SEAT IBIZA 2011

EGR water cooled renewal

If you ever have to do one...

Not so easy to get at. Located on the rear face of the cylinder block underneath the exhaust manifold and turbo.

First time I've exchanged one on this model...

Removal...

My own methods...

Working under bonnet...

Remove air box, remove rubber hose section of air intake at rear face of engine above gearbox. The plastic air intake tube can be unbolted from rear face of cylinder block (one torx bolt). No need to remove from intercooler.

There is a water bypass tube held on the rear face of the cylinder block that goes to the EGR valve housing. Two torx bolts. Loosen them but do not remove them.

Remove the exhaust DPF pipe from the exhaust manifold to turbo. One retaining ring held on with a allen key bolt. You'll need to tap free the seal and once loose don't loose the steel washer between the exhaust manifold and DPF pipe.

Working underneath the car... 

Remove sub frame (quick and easy job) Allows good access to rear face of cylinder  block.

There is two metal bypass tubes. One goes to the cylinder block which is on the left side adjacent the EGR solenoid. The two torx bolts loosened are at the other end just loosened. Remove the two remaining torx bolts and the tube will swing loose.

Remove the exhaust bypass tube from the EGR assembly and exhaust manifold. Caution... The two 12 mm nuts can be very tight and shear the studs. One of two did shear on me so I had to get the oxygen welder out and heat the manifold to remove the broken stub.

Remove the two torx bolts that secure the oil feed pipe to the turbo oil return pipe. These are fidly to get at but doabul.

Remove the two torx bolts from the turbo oil return pipe from the turbo. Remove the 27 mm bolt from the lower cylinder block that secures the oil return pipe.

Remove the turbo oil supply pipe from the lower cylinder block.

Disconnect the EGR multiplug, and disconnect the vacuum hose. Disconnect the two water hoses and use hose clamps to prevent loosing all the coolant.

Remove the upper two torx bolts that secure the EGR cooler to the cylinder block first. Note that the torx bolts are different lengths. The long ones go to the left side of the EGR while the short ones go to the right side. Remove the lower two torx bolts. 

Remove the EGR cooler from the cylinder block. 

Refitting is the reversal. Note, common sense prevails. Refit the lower torx bolts to the EGR cooler first to hold and secure the cooler in place. Use an inch long 1/2 extension with the torx key to locate and fit the two top torx bolts back into the cooler and cylinder block. Don't do what I was told to do and leave the top torx bolts out by my work colleague, there not that difficult to refit. 

When you refit the components, make sure that you put the two torx bolts into the turbo oil return housing before you try to secure to pipe to the cylinder block. You don't want to damage the threads in the turbo housing. care and patence are required here. Before refitting to the block ensure that the turbo oil feed pipe to resecured to the oil return pipe using the two C shaped mountings and torx bolts. These are fidly but again doabul. Now secure the pipe to the cylinder block.

Now refit the exhaust bypass pipe and the coolant pipe from the cylinder block to EGR cooler. Use the new gaskets if supplied.

The rest is the reversal of the above. Remember to top up the coolant and clear the DTCs, and then do a good road test. 

They look very difficult to do but with patence they are not that bad to do really.