Removing and installing fuel hoses in engine compartment, 6.0 bar low pressure fuel system — VW

Removing and installing fuel hoses in engine compartment, 6.0 bar low pressure fuel system
Note
Applies for version A and version B.
Note
On this engine, some of the connections for the pressurised fuel hoses have what is known as a 2 wave profile section
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with an engagement lip. This reduces the likelihood of fuel system leaks.
When the fuel hoses are removed, the very thin sealing layer on the inside of the fuel hoses is damaged.
This damage cannot be detected with the naked eye. After some time, it leads to leaks in the fuel system.
If the fuel filter only has to be removed to gain space, leave the fuel hoses on the fuel filter and high-pressure pump. To prevent having to renew these hoses unnecessarily, place the fuel filter on the engine with the hoses still attached
Caution
After removing the fuel hoses from the connections with wave profile section and engagement lip, these fuel hoses have to be replaced.
Wave profile section
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and engagement lip
Upper part of fuel filter
Fuel temperature sender
G81
Note
If other components are just removed, check whether it is really necessary to disconnect the fuel system from components with wave section and engagement lip.
Use other fuel system connection points in the engine compartment.
If a fuel hose cannot be removed from the connections by hand:
Caution
Never insert a screwdriver or similar tool between the hose and the connection!
Risk of damage to the connection - Component has to be renewed.
Turn fuel hose with suitable pliers and pull off hose.
If fuel hose still cannot be removed from the connection:
Only cut open the textile layer of the fuel hose lengthways and pull hose off.
The inner rubber layer must not be cut. If the connection is damaged, the entire component must be renewed.
Note
Before attaching a new fuel hose, remove grease, oil and dirt thoroughly from the hose connection. Do not use any metal tools to do this as they could damage the hose connection.
Attach fuel hose to connection without lubricant and then secure with spring-type clip.