SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger Removing → Anchor. 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  Pliers for spring-type clips -VAS 5024A- or Pliers -V.A.G 1921-, see equivalent → Anchor

t  Extraction tool -T40039-, see equivalent → Anchor t  Engine sealing plug set -VAS 6122-, see equivalent → Anchor

Removing –  Remove the engine cover, by pulling carefully pulling it upwards. –  Unplug connector -1- from air mass meter -G70-. –  Separate the air hose -2-. –  Unscrew the bolt -4- and remove the air filter housing.   Note Disregard: -Pos. 3-. –  Drain coolant → Chapter. –  Remove the primary exhaust pipe with catalytic converter → Chapter.

–  Remove the right hand side soundproofing by releasing the fasteners -1, 2, 3-.

–  Unscrew bolts -arrows-. –  Remove the air conduit guard -Pos. 1 and 2-. Vehicles with front-wheel drive

–  Unbolt heat shield for right-hand side driveshaft -arrows-. Four wheel drive vehicles

–  Unscrew the insulating panel for the right half shaft from its mounting at the angular gears -arrows-.

–  Unplug the connectors -1 and 2- and move the cable to one side -arrows-.

–  Unscrew bolts -1 and 2- and extract the turbocharger.

–  Unscrew the hollow bolt -2- and move the coolant tube to one side. Vehicles with front-wheel drive –  Unscrew the bolts -1- for the oil return line. Four wheel drive vehicles –  Unscrew bolts for oil return line on crankcase. Continued for all vehicles –  Unscrew the bolts -3- for the oil supply line. Vehicles with engine code BYT

–  Disconnect the air hoses -1, 2, 3, 4, 5-. –  Disconnect the connectors -3- from ignition coils.

–  Remove ignition coils using puller -T40039-.

–  Unscrew the cap -arrow-. –  Unscrew the bolts -1 to 6- and remove the oil settling tank. –  Release the vacuum pipe. –  Replace the cap. Continued for all vehicles

–  Disconnect the plugs from the ignition coils and place the wiring harness to the side.

–  Remove the coolant line in the direction of the coolant expansion reservoir-arrows-.   Note To show the work sequence more clearly, the sequence is described for a removed engine.

–  Release the tabs by pressing, disconnect the air hose -2- and move to one side. –  Unscrew the bolts -arrows- for the air pipes. –  Remove the pipe here by releasing the hose clamp -3-.   Note Disregard: -Pos. 1-. –  Plug exhaust gas turbocharger with engine plug set -VAS 6122-.

–  Remove the thermal protection plate -arrows-.   Note

On the 2.0l engines, it is necessary to unscrew bolt -2- from the heat shield with a 6 mm hex. socket wrench-A-. The socket must have a length of at least 5 cm -B-. If the socket is reduced to 6 mm at the tip, it is too thick. –  Unscrew the turbocharger oil supply conduit -4-. Vehicles with engine codes BZB, CCZB, CDAA

–  Remove bolts -1 and 5-. –  Remove coolant hose -3-. –  Push the coolant air outlet pipe forwards with the hoses -2 and 6- and the earth cable -4- connected.

–  Disconnect vacuum line -1- at separation point -2- and expose line.   Note Disregard: -Items 3, 4 and arrows-. Continued for all vehicles

–  Disconnect the vacuum pipe -1- to the active carbon filter by pressing the release tab.   Note Disregard: -Pos. 2-. –  Separate the vacuum pipe from the front coolant pipes.

–  Remove the active carbon deposit (with all the connections in place) from the bracket by pulling upwards -arrow- and leave it to one side.

–  Separate and push the coolant hose to one side -arrow-.

–  Remove nuts -arrows-. –  Lift out turbocharger with exhaust manifold. Installing   Caution If a mechanical fault is detected on the turbocharger, for example, a broken blade wheel, changing the turbocharger is not enough. To prevent this from causing further damage, perform the following repairs: t  Ensure that the air filter housing, the cartridge and the vacuum hoses are not dirty. t  Ensure that there are no foreign bodies in the supercharger air circuit and the intercooler. If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew the charge air cooler if necessary. l  Tightening torques → Chapter Reassembly is carried out in the reverse order; note the following:   Note t  Replace the seals, the gaskets, O-rings and the self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply line. t  Hose connections and hoses for charge air system must be free from oil and grease before fitting. t  Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue. –  Fit the coolant recycling pipes → Chapter. –  Exhaust pipe with catalytic converter: Installing → Chapter. –  Align exhaust system without tension → Chapter –  Fit the supercharger air system hoses and observe the assembly instructions → Chapter. –  Fill up coolant → Chapter. –  Check oil level → Chapter.   Note After installing exhaust turbocharger, allow engine to idle for approx. 1 minute to ensure that the turbocharger is lubricated. Tightening torques

Qty.		Nm
Exhaust manifold/exhaust gas turbocharger on cylinder head 1) 2)		Observe tightening sequence → Fig..
Oil supply pipe to the turbocharger		20 + 45°
Oil return pipe to the turbocharger		9
Fuel supply line on turbocharger		20 + 45°
Mount for exhaust gas turbocharger on cylinder block 2)		30
Mount for exhaust gas turbocharger on exhaust gas turbocharger 2)		30
Right hand side supercharger air tube to the oil sump		10
Heat shield on cylinder head M8 and M12		20

1) Renew nuts 2) Use hot bolt paste → ETKA (Electronics Parts Catalogue)