SEAT Workshop Service and Repair Manuals

Intake manifold: removing and installing t  Removing → Anchor t  Installing → Anchor t  Tightening torques → Anchor Removing   WARNING Take into account the safety precautions for fuel pressure reduction in the high-pressure system → Chapter.   Note t  Observe safety precautions → Chapter. t  Observe rules for cleanliness → Chapter. t  The combustion chamber sealing ring (Teflon) and the O-ring must always be replaced. –  Remove the throttle valve control unit -J338- → Chapter. –  Disconnect all the necessary electrical connections.

–  Disconnect the vacuum hose between the intake manifold and the intake manifold vacuum pump.   WARNING t  For safety reasons, the fuse SC27 located in the fuse holder on the left-hand side of the instrument panel must be removed before the fuel system is opened, because the fuel pump can be activated by the door contact switch in the driver’s door. t  Fuel supply line is pressurised. Wear safety goggles and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then eliminate the pressure by carefully separating the pipe.   Note t  This vacuum hose and the vacuum pump (located at rear of cylinder head) are only fitted on vehicles with automatic gearbox. t  Ignore Items 1 and 2 in figure.

–  Remove hose connections -arrows- from cylinder head cover.   Note The fuel system must not be under any pressure.

–  Remove the fuel supply tube -2-. Press the unlocking button. –  Disconnect the fuel return line -3-. Press the unlocking button.

–  Remove the 2 fuel pipes from the high pressure pump.

–  Disconnect electrical connector -1- from the fuel pressure sender -G247-.

–  Remove bolt -left arrow- for water pipe from intake manifold.

–  Pull out oil dipstick and unscrew bolt -arrow- for dipstick guide tube.

Procedure only for »engines with engine codes BWJ, CDLD, CDLA« –  Disconnect connector -3-. –  Remove bolt -arrow-. –  Detach hose -2-. –  Loosen hose clip -1-, pull turbocharger air recirculation valve -N249- off air pipe and move clear (hose -4- remains connected).

For all engine codes –  Loosen hose clip -2- and detach air pipe from throttle valve module -J338-.   Note Ignore positions -1, 3 and 4-.

–  Disconnect oil dipstick guide -2- at separating point.

–  Disconnect electrical connection -1- on throttle valve control unit -J338-. –  Unscrew the bolts -arrow- and remove the throttle valve control unit -J338-.

–  Unscrew nut -2- and bolt -1-; remove support for intake manifold. –  Loosen all the bolts of the intake manifold. –  Carefully remove the intake manifold and the fuel rail from the cylinder head.   Note The injector units may remain on the fuel rail. –  Remove fuel distributor → Chapter. Installing Installation is in the reverse sequence of removal. In the process, note the following: If an injector has been extracted from the cylinder head when removing the intake manifold, replace the Teflon seal of the injector → Chapter. Renew the O-rings between injector and fuel rail and lubricate with clean engine oil. Position the intake manifold with together with fuel rail together and press onto the injectors evenly all round. After replacing the intake manifold flap motor -V157- or the intake manifold, the intake manifold flap potentiometer -G336- must always be adapted to the engine control unit → Vehicle diagnostic tester„Guided Functions“. Tightening torques

Tightening torque	Nm
Intake manifold securing bolts	10
Intake manifold support bolt	23
Intake manifold support nut	10
Fuel supply piping to high pressure pump	25
Fuel return piping to high pressure pump (replace)	17
Bolts of the intake manifold flap motor -V157-	7