SEAT Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Test box V.A.G 1598/31
• ◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
• ◆ Diode test lamp V.A.G 1527
• ◆ Adapter set V.A.G 1594
• ◆ Current flow diagram

Check conditions

• ● → All fuses must be OK.
• ● Engine speed sender must be OK, checking .
• ● The battery voltage must be at least 11.5 V.
• ● Fuel pump relay must be OK

Test sequence

• ‒ First check injection valves during final control diagnosis .

If one or more injectors do not click:

• ‒ Remove intake manifold:

=> Repair group 15; Removing and installing cylinder head; Removing and installing cylinder head cover

Note:

Seal intake ports in cylinder head with a clean cloth.

• ‒ Pull connectors off injectors.

Checking resistance of injectors

• ‒ → Check resistance of injectors between contacts.
      Specification: 13.0...19.0 ω

Note:

The resistance figures are valid for approx. 20 °C. At higher temperatures the resistance figures will increase.

If the specification is not attained:

• ‒ Renew defective injector.

Pay attention to the following when installing the injectors:

• ◆ Renew O-rings on all injectors and lightly moisten with clean engine oil.
• ◆ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
• ◆ Set fuel distributor with secured injectors on cylinder head and press in evenly.
• ◆ The connectors must audibly engage in the injectors when pushed on.

• ‒ Interrogate fault memory, if necessary, repair any faults and then erase fault memory => Page 01-16, interrogating and erasing fault memory.
• ‒ Read-out the readiness code=> Page 01-64.

Checking voltage supply

• ‒ Pull connectors off injectors.

• ‒ → Connect diode test lamp to contact 1 and earth of relevant injector connector.
• ‒ Operate the starter and check the voltage supply for the injector.
      The LED must light up

If the LED does not light up:

• ‒ Switch off ignition.
• ‒ Check wire between 2 pin connector contact 1 and fuel pump relay (J17) for open circuit using current flow diagram.
      Wire resistance: max. 1.5 ω

Checking activation and wiring

• ‒ Pull connectors off injectors.
• ‒ → Connect diode test lamp V.A.G 1527 to connector contacts of the injector to be tested using cables from V.A.G 1594.
• ‒ Operate starter and check the activation for the injector.
      The LED must flicker

Note:

The flickering is difficult to recognise.

If the LED does not flicker:

• ‒ Switch off ignition.

• ‒ Remove battery.
• ‒ → Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains disconnected.

• ‒ → Check wiring for open circuit between test box and the 2-pin connectors for the injectors using current flow diagram.
      Injector 1: Contact 2+socket 96
      Injector 2: Contact 2+socket 112
      Injector 3: Contact 2+socket 88
      Injector 4: Contact 2+socket 113
      Injector 5: Contact 2+socket 97
      Injector 6: Contact 2+socket 89
      Wire resistance: Max.1.5 ω
• ‒ Additionally check wires for short to one another.
      Specification: ∞ω

If there is no fault in the wiring and the resistance measurement values are OK.:

• ‒ Replace engine control unit
  => Page 24-150.

Checking injectors for leaks and quantity injected

Special tools, workshop equipment, test and measuring appliances and aux. items required

• ◆ V.A.G 1348/3 Remote control
• ◆ V.A.G 1348/3-2 Adapter
• ◆ V.A.G 1602 Calibration tester

Test conditions

• ● Check that the fuel pressure is in order=>Page24-101, Checking fuel pressure regulator and holding pressure.

Test sequence

• ‒ Remove intake manifold:

=> Repair group 15; Removing and installing cylinder head; Removing and installing cylinder head cover

• ‒ Then remove complete fuel rail (fuel pipes/hoses remain connected).
  => Page 24-24, Dismantling and assembling fuel rail.

Checking for leaks

• ‒ Introduce final control diagnosis => Page 01-89; the fuel pump must run.

Note:

This work sequence allows the fuel pump to run when the engine is not running.

• ‒ Check injector for leaks (visual check). Only 1 to 2 drops per minute must emit from each valve when fuel pump is running.

Note:

The final control diagnosis and, with it, the running fuel pump are shut off after a minute.

If the fuel loss is greater:

• ‒ Switch off ignition.
• ‒ Renew defective injector.

Pay attention to the following when installing the injectors:

• ◆ Renew O-rings on all injectors and lightly moisten with clean engine oil.
• ◆ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
• ◆ Set fuel distributor with secured injectors on cylinder head and press in evenly.
• ◆ The connectors must audibly engage in the injectors when pushed on.

• ‒ Interrogate fault memory, if necessary, repair any faults and then erase fault memory => Page 01-16, interrogating and erasing fault memory.
• ‒ Read-out the readiness code=> Page 01-64.

Checking injected quantity

• ‒ → Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains disconnected.
• ‒ Switch on ignition.
• ‒ Bridge sockets 2+65 of test box with adapter cables from V.A.G 1594. Fuel pump must start.

Note:

This work sequence allows the fuel pump to run when the engine is not running.

• ‒ Insert injector to be checked in a measuring glass of tester for injected quantity V.A.G 1602.

• ‒ → Connect one contact of the injector to be tested to engine earth using auxiliary cables from V.A.G 1594.
• ‒ Connect the second injector contact with auxiliary cable to remote control V.A.G 1348/3 using adapter cable V.A.G 1348/3-2.
• ‒ Connect crocodile clip to battery (+).
• ‒ Operate remote control V.A.G 1348/3 for 30 seconds.
• ‒ Repeat check on the other injectors. To do this use new measuring beakers.
• ‒ After all injectors have been activated, place the measuring glasses on a horizontal surface and compare the injected quantity.
      Specification: 110...130 ml per injector

If the measured values of one or more injectors are above or below the prescribed specifications:

• ‒ Switch off ignition.
• ‒ Renew defective injector.

Pay attention to the following when installing the injectors:

• ◆ Renew O-rings on all injectors and lightly moisten with clean engine oil.
• ◆ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
• ◆ Set fuel distributor with secured injectors on cylinder head and press in evenly.
• ◆ The connectors must audibly engage in the injectors when pushed on.

• ‒ Interrogate fault memory, if necessary, repair any faults and then erase fault memory => Page 01-16, interrogating and erasing fault memory.
• ‒ Read-out the readiness code=> Page 01-64.