SEAT Workshop Service and Repair Manuals

Intake manifold complete: Removing and fitting   Note t  Installing and removing intake manifold upper section and intake manifold lower section together. t  Observe safety precautions → Chapter. t  Observe rules for cleanliness → Chapter.

Removal: –  Unscrew both hexagon bolts -1- and remove the protective cover -2-.

Altea, Altea XL 2009► –  Start the engine, accelerate to a minimum speed of 1200 rpm and wait until the fuel selection switch (Petrol / Gas) -E395- is positioned to Gas -1-.

Leon 2009► –  Start the engine, accelerate to a minimum speed of 1200 rpm and wait until the fuel selection switch (Petrol / Gas) -E395- is positioned to Gas -1-.

Continued for all vehicles –  Disconnect the connector of the valve for the gas tank -N495--arrow- .

Altea, Altea XL 2009► –  Wait until thefuel selection switch (Petrol / Gas) -E395--1- releases a fault message.

Leon 2009► –  Wait until thefuel selection switch (Petrol / Gas) -E395--1- releases a fault message.   Note The fault message occurs optically as well as acoustically. Continued for all vehicles –  Disconnect the plug connector on the fuel rail.   WARNING Gas may escape when opening the gas line. Wear safety goggles and appropriate clothing to avoid injury to eyes and burns. Wind the separation point in a rag and open carefully.

Gas distribution rail: Altea, Altea XL 2009► –  Loosen the bracket -1- and remove the hose from the gas distribution rail -in the direction of the arrow-.

Gas distribution rail: Leon 2009► –  Loosen the bracket -2- and remove the hose from the gas distribution rail -in the direction of the arrow-. –  Remove the intake manifold hose between the throttle control unit -J338- and the air filter.

–  Separate the vacuum hose -arrow- to the brake servo on the intake manifold.

–  Unplug connector -1- from secondary air pump motor. –  Disconnect the pressure hoses -2- and -3- on the motor for the secondary air pump. –  Remove the dipstick together with the dipstick funnel and the bracket for the secondary air pump.

–  Unscrew the bracket with motor for secondary air pump from the intake manifold -arrows-.

–  Unscrew the bolts on the fuel rail and remove the expansion rivets from the fuel rail cable guide -arrows-.   Note The fuel line may remain connected on the fuel rail.

–  Disconnect the electric plug connection -arrows- and clip the cable from the intake manifold. –  The solenoid 1 for the activated charcoal filter system -N80- and unclip the coolant hose at the intake manifold.

–  Pull off the connecter -1- and remove the throttle control unit -J338--arrows-.

–  Unscrew one bolt on the left and right respectively -arrow- at the rear attachment of the intake manifold.

–  Unscrew the remaining bolts -arrows- from the lower part of the intake manifold to the cylinder head.

–  Loosen the cable guide from the fuel distributor and equally pull the fuel distributer from the intake manifold bottom part together with injectors. –  Remove the intake manifold from the cylinder head and place the fuel distributor together with injectors and set it down on a clean cloth in the engine compartment.   Note Cover the intake conduits on the cylinder head with a clean cloth. Installing Installation is carried out in the reverse order; noting the following in the process: –  Renew seals between intake manifold and cylinder head. –  Renew seals between injector and intake manifold and lubricate with clean engine oil. –  Position fuel rail together with injectors (properly secured) against intake manifold and press into place evenly all round. –  Check the tightness of the gas hose connections using the Gas leak detector -VAS 6227-.   Note Secure the hose connections with original clamps. Tightening torques

Part		Nm
Intake manifold to cylinder head		25
Intake manifold to support element		8
Secondary air pump bracket to intake manifold		8
Gas distribution rail on the intake manifold		3
Throttle valve adjuster to intake manifold		8