Volkswagen CJDA Workshop Manual page 392

3
Industriemotoren - Industrial Engines 2009 ▶
Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015
– Tighten union nuts on injection line hand-tight without any
tool to start with. Ensure that line correctly gets into its seat.
– If necessary, proceed in the same way with other injection
lines.
– Retighten fuel rail if necessary. Specified torque
⇒ P age
362.
– Tighten union nuts of all new injection lines using torque
wrench -V.A.G 1331- and socket bit -T40055-. Specified tor-
⇒ P age
que 362.
Installing fuel line (between high pressure pump and fuel
rail) or a complete set of lines
– If it has not been done yet, loosen securing bolts of fuel rail
and ensure that fuel rail can be moved.
– Remove the packaging from the fuel line between high pres-
sure pump and fuel rail. Remove the sealing plugs and in-
stall the line just by itself.
– Tighten union nuts on injection line hand-tight without any
tool to start with. Ensure that line correctly gets into its seat.
– If a complete set needs to be installed, adopt the same pro-
cedure for all 4 injection lines.
– Slide all securing clamps over fuel line and observe align-
ment.
– Screw in clamp securing bolts about 3 turns.
– Retighten fuel rail.
WARNING
The securing clamp for the high-pressure line between
the high-pressure pump and high-pressure accumulator
(fuel rail) must always be installed in the correct position.
Otherwise fatigue failures or stress ruptures may occur in
the high-pressure line.
– Tighten securing clamp at top of intake manifold to 8 Nm.
– Tighten union nuts of all new injection lines using torque
wrench -V.A.G 1331- and socket bit -T40055-. Specified tor-
⇒ P age
que 362.
– Now tighten remaining 2 securing clamps to 8 Nm.
– Press return line connections carefully over the seals and
onto the injectors (check seal for damage). You should hear
them click into place. Then press the release pin downwards
carefully.
⇒ P age
– Filling fuel system
376 Repair Group 23 - Mixture preparation - injection
383.