SEAT Workshop Service and Repair Manuals

Checking injectors Checking activation Special tools and workshop equipment required t  Test box -V.A.G 1598/22- t  Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715- t  Diode test lamp -V.A.G 1527- t  Adapter set -V.A.G 1594- t  Current flow diagram Check conditions

l  All fuses must be OK. l  Earth connection between engine (on gearbox bell housing) and body (below battery) OK. l  Earth connection in plenum chamber OK. l  The battery voltage must be at least 11.5 V. l  Engine speed sender must be OK, checking< qv-kap ziel="MGAKK2407110160">. l  Hall sender must be OK, checking → Chapter. l  Fuel pump relay must be OK Test sequence –  Remove air cleaner → Fig..

–  Pull 4 pin connector off ignition transformer -arrow-.

–  Pull plug -arrows- off all injectors.

–  Connect diode test lamp -V.A.G 1527- using aux. cables from -V.A.G 1594- to connector contacts of Cyl. 1. –  Operate the starter and check the voltage supply for No. 1 cylinder injector. The LED must light up –  Repeat check at the injector connectors for Cyls. 2...4. –  Switch off ignition. If the LED does not light up on any cylinder:

–  Connect diode test lamp to Cyl. 1 connector, contact 1 and earth. The LED must light up –  Repeat check at the injector connectors for Cyls. 2...4. 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 according to current flow diagram. Wire resistance: max. 1.5 Ω If the LED does not light up on one or several cylinders: –  Remove wiper arms and cowl panel: → Electrical system; Rep. Gr.92

–  Connect test box -V.A.G 1598/22- to control unit wiring harness.

–  Check wires between test box and 2-pin connectors for injectors (connector to control unit) for open circuit using current flow diagram. Injector 1: contact 2+socket 79 Injector 2: contact 2+socket 59 Injector 3: contact 2+socket 73 Injector 4: contact 2+socket 65 Injector: max. 1.5 Ω –  Additionally check wires for short to one another. Specification: ∞Ω –  Check wiring between connector contacts 1 of injectors for open circuit to one another. Wire resistance: Max. 1.5 Ω Checking resistance of injectors Test sequence

–  Check resistance of injectors between contacts. Specification: 12...17 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 → Item. Perform installation of injectors in reverse order. When doing this note the following: t  Renew O-rings on all injectors and lightly moisten with clean engine oil. t  Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips. t  With injectors secured to fuel rail, fit fuel rail on cylinder head and press in evenly.

Checking spray pattern and for leaks

Special tools and workshop equipment required

t	Dynamometric wrenches -SAT 8010-

t	Adapter set -V.A.G 1594 A-

t	Digital potentiometer -V.A.G 1630-

t	Measuring container

Test conditions l  The fuel pressure must be in order, checking → Chapter, checking fuel pressure regulator and holding pressure. Test sequence –  Remove air cleaner → Fig..

–  Pull 4 pin connector off ignition transformer -arrow-.

–  Pull the 4 pin connector off coolant temperature sender -G62- with coolant temperature gauge sender -G2--arrow-.

–  Connect digital potentiometer -V.A.G 1630- using aux. cables from -V.A.G 1594- to connector contacts 1+3 and set connected side to 15 kΩ.

–  Pull the vacuum hose off fuel pressure regulator -arrow-. –  Unclip injector wiring harness on fuel rail. –  Remove fuel rail complete with injectors from cylinder head (fuel hoses remain connected) → Item.

–  Hold a small container under the injector to be checked and pull connectors off all other injectors. –  Have 2nd person operate starter. Injector must spray in pulses. –  Repeat check with other injectors ensuring that injector to be checked is only connected. –  Switch off ignition and afterwards check injectors for leaks. No more than 2 drops/min may leak from each injector. If the fuel loss is greater: –  Switch off ignition. –  Renew defective injector → Item. Perform installation of injectors in reverse order. When doing this note the following: t  Renew O-rings on all injectors and lightly moisten with clean engine oil. t  Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips. t  With injectors secured to fuel rail, fit fuel rail on cylinder head and press in evenly.