Volkswagen Workshop Service and Repair Manuals

Removing and installing O-rings for unit injector For unit injectors with solenoid valve: Special tools and workshop equipment required

t  Assembly sleeve -T10164/1- t  Assembly sleeve -T10164/2- For unit injectors with piezo elements (identifying feature: octagonal feature on end of injector): Special tools and workshop equipment required

t  Assembly sleeves -T10308- Removing –  Remove unit injector → Chapter. –  Lever old O-rings very carefully off unit injector using a „soft“ tool. –  Above all ensure that burrs are not caused on the seating for the O-ring. Installing   Note t  Always use the assembly sleeves to fit the O-rings. There is a danger of damaging the O-rings if the sleeves are not used. The procedure for both types of assembly sleeves is the same. t  Take care to ensure correct allocation of O-rings to grooves. t  Prevent O-rings from rolling when sliding them on. The O-rings must not be twisted in their seats in unit injector. –  Clean seating surfaces for O-rings on unit injector very carefully.

–  Slide assembly sleeve -T10164/1- or assembly sleeve -T10308/1- onto stop on unit injector. –  Push the upper, thicker O-ring carefully onto assembly sleeve and into seat on unit injector. Ensure that it is correctly positioned → Fig.. –  Remove assembly sleeve.

–  Slide assembly sleeve -T10164/2- or assembly sleeve -T10308/2- onto stop on unit injector. –  Slide lower O-ring, marked white, carefully on to assembly sleeve and into seat on unit injector. Ensure that it is correctly positioned. Unit injector with solenoid valve → Fig. Unit injectors with piezo elements (identifying feature: octagonal feature on end of injector) → Fig.

Position of O-rings -arrows- for unit injectors with solenoid valve

Position of O-rings -arrows- for unit injectors with piezo elements (identifying feature: octagonal feature on end of injector -A-) –  Remove assembly sleeve.