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	Socket wrench insert -T40055-, see equivalent → Anchor

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

t	Ratchet 1/2' x 9-12 -VAG 1331/1-, see equivalent → Anchor

t  Torque wrench insert -VAG 1331/6-, see equivalent → Anchor t  Injector remover -T10415- Removing   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Always follow these rules for cleanliness and instructions before starting work and while working on the fuel system. t  Prior to opening the fuel system, place a clean cloth around the joint and carefully loosen this to reduce the pressure.

–  Loosen the engine cover at the locations -arrows- and remove.   Caution t  Mark the injector correspondence to the cylinder. 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 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. –  Unscrew union nuts of relevant high-pressure line -1 to 4- and remove corresponding high-pressure line. –  Unscrew securing bolt of clamping piece -1- of injector to be removed.

–  Fit puller -T10055- with puller -T10415- and pull injector out upwards using tapping movements.   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 always be replaced with each removal or installation: „Copper washer“, „O-ring from the injector bore“ and „O-ring from the injector valve return connection“. l  The following components and seals or O-rings must always be replaced when an injector valve 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 taper seat of respective high-pressure line for deformation and cracks. t  The line hole must not be deformed, constricted or damaged. t  Corroded lines should no longer be used. When reusing injectors: –  Spray tip of injector nozzle with rust-releasing spray. Wait approx. 5 minutes and wipe off soot and oil particles with a cloth. –  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.   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.

–  Replace the sealing ring of the adapter shaft of the injector. For this purpose use the assembly cap -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.

–  Tighten the high pressure lines on the injectors using the torque wrench -VAG 1331- with socket 1/2' x 9-12 -VAG 1331/1- and socket -T40055-.

–  To tighten the high-pressure lines on the rail element, use the torque wrench -VAG 1331- with the torque wrench insert -VAG 1331/6-. t  Maintain the tightening torques: Installing high-pressure pipes → Chapter t  Specified torques: see component overview of the fuel system → Chapter –  Press the connections of the return lines carefully on the sealing ring on the injector valve (first check that the sealing ring is not damaged). The catch should engage audibly. Then press release pin down carefully. After renewing one or more injectors the correction values of the new injectors must be entered in the engine control unit → Vehicle diagnostic, testing and information system VAS 5051. Also check that the correct correction values are entered in the engine control unit for all other injectors. Do not attempt to re-enter these values if the correct values are already stored in the engine control unit. –  Purge the fuel system → Chapter.   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 off ignition. –  Check the complete fuel system including all 4 return line connections for leaks. 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. –  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.