SEAT Workshop Service and Repair Manuals

Removing and installing exhaust gas recirculation cooler t  Removing → Anchor. t  Installing → Anchor.

Special tools and workshop equipment required

t	Hose clamp -3094-, see equivalent → Anchor

t	Lever -80 200-, see equivalent → Anchor

t	Tray -VAS 6208-, see equivalent → Anchor

t	Base -VAS 6499-, see equivalent → Anchor

Removing . –  Remove the engine cover upwards -arrows-.

–  Uncouple the electrical connector -5- for the exhaust gas temperature sender 3 -G495- and free the electrical wiring from their fastenings. –  Uncouple the electrical connector -2- for the exhaust gas temperature sender 4 -G648- and free the electrical wiring from their fastenings. –  Uncouple the electrical connector -4- from the Lambda probe -G39- and free the electrical wiring from their fastenings.   Note Ignore positions -1, 2 and 3-.

–  Loosen and remove the clip -1- between the particle filter and exhaust gas turbocharger.

–  Disconnect the connector -2-, undo the bolt -3- and remove the pressure sensor 1 of exhaust gases -G450- with bracket in the direction of the -arrow-. Place on the particle filter. –  Unscrew the bolt -1- from the upper support of the particle filter mount.

–  Fit the centre noise insulation -fasteners 1 ... 3-.

–  Remove the right wheel housing -Fixing parts 1 ... 3-.

–  Unscrew the right link rod from the stabiliser bar -arrow-.

Front-wheel drive vehicles –  Unbolt heat shield for right drive shaft -arrows-.

–  Unbolt right half shafts from gearbox flange or the intermediate bearing. –  Tie the left half-shaft leaving it suspended. –  Turn the steering toward the right. –  Tilt the right-half shaft forwards and strap it to the sill -arrow-, as shown in the image. Vehicles with four-wheel drive –  Remove the cardan shaft → final group 0AV; Rep. gr.39.

–  Unscrew the heat protection plate for the right cardan shaft using the socket SW 8 -3247- from its attachment -arrow-. –  Remove right-hand articulated shaft: → Running gear, shafts, steering; Rep. gr.40.

–  Remove the right flange shaft → 6-speed manual gearbox 02Q, four-wheel drive; Rep. gr.39.

Continuation for all vehicles –  Unscrew bolts -1 ... 3- and take pendulum support out.

–  Remove nuts -1- and -2- and detach bracket for particulate filter.

–  Unscrew securing nuts from the clamp -1-. –  Remove the front cross member from the underbody -arrows-.   Note The mounting on the front section of the exhaust pipe with particle filter should not be bent by more than 10° otherwise there is a risk of damage.

–  Unscrew the suspension element -arrow-. –  Partially remove the front part of the exhaust tube with particulate filter and position it over the steering box.

–  Unscrew the nuts -2- and the bolts -3- and remove the connecting pipe for exhaust gas recirculation. –  Place the drip tray -VAS 6208- under the engine.

–  Unscrew nuts -1-, the bolt -2- and the hollow belt -3-. –  Remove the exhaust gas turbocharger bracket foot together with the oil return hose .

–  Disconnect the coolant hoses using the hose clip -3094- and remove from the exhaust gas recirculation. For this purpose, loosen the clip -arrow-. –  Remove the pressure switch thermal protection hose.

–  Unscrew the bolts -1- in the connecting pipe for exhaust gas recirculation. –  Disconnect the pressure hose -2- from the low pressure actuator and release the hose. –  Unscrew the bolts -arrows- and remove the exhaust gas recirculation radiator between the level tunnel and the front mechanical bracket bridge. Installing . l  Specified torque → Chapter. Installation is carried out in the reverse order; note the following:   Note t  Renew seals, gaskets and self-locking nuts. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Reinstall heat insulation sleeve in original position when installing. –  Install support for turbocharger → Chapter. –  Mount the particle filter → Chapter. –  Aligning exhaust system free of stress → Chapter. –  Mount the right half-shaft → Rep. gr.40. –  Check oil level → Chapter. –  Check coolant level → Anchor.   Note After fitting the turbocharger, allow the engine to run at idle for about 1 minute, without accelerating; this will lubricate the turbocharger.