Injectors – assembly overview and fastening

• 1 Injector
  • Removing and installing ⇒ 3.3 Checking return flow rate of injectors with engine running
  • When removing and installing, always renew the following components and seals/O- rings: “copper seal”, “O- ring for injector bore”, “bolt for clamping piece”.
  • The following components and seals or O- rings must always be renewed when an injector is renewed: “copper seal”, “O-ring for injector bore”, “bolt for clamping piece”.
  • Before reusing the “high-pressure line”, taper seals must be visually checked:
  • Always renew if damaged, e.g. transverse scores, corrosion.
  • Before installing, clean injector bore using cleaning set - VAS 6811-
  • If they are to be re-installed, injectors, highpressure fuel lines and clamping pieces must always be re-fitted in their original positions (i.e. on the same cylinder).
• 2 O-ring
  • O-rings are only to be renewed if necessary.
  • Removing and installing ⇒ 3.1 Assembly overview - injectors
• 3 Fuel return lines
  • To high-pressure pump
  • The fuel return line must be free of kinks, damage and blockages.
  • Do not dismantle the fuel return lines.
• 4 Seal in connector
  • Renew
• 5 Connector
  • If connector is removed:
  • Renew connector seal.
• 6 Copper washer
  • Renew
• 7 O-ring
  • Renew
• 8 Clamping piece
• 9 Bolt for clamp
  • Renew
  • 8 Nm + 270°
• 10 Injector union

Removing

Proceed with extreme caution. Avoid damage to fuel return line.

• Lever old O-ring very carefully off fuel return line.

Do not work with a sharp-edged tool.

Installing

Proceed with extreme caution. Avoid damage to the O-ring and fuel return line.

• Clean seating surfaces for O-rings on fuel return line very carefully.

When renewing O-ring, do not use any solvent, etc., to remove graphite coating.

• Carefully push O-ring -1- on its seat -2-.