SEAT Workshop Service and Repair Manuals

Removing and installing rail element (high-pressure reservoir)

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

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

t	Torque wrench -VAG 1331-, see equivalent → Anchor.

t	Ratchet 1/2' x 9-12 No.(735/10) -VAG 1331/1-, see equivalent → Anchor

t	Torque wrench insert -VAG 1331/6-, see equivalent → Anchor

t  Base -3314-, see equivalent → Anchor Removal:   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system.

–  Loosen the engine cover at the locations -arrows- and remove.

–  Unscrew bolt -3- from retainer for high-pressure line. –  Remove the high-pressure fuel line -2-; For this purpose, unscrew the union nut of the high-pressure fuel pump -4- as well as the Common Rail (high-pressure reservoir) -1-.   Note

The bracket (to the engine mount) must have space to move to be able to unscrew the union nut on the high-pressure pump. Slacken the bolts -4- for this purpose.

Altea - Altea XL - Leon –  Unscrew the securing bolts -arrows- and put the coolant return line to the side.

All vehicles (continued): –  Remove securing bolts -arrows-.

–  Unplug electrical connection -2- from the fuel pressure sender -G 247--C-.   Note Ignore -item 1-. –  In order not to damage the vacuum lines above the plug connectors of the glow plugs, remove the metal clip for fixing the vacuum line to the intake pipe and place the vacuum line to the side.

–  Open cable guide fasteners -arrows- to free wiring harness.

–  Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B- and pull plugs off glow pin plugs.

–  Remove the connector of the glow plug carefully -in the direction of the arrow-.   Caution Make sure that no wiring connections are damaged when disconnecting the connectors. Otherwise the whole wiring harness will need to be renewed. Do not compress the pliers -3314- too firmly to separate the connectors, otherwise the support sleeve may be damaged.

–  Pull off electrical connectors -1 and 4-. –  Pull off fuel return hose -2-.   Note Ignore -item 3-.

–  Pull off electrical connectors -6 and 7-. 6 -  Fuel pressure regulating valve -N276- 7 -  Exhaust gas recirculation cooler changeover valve -N345-   Caution t  Mark allocation of high-pressure pipe to cylinder. They must only be re-installed on the same cylinders. t  Observe rules for cleanliness when working on the injection system. t  Plug open connections with suitable sealing caps immediately. –  Remove the high pressure line between the injectors (piezo injectors) and the common rail (high pressure lines).   Note

Counterhold on high-pressure union -A- when loosening high-pressure line. –  After removal, lay high-pressure lines on a clean cloth.

–  Remove the common rail (high-pressure reservoir). To do this, unscrew bolts -arrows-. Installation Installation is carried out in reverse order, noting the following:

–  First tighten the securing bolts -arrows- to max. 1 - 2 Nm. l  It must be possible to move the rail so the hoses can be fitted free of tension. –  Install high-pressure pipes → Chapter.   Note t  Renew retaining clips. t  Note identification marks for cylinder allocation when re-installing high-pressure pipes. t  The high-pressure lines can be reused after undergoing the following tests: t  Check taper seat of respective high-pressure line for deformation and cracks. t  The bore of the pipe must not be distorted, restricted or otherwise damaged. t  Corroded lines should no longer be used. t  Tightening torques: Fuel system - Component overview → Chapter