General Repair Information
WARNING: This page is about a different car, the 2015 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Follow the points below to avoid running the high pressure pump dry (very low tolerances) and to start the engine quickly after replacing the components:
- If fuel system components between the fuel tank and high pressure fuel pump are removed or replaced, then the fuel system must be filled/bleed before the first engine start. Refer to FUEL SYSTEM, FILLING/BLEEDING .
- Clean the work area and tools before working on the injection system.
- Check the fuel injector and component locations for damage and debris before installing. Make sure the shaft for the fuel injector is clean. Clean the shaft with a clean cleaning cloth if necessary. While doing so, do not damage the shaft (no sharp-edged tools!).
- If the high pressure lines are not going to be replaced, they must be marked when being removed. The high pressure lines may only be installed again on the same cylinder.
- Be careful not to damage the fuel injector when removing the old copper gasket.
- Check all the new O-rings for damage before installing. Lubricate the O-rings with assembly oil or engine oil before installing.
- Align the high pressure lines without tension. First tighten all connections hand-tight and then tighten them again to the tightening specification.
- Never bend the high pressure lines.
- It is permitted to use tools only for tightening and loosening the lines on the entire high pressure system. All other installation or removal procedures must be performed by hand without using any tools.
- Press the fuel return hoses onto the injectors by hand and from the top until it audibly locks onto each injector (when doing this, do not press the release pin). Then press the release pin downward. Check the fuel return hoses by pulling upward by hand for secure fit and for leaks.
- Disassembling the individual Common Rail components is not permitted. In the case of an error the complete component must be replaced.
- Do not perform any work on the Common Rail system with the engine is running.
- Do not bleed the Common Rail system by loosening any high pressure components after starting the engine.
- Any cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
- Fuel hoses in the engine compartment may only be secured with spring clamps. The use of clamps or screw-type clamps is not permitted.