Volkswagen Workshop Service and Repair Manuals

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

t  Torque wrench -V.A.G 1331-

t  Socket -T40055-   Caution To ensure the injector lines are fitted free of stress, loosen rail and, if necessary, move rail slightly. The lines must never be bent or tensioned. Tension would otherwise cause the respective line to break in the long-term.   Note This section describes how to install new injection lines. If you wish to re-use existing injection lines, you must check the points listed under → Item. Apart from that the procedure is identical. Installing individual injection lines (cylinders 1 to 4, between rail and injector) –  Remove the new injector line from the packaging. Remove the sealing plugs and install the line just by itself between rail and injector. –  Ensure that line is inserted correctly into seat. –  Screw injection line union nuts on „fully“ hand-tight without any tool to start with. –  If necessary, proceed in the same way with other injection lines. –  Retighten fuel rail if necessary. Specified torque → Item.

–  Tighten union nuts of all new injection lines using torque wrench -V.A.G 1331- and socket bit -T40055-. Specified torque → Item. Installing fuel line (between high pressure pump and fuel rail) or a complete set of lines –  If it has not been done yet, loosen securing bolts of fuel rail and ensure that fuel rail can be moved. –  Remove the packaging from the fuel line between high pressure pump and rail. Remove the sealing plugs and install the line just by itself. –  Ensure that line is inserted correctly into seat. –  Screw injection line union nuts „fully“ onto high-pressure pump hand-tight without any tool to start with. –  If a complete set needs to be installed, adopt the same procedure for all 4 injection lines.

–  Slide all 3 securing clamps over fuel line and observe alignment. –  Screw in clamp securing bolts about 3 turns. –  Retighten fuel rail. Specified torque → Item. –  Tighten securing clamp at top of intake manifold to 8 Nm.

–  Tighten union nuts of all new injection lines using torque wrench -V.A.G 1331- and socket bit -T40055-. Specified torque → Item. –  Now tighten remaining 2 securing clamps to 8 Nm. –  Fit vibration dampers to high-pressure lines as shown in illustration → Fig..

Vibration damper positions –  Press return line connections carefully over the seals and onto the injectors (check seal for damage). You should hear them click into place. Then press the release pin downwards carefully. –  Filling fuel system → Chapter.