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Injection commencement: verification and adjustment > < Removing

Leon Mk2

Fitting
Fitting
   
–  When the pump is being replaced, all of the flat connectors of the multi connector should be removed -2-.
  Note!
Replacement injection pumps do not come fitted with a multi connector. The cable contacts of the multi connector must coordinate with the electric circuit diagram → Current flow diagrams, Electrical fault finding and Fitting locations
–  Fit the injection pump to the console, securing it firstly with the conical nut of the rear attachment.
–  Centre the injection pump on the oblong screw holes of the console and tighten the attachment bolts of the pump by hand.
  N23-0048
–  Fit the cogwheel of the injection pump and secure it by using the -T20102- tool.
  Note!
To fit the cogwheel, ensure that the pin is positioned correctly.
–  Tighten the bolts of the injection pump cogwheel.
   Tightening torque: 25 Nm
–  Loosen by a 1/2 turn the attachment bolt of the camshaft cogwheel. To do this, immobilise the cogwheel using the -T20018A- tool.
  Note!
The timing adjustment ruler -T20038- should never be used as a securing tool for the loosening and tightening of the camshaft cogwheel. Always use the -T20018A- tool.
  E23-0038
–  Pass a punch through the hole in the rear protection of the notched belt and remove the cogwheel from the camshaft cone by a knock with a hammer (to the punch).
–  Remove the cogwheel from the camshaft.
–  Verify that the TDC mark on the engine flywheel and the reference mark coincide.
–  Fit the distribution belt onto the injection pump cogwheel and the tension pulley, position the camshaft cogwheel on the distribution belt and attach it to the camshaft in such a way that it may still rotate fully.
–  Remove the tool -T20102- blocking the injection pump cogwheel.
  E13-0043
–  Stress the notched belt. To do this, turn the U-30009A timing belt tightening tool clockwise on the off centre of the tension pulley, until the notch and the bump are facing each other.
  Note!
If the off-centre has been turned too much, it must be released fully and stressed once more. Do not turn the off centre backwards.
–  Tighten the tension pulley nut.
   Tightening torque: 20 Nm
–  Remove the attachment bolt and separate the cogwheel from the camshaft.
   Tightening torque: 45 Nm
–  Remove the adjustment tool from the camshaft.
–  Turn the crankshaft in the normal rotation direction of the engine until arriving at the TDC point for cylinder 1.
Ensure once more that the marks coincide:
–  The OT (TDC) mark on the fly wheel.
–  The adjustment tool on the camshaft.
–  The -T20102- camshaft pinion locking tool on the cogwheel of the injection pump.
–  The adjustment of the tension roller (notch and bump).
–  If the notch does not coincide with the bump, the stressing of the tension pulley must be redone. In order to do this, the tension roller must be retained by the U-30009A timing belt pulley-tightening tool. Loosen the attachment nut and turn the off-centre clockwise until the notch and the bump coincide.
   Tightening torque: 20 Nm
–  Once again, turn the crankshaft twice in the normal rotation direction of the engine until reaching the TDC of cylinder 1 again.
–  Repeat the check.
–  Connect the injection tubes, fuel tubes and the electric cables.
  Note!
Do not confuse the seal bolts from the fuel supply line and the fuel return line. The seal bolt for the fuel return tube has a smaller hole and is marked OUT on the hexagonal head.
For fitting, the operations are carried out in reverse order, taking the following into account:
–  Verify and adjust the engine idle speed and full speed → Chapter.
  N13-0166

Injection commencement: verification and adjustment > < Removing