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Removing and installing intake manifold with fuel rail > < Intake manifold - exploded view

Leon Mk2

Fuel rail - exploded view
Fuel rail - exploded view
  WARNING
Important information for using an engine with one of the designated spare parts (replacement engine):
t  Take note that the roller tappet → Item is not included in the scope of supply of the new replacement engine.
t  When exchanging the replacement engine, the roller tappet → Item has to be used, as long as this is possible.
t  The following parts will be influenced if the roller tappet is not installed: Camshaft, high-pressure pump and cylinder head cover.
t  The cylinder head may also be influenced as a result of damage to the bolt of the high-pressure pump.
t  The engine will be damaged permanently if the valves make contact with the piston.
   
1 - Injector
q   With combustion chamber ring seal (Teflon ring seal): always renew
q   Replace the O-rings.
q   Ensure correct installation position
q   Removing and installing → Chapter
2 - Support ring
3 - Fuel rail
q   Removing and installing → Chapter
4 - Mechanical single piston high pressure pump
q   With fuel pressure regulating valve -N276-
q   An electric fuel pump (fitted in fuel tank) supplies fuel to the mechanical high-pressure pump
q   When installing the high-pressure fuel pump, it is essential to ensure that no dirt enters the fuel system.
q   The fuel system must not be under pressure when installing the high-pressure pump; procedure for reducing fuel pressure → Chapter
q   Fuel pipes must be free of tension when installed.
q   Removing and installing → Chapter
5 - Roller tappet
6 - Fuel pressure regulating valve -N276-
7 - Bolts for high-pressure pump
q   Replace
q   10 Nm
8 - Connecting piece for fuel supply line on fuel rail
q   Replace
q   25 Nm
9 - Union nut for fuel supply line
q   20 Nm
10 - Air flow control flaps (port separator plates)
11 - Seal
q   Replace
12 - Intake manifold
q   Removing and installing → Chapter
13 - Vacuum unit for air flow control flaps (port separator plates)
14 - Throttle valve module -J338-, throttle valve drive for electric throttle -G186-
q   Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for electric throttle -G188-
q   Throttle valve module -J338- must be re-adapted to engine control unit -J623- each time it is removed, installed or renewed; see → Vehicle diagnostic, testing and information system VAS 5051„Guided Functions“
q   7 Nm
15 - Bolts for intake manifold
q   9 Nm
16 - Intake manifold flap potentiometer -G336-
q   If the intake manifold flap potentiometer -G336- has been renewed, the intake manifold flap potentiometer -G336- must be re-adapted to engine control unit -J623-. For this purpose, select → Vehicle diagnostic, testing and information system VAS 5051 in the „Guided Functions“.
q   After the intake manifold flap potentiometer -G336- or intake manifold has been removed or installed, the intake manifold flap potentiometer -G336- must always be adapted to the engine control unit -J623-. For this purpose, select → Vehicle diagnostic, testing and information system VAS 5051 in the „Guided Functions“.
17 - Fuel pressure sender -G247-
q   27 Nm
q   Lubricate threads lightly with clean engine oil
q   Always renew connecting piece and tighten to 25 Nm
q   Removing and installing → Chapter

   

Removing and installing intake manifold with fuel rail > < Intake manifold - exploded view