Replacing the O-rings of the pump-injector (diesel engine) (VW Touareg 1)

Removal

Remove the pump injectors.

Remove the O-rings from the unit injector with extreme care.

Make sure that no burrs appear at the seating location of the sealing rings.

Installation

NOTE: When installing O-rings, always use T10056 mounting sleeves. Otherwise, there is a high risk of damage to the O-rings.

Sliding application of O-rings without identifying colour marking.

Make sure that the O-rings and grooves are in the correct ratio: the thickness of the rings decreases towards the nozzle.

Avoid roller movement when installing O-rings. O-rings must not be twisted in the unit injector seat.

Remove the heat-insulating seal together with the retaining ring.

Thoroughly clean the sealing surfaces of the circular cross-section seals on the unit injector.

(The original information is posted on the resource: vwmanual)

Insert the mounting sleeve T10056/1 into the pump-injector until it stops (fig. 2.296).



Carefully insert the top, thick O-ring into the mounting sleeve and into the unit injector socket.

Remove the mounting sleeve.

Insert the mounting sleeve T10056/2 into the pump injector until it stops.



Carefully insert the medium, thin sealing ring into the mounting sleeve and into the unit injector socket.

Remove the mounting sleeve. Insert the mounting sleeve T10056/3 into the unit injector until it stops.

Carefully insert the lower sealing ring into the mounting sleeve and into the unit injector socket. Remove the mounting sleeve. Install a new heat-insulating seal together with the retaining ring.

Install the pump injector.