Volkswagen CJDA Workshop Manual page 391

– After completing the repair, road-test the vehicle over a dis-
tance of at least 20 km. Accelerate with full throttle at least
once. Then inspect the high-pressure section of the fuel sys-
tem again for leaks.
Note
If there is any air left in the fuel system, the engine may switch
to the limp mode during the road test/test run. Switch off the en-
gine and clear the event memory. Then, continue road test/test
run.
1.10.3 Installing high-pressure lines
Special tools and workshop equipment required
◆ Torque wrench -V.A.G 1331-
◆ Socket -T40055-
Caution
To ensure the injector lines are fitted free of stress, loosen
fuel rail and, if necessary, move rail slightly. The lines must
never be bent or tensioned. Tension would otherwise
cause the respective line to break in the long-term.
Note
◆ This section describes how to install new injection lines. If al-
ready fitted injection lines are to be used again, perform the
following checks. Apart from that the procedure is identical.
◆ 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.
Installing individual injection lines (cylinder 1 to 4, between
fuel rail and injector)
– If it has not been done yet, loosen securing bolts of clamping
pieces and ensure that injectors can be rotated.
– Remove the new injector line from the packaging. Remove
the sealing plugs and install the line just by itself between
fuel rail and injector.
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
375