SEAT Workshop Service and Repair Manuals

Exhaust gas turbocharger : Removing and installing t  Removing → Anchor. t  Installing → 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  Hose clamp -3094-, see equivalent → Anchor

t  Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor Removing   Note Heat insulation sleeves which are removed must be fitted in the same position when installing.

–  Release quick-fasteners -1- and -2- and take off front noise insulation.

–  Unscrew bracket -2- for turbocharger. –  Unscrew oil return pipe -1- at turbocharger and move clear. –  Remove the air intake hoses -4- and -5- from the exhaust gas turbocharger. –  Remove banjo bolt -3- for pressure pipe. –  Disconnect hose -1- at vacuum unit for charge pressure regulating valve from turbocharger. –  Disconnect the refrigerant supply hose at the bottom of the exhaust gas turbocharger using the hose clamp -3094-.

–  Release quick fasteners -arrows- and remove engine cover panel. –  Remove the air filter housing → Chapter.

–  Remove secondary air pipe (detach hoses -arrows- and unscrew bolts -1-).

–  Remove heat shield -3- from secondary air pipe -1- and from cylinder head cover.   Note Ignore -item 2-.

–  Unfasten sleeve on coolant return hose. –  Clamp off coolant return hose going to turbocharger using a hose clamp -3094-. –  Loosen hose clip -4- and disconnect coolant return hose from turbocharger connection. The connection remains fitted on the turbocharger.

–  Remove bolts -1- and -3- on oil supply pipe. –  Unscrew oil supply pipe -5- at turbocharger.   Note The flexible joint (de-coupling element) in the exhaust system must not be bent more than 10° – otherwise it can be damaged. –  Unscrew bolts -6- securing catalytic converter to turbocharger. –  Unscrew bolts -2- securing turbocharger to exhaust manifold. –  Move turbocharger to side, loosen retaining bracket and banjo bolt for coolant supply pipe on turbocharger. –  Remove turbocharger. Installing Reassembly is carried out in the reverse order; note the following:   Note t  Always replace seals, gaskets and self-locking nuts. t  The hose brackets and the hoses of the charged air system must be free from oil and grease prior to mounting. t  Re-attach all heat insulation sleeves at the same locations when re-installing. t  Secure all screw joints with serial hose clips → Spare parts catalogue. –  Perform the following operations before securing the turbocharger: –  Fit bracket of coolant supply hose loosely to vacuum unit for charge pressure regulating valve. –  Tighten banjo bolt to 35 Nm, then tighten securing bolt of bracket to 10 Nm.   Note Charge the turbocharger with engine oil using the connection sleeve of the oil supply pipe. –  Check oil level → Chapter. –  Fill up with coolant → Anchor.   Note After fitting the turbocharger, allow the engine to run at idle for about 1 minute, without accelerating; this will lubricate the turbocharger. Tightening torques

Component		Nm
Coolant supply pipe to turbocharger		35
Coolant supply pipe bracket to turbocharger		10
Turbocharger to exhaust manifold		35 → Remark → Remark
Catalytic converter to turbocharger		30
Turbocharger oil backflow tubing		10
Oil supply line on the turbocharger		23
Oil supply pipe bracket to cylinder head		23
Heat shield to:	Line for secondary air	3,5
	Cylinder head	3,5
Bracket for turbocharger to:	cylinder block	25
	Turbocharger	30
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5,5

1)  Renew bolts 2)  Coat thread and contact surface of bolt head with high-temperature paste; → Parts catalogue