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Assembly overview - high-pressure pump > < Removing high-pressure line between high-pressure accumulator and high-pressure pump

Leon Mk2

Installing high-pressure lines
Installing high-pressure lines
  Caution
To make the tension-free installation of the injection lines easier, loosen the high-pressure reservoir (Common Rail) and the injectors (piezo injectors) and move a little. The lines must never be bent or tensioned. Tension would otherwise cause the respective line to break in the long-term.
  Note
t  The use of tools for adjusting the position of the Common Rail (high-pressure reservoirs) / the injectors (piezo injectors) is not permitted.
t  Note identification marks for cylinder allocation when re-installing high-pressure pipes.
t  The high-pressure lines can be reused after undergoing the following tests:
t  Check taper seat of respective high-pressure line for deformation and cracks.
t  The bore of the pipe must not be distorted, restricted or otherwise damaged.
t  Corroded lines should no longer be used.
–  Extract soiling from taper seat on rail element (high-pressure accumulator).
–  Clean fuel pipe and end of pipe using cleaning solution and dry with compressed air.
–  Lubricate threads of union nuts with fuel.
–  First position the injector lines from the Common Rail (High-pressure reservoir) to the injectors by hand and then tighten the union nuts by hand.
–  Then install the high-pressure line from the high-pressure pump to the rail element (high-pressure accumulator).
The assembly sleeve -T10411- determines the correct distance between the fuel pressure sender -G247- and high-pressure line.
   
–  Slide the assembly sleeve -T10411- onto the pressure sender.
  Note
t  The assembly sleeve -T10411- determines the correct distance between the fuel pressure sender -G247- and high-pressure line.
  N23-10308
t  The bracket (to the engine mount) must have space to move to be able to screw the union nut onto the high-pressure pump. Slacken the bolts -4- for this purpose.
–  Only tighten the union nuts on the high-pressure line from the high-pressure pump to the rail element (high-pressure accumulator) by hand.
The further final assembly follows the sequence described.
  N23-10286
Operation process
–  Tighten the high pressure lines on the Common Rail (high-pressure reservoir) and the injectors with the specified tightening torque → Item.
–  For tightening the injector lines, use the torque wrench -VAG 1331- with 1/2' x 9-12 Ref. (735/10) ratchet -VAG 1331/1- and socket -T40055-.
–  Tighten high-pressure line -2- between high-pressure pump and rail element (high-pressure accumulator) first at high-pressure pump -4- and then at rail element (high-pressure accumulator) -1-.
  A13-10038
–  Tighten bolt -3- for retainer for high-pressure line.
t  Tightening torques: Fuel system - Component overview → Chapter
t  Bolt on bracket (for mounting engine).
–  Remove the assembly sleeve -T10411-.
–  Connect the electric connector to the fuel pressure sender -G247-.
–  Carefully press the connections of the return lines into the injector (first check that the sealing ring is not damaged). The retainer must engage audibly.
–  Insert the pressure retention valve into the existing bracket in the cylinder head cover.
  Note
t  After renewing the injectors „perform adaption of the correction values“ → Vehicle diagnostic tester.
t  „Reading / adapting“ correction values.
–  Filling fuel system → Chapter.
–  Run engine at idling speed for several minutes and then switch off.
–  Switch ignition OFF.
–  Check the complete fuel system and return line connections for leaks.
Renew affected component if leakage still occurs after tightening to correct torque.
–  Perform a test drive. In doing so, accelerate with full gas at least one time.
–  Immediately check again the high pressure zone to look for leaks.
  Note
If air should still be found in the fuel system, the engine only runs with the emergency program. Switch off the engine and erase the fault memory → Vehicle diagnostic tester. Then continue road test.
  A23-10432

Assembly overview - high-pressure pump > < Removing high-pressure line between high-pressure accumulator and high-pressure pump