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Fitting location of the clamping piece of the high pressure line in the injectors (piezo injectors): Removing and installing > < System overview (Altea - Altea XL - Leon)

Leon Mk2

Fuel system: Exploded view of components
Fuel system: Exploded view of components
  Caution
When installing a new partial engine, the clamping pieces of the injector must be tightened to the specified tightening torque following installation of the high pressure lines → Item. The clamping pieces are supplied tightened »hand tight« so that the position of the injectors can be adjusted during the installation of the high pressure lines. Non-observance of these details may lead to damage to the engine.
  WARNING
t  Always read rules for cleanliness and instructions for working on fuel system → Chapter.
t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system.
  Caution
To prevent the high-pressure fuel pump from running while it is empty (very tight tolerances) and to ensure that the engine starts quickly after parts have been renewed, it is important to observe the following:
t  If components of the fuel system between the fuel tank and the high-pressure fuel pump are removed or renewed, the basic setting „check the fuel system pressurisation pump“ must be performed to bleed the fuel system.
t  If a fuel pump, fuel line (between the fuel tank and the high-pressure fuel pump) or fuel filter are removed or renewed, the basic setting „Checking fuel system pressurisation pump“ must be performed »ONCE« before the engine is started for the first time.
t  If the high-pressure fuel pump is removed or renewed, the basic setting „Checking fuel system pressurisation pump“ must be performed »THREE TIMES« before the engine is started for the first time.
t  First fuel filling after installing the high-pressure pump → Chapter.
  Note
The high-pressure pump will be damaged if the first fuel filling procedure is not performed.
   
1 - Fuel return lines
q   Flexible
q   To fuel tank
q   Fuel return line must not be kinked, damaged or clogged
q   The fuel return lines must not be dismantled.
q   The pressure retention valve maintains a residual pressure in the return lines.
q   This residual pressure is required for the operation of the injectors (piezo injectors).
q   O-ring for fuel return lines: removing and fitting → Anchor
q   Check pressure retention valve → Chapter.
2 - Fuel pressure regulating valve -N276-
q   Cannot be used again
q   removing and fitting → Chapter
q   80 Nm
3 - Fuel return lines
q   Rigid
4 - Bolt, 10 Nm
5 - High-pressure pump
q   Removing and installing → Chapter.
q   With fuel metering valve -N290- (do not open).
q   After renewing, a first fuel filling must be performed (never allow the pump to run while it is still empty) → Chapter.
6 - Tighten to 20 Nm + 180°
7 - Hub
q   With sender ring.
q   Use counterhold tool -T10051- to loosen and tighten.
q   To remove use the extractor -T40064-
8 - Nut, 95 Nm
9 - High-pressure pump sprocket, tighten the screws to 20 Nm + a further 90°
10 - Bolt, 20 Nm + 45° further
11 - Bolt, 10 Nm
12 - High-pressure line, 28 Nm
q   Between high-pressure pump and high-pressure accumulator (fuel rail).
q   Install free of stress
  Note
t  The high-pressure lines may be re-used after the following checks:
t  Check taper seat of high-pressure line for deformation and cracks.
t  The bore of the pipe must not be distorted, restricted or otherwise damaged.
t  Corroded lines should no longer be used.
13 - Fuel pressure sender -G247-, 100 Nm
q   removing and fitting → Chapter
14 - High-pressure accumulator (fuel rail)
q   removing and fitting → Chapter
15 - Bolt, 22 Nm
16 - High-pressure lines, 28 Nm
q   removing and fitting → Chapter
q   Between the high pressure reservoir (Rail) and the injectors (piezo injectors).
q   Do not mix them up
q   High-pressure lines may only be re-installed on the same cylinder.
q   Install free of stress
  Note
t  Note identification marks for cylinder allocation when re-installing high-pressure pipes.
t  The high-pressure lines can be reused after undergoing the following tests:
t  Check taper seat of respective high-pressure line for deformation and cracks.
t  The bore of the pipe must not be distorted, restricted or otherwise damaged.
t  Corroded lines should no longer be used.
17 - Seal
q   Replace the cover of the roller rocker arms if damaged
18 - Seal
19 - Injector (piezo injectors)
q   removing and fitting → Chapter
q   The following components and seals or O-rings must always be replaced when an injector valve is removed or refitted: „Screws of the clamping piece“„Copper washer“„O-ring in the adapter shaft of the injector valve“„O-ring from the injector valve return connection“
q   Following components and seals or O-rings must be changed after the injection valve is replaced each time. „Screws of the clamping piece“„Injection pipe“, „Copper washer“„O-ring in the adapter shaft of the injector valve“„O-ring on the injector valve return connection“
q   If they are to be removed, the injectors and high-pressure fuel pipes must always be re-fitted in their original positions (i.e. on the same cylinder).
20 - Bolt for clamp
q   Replace
First tighten securing bolts only to Max: 1 - 2 Nm.
After installing the high-pressure lines. Final tightening torque: 8 Nm + turn 180° further
21 - O-ring for fuel return lines
q   The following component is to be renewed every time the fuel return line is removed and installed: „Retaining clips for the return line“
q   Only renew O-ring if necessary

O-ring for fuel return lines: Removing and installing
Removal:
Proceed with extreme caution. Avoid damage to fuel return line.
–  Lever old O-ring very carefully off fuel return line.
Do not use any sharp-edged tool.
Installation
  Note
Prevent O-rings from rolling when sliding them on. The O-rings must not be twisted in their seats in fuel return line.
Proceed with extreme caution. Avoid damage to the O-ring and fuel return line.
–  Clean seating surfaces for O-rings on fuel return line very carefully.
   
–  Carefully push O-ring -1- on its seat -2-.
  N23-10429

Fitting location of the clamping piece of the high pressure line in the injectors (piezo injectors): Removing and installing > < System overview (Altea - Altea XL - Leon)