SEAT Workshop Service and Repair Manuals

Removing and installing intake manifold with fuel rail If intake manifold is renewed, intake manifold flap potentiometer -G336- must be adapted to engine control unit -J623- using a vehicle diagnosis tester.

Special tools and workshop equipment required

t	Socket and key -T10347-

t	Oil filter tool -3417-

t	Torque wrench -V.A.G 1331-

Note t  Always follow safety precautions → Chapter. t  Observe rules for cleanliness → Chapter. t  The injectors can only be accessed after removal of the intake manifold and fuel rail with air flow control flap. t  The combustion chamber (Teflon) ring seal and the O-ring must always be renewed. t  Intake manifold - Assembly overview → Chapter t  Fuel rail - exploded view → Chapter   WARNING The fuel system is pressurised. The pressure in the high-pressure components of the injection system must be reduced to a residual pressure prior to opening. High pressure system pressure reduction → Chapter. Removing: –  Remove engine cover → Chapter. –  Clean joint between intake manifold and cylinder head. –  Remove the air filter housing → Chapter.

–  Disconnect vacuum line -arrow- to activated charcoal filter. –  Unplug the following electrical connectors: t  Intake air temperature sender -G42--1- t  Throttle valve control unit -J338--2- t  Activated charcoal filter solenoid valve 1 -N80- t  Hall sender -G40-

–  Disconnect vacuum line -1- at position marked -2- and remove crankcase breather hose -3-.

–  Unscrew bolts -arrows- for fuel supply pipe and lay the pipe aside.   Note The fuel system must not be under pressure.

–  Undo fuel pipe union nut -lower arrow-.

–  Pull vacuum pipe -arrow- from intake manifold flap valve -N316-.

–  Unscrew coolant pipe bolts -arrows- from intake manifold .

–  Pull electrical connector -1- from fuel pressure sender -G247-.

–  Release hose clip -2-. –  Remove bolt -4-. –  Unplug electrical connector -arrow-. –  Remove the sound insulation → Bodywork, exterior installation work; Rep. gr.50

–  Remove charge air hose -A- and seal charge air cooler with a clean cloth.

–  Remove bolt -1- and take out air pipe downwards.

–  Detach electrical connectors -1…3- and unscrew retainer from intake manifold.

–  Remove the throttle valve module -J338--arrows-.

–  Remove the intake manifold support by unscrewing the nut -1- and the bolt -2-. –  Remove oil filter.

–  Loosen cable retainer -arrows-.

–  Disconnect line -arrow- from intake manifold.

–  Unscrew nuts -A- and bolts -arrows- from intake manifold with socket wrench -T10347-. –  Carefully remove the intake manifold and the fuel rail from the cylinder head.

–  Disconnect electrical connector -arrow- from intake manifold flap potentiometer -G336- and remove intake manifold. –  Block off the intake ports with a clean cloth.   Note The injectors can remain in the fuel rail. –  Remove fuel rail from intake manifold → Chapter. Installing: l  Injectors are located in cylinder head. Install the injectors → Chapter –  Fit intake manifold onto studs (left and right) on cylinder head.   Note Observe correct installation position of injectors and on cable retainer (below intake manifold) when positioning intake manifold. l  If, during intake manifold installation, the intake manifold has to be pulled out again slightly and the injectors remain in the fuel rail. Then pull the injectors out from the fuel rail again and insert the injectors into the cylinder head again. Further assembly is basically the reverse of the dismantling sequence. The following should be taken into account:

–  On engaging cable retainer onto intake manifold, also clip in the other two retainers. Tightening torques: refer to assembly overview of intake manifold → Chapter. Tightening torques: refer to assembly overview of fuel rail → Chapter.