SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger   Note The turbocharger can only be replaced completely with the exhaust manifold and the charge pressure actuator -V465-. 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  Base -VAS 6340-, see equivalent → Anchor

t  Torque wrench -VAG 1331-, see equivalent → Anchor.   Caution If the turbocharger has suffered mechanical damage (e.g. damaged compressor wheel), it is not sufficient merely to fit a new turbocharger. To avoid subsequent damage, carry out the following operations: 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. Removing   Note To carry out this work it will be necessary to disconnect battery earth strap. For this purpose, first check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. –  Disconnect battery → Electrical system; Rep. gr.27 –  Remove the Poly V-belt → Chapter. –  Drain coolant → Chapter.

–  Remove the coolant hose -1- and the connector -2- from the turbocharger.

–  Extract the bolts -1- and remove the retaining clip. –  Disconnect the connector -2- in the charge pressure sender -G31- with the input air temperature sender 2 -G299-. –  Release the retainer in the direction of the -arrow- and first remove the pressure pipe -3- from the throttle valve module -J338- and then from the exhaust gas turbocharger. –  Open the cover -4- and remove the fastening bolt.

–  Remove spark plug connector -arrows- with puller -T10112- and move the ignition line to the rear. –  Remove the coolant pipe from the coolant tube -1-.

–  Unscrew union screw -4- from the oil pipe. –  Unscrew the bolts -2- and -3- and remove the oil and coolant lines. –  Remove the Lambda probe -G39--5-. –  Unscrew the upper securing screw of the alternator and press the alternator downwards a little. –  Unscrew the fastening bolts -arrows- and remove the heat shield from the turbocharger.

–  Remove the bracket -1- . –  Unscrew the securing bolts on the turbocharger -arrows-. –  Separate the under body protection.

Altea, Altea XL, Leon –  Unplug connectors -1-. –  Unscrew securing nuts -2-. –  Undo the securing nuts -3- and remove the catalytic converter downwards.

Ibiza –  Unplug connector -1-. –  Remove the Lambda probes after the catalytic converter -G130--2-.

–  Remove securing bolts -1-. –  Remove the suspension -2- from bolt.

–  Loosen the fixing screws of the clamping sleeve -arrows- and push to rear. –  Remove the catalytic converter with exhaust pipe downwards.

Continued for all vehicles –  Unscrew the fastening bolts -1- from the oil return pipe -2- and remove the pipe from the turbocharger. –  Remove the securing bolt of the heat shield -3- and the exhaust manifold plate.

–  Unscrew the fastening nuts of the exhaust pipe -arrows-. –  Remove the exhaust manifold together with the exhaust turbocharger from the cylinder head. –  Remove the mounting pin seal. Installing –  Attach the exhaust turbocharger with the exhaust manifold and a new gasket to the cylinder head.   Caution Tighten the fixing nuts in 3 stages when considering the following tightening sequences . In this way, the correct seating of the seal is guaranteed. If they are not tightened in 3 stages, leaks will be caused between the cylinder head and the exhaust manifold. –  Tighten the nuts in the specified sequence -A - to -H- in 3 stages. 1st stage: 18 Nm 2nd stage: 12 Nm

3rd stage: 12 Nm Further assembly is carried out in the reverse order, note the following: t  Always replace seals, gaskets and self-locking nuts. t  Fill turbocharger with engine oil at oil supply pipe connection. t  After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. t  Secure the hose connections with original clamps. Tightening torques: Exhaust gas turbocharger – Assembly overview, Part I → Chapter Exhaust gas turbocharger – Assembly overview, Part II → Chapter Catalytic converter and attaching parts - Assembly overview → Chapter –  Install the alternator → Electrical system; Rep. gr.27. –  Poly-V belt: Installing → Chapter. –  Fill up with coolant → Chapter. –  Connect battery → Electrical system; Rep. gr.27.