SEAT Workshop Service and Repair Manuals > Leon Mk1 > Power unit | 4 cylinder Injected engine (engine 1.8 l and 2.0 l, timing chain) | Exhaust turbocharger, G-charger | Charge air system | Removing and installing charge air cooler

Removing and installing charge air cooler

Removing

–	Remove the radiator → Chapter.

–	Remove the front bumper cover → Exterior body installation work; Rep. gr.63.

–	Unplug electrical connection -1- from the coolant temperature sender -G17-.

–	Unscrew the bolts -2- in the left hand side and right hand side intercooler air pipes.

–	Release the air pipes -3-; to do this move them slightly upwards.

–	Move the air pipes to the left hand side of the vehicle and take out from behind the bumper.

WARNING

Risk of injury due to refrigerant.

The air conditioning refrigerant circuit must not be opened.

Caution

Danger of damage to refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant pipes and hoses.

–	Unscrew the bolt for the clamp holding the refrigerant line, beside the longitudinal member.

–	Unscrew securing bolts -2- of condenser.

–	Unscrew securing bolts -1- of intercooler.

–	Swivel intercooler slightly backwards.

–	Unscrew the bolt from the refrigerant line bracket on the lower right hand side of the intercooler.

–	Swivel the condenser forwards, insert into the opening in the lock plate carrier.

–	Release the intercooler from the lock plate carrier and remove it diagonally downwards.

Installing

Reassembly is carried out in the reverse order; note the following:

Note

t	Renew seal.

t	Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue.

–	Installing radiator → Chapter.

–	Fit the front bumper cover → Exterior body installation work; Rep. gr.63.

–	Fit the supercharger air system hoses and observe the assembly instructions → Chapter.

Engine code CCZB

–	Install air hoses with screw clamps → Fig.

All vehicles (continued):

–	Fill up coolant → Chapter.

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