SEAT Workshop Service and Repair Manuals

Injectors: Removing and installing t  Injectors: Removing → Anchor t  Injectors: 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	Extractor -T10055-, see equivalent → Anchor

t	Slider -T10377-, see equivalent → Anchor

t	Measuring container -T40055-, see equivalent → Anchor

t	Torque wrench -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  Adapter -T10415-, see equivalent → Anchor Removing .   WARNING t  When carrying out work on the fuel system, always observe the guidelines for cleanliness and the instructions → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system.

–  Remove the engine cover upwards -arrows-.   Caution t  Mark cylinder numbers on injectors. They must always be re-installed on the same cylinders. t  The safety measures when working on the injection system must be observed. t  Opened connections must be sealed immediately using a suitable plug.

–  Pull return line connections off at injectors. To do this, press bows -1- and -2- down and simultaneously pull release pin upwards -arrow-.

–  Remove the plugs -arrows- of the injectors, which should be disassembled.   Caution When releasing high-pressure line, counterhold high-pressure connection using an open-ended spanner. Leaks occur if high-pressure connection is released. –  Loosen union nuts for high-pressure pipes at injectors using socket -T40055-, 17 mm. –  Loosen union nuts for high-pressure pipes at rail element using tool insert, AF 17 -V.A.G 1331/6-. –  Unscrew securing bolt of clamping piece -1- of injector to be removed.

–  Set the extractor -T10055- with the Adapter -T10415- and pull out the injector upwards with light knocking motions.   Note Pull injector out using rotary movements in order not to damage sealing lip. –  After removal, lay injectors on a clean cloth. Important instructions for installing injectors: l  The following components and seals or O-rings must be replaced after each installation or removal: „Copper washer“„O-ring of the injector valve adapter shaft“ and „O-ring on the injector valve return connection“. l  The following components and seals or O-rings must always be replaced when an injector is renewed: „Clamping piece“, „Copper washer“, „O-ring from the injector bore“, „O-ring from the injector valve return connection“ l  Lubricate all O-rings with engine oil or assembly oil before installing.   Note t  Observe cylinder specific markings when reusing high-pressure lines. t  The high-pressure pipes can be re-used after performing the following checks: t  Check sealing cone on corresponding high pressure line for deformation and cracks. t  The inside of the line must not show any signs of deformation, changes or damage. t  Rusty lines must not be used again. If a used injector is being re-installed: –  Spray tip of injector nozzle with rust-releasing spray. Wait approx. 5 minutes and wipe off soot particles and oil with a cloth. –  With severe contamination of an injector additionally the tip of the injector unit must be cleaned with a soft brass brush, so that the copper sealing ring can be lightly removed (no scratches should occur due to the brush on the jets of the injectors). –  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 seat 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-. –  To avoid damaging O-ring, carefully slide new, oiled O-ring onto fuel return connection. –  Fit the injectors. –  Tighten union nuts on high-pressure lines hand-tight. Ensure that connections are not under tension. l  Specified torques → Chapter.

–  To tighten unions of high-pressure pipes at injectors, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket -T40055-.

–  To tighten unions of high-pressure pipes at rail elements, use torque wrench -V.A.G 1331- with tool insert, AF 17 -V.A.G 1331/6-. t  Observe the tightening torques: Installing high-pressure lines → Chapter. –  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“ for the new injectors must be written into the engine control unit → Vehicle diagnostic, testing and information system VAS 5051. Additionally check that the „injector delivery calibration values“ are correctly entered for all the other injectors. Do not attempt to re-enter these values if the correct values are already stored in the engine control unit. –  Bleeding the fuel system → Chapter.   Note The high-pressure connections must not be opened for bleeding. –  Run engine at idling speed for several minutes and then switch off. –  Switch ignition OFF. –  Check the complete fuel system including the 4 return line connections for leaks → Chapter. Renew the affected component if leakage still occurs after tightening to the correct torque.   Note The return lines can only be renewed together with the pressure retention valve as one unit. –  Perform a road test over a distance of at least 20 km and, in doing so, operate the accelerator with full gas (full speed) at least one time. Then the tightness of the high-pressure system must be checked again.   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 clear the fault memory. Then continue road test.