O-rings for unit injector, removing and installing: Installing

WARNING: This page is about a different car, the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Always use the assembly sleeves to install the O-rings. There is a danger of damaging the O-rings if the sleeves are not used.
There has been a gradual introduction of O-rings with no colored markings. Ensure that the O-rings are allocated correctly to their respective grooves: Ring size decreases towards nozzle.
Prevent the O-rings from rolling when sliding them on. The O-rings must not be twisted when seated in the unit injector.

Pull heat shield seat off together with securing clip.
Clean O-ring seating surfaces on unit injector very carefully.

Fig 1: Identifying Assembly Sleeve T10056/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide assembly sleeve T10056/1 onto stop on unit injector.
Slide upper, thicker O-ring carefully on to assembly sleeve and into seat on unit injector.
Remove assembly sleeve.

Fig 2: Identifying Assembly Sleeve T10056/2

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide assembly sleeve T10056/2 onto stop on unit injector.
Slide middle, thinner O-ring carefully on to assembly sleeve and into seat on unit injector.
Remove assembly sleeve.

Fig 3: Identifying Assembly Sleeve T10056/3

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide assembly sleeve T10056/3 onto stop on unit injector.
Slide lower O-ring carefully on to assembly sleeve and into seat on unit injector.
Remove assembly sleeve.
Install new heat shield seal together with circlip.
Install unit injector. Refer to Unit injector, removing and installing .