SEAT Workshop Service and Repair Manuals

Intake manifold: removing and installing t  Removing → Anchor t  Installing → 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  Pliers -T20174- or pliers -SAT 1105-, see equivalent → Anchor

Special tools and equipment for engines with particulate filter

t	Socket wrench e/c 22 -T20202A-, see equivalent → Anchor

t	Socket wrench e/c 17 -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

Removing

–  Release the fasteners -arrows- to remove the central soundproofing panel.

–  Unscrew the bolts -arrows- and remove the heat protecting plate. –  Remove right-hand articulated shaft: → Running gear, shafts, steering; Rep. gr.40. Only for engines with particulate filter

–  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-. Continue for all engines

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

–  Separate the clamps -arrows- and remove the supercharger hose -1-.

–  Detach electrical connector -1- of the engine intake manifold flap -V157-. –  Unscrew the bolts -arrows- and remove the intake manifold flap motor -V157-.   Note For improved understanding, it is shown from the rear in the illustration with engine removed.

–  Disconnect the electrical connector -1- on the exhaust gas recirculation valve -N18- with the potentiometer for regulating exhaust gases -G212-. –  Remove the electrical harness from the brackets and move to one side. –  Remove bolts -arrows-. –  Remove the exhaust gas recirculation valve -N18- of the intake manifold. Only for engines with particulate filter

–  Disconnect the connectors -1-, -2-, -3- and -4- and remove them from their housings.

–  Undo the pressure pipe -3- of the particulate filter using the socket wrench E/C 17 -T20211-. –  Undo the lambda probe -G39--1- using the socket wrench E/C 22 -T20202A- and the "ratchet 1/2" x 9-12" -VAG 1331/1-. –  Unscrew the bolts -arrows- and free heatproof plate of the particulate filter -4- without removing it.

–  Undo the exhaust gas temperature sender 2, bench 1 -G448--2- using the socket wrench E/C 17 -T20211- and the "ratchet 1/2" x 9-12" -VAG 1331/1-.

–  Disconnect the electrical connector -arrow- for temperature sender 1 of the exhaust gases -G450-. –  Unscrew exhaust gas pressure sensor 1 -G450- and remove together with the pressure hoses. –  Remove the heatproof plate of the particulate filter. –  Unscrew the brackets of the particulate filter → Item.

–  Remove the bolts -arrows- and remove the upper support of the particulate filter. Only for engines without particulate filter –  Remove the bracket for front exhaust pipe → Item. Continue for all engines

–  Unscrew the nuts on the double clamp -1-.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

–  Remove the support bolts of the particle filter and the engine block, and remove the support. –  Remove the front exhaust pipe with the particulate filter / catalytic converter and place it on the power steering. –  Separate the low pressure hoses if necessary.

–  Remove the bolts -arrows- which are in the flange found between the exhaust gas recirculation radiator and the intake manifold.

–  Remove the air filter intake hose -3-. –  Detach connection hose -2-.

–  Unscrew the nuts -arrows- and take connecting pipe for exhaust gas recirculation off.

–  Remove the bolts -1-, -2- and the hollow bolt -3- and remove the oil return pipe.

–  Remove the thermal protection plate on the left of the exhaust manifold -arrows-. –  Remove air filter → Chapter.

–  Undo the fastening bolts of the turbocharger and of the bracket -arrows-.

–  Remove nuts -arrows-. –  Remove the exhaust manifold assembly/turbocharger and place it on the power steering. –  Remove the six bolts which secure the intake manifold to the cylinder head and remove it from the top. Installing Install in the reverse order from removal, remembering the following:   Note t  Apply the correct tightening torques. t  Renew seals, gaskets and self-locking nuts. t  Note the installation position of intake manifold gasket. 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) → Parts catalogue.