Leon Mk2
| Engine: disassembly and assembly |
Note!| t | When repairing the engine, if significant quantities of metal shavings and particles due to wear or abrasion, e.g. damage to the mount or connecting rod bearings are found in the oil, in order to avoid further damage, not only must the oil lines be cleaned carefully but the oil radiator must also be replaced. |
| t | Before installation work, oil the support and slide surfaces. |
| I → Anchor II → Anchor III → Anchor |
| Part I |
| 1 - | Upper part of the toothed belt shield |
| 2 - | Toothed belt |
| q | Before removing, mark the direction of rotation |
| q | Check for wear |
| q | Do not fold |
| q | Remove and install → Chapter |
| 3 - | 20 Nm + 45° (1/8 turn) |
| 4 - | Tensioning roller |
| 5 - | 100 Nm |
| 6 - | 25 Nm |
| 7 - | Camshaft pinion |
| 8 - | Hub |
| q | With sender rotor |
| q | For loosening and tightening, use countersupport -T10051- |
| q | For removing, use extractor -T10052- |
| q | Remove and install → Fig. Camshaft: removing and installing |
| 9 - | 10 Nm |
| 10 - | Rear toothed belt shield |
| 11 - | Plug |
| q | Replace if worn |
| 12 - | Toothed belt tensioner |
| 13 - | Return roller |
| 14 - | Coolant pump |
| q | Remove and install → Chapter |
| 15 - | Toothed belt-crankshaft pinion |
| 16 - | 120 Nm + 1/4 turn (90°) |
| q | Replace |
| q | For loosening and tightening use countersupport -T20018A- |
| q | Do not oil or grease the thread or the collar |
| q | Retighten in various stages |
| 17 - | 15 Nm |
| q | For the vane pump |
| 18 - | 20 Nm |
| 19 - | Lower toothed belt shield |
| 20 - | Pulley/vibration dampener |
| q | Installation is only possible in one position - the holes are arrayed asymmetrically |
| 21 - | 10 Nm + 1/4 turn (90°) |
| 22 - | Middle toothed belt shield |
| Part II |
| 1 - | Cylinderhead cover |
| q | With oil filler hole |
| q | If the cylinderhead cover is worn, the oil filler hole must also be replaced |
| q | Before fitting it, clean the filling surface well with a clean cloth |
| 2 - | To turbocompressor |
| 3 - | 10 Nm |
| q | First tighten all the bolts by hand |
| q | Then, tighten the two upper bolts first and then the other bolts in a crossing pattern from inside out to the correct tightening torque |
| 4 - | Pressure regulator valve |
| q | To the engine block vent |
| 5 - | Plug |
| q | Replace the gasket if worn |
| 6 - | Ring gasket |
| q | Replace if worn |
| 7 - | Oil filler hole |
| q | Replace |
| 8 - | Support |
| q | With fuel line |
| 9 - | Cylinderhead cover gasket |
| q | Replace if worn |
| 10 - | 20 Nm |
| 11 - | Ring |
| 12 - | 10 Nm |
| 13 - | Middle connector |
| q | For the pump injector |
| 14 - | From the brake servo |
| 15 - | Tandem pump |
| q | For the fuel supply and the vacuum |
| q | Remove and install → Chapter |
| q | Test → Chapter |
| 16 - | 25 Nm |
| 17 - | Supply hose |
| q | From the fuel filter → Chapter |
| q | White or white mark |
| q | Check for firm seating |
| q | Immobilise with elastic strip clamps |
| 18 - | Return hose |
| q | To the fuel filter → Chapter |
| q | Blue or blue mark |
| q | Check for firm seating |
| q | Immobilise with elastic strip clamps |
| 19 - | Gasket |
| q | Replace |
| 20 - | Bolt, 10 Nm |
| q | For the engine cover |
| 21 - | Support |
| 22 - | Hexagonal conical nut |
| 23 - | Cylinderhead gasket |
| q | Replace |
| q | Check the identification → Chapter |
| q | After replacing it, change all the coolant |
| 24 - | Hall sender -G40- |
| q | For the camshaft position |
| q | For removing, remove the sealing plug from the rear of the toothed belt shield |
| q | Test: → Chapter |
| 25 - | Cylinderhead bolt |
| q | Replace |
| q | Follow the installation order when loosening and tightening → Anchor, cylinderhead: removing and installing |
| q | Before installation, fit the washers on the cylinderhead → Item, Valve activation: repairing |
| 26 - | Pump injector |
| q | Remove and install → Chapter |
| Part III |
| 1 - | 45 Nm |
| 2 - | Engine support |
| 3 - | Engine block |
| q | Sealing flanges and engine flywheel: removing and installing → Chapter |
| q | Piston and connecting rod: disassembly and assembly → Chapter |
| 4 - | Connection sleeve, 40 Nm |
| q | For the turbocompressor oil return line |
| q | Replace |
| 5 - | Spacer bushing |
| 6 - | Rubber bushing |
| 7 - | Support |
| q | For connectors of the camshaft position Hall sender -G40- and engine revs sender -G28- |
| 8 - | 10 Nm |
| 9 - | Gasket |
| q | Replace |
| 10 - | Oil filter support |
| q | Disassemble and assemble → Anchor |
| 11 - | 15 Nm + 1/4 turn (90°) |
| q | Replace |
| q | Fit the upper left and lower right bolts first and then tighten the four bolts in a cross pattern |
| 12 - | O-ring |
| q | Replace |
| 13 - | 15 Nm |
| 14 - | 15 Nm + 1/4 turn (90°) |
| q | Test → Vehicle diagnosis, testing and information system VAS 5051 |
| 15 - | Connection sleeve |
| q | For coolant thermostat |
| 16 - | Coolant thermostat |
| q | Remove and install → Chapter |
| 17 - | 45 Nm |
| q | Follow the tightening order → Fig. |
| 18 - | Compact support |
| q | For alternator, air conditioning compressor, power steering vane pump and Poly-V belt tensioner |
| 19 - | Tensioner |
| q | For the Poly-V belt |
| 20 - | 25 Nm |
| 21 - | Oil sump |
| q | Before installation, clean the sealing surface |
| q | Install with silicone-base sealant -D 176 404 A2- → Fig. |
| q | To remove the oil sump the gearbox must be removed → 5-speed manual gearbox 02J; Rep. Gr.34 |
| 22 - | 15 Nm |
| q | To remove the bolts that hold the sump (gearbox side), the gearbox must be removed → 5-speed manual gearbox 02J; Rep. Gr.34 |
| 23 - | Cover |
| q | With gasket |
| q | Clean the filter if dirty |
| 24 - | Axle support |
| q | Before installation check that alignment sleeve for centring the engine block is there and that it is fitted on the axle support |
| q | Remove and install → Chapter |
| 25 - | Shield |
| q | For the articulated half-shaft |
