Volkswagen CJDA Workshop Manual page 370

3
Industriemotoren - Industrial Engines 2009 ▶
Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015
1.3 Observe safety precautions when work-
ing on diesel direct injection fuel sys-
tem
WARNING
When doing any repair work, pay attention to the follow-
ing due to the cramped conditions:
◆ Route all the various lines (e.g. for fuel, hydraulics,
activated charcoal filter system, coolant, refrigerant,
brake fluid and vacuum) and electrical wiring in their
original positions.
◆ Ensure that there is sufficient clearance to all moving
or hot components.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
◆ Always switch off the ignition before connecting or discon-
necting injection and glow plug system wiring or tester ca-
bles.
◆ If the engine is to be turned at starter speed without starting,
e.g. to check compression, pull connector -A- off injectors.
◆ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control
unit could be damaged.
Note the following if testers and measuring instruments have to
be used during a road test:
◆ The test and measuring equipment must always be secured
and operated by a 2nd person.
1.4 Rules for cleanliness
When working on fuel supply and injection system, pay careful
attention to the following "rules" for cleanliness:
◆ Thoroughly clean all unions and surrounding areas before
disconnecting.
◆ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
◆ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
◆ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
◆ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
◆ When system is open: do not work with compressed air if
this can be avoided. Do not move vehicle/machine unless
absolutely necessary.
354 Repair Group 23 - Mixture preparation - injection