SEAT Workshop Service and Repair Manuals

Removing and installing injectors t  Removing → Anchor t  Installing new injectors → Anchor t  Installing used injectors → 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

Insert e/c 17 terminal -V.A.G 1331/6-, see equivalent → Anchor Removing   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system.

–  Disconnect the engine cover-arrow-. –  Take noise insulation off cylinder head cover.   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.

–  Disconnect the return line connections on the injectors. To do so, press both tabs down and at the same time pull centre piece up to release connection -arrow-.   Note t  Should you not be able to pull the return line connection upwards, open the connection by turning it with a small screwdriver.

t  Pay attention to absolute cleanliness. No dirt may get into the extracted injector return lines or the injector connections.

–  Disconnect the electric connection -1- of the injectors to be removed. –  Unscrew the union nuts for high-pressure pipes on injectors using socket -T40055- 17 mm. –  Loosen union nuts on high pressure lines with socket wrench attachment SW 17 -V.A.G 1331/6- on high pressure reservoir.

–  Loosen the covers of the injectors -arrow-. –  Pull covers upwards and turn them 1/4 turn (90°).   Caution The fixing nuts of the injectors may fall into the cylinder head when unscrewing. Proceed very carefully to prevent unnecessary assembly work or subsequent damage.

–  Loosen the nuts of the clamping shoe for fixing of the injectors -arrow-.

–  Set the extractor -T10055- with the Adapter -T10055/1- as shown and pull out the injector upwards using knocking motions. –  Put down the removed injectors on clean rag. Installing new 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“„O-ring on the injector valve return connection“. l  Following components and seals or O-rings must be changed after the injection valve is replaced each time. „Clamping piece“„Copper washer“„O-ring in the adapter shaft of the injector valve“, „O-ring on the injector valve return connection“ and „high pressure lines“. l  The injectors must always be reassembled in the cylinder, in which they were found before the disassembly. l  Before the assembly, make sure that the injectors and their respective adapters are clean. l  The injectors must be in perfect condition. l  Lubricate all O-rings with engine oil or assembly oil before installing.   Note t  Note identification marks for cylinder allocation when re-installing high-pressure pipes. t  The high-pressure lines can principally be reuse according to the following test: t  Check sealing cone on corresponding high pressure line for deformation and cracks. t  The bore of the high-pressure line must not be distorted, restricted or damaged in any other way. t  Corroded high-pressure lines must not be used again. Installing used injectors –  An anti-corrosion spray must be sprayed at the end of the injector. After 5 min the rust- and oil residues are wiped 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). –  For disassembly of the old copper seal ring of the injector the seal ring must be carefully pressed together carefully in screw driver, till it cannot be turned any more manually between the clamping jaw. 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. –  Assemble the new copper sealing ring with a plastic cap.

–  Thus the O-ring is not damaged, move the new O-ring-2-for the connection of the fuel return line on the assembly pin-1-.   Caution Avoid damage to sealing surfaces of the injector. 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.

–  Replace the seal of the injector. For this purpose use the assembly cap -T10377-. –  To avoid damaging the new seal, lubricate this and carefully insert in the fuel return connection line. –  Attach the cover of the injectors. –  Push the clamping shoe over the injector. Note their assembly position → Fig. –  Insert the injector in the adapter shaft of the injector valve.   Caution When removing securing nuts on injector there is a risk that the relevant nut will fall into the cylinder head. You must therefore proceed very carefully in order to avoid unnecessary assembly work or further damage. –  Tighten union nuts on high-pressure lines hand-tight. Ensure that connections are not under tension. –  Turn the cover of the injectors in order to move them to the installation position and screw them tight.

–  To tighten high pressure lines on injection units, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket wrench attachment -T40055-.

–  To tighten the high-pressure line to the high-pressure reservoir, use torque wrench -V.A.G 1331- with 17 mm tool insert -V.A.G 1331/6-. t  Maintain the tightening torques: Installing high-pressure pipes → Chapter t  Tightening torques: refer to exploded view of fuel system → Chapter –  Press return line connections carefully over seals and onto injectors (check seal for damage before connecting return line). You should hear them click into place. Then press the release pin downwards carefully. After replacement of 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 → Chapter. 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 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. –  Then, road-test the vehicle for more than 20 km. Accelerate with full throttle at least once. Then check high-pressure part of fuel system again for leakage.   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. Turn off the engine and erase event memory. Then continue road test.