Removing and installing high-pressure lines: VW Polo 6R (CAYC, CBAA, CBAB, CBAC, …)

🧭 Before you start

Fits: VW Polo 6R (2009–2014)

• Special tools named: T10411

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• The bracket (for engine mounting) must be movable to screw union nut on high-pressure pump; loosen bolts (4) for this.Support sleeve T10411 specifies the correct distance between fuel pressure sender G247 and high-pressure line.
• If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off engine and erase event memory entries . Then continue road test.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ To position injection lines better and stress-free, loosen high-pressure accumulator (fuel rail) and injectors and shift them slightly. The lines must never be bent or tensioned. Tension would otherwise cause the respective line to break in the long-term. — Use a vacuum-type cleaner to remove dirt from taper seat on high-pressure accumulator (fuel rail).
2. Clean fuel line and head of line using cold cleaning solvent and dry using compressed air.
3. Moisten union nut thread with fuel.
4. Initially fit the injection lines from the high-pressure accumulator (fuel rail) to the injector by hand; tighten the union nuts hand-tight only.
5. Next install the high-pressure line from the high-pressure pump to the high-pressure accumulator (fuel rail).

6. Only tighten the union nuts on the high-pressure line from the high-pressure pump to the high-pressure accumulator (fuel rail) by hand.
7. Tighten high-pressure lines on high-pressure accumulator (fuel rail) and injectors to specified torque .
8. To tighten injection lines, use torque wrenchV.A.G 1331 with ratchetV.A.G 1331/1 and socket T40055.
9. Tighten high-pressure accumulator (fuel rail) to specified torque.
10. To install high-pressure line between high-pressure pump and high-pressure accumulator (fuel rail), slide support sleeve T10411 onto fuel pressure sender G247. [Note: The bracket (for engine mounting) must be movable to screw union nut on high-pressure pump; loosen bolts (4) for this.Support sleeve T10411 specifies the correct distance between fuel pressure sender G247 and high-pressure line.]
11. Tighten high-pressure line (2) between high-pressure pump and high-pressure accumulator (fuel rail) first at high-pressure pump (5) and then at high-pressure accumulator (fuel rail) (1).
12. Tighten bolt (3) for retainer for high-pressure line.
13. Remove support sleeve T10411.
14. Reconnect connector to fuel pressure sender G247.
15. Carefully press return line connections into injectors. (First check seal for damage). You should hear them click into place.
16. Filling fuel system .
17. Start engine and run at idling speed for a few minutes, then switch off again.
18. Switch off ignition.
19. Check the complete fuel system and return line connections for leaks.
20. Then test drive the vehicle, accelerating to full throttle at least once.
21. Then check high-pressure part of fuel system again for leakage. [Note: If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off engine and erase event memory entries . Then continue road test.]

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