Volkswagen CJDA Workshop Manual page 389

1.10.2 Installing
Important instructions for installing injectors
● When removing and installing or renewing an injector, al-
ways renew the following components and seals/O-rings:
"clamping piece", "copper seal", "O-ring for injector bore" and
"O-ring for injector return connection".
● Used injectors may only be re-installed on the same cylinder.
● Make sure that the injectors and the installation area are
clean before installing.
● The injectors must be completely undamaged.
● Lubricate all O-rings with engine oil or assembly oil before
installing.
● 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 dam-
age the sealing surface.
Note
◆ Observe cylinder-specific markings when reusing high-pres-
sure lines.
◆ The high-pressure lines may be re-used after the following
checks:
◆ Check taper seat of respective high-pressure line for defor-
mation and cracks.
◆ The inside of the line must not be deformed, constricted or
damaged.
◆ Corroded lines should no longer be used.
If a used injector is being re-installed:
– Spray tip of injector nozzle with rust-releasing spray. Wait
approx. 5 minutes and wipe off soot particles and oil 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.
– Use a plastic bush to fit the new copper seal.
– To prevent damage to the new O-ring -2- for the fuel return
line connection, push it over assembly tool -1-.
Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015
Industriemotoren - Industrial Engines 2009 ▶
1 Repairing diesel direct injection system
3
373