SEAT Workshop Service and Repair Manuals

Exhaust gas turbocharger : removing and installing - Vehicles with all-wheel drive and engine code BMN t  Removing → Anchor t  Fitting → Anchor t  Specified 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	Socket wrench 22 mm -T20202A-, see equivalent → Anchor

t	Socket wrench 17 mm -T20211-, see equivalent → Anchor

t	Articulated wrench e/c 17 -T20212-, see equivalent → Anchor

t	"Ratchet 1/2"" x 9-12" -VAG 1331/1-, see equivalent → Anchor

t  Torque wrench -SAT 8010-, see equivalent → Anchor.

t  counterhold -T20127-, see equivalent → Anchor t  Collared hex bolt M12x1.5x70 -N 910 398 01-

Removing –  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards.

–  Remove the switching valve for the radiator for the exhaust gas recirculation -N345-- 2- from its bracket. –  Detach the electrical connectors -1- and -3- and leave the wires free. –  Detach the pressure hoses -4, 5, 6- and free them. –  Unscrew bolts -arrows-.   Note Ignore positions -5- and -6-.

–  Uncouple the electrical connector -5- for the temperature sender before particle filter -G448- and free the electrical wire.

–  Undo the lambda probe -G39--3- using the socket wrench E/C 22 -T20202A- and the "ratchet 1/2"" x 9-12" -VAG 1331/1-. –  Unbolt the support -2- of the pressure hoses. –  Undo the temperature sender before the particle filter -G448--5- using the socket wrench E/C 17 -T20211- and the "ratchet 1/2"" x 9-12" -VAG 1331/1-. –  Unscrew the pressure hoses -4- of the particle filter with the socket wrench E/C 17 -T20211- and the "ratchet 1/2"" x 9-12" -VAG 1331/1-. –  Release the clamp -1- for the particulate filter and remove it.

–  Remove the air conduit cover by releasing the side tabs -arrows-.

–  Unclip the air conduit in the lower part by releasing the tabs -arrows-. –  Remove the lower section of the air duct together with the air hose.

–  Separate the electrical connector -1- from the air mass gauge -G70-. –  Uncouple the flexible air hose -3- and the flexible air conduit -2-. –  Unscrew the bolt -4- and remove the air filter housing.

–  Detach the flexible tube -2- from the crankcase breather. –  Remove the flexible air hose -4- and the pressure hoses -3- together with the air conduit flexible hose. –  Loosen the clamp -1-. –  Turn back the flexible air conduction tube and detach it from the exhaust gas turbo compressor.

–  Separate the pressure hose -arrow- in the servo-brake amplifier.

–  Unscrew bolt -1-. –  Remove the oil supply hose -3- of the turbocharger. –  Pull the fastening tabs out a little -arrows- and remove the air hose.   Note Item -2- can be disregarded.

–  Lay the electric line of the exhaust gas temperature sender 1 -G235--Item 1- free. –  Unscrew the bolts -arrows- and remove the heat protecting plate.

–  Remove the right front wheel. –  Remove centre noise insulation -mounting parts 1 ... 3-.

–  Remove the right soundproofing -Anchorage parts 1 ... 3-.

–  Unscrew the right link rod from the stabiliser bar -arrow-.

–  Unscrew the insulating panel for the right half shaft from its mounting at the angular gears -arrows-. –  Dismount the right half-shaft → Rep. Gr.39.

–  Unbolt the pressure pipe -2- using the articulated wrench E/C 17 -T20212-. –  Unbolt the temperature sender after the particulate filter -G527--1- using the articulated wrench E/C 17 -T20212-.

–  Unscrew bolts -1 ... 3- and remove pendulum arm support.

–  Check to see if a -coloured dot- is marked on the flexible disk and on the flange on the front tapered unit-arrows-. If there are no marks, the position of the flexible disc with regard to the flange on the front tapered unit should be marked -arrows-.   Caution Mark the position of the bolts, as some of these may have balance washers to prevent vibration.   Note t  Remember not to unscrew the bolts completely.-1-

t  Unscrew the bolts one or two turns -1- from the central elastic mount for the cardan shaft.

–  Release the flector on the cardan shaft on the bevel gear -arrows-, supporting it with a lever held against the triangular flange.   Note

t  Do not allow the cardan shaft to fall to one side when removing; Keep it horizontal when separating from the centring pivot. Do not damage the O-ring on the centring bush-arrow-. t  The flexible disk and vibration damper cannot be separated. Place the cardan shaft on the steering box.

–  Unscrew nuts -1- and -3-, as well as the screw -2- and remove the particle filter support.

–  Unscrew securing nuts from the clamp -1-. In that case it is not necessary to unscrew nuts -arrows-.

–  Unscrew the suspension element -arrow-.   Note The vibration damper on the front section of the exhaust pipe with particle filter should not be bent by more than 10°. Otherwise there is a risk of damage being caused. –  Partially remove the front part of the exhaust tube with particulate filter and position it over the steering box.

–  Unscrew the nuts -1- and remove the heat protection plate to the left of the exhaust manifold. –  Unscrew the nuts -2- and the bolts -3- and remove the connecting pipe for exhaust gas recirculation.

–  Unscrew nuts -1-, the bolt -2- and the hollow bolt -3-. –  Remove the exhaust gas turbocharger bracket together with the oil return hose.

–  Unscrew bolts -arrows-.   Note To align the assembly centre fit the counterhold -T20127- to the anchorage points as shown in the figure.

–  For safety reasons, place the retaining tool -T20127- in the engine and in the shop crane, as shown in the figure.   DANGER! Ensure that the hooks are closed with the security rings.

–  Remove the mechanical group bracket bolt, on the engine side nearest the particulate filter, and replace it with the collared hex bolt M12x1.5x70 -N 910 398 01-. –  Thread the collared hex bolt M12x1.5x90 -N 910 398 01- to the engine bracket as far as it goes. –  Next keep unscrewing the mechanical group bracket bolt, on the engine side nearest the radiator, from its housing without completely removing it.   Note With this you will lower the engine 15 mm which is sufficient to be able to remove the turbocharger with exhaust manifold on the upper part between the cylinder block and the plenum. –  Remove the turbocharger with intake manifold upwards. Fitting Installation is carried out in the reverse sequence; note the following:   Note t  Always replace gaskets, O-rings and self-locking nuts. t  Charge the turbocharger with engine oil using the connection sleeve of the oil supply pipe. t  Secure hose unions with hose clamps the same as those of the series → Electronic parts catalogue. –  Mount the right short axle → Rep. Gr.39 –  Couple the front section of the cardan shaft → Rep. Gr.39. –  Install the exhaust system and align free of stress → Chapter. –  Fit the charge air system lines, follow the instructions during this → Chapter. –  Check oil level . → Chapter.   Note After fitting the turbocharger, allow the engine to run at idle for about 1 minute, without accelerating; this will lubricate the turbocharger. Specified torques .

Component			Nm
Exhaust manifold/turbocharger to cylinder head			25 1)
Turbocharger oil backflow tubing			15
Turbocharger support to	Turbocharger		25
	cylinder block		60
Heat protection plate to the exhaust manifold			25 1)
Exhaust gas recirculation joint hose	exhaust gas recirculation radiator		22
	Exhaust manifold		25 1)
Pendulum support to gearbox			40 + 90° 1)2)
Heat shield of the axle shaft to engine block			35
Heat shield to turbocharger			10
Solenoid bracket to the cylinder head			10
l  1) Replace the screws / bolts l  2) 90° equals a fourth of a turn.