SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger

Special tools and workshop equipment required

t	Pliers for clamps -VAS 5024 A-

t	Bit XZN 10 -T10154-

t	Accessories: -T10099-

t	Engine bung set -VAS 6122-

t	Torque wrench -V.A.G 1331-

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, the following work must be carried out: t  Check air filter housing, air filter element and intake hoses for dirt / soiling. t  Check the whole charge air path and charge air cooler for foreign objects. 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: –  Remove the sound insulation → Bodywork, exterior installation work; Rep. gr.50 –  Remove right wheel housing liner → Bodywork, exterior fitting work; Rep. gr.66. –  Drain coolant → Chapter.

–  Remove bolts -arrows-. –  Remove air pipe (lift clips -item 1 and 2-).

–  Unscrew bolts -1- for the right drive shaft heat shield. –  Removing catalytic converters with front exhaust pipe → Chapter.

–  Separate electrical wiring connections -1 and 2- and place electrical wiring to one side -arrows-.

Vehicles with auxiliary heater: –  Unscrew bolts -1 and 2- and move coolant pipes to the left.

All vehicles: –  Unscrew bolt -1- with bit XZN 10 -T10154-. –  Remove bolt -2-.

–  Remove banjo bolt -2- and move coolant pipe clear to one side. –  Remove bolts -1- on oil return pipe. –  Remove bolt -3- on oil supply pipe. –  Remove the air filter housing → Chapter. –  Detach engine cover panel.

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

–  Remove bolt -arrow- for air pipe. –  Loosen hose clip -1- and remove air pipe. –  Press release tabs and disconnect air hose -2-. –  Seal turbocharger with engine bung set -VAS 6122-.

–  Remove coolant hose -1-. –  Unscrew bolts -2 and 3-.

–  Pull off coolant hose -1-, unscrew bolt -2- and place coolant pipe -A- to one side.

–  Remove the heat shield -arrows-. –  Remove oil supply pipe from turbocharger -1-.   Note

Unscrew the lower bolt from the heat shield using a 6 mm Allen key socket -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.

–  Pull off vacuum line -arrow-.

–  Disconnect coolant hose -arrow- and move it clear.

–  Remove nuts -arrows-. –  Remove the intake manifold/turbocharger upwards. Installing:   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, the following work must be carried out: t  Check air filter housing, air filter element and intake hoses for dirt / soiling. t  Check the whole charge air path and charge air cooler for foreign objects. If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew the charge air cooler if necessary. Installation is carried out in the reverse order; note the following: t  Assembly of hose connections → Chapter. t  Always replace seals, gaskets and self-locking nuts. t  Fill the turbocharger at the coupling of the oil supply pipe with engine oil. t  After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. t  The coolant return pipe → Item must be fitted together with the turbocharger. t  The couplings and air hoses of the supercharging system must be free from oil and grease before assembling. However (applies only to quick-release couplings); the seal and the sealing surface of quick-release couplings should be lubricated lightly with oil → Chapter. t  Secure the hose connections with original clamps. Tightening torques → Chapter

Component		Nm
Exhaust manifold/exhaust gas turbocharger on cylinder head 1) 2)		Observe tightening sequence → Fig..
Oil supply line to turbocharger (M12 banjo bolt)		33 Nm
Oil return pipe to the turbocharger		9
Coolant supply line to turbocharger (M14 banjo bolt)		38 Nm
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 high-temperature paste → ETKA (Electronic Parts Catalogue)