1.2 TDI CR engine (EA189) · Mixture preparation – injection · Injectors, fuel rail

Removing and installing high-pressure lines

Special tools and workshop equipment required

  • Torque wrench - V.A.G 1331-
  • Ratchet wrench - V.A.G 1331/1-
  • Tool insert 17 mm - V.A.G 1331/6-
  • Socket - T40055-
  • Support sleeve - T10411-
  • Engine plug set - VAS 6122-
  • Use a vacuum-type cleaner to remove dirt from taper seat on fuel rail (fuel rail).
  • 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 fuel rail to injector by hand first; tighten union nuts hand-tight only.
  • Then, fit high-pressure line from high-pressure pump to fuel rail.
  • Tighten union nuts of high-pressure line from high-pressure pump to fuel rail hand-tight only.

The further final assembly follows the sequence described.

Sequence

  • Tighten high-pressure lines on fuel rail and injectors to specified torque ⇒ Item 1 (page 207).
  • To tighten injection lines, use torque wrench - V.A.G 1331- with ratchet - V.A.G 1331/1- and socket - T40055-.
  • Tighten fuel rail to specified torque.
  • To install high-pressure line between high-pressure pump and fuel rail, slide support sleeve -T10411- onto fuel pressure sender - G247-.
  • Tighten high-pressure line -2- between high-pressure pump and fuel rail first at high-pressure pump -5- and then at fuel rail -1-.
  • Tighten bolt -3- for retainer for high-pressure line.
  • Remove support sleeve - T10411-.
  • Reconnect connector to fuel pressure sender - G247-.
  • Carefully press return line connections into injectors. (First check seal for damage). You should hear them click into place.
  • Filling fuel system ⇒ 1.3 Filling/bleeding fuel system.
  • Start engine and run at idling speed for a few minutes, then switch off again.
  • 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.