SEAT Workshop Service and Repair Manuals

Removing and installing injectors t  Removing → Anchor t  Fitting → 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	Extractor -T10055-, see equivalent → Anchor

t	Slider -T10377-, see equivalent → Anchor

t	Measuring container -T40055-, see equivalent → Anchor

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

t	Ratchet -V.A.G 1331/1-, see equivalent → Anchor

t  Insert e/c 17 terminal -V.A.G 1331/6-, see equivalent → Anchor t  Injector remover -T10415- Removing   Caution Risk of malfunctions caused by dirt. Observe → Chapter „Rules for cleanliness and instructions for working on fuel system“.

–  Remove engine cover panel -arrows-.   Caution t  If the high-pressure reservoir, the high pressure pump and/or the injection units are to be replaced, also replace high pressure hoses connected to these. t  Mark cylinder numbers on injectors. They must always 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.

–  Pull return line connections off injectors; to do so, press tabs -1- and -2- down and at the same time pull release pin upwards -arrow-.

–  Unplug electrical connectors -arrows- at injectors. –  Loosen union nuts of high-pressure pipes -1 to 4-.

–  Unscrew bolt -1- for clamping piece.   Note The clamping piece remains in the installation position until the nozzle unit is removed.   Caution Risk of damage if the clamping pieces buckle on the nozzle unit First detach injectors for cylinders 2 and 4; then detach injectors for cylinders 1 and 3, and at the same time detach clamping piece. –  Apply puller -T10055- with puller -T10415- as shown in illustration, and pull out injector upwards.   Note To avoid damaging the sealing lip, rotate the injector while pulling it out. –  After removal, lay injectors on a clean cloth. Installing new injectors When installing new injectors, the following components must be renewed: t  Clamping piece t  Copper seal t  Renew O-ring for injector bore. t  O-ring for fuel return line connection   Note t  Note identification marks for cylinder allocation when re-installing high-pressure pipes. t  The high-pressure pipes can be re-used after performing the following checks: 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. Installing used injectors When re-installing used injectors, the following components must be renewed: t  Clamping piece t  Copper seal t  Renew O-ring for injector bore. t  O-ring for fuel return line connection –  Spray tip of injector nozzle with rust-releasing spray. Wait approx. 5 minutes and wipe off soot particles and oil with a cloth. –  If an injector is very dirty, the tip of the nozzle should also be cleaned with a soft brass wire brush to make it easier to remove the copper seal. Do not apply the wire brush to the bores in the nozzle. –  To remove the old copper seal from the injector, clamp the seal carefully in a vice so that it is just held between the jaws without turning. Then carefully pull and twist the injector out of the copper seal by hand. –  Clean off deposits under the copper seal using a suitable scraper.   Caution To remove carbon deposits from the injector sealing surface, clean the injector bore in the cylinder head with a cloth soaked in engine oil or rust solvent. Take care not to damage the sealing surface.

–  Renew O-ring for injector bore using assembly sleeve -T10377-. –  Install injectors.   Note If injector seals in cylinder head cover are damaged, renew damaged seals → Chapter. –  Tighten union nuts on high-pressure lines hand-tight. Ensure that connections are not under tension. l  Tightening torque → Chapter „Nozzle units: Assembly overview“ –  Press return line connections carefully over seals and onto injectors (check seal for damage before connecting return line). The catch should engage audibly. Then press release pin down carefully. After renewing one or more injectors, the „injector delivery calibration values“ and „injector voltage calibration values“ for the new injectors must be written into the engine control unit. Additionally, check that the „injector delivery calibration values“ and „injector voltage calibration values“ are correctly entered for all the other injectors. Do NOT attempt to re-enter these calibration values if the correct values are already stored in the engine control unit. Bleeding fuel system and checking for leaks   Note The fuel system is self-bleeding; do not open the high-pressure connections. –  Run engine at idling speed for several minutes and then switch off. –  Switch ignition OFF. –  Check the complete fuel system including all 4 return line connections for leaks. Renew affected component if leakage still occurs after tightening to correct torque.   Note The return lines can only be renewed together with the pressure retention valve as one unit. –  After completing the repair, road-test the vehicle over a distance of at least 20 km. Accelerate with full throttle at least once. Then inspect the high-pressure section of the fuel system again for leaks.   Note If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off the engine and erase the fault memory. Then continue road test.