Volkswagen Workshop Service and Repair Manuals

Removing and installing high-pressure accumulator Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Ratchet -V.A.G 1331/1-

t  Tool insert 17 mm -V.A.G 1331/6-

t  Socket -T40055-

t  Pliers -3314- »Carry out the following work sequence« Removing   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Always follow these rules for cleanliness and instructions before starting work and while working on the fuel system. –  Remove engine cover panel → Chapter. –  Unscrew bolt -3- from retainer for high-pressure line.

–  Remove fuel high-pressure line -2-. To do this, release union nuts on high-pressure pump -4- and high-pressure accumulator -1-.   Note

The lifting eye (for engine mounting) must be movable in order to unscrew union nut on high-pressure pump; loosen bolts -4- to do this.

–  Open cable guide fasteners -arrows- to free wiring harness.

–  Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B-.

–  Carefully pull connectors off glow pin plugs in direction of -arrow-.

–  Pull off electrical connectors -1 and 4-. –  Pull off fuel return hose -2-.

–  Disconnect electrical connectors -1, 6 and 7-.   Caution t  Mark allocation of high-pressure lines to cylinders. They must always be re-installed on the same cylinders. t  Observe rules for cleanliness when working on the injection system. t  Plug open connections with suitable sealing caps immediately. –  Remove high-pressure lines between high-pressure accumulator and injectors.   Note

Counterhold on high-pressure union -A- when loosening high-pressure line. –  After removal, lay high-pressure lines on a clean cloth. –  Remove high-pressure accumulator, for this purpose unscrew two bolts. Installing Installation is carried out in the reverse order. When installing, note the following:

–  Initially tighten securing bolts -arrows- to just max. 1 - 2 Nm. l  It must be possible to move the rail so the hoses can be fitted free of tension. –  Install high-pressure lines → Chapter.   Note t  Renew retaining clips. t  Observe cylinder specific markings when reusing high-pressure lines. t  The high-pressure lines may be re-used after the following checks: t  Check taper seat of respective high-pressure line for deformation and cracks. t  The line hole must not be deformed, constricted or damaged. t  Corroded lines should no longer be used. t  Specified torques: assembly overview - fuel system → Chapter.