SEAT Workshop Service and Repair Manuals

Injector-pump: removing and fitting t  Removing → Anchor t  Fitting and adjusting → 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	Torque wrench -SAT 8010-, see equivalent → Anchor.

t	Wrench -T10054-, see equivalent → Anchor

t	Extractor -T10133-, see equivalent → Anchor

t	Extractor -T10163-, see equivalent → Anchor

t	Socket -T20020-, see equivalent → Anchor

t	Wrench -T20045-, see equivalent → Anchor

t  Pressure tool -T20034D-, see equivalent → Anchor Removing –  Dismount the cylinder head cover engine codes (AZV BKD) → Chapter engine codes (BMN) → Chapter –  Remove the wiring harness of the injector pump units → Chapter and lay aside. The main connector of the wiring harness may remain in the cylinder head. –  Rotate the crankshaft until the pair of cams belonging to the cylinder of the injector pump unit concerned both face upwards.

–  Unscrew the retention nuts -2- of the adjustment bolts -1- on all injector pump units. –  Unscrew the adjustment bolts until the corresponding rocker arm sits on the injector pump unit follower spring.

–  Using the spanner -T20045- unscrew the bolts -1-, -3- and -5- securing the rocker shafts beginning by the outside towards the inside and remove the shaft. –  Loosen the bolts -2- and -4- alternately in several steps and unscrew them.   Note Do not extract the rocker arm shaft bolts because the parts are secured on the shaft. If necessary, mark the correspondence of the rocker lever. –  Remove the rocker lever shaft.

–  Unscrew the bolts -arrows- with the wrench -T10054 - .

–  Pull out the marker pin -1- from the injector pump unit concerned.

–  Apply the extractor -T10163- to the bolts holes on the injector pump unit. –  Rotate the spindle slightly -A- against the injector pump unit. Tighten the counter nut -B- by hand. –  Remove the injector pump unit from its allotment in the cylinder head by pulling down and tapping gently using the tapper -T10133/3-.   Note For the installation, mark the correspondence between the injector pump units and the cylinders. Fitting and adjusting   Caution The adjuster screw in the rocker lever and the spherical nut of the injector pump should be replaced when the injector pumps are adjusted using the adjuster screw. If this is disregarded, these components will be exposed to excessive wearing. . The securing bolts of the injector pump units must be replaced. –  Before fitting the injector pump assembly, ensure that the new seals are correctly seated.   Note t  Replace the injector unit bolts. t  The new injector pump units are supplied with new O-rings. t  When fitting the new injector pump unit, the corresponding adjustment bolts on the rocker lever must also be replaced. t  When refitting the used injector pump unit replace the O-rings → Chapter. t  The seals should not be twisted. –  Oil the seals and the injector pump unit rod. –  Check the seating of the injector pump unit in the cylinder head for dirt or particles (shavings/carbonized particles, etc.) and clean as necessary using compressed air. –  Carefully place the injector pump unit in the seat of the cylinder head.

–  Fit the pressure tool -T20034D- using the adapter -T20034/35- onto the cylinder head cap holder module.   Caution If the securing bolts pull the injector pump unit downwards, there is a danger that the injector pump will be out-of-true in its seat. This might lead to deficiencies in the dynamic behaviour and problems when starting. Therefore, first place the injector pump unit in its seat and then bolt it. –  Place the new securing bolts in position and carefully hand tighten them without using force until they reach the limit. –  Carefully fit the injector pump unit in the seat of the cylinder head using the pressure tool -T20034D- and the adapter -T20034/35-. –  Tighten the securing bolts of the injector pump unit by hand and without applying force using the cell -T10054- only as far as the limit. –  Tighten all of the new attachment bolts as indicated below: 1. Stage = 3 Nm 2. Stage = 90° (1/4 turn). 3. Stage = 180° (1/2 turn).

–  Fit the rocker lever shaft and evenly hand tighten the new fastening bolts in the order 1... 5 by hand. –  Then using same sequence, tighten to 20 Nm and 90° (1/4 turn) further.

–  Apply a gauge to the adjustment bolt of the injector pump unit as shown in the illustration. –  Rotate the crankshaft in the normal direction of rotation until the roller of the rocker lever is on the point of the cam. l  The side of the roller -arrow A- is in the highest point l  The dial gauge -arrow B- is in the lowest point. –  Remove the dial 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. Rest of installation is carried out in the reverse sequence, observing the following: –  Mount the cylinder head cover engine codes (AZV BKD) → Chapter engine codes (BMN) → Chapter