbocharger to the engine block by hand. –  Fix the screw -3- to the exhaust turbocharger. –  Then move the union nut-2- and the banjo bolt -5- for the oil supply line. –  Then insert the bolt -1- → Item, the banjo bolt -4- in the cylinder block → Item and tighten the support of the exhaust gas turbocharger -3- → Item one after another and in several stages to the specified tightening torque. –  Finally tighten the bolt on the oil supply line/turbocharger support clamp. Tightening torques → Chapter

–  Install the connecting pipe -2- for the exhaust gas recirculation → Chapter. –  Mount air intake hoses with screw clamps → Fig.. –  Connect vacuum hoses → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install air cleaner housing → Chapter. –  Mount the particle filter → Chapter. –  Check oil level → Chapter.