SEAT Workshop Service and Repair Manuals

Exhaust gas turbocharger : Installing and removing, engine code letters BJB, BKC, BXE, BXF t  Removing → Anchor t  Installing → Anchor t  Tightening torques → 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  Torque wrench kit -SAT 8010-, see equivalent → Anchor

t  Base -T20174-, see equivalent → Anchor Removing

–  Pull the oil dipstick -1- out of the guide tube. –  Lift the engine cover by the sides -arrows 2- and pull it out forwards -arrow 3-. –  Replace the oil dipstick in the guide tube.

–  Unplug electrical connector -2- at air mass meter -G70-. –  Disconnect the breather hose -1- and the air conduit hoses -3- and -5-. –  Remove bolt -4- and take out air cleaner housing.

–  Unplug electrical connector -1- from the oil pressure switch -F1-. –  Remove oil pressure switch -1-. –  Remove the oil supply tube -2- on the oil filter support. –  Remove the oil supply tube on the support -3-.

–  Leave the ducts to one side -1..3- in the air duct. –  Remove air duct by lifting retaining clips -arrows- slightly.   Note The coolant hose -1- and fuel pipes -2- and -3- must remain connected. Engine code letters BKC, BXE, BXF

–  Detach electrical connector -arrow- from the intake manifold flap motor -V157- . –  Unscrew the bolts crossways -1 ... 3- and remove the Intake manifold flap motor -V157- . Continued for all vehicles

–  Pull off vacuum hose -3- from the exhaust gas recirculation valve -N18-. –  Extract the tube going to the crankshaft breather case -4- on the air duct tube. –  Release the spring types clips -1- on the exhaust gas turbocharger using the tool -T20174- . –  Leave the vacuum hoses open -arrow-. –  Unscrew bolts -2- and -5- and remove the air duct.

–  Disconnect hose going to vacuum unit for charge pressure control at separating point -arrow-.

–  Remove central noise insulation -Attachment parts 1 ... 3-.

–  Remove the noise insulation on the right side -Attachment parts 1 ... 3-.

–  Unscrew bolts -1- and -2-. –  Remove air hose (right-side) by lifting retaining clips -arrows- slightly. –  Unscrew the right drive shaft from gearbox flange. –  Remove front exhaust pipe → Chapter.

–  Unscrew bolts -2- and -3- from the pendulum support.   Note The bolt -1- must remain in place.

–  Remove air hose from the turbo compressor by lifting retaining clips -arrows- slightly.

–  Unscrew bolts -1- and -2- and take the turbocharger bracket off. –  Remove the oil return pipe -3- from the engine block.

–  Unscrew the oil supply pipe on the turbocharger and the exhaust gas manifold -arrows- and put it to one side.

–  Remove the connecting pipe for exhaust gas recirculation -arrows-.   Note Illustration shows an engine with code BKC. For vehicles with the identification letters BJB, the exhaust gas recirculation connecting pipe goes from the exhaust manifold to the intake manifold → Item

–  Remove the thermal protection plate from the exhaust manifold -arrows-.

–  Unscrew nuts -arrows-. –  Push the engine forwards and remove the exhaust manifold/turbocharger assembly between the subframe and the body work. Installing Continue the installation in the reverse order of removal sequence, observing the following:   Note t  Always replace seals, gaskets and self-locking nuts. t  Charge the turbocharger with engine oil using the connection sleeve of the oil supply pipe. t  The sleeves for the hoses and the supercharger air flow tubes should be free of oil and grease before fitting. t  Secure all hose connections with the correct hose clips (same as original equipment) → Electronic spare parts catalogue. –  Install the exhaust system and align free of stress → Chapter. –  Fit the supercharger air system hoses and observe the assembly instructions → Chapter. –  Check oil level → Chapter.   Note After fitting the turbocharger, let the engine run for about 1 minute at idle speed, without accelerating, to ensure correct lubrication of the turbocharger. Tightening torques

Component		Nm
Exhaust manifold/turbocharger to cylinder head		25 → Remark
Thermal protection plate to the exhaust manifold/turbocharger		20 → Remark
Connecting pipe for	Oscillating valve	22
Exhaust gas recirculation to	Exhaust manifold	22 → Remark
Oil supply pipe to the turbocharger		22
Oil supply pipe bracket to the exhaust manifold		20 → Remark
Turbocharger bracket to engine block		40
Turbocharger bracket to turbocharger		20
Oil return pipe to the engine block		40
Right hand side supercharger air tube to the oil sump		10
Rear air pipe to bracket		10
Oil supply pipe to oil filter bracket		25
Oil pressure switch to oil filter bracket		20

1)  Renew nuts.