SEAT Workshop Service and Repair Manuals

Removing and installing intake manifold 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	Base -3314-, see equivalent → Anchor

t	Socket wrench insert -T40055-, see equivalent → Anchor

t	Socket XZN 8 -T40159-, see equivalent → Anchor

t	Torque wrench (5 - 50 Nm) -V.A.G 1331-, see equivalent → Anchor

t	Ratchet 1/2' x 9-12 -VAG 1331/1-, see equivalent → Anchor

t	Insert e/c 17 terminal -V.A.G 1331/6-, see equivalent → Anchor

Removing .   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Always follow these rules for cleanliness and instructions before starting work and while working on the fuel system.

–  Remove the engine cover upwards -arrows-. –  Take noise insulation off cylinder head cover.

–  Fit the centre noise insulation -fasteners 1 ... 3-.

–  Remove air hose; loosen hose clip -2- and raise retaining clip -1- for this.

–  Unscrew bolts -1- and -3-. –  Slacken hose clip -5- at intake manifold flap motor -V157-, detach air pipe -2- but do not remove.   Note Disregard: -Pos. 4-.   Caution Pay particular attention not to damage the wires when removing the connections, because otherwise it would be necessary to replace the entire wiring harness. Do not press pliers -3314- together excessively when removing the connection, because otherwise the bearing supports could be damaged.

–  Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B-.

–  Unplug electrical connectors -5- from glow plugs. –  Unscrew union nuts at high-pressure pump -6- and rail element -1- and remove high-pressure fuel pipe. –  Remove bolts -arrows- securing retainers for high-pressure fuel pipe. –  Move wiring harness -2- clear. –  Detach fuel return lines -3, 4 and 7-.

–  Remove securing bolt -arrow- and take out return line. –  Remove bolt from bracket -4- for exhaust gas recirculation cooler change-over valve -N345-. –  Unplug connectors -9- from exhaust gas recirculation valve -N18- and throttle valve module -J338--7-. –  Remove bolts -6- from connecting pipe for exhaust gas recirculation. –  Open hose clip -8- securing air hose and disconnect hose downwards from intake manifold flap motor -V157-. –  Remove bolt -9- on bracket for oil dipstick. –  Remove bolts securing intake manifold in diagonal sequence starting from outside and working inwards using socket XZN 8 -T40159-. –  Remove the intake manifold. Installing . Carry out the assembly operations in reverse order to those described for the disassembly, taking the following into account: –  Renew seals and gaskets. –  Tighten the fastening bolts of the intake manifold crosswise from the outside to the inside. t  Specified torques → Chapter. –  Install air pipe at the front → Chapter.

Install the air hoses with plug-in connector .   Note t  Renew seal if damaged. t  Make sure that the seal is correctly seated in the groove on the complete circumference of the air pipe/hose. t  Apply a thin coating of silicon-free lubricant to the sealing area and the seal. –  Release retaining clip (position -1-). –  Push air pipe/hose in as far as stop and press retaining clip to lock -2-. –  Press air pipe/hose again and pull again to check that plug-in connector is correctly engaged. –  Fit the centre sound proofing → Exterior body installation work; Rep. gr.50 .