Fuel System Components Overview

Follow the points below to avoid running the high pressure fuel pump dry and to start the engine quickly after replacing the components:

• It is necessary to perform the "check the transfer fuel pump" basic setting >>once << to bleed the fuel system before starting the engine for the first time if the fuel pump, a fuel line or the fuel filter was removed.
• The "check the transfer fuel pump" basic setting must be performed >>three times<< for bleeding the fuel system before starting the engine for the first time if the fuel high pressure pump was removed or replaced.

Fig 1: Identifying Fuel Rail And Injectors Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Protective Strip 
   • For the fuel rail and high pressure lines.
2. Fuel Return Lines 
   • With the pressure retention valve.
   • Checking the pressure retention valve. Refer to PRESSURE RETENTION VALVE IN FUEL RETURN LINE, CHECKING .
   • Pay attention to the different installation stages. Refer to Fig 3.
3. Bolt/Nut 
   • 8 Nm
   • Allocation, refer to Fig 4.
4. Fuel Return Line 
   • Blue or with a blue mark.
   • Make sure it is secure.
   • To the fuel filter.
5. High Pressure Lines 
   • 28 Nm
   • Between the fuel rail and the fuel injectors.
     CAUTION:

     The high pressure lines can be reused only after the following checks:

     • Check the sealing cone on each high pressure line for damage and deformation.
     • The bore in the line must not be deformed or narrowed.
     • Do not use corroded lines again.
   • Install without tension, refer to HIGH PRESSURE LINES, INSTALLING .
6. Fuel Pressure Regulator Valve -N276- 
   • 80 Nm
   • Checking, refer to FUEL PRESSURE REGULATOR VALVE, CHECKING .
   • Removing and installing, refer to Fuel Pressure Regulator Valve -N276- .
7. Fuel Rail (High Pressure Reservoir) 
8. Fuel Temperature Sensor -G81- 
9. Fuel Supply Line 
   • Make sure it is secure.
   • Between the fuel temperature sensor and the high pressure pump.
10. High Pressure Pump 
    • Removing and installing, refer to HIGH PRESSURE PUMP .
    • Tightening specification for the toothed belt gear, refer to TOOTHED BELT DRIVE OVERVIEW .
11. Bolt 
    • 20 Nm
    • Tighten the long bolts an additional 180° (1/2) turn.
    • Tighten the short bolts an additional 45° (1/8) turn.
    • Always replace.
12. Bracket 
    • For the fuel temperature sensor.
13. Fuel Supply Line 
    • White or with a white mark.
    • Make sure it is secure.
    • From the auxiliary fuel pump -V393- or fuel pump 2 -V277-.
14. Fuel Pressure Sensor -G247- 
    • 100 Nm
    • Removing and installing, refer to Fuel Pressure Sensor -G247- .
15. Bolt 
    • 22 Nm
16. Tensioning Plate 
    • Always replace.
    • Note the installed position, refer to Fig 2.
17. Nut 
    • 10 Nm
18. Sealing Cap 
19. Bolt 
    • 5 Nm
20. Fuel Injector (Piezo Injector) 
    • Removing and installing, refer to FUEL INJECTOR .
    • The following parts and seals or O-rings must be replaced during each removal or installation, or when a fuel injector is being replaced: "Copper washer", "injector shaft O-ring", "injector return O-ring"
    • Install any removed injectors back into their original location (cylinder).
    • Visually check the sealing cones before reusing the "fuel injector high pressure line" again.
      • Check the sealing cone on each high pressure line for damage and deformation.
      • The bore in the line must not be deformed or narrowed.
      • Do not reuse corroded lines again.
21. High Pressure Line 
    • 28 Nm
    • Between the high pressure pump and the fuel rail.

Fig 2: Identifying Tensioning Plate Installed Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 3: Identifying Fuel Return Line Differences

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-A-, no ribbing: Secure the return fuel line

-B-, with ribbing: DO NOT use a clamp to connect the overflow oil line.

Fig 4: Identifying Clamps Installed Over Fuel Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.