SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Base -T20174-, see equivalent → Anchor

t	Socket wrench 22 mm -T20202A-, see equivalent → Anchor

t	Socket wrench 17 mm -T20211-, see equivalent → Anchor

t	Articulated wrench e/c 17 -T20212-, see equivalent → Anchor

t	Ratchet 1/2' x 9-12 -VAG 1331/1-, see equivalent → Anchor

t  Removing → Anchor t  Installing → Anchor

Removing –  Release the fasteners -arrows- to remove the central soundproofing panel.

–  Unscrew the bolts -arrows- and remove the heat protecting plate. –  Remove the right articulated drive shafts → Removing and installing articulated drive shafts; Rep. gr.40.

–  Unbolt the pressure pipe -2- using the articulated wrench E/C 17 -T20212-. –  Unbolt the temperature sender after the particulate filter -G527--1- using the articulated wrench E/C 17 -T20212-.

–  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards.

–  Separate the clamps -arrows- and remove the supercharger hose -1-.

–  Detach electrical connector -1- of the engine intake manifold flap -V157-. –  Unscrew the bolts -arrows- and remove the intake manifold flap motor -V157-.   Note For improved understanding, it is shown from the rear in the illustration with engine removed.

–  Disconnect the electrical connector -1- on the exhaust gas recirculation valve -N18- with the potentiometer for regulating exhaust gases -G212-. –  Remove the electrical harness from the brackets and move to one side. –  Remove bolts -arrows-. –  Remove the exhaust gas recirculation valve -N18- of the intake manifold.

–  Disconnect the connectors -1-, -2-, -3- and -4- and remove them from their housings.

–  Undo the pressure pipe -3- of the particulate filter using the socket wrench E/C 17 -T20211-. –  Undo the lambda probe -G39--1- using the socket wrench E/C 22 -T20202A- and the "ratchet 1/2" x 9-12" -VAG 1331/1-. –  Unscrew the bolts -arrows- and free heatproof plate of the particulate filter -4- without removing it.

–  Undo the exhaust gas temperature sender 2, bench 1 -G448--2- using the socket wrench E/C 17 -T20211- and the "ratchet 1/2" x 9-12" -VAG 1331/1-.

–  Disconnect the electrical connector -arrow- for temperature sender 1 of the exhaust gases -G450-. –  Undo the nuts -1- and remove the exhaust gas pressure sensor 1 -G450- together with the pressure pipes. –  Remove the heatproof plate of the particulate filter.

–  Unscrew the brackets -5- of the particle filter.

–  Unscrew the nuts on the double clamp -1-. In that case it is not necessary to unscrew nuts -arrows-.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

–  Remove the support bolts of the particle filter and the engine block, and remove the support. –  Remove the front part of the exhaust pipe with the particulate filter and place it on the power steering. –  Separate the low pressure hoses if necessary.

–  Remove the bolts -arrows- which are in the flange found between the exhaust gas recirculation radiator and the intake manifold.

–  Remove the air filter intake hose -3-. –  Detach connection hose -2-.

–  Unscrew the nuts -arrows- and take connecting pipe for exhaust gas recirculation off.

–  Remove the bolts -1-, -2- and the hollow bolt -3- and remove the oil return pipe.

–  Remove the thermal protection plate on the left of the exhaust manifold -arrows-. –  Remove air filter → Chapter. –  Remove the air hose from the turbocharger and the intercooler → Item. –  Unscrew the bolts → Itemand remove the cable clip. –  Remove the air hose from the engine compartment downwards.

–  Unscrew the oil delivery tube coupling nut -3- and the securing bolt -4- from its housing.

–  Undo the fastening bolts of the turbocharger and of the bracket -arrows-. –  Remove oil supply pipe.

–  Remove nuts -arrows-. –  Remove the exhaust manifold assembly/turbocharger and place it on the power steering. –  Remove intake manifold → Chapter. –  Remove cylinder head cover → Chapter. –  Remove the exhaust manifold assembly/turbocharger from the top.   Caution After removing the exhaust manifold/turbocharger unit, fit the cylinder head cover, to prevent foreign agents filtering into the engine. Installing Continue the installation in the reverse order of removal sequence, observing the following:   Note t  Always replace seals, gaskets and self-locking nuts. t  Charge the turbocharger with engine oil using the connection sleeve of the oil supply pipe. t  The sleeves for the hoses and the supercharger air flow tubes should be free of oil and grease before fitting. t  Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue. t  After fitting the exhaust gas turbocharger, allow the engine to run at idle for about 1 minute, without accelerating; this will lubricate the turbocharger. –  Check oil level . → Fig..