SEAT Workshop Service and Repair Manuals

Removing and installing high-pressure pump t  Removing → Anchor t  Installing → Anchor   Caution t  Risk of irreparable damage to high-pressure pump if allowed to run dry. t  The high-pressure pump must first be filled with fuel before the engine is started → Chapter. (It is important not to allow the high-pressure pump to run while still empty.) t  Protect open fuel connections from dirt entrainment using suitable methods under all circumstances. t  Always observe rules for cleanliness and instructions when working on fuel system → Chapter.

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

Special tools and workshop equipment required

t	Hose clamp -T10051-, see equivalent → Anchor

t	Removal tool -T40064-, see equivalent → Anchor

t	Tappet -T40064/1-, see equivalent → Anchor

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

t  Base -3314-, see equivalent → Anchor Removing   Caution Risk of damage due to soiling. Note → Chapter The high-pressure fuel pump has very close tolerances and must not be allowed to run without fuel. To prevent this and to enable the engine to start quickly after parts have been renewed, it is important to observe the following: If a high-pressure pump is removed or renewed, fuel system bleeding must be carried out before starting the engine for the first time. Procedure for the initial fuel filling → Chapter –  Take toothed belt off camshaft and high-pressure pump → Chapter.

–  Separate connector -1- from fuel temperature sender -G81-.

Ibiza –  Hang out the coolant return hose -arrows- and move the coolant line to one side. 1)  There are different installation positions for the coolant return hose.

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.

–  Disconnect fuel supply line -arrow- on high pressure pump.

–  Unscrew the bolts -1, 3, 4-. Unplug the connector -arrow- from the fuel metering valve -N290-.

–  Unscrew bolts -4- and then remove bracket.

–  Disconnect the fuel return line -2-.

–  Remove the high pressure fuel line between the high-pressure pump and the high-pressure accumulator (Common Rail) → Item.

–  Undo the bolts -2- and remove the gear wheel of the high-pressure pump.

–  Counterhold hub of high-pressure pump using counterhold -T10051- and unscrew securing nut -1-.

–  Apply puller -T40064- with thrust piece -T40064/1- and pin -T40064/2- as shown and pull hub off high-pressure pump. If necessary, counter-hold with a 24 mm open-ended spanner

–  Unscrew securing bolts -arrows- for high-pressure pump. –  Remove high-pressure pump. Installing Installation is carried out in reverse order, noting the following: Toothed belt tightening torque (Altea - Altea XL - Leon) → Chapter. Toothed belt tightening torque (Ibiza) → Chapter.

Tightening torques -1,3,4-. In Fig. 1 = 8 Nm In Fig. 3 = 8 Nm In illustration 4 = 20 Nm After any work on the fuel system –  Connecting the central diagnosis –  Interrogate fault memory and erase stored fault if necessary.   Caution t  The high-pressure pump must first be filled with fuel before the engine is started. The high-pressure pump must not be allowed to run while still empty. Initial fuel filling → Chapter. t  Running when dry causes irreparable damage to high-pressure pump. –  Filling/bleeding high-pressure pump/fuel system → Chapter. –  Perform the function „Resetting engine control unit programmed values“ in „Guided functions“.