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Removing and installing high-pressure pump > < Removing high-pressure line between high-pressure accumulator and high-pressure pump

Polo Mk5

Installing high-pressure lines
Installing high-pressure lines
  Caution
To position injection lines more easily and stress-free, loosen and shift high-pressure accumulator and injectors slightly if necessary. The lines must never be bent or tensioned. Tension would otherwise cause the respective line to break in the long-term.
  Note
t  Tools must not be used to align the high-pressure accumulator element (high-pressure accumulator) / the injectors.
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.
–  Use a vacuum-type cleaner to remove dirt from taper seat on high-pressure accumulator.
–  Clean fuel line and head of line using cold cleaning solvent and dry using compressed air.
–  Moisten union nut thread with fuel.
–  Fit injection lines from high-pressure accumulator to injector by hand first, only hand-tighten union nuts.
Next install high-pressure line from high-pressure pump to high-pressure accumulator.
   
–  To install high-pressure line between high-pressure pump and high-pressure accumulator, slide support sleeve -T10411- onto fuel pressure sender -G 247-.
  Note
t  The lifting eye (for engine mounting) must be movable in order to fit union nut on high-pressure pump; loosen bolts -4- to do this.
  N23-10308
t  Support sleeve -T10411- specifies the correct distance between fuel pressure sender -G 247- and high-pressure line.
–  Only tighten union nuts on high-pressure line from high-pressure pump to high-pressure accumulator by hand.
–  Next install high-pressure line from high-pressure pump to high-pressure accumulator.
–  Only tighten union nuts on high-pressure line from high-pressure pump to high-pressure accumulator by hand.
The further final assembly follows the sequence described.
Sequence
  N23-10286
–  Tighten high-pressure lines on high-pressure accumulator and injector to specified torque → Item.
–  To tighten injector lines, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and 17 mm socket -T40055-.
–  Tighten high-pressure line -2- between high-pressure pump and high-pressure accumulator first at high-pressure pump -4- and then at high-pressure accumulator -1-.
  A13-10038
–  Tighten bolt -3- for retainer for high-pressure line.
t  Specified torques: assembly overview - fuel system → Chapter.
t  Firmly screw lifting eye in → Item.
–  Remove the support sleeve -T10411 -.
–  Tighten high-pressure accumulator to specified torque → Item.
–  Tighten bolts for clamps to final tightening torque → Item.
–  Reconnect connector to fuel pressure sender -G247-.
–  Press return line connections carefully onto injectors (check seal for damage before connecting return line). You should hear them click into place.
–  Engage pressure retention valve in retainer provided on the cylinder head cover.
  Note
t  After renewing the injectors „perform adaption of the correction values“ → Vehicle diagnostic, testing and information system VAS 5051.
t  „Reading / adapting injector correction values“.
–  Filling fuel system → Chapter.
–  Run engine at idling speed for several minutes and then switch off.
–  Switch off ignition.
–  Check the complete fuel system and return line connections for leaks.
Renew the affected component if leakage still occurs after tightening to the correct torque.
–  Then test drive the vehicle, accelerating to full throttle at least once.
–  Then check high-pressure part of fuel system again for leakage.
  Note
If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off the engine and erase event memory → Vehicle diagnostic, testing and information system VAS 5051. Then continue road test.
  A23-10432

Removing and installing high-pressure pump > < Removing high-pressure line between high-pressure accumulator and high-pressure pump