SEAT Workshop Service and Repair Manuals

Injector pump unit: removing and fitting t  Removing → Anchor t  Installing → 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	1/2" xzn wrench spanner kit -SAT 1006/2-, see equivalent → Anchor

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Extractor -T10055A-, see equivalent → Anchor

t	Socket -T20020-, see equivalent → Anchor

t	Measuring tool -T20110B-, see equivalent → Anchor

Removing –  Remove cylinder head cover → Chapter. –  Turn crankshaft until the pair of cams of the injector-pump assembly point upwards for the unit injector which is to be removed or fitted.

–  Loosen lock nuts on adjuster screws -1- and turn adjuster screws out until the relevant rocker arm does not have contact with the spherical spring of the injector pumps. –  With the help of a suitable socket from the kit -SAT 1006/2-, loosen the bolts -2- attaching the rocker axle, beginning at the outside and moving towards the interior, and then remove the rocker axle. –  Using the corresponding ball head tool from the kit -SAT 1006/2-, remove support block securing bolts -3- and remove the block.   Note Take care not to damage the wiring when separating the connector in the pump injector. –  Remove the injector-pump unit connector without damaging the wiring. Respect the matching injector-pump units and cylinders.

–  Instead of the attachment stopper, fit the extractor -T10055A- in the direction of the camshaft into the lateral groove of the injector pump. –  Carefully pull injector-pump assembly out of cylinder head seat with gentle taps Installing   Note t  The adjuster screw and the spherical nut of the injector pump should be replaced when the injector pumps are adjusted. t  New injector-pump units are supplied with O rings and heat shield seal. t  Grease using G 000 100 → Electronic parts catalogue the contact surfaces between the spherical head pin and the adjustment bolt. –  If a used injector pump is to be fitted, replace all of the O-rings and the heat proof seal → Chapter. –  Before fitting the injection pump, check the correct seating of the three seals, the heat-proof joint and the securing washer.   Note The O-rings must not be twisted. –  Oil all of the O-rings and fit the injector pump very carefully into its allotment on the cylinder head. –  Press evenly, insert the injection pump to the limit of its allotment on the cylinder head. –  Fit the attachment stopper into the lateral groove of the injection pump.   Note t  If the injector-pump unit is not at right angles to the tensioning block the securing bolt may loosen and this can damage the unit injector or the cylinder head. t  There are two models of injection pump. One of them is equipped with a nut for the larger electronic valve. For this reason, follow the specific instructions for each one of these as follows:

Injection pump with larger electronic valve nut –  Insert the injector pump adaptor -T20110A/3- by the larger end and move the injector pump until the cylindrical part of the injector nut touches the centring device. Injection pump with smaller electronic valve nut –  Insert the injector pump adaptor -T20110A/3- by the thinner end and move the injector pump until the cylindrical part of the injector nut touches the centring device. All: –  If necessary, readjust the injector pump unit and tighten the securing bolt for the attachment block as follows: Tightening torque: 12 Nm +270° (3/4 turn) (retightening may be done in various stages).

–  Fit the rocker axle and tighten the new attachment bolts as described below. –  Tighten evenly and by hand, the interior bolts -2- followed by the exterior bolts -1-. Then using same sequence, tighten to 20 Nm and 90° (1/4 turn) further.

–  Position a dial gauge on the adjuster screw of the injector-pump unit as shown. –  Turn the crankshaft in engine direction of rotation until the roller of the rocker arm is positioned on the peak of the drive cam tab. The roller side -arrow A- is found on the highest point, gauge -arrow B- is at the lowest point. –  Remove the gauge. –  Now turn the adjuster screw into rocker arm until significant resistance can be felt (injector-pump unit is at limit stop).

–  Screw out the adjustment screw from the end by 180°. –  Maintain the adjustment bolt in this position and tighten the counter nut to a torque of 30 Nm. –  Connect the connector for the injector-pump unit. –  Install the cylinder head cover → Chapter. –  Install notched belt guard.