Date registered: Oct 2009
Vehicle: 2000 VW Golf Variant
Location: Leiden, Netherlands
Mentioned: 0 Post(s)
Quoted: 4 Post(s)
Nothing should come out of the hard lines when you use the hand pump. The hand pump is only there to fill the fuel filter and fuel chamber of the IP. After that the IP takes over. It can take a while to start if the hard lines are empty and some people leave them open at the injector until fuel comes out, but that is not really necessary.
The pressure relief valves open at about 70 bar pressure (1015 psi), so the hand pump cannot open them.
The pressure relief valves are best left in place, because when you open the valve holders, you have to renew the copper washer, otherwise it will leak internally. These are special copper washers, you cannot use generic ones. They are not expensive luckily. Get them at the dealer or specialised diesel shop. There are rubber O rings which can get damaged too and must in that case be replaced.
Special care should also be taken to the correct torque of the valve holders: First 30 Nm and loosen, 30 Nm again and loosen, then torque to 35 Nm and you are done. If overtorqued, the pump housing can get damaged or it can leak.