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Lambda probe and pressure differential sender > < Charge air cooler

Leon Mk1

Nozzle units: Assembly overview
Nozzle units: Assembly overview
  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. If these instructions are not observed, the engine could be damaged.
   
1 - Seal
q   In cylinder head cover
q   Removing and installing → Chapter.
2 - Copper seal
q   Replace
3 - O ring
q   Replace
4 - Injector
q   If they are to be re-installed, the injectors, high-pressure pipes and clamping pieces must always be re-fitted on the same cylinder
q   Removing and installing → Chapter.
5 - O ring
q   Replace
6 - Fuel return line
q   To fuel tank.
q   With restrictor
q   Must not be kinked, damaged or clogged
q   Do not dismantle
q   The restrictor maintains a constant residual pressure in the fuel return lines
q   This residual pressure is required for the control function of the injectors
q   After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then check fuel return lines for leaks
7 - Bolt.
q   Replace
q   8 Nm + 180°
8 - Clamping piece
q   Mark allocation for re-installation; pay attention to marking when installing
q   Also renew clamping piece if injector is renewed
q   Installation position → Fig.
9 - High-pressure line
q   Between fuel rail and injectors
  Note
t  The high-pressure lines may be re-used after the following checks:
t  Check taper seat 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.
q   Install free of stress
q   Lubricate threads of union nuts with clean engine oil
q   25 Nm.
10 - Bolt.
q   22 Nm.
11 - High pressure reservoir
q   Removing and installing → Chapter.
12 - Fuel return hose
13 - Fuel pressure regulating valve -N276-
q   Always renew if removed
q   Removing and installing → Chapter.
q   80 Nm.
q   After renewing high-pressure pump or fuel pressure regulating valve -N276-, learnt values must be re-adapted; see „Guided Functions“ in → Vehicle diagnostic tester
14 - O ring
q   Replace
15 - High-pressure line
q   Between high-pressure pump and fuel rail
  Note
t  Note identification marks for cylinder allocation when re-installing high-pressure pipes.
t  The high-pressure pipes can be re-used after performing the following checks:
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.
q   Install free of stress
q   Lubricate threads of union nuts with clean engine oil
q   25 Nm.
16 - Bolt.
q   8 Nm.
17 - Fuel pressure sender -G247-
q   Removing and installing → Chapter.
q   100 Nm.
18 - Grommet
q   In cylinder head cover

   
Installation position of clamping piece
l  One clamping piece is always used to secure two injectors.
l  The bulge -arrow- of the clamping piece should point downwards.
  A23-10407

Lambda probe and pressure differential sender > < Charge air cooler