High Pressure Lines, Installing: Notes

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Torque Wrench 5-50 Nm VAG 1331
Socket T40055

CAUTION: Loosen the rail and move it slightly. This makes it possible to mount the fuel injection line free of tension. The lines must not be bent or under stress. Long term this would cause the line to break.

NOTE: The following describes installing new fuel injection lines. The fuel injector lines can be reused only after the following checks have been performed -item 5-. The procedure is identical.

Installing the separate fuel injection lines (cylinders 1 through 4 between the rail and the fuel injector)

Tightening specifications. Refer to HIGH PRESSURE PUMP OVERVIEW .

-- Remove the new fuel injection line from its packaging, remove the plug and mount the line between the rail and the fuel injector immediately.

-- Tighten the union nuts on the fuel injection line first by hand without using any tools. Make sure the line is installed correctly.

-- Proceed the same way with the other fuel injection lines.

-- Tighten the rail again to the tightening specification, if necessary.

-- Tighten the union nuts on all the newly installed fuel injection lines to the tightening specification using Torque Wrench VAG 1331 and Socket T40055.

Fig 1: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench VAG 1331 With Ratchet VAG 1331/1 And Socket 17 Mm T40055

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing the fuel line (between the high pressure pump and the rail) or the entire wiring harness

Tightening specifications. Refer to FUEL INJECTORS OVERVIEW .

-- Loosen the bolts on the rail and make sure it is possible to move the rail.

-- Remove the packaging from the fuel line between the high pressure pump and the rail. Then remove the plug and install the line immediately.

-- Tighten the union nuts on the fuel injection line first by hand without using any tools. Make sure the line is installed correctly.

-- If the entire wiring harness must be installed, the proceed the same way with the four fuel injection lines.

-- Slide all 3 clamps over the fuel line. Make sure they line up.

Fig 2: Identifying Clamps Installed Over Fuel Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the clamp screws approximately three thread turns.

-- Tighten the rail again.

-- Tighten the top clamp on the intake manifold to 8 Nm.

-- Tighten the union nuts to the tightening specification using the Torque Wrench VAG 1331 and the Socket T40055.

Fig 3: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench VAG 1331 With Ratchet VAG 1331/1 And Socket 17 Mm T40055

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the other two clamps to 8 Nm.

-- Press the return line connections carefully over the sealing ring onto the injector (check the sealing ring first for damage). The connection must engage audibly. Then press the release pin down carefully.

-- Fill the fuel system. Refer to FUEL SYSTEM, FILLING/BLEEDING .