Skoda Workshop Service and Repair Manuals

Removing and installing the high pressure pump Removing   Note t  Safety precautions when working on the fuel supply system → Chapter. t  Rules of cleanliness when working on the fuel supply system → Chapter. –  Switch off the ignition and all electrical components and take out the ignition key.   WARNING The injection system consists of a high pressure part (max. pressure of 12 MPa = 120 bar) and a low pressure part (pressure of approx. 0.6 MPa = 6 bar). t  Before opening the high pressure area, e.g. removing the high pressure pump, the fuel distributor, the injection valves, the fuel pipes or the fuel pressure sender -G247-, the fuel pressure in the high pressure area with a remaining pressure of approx. 0.6 MPa (6 bar) must be reduced. t  The procedure for this is described in the chapter “release pressure in the high pressure area of the fuel system” → Chapter.

–  Release screws -2- and remove retaining clip -1-. –  Disconnect plug -3- from charge pressure sender -G31- with intake air temperature sender 2 -G299-. –  Unhook the hoses at the pressure pipe and open the cable guide. –  Press the retaining clips -arrows- towards the outside and pull the pressure pipe out towards the top. –  Then pull off the pressure pipe from the exhaust turbocharger.   Note Hold the screwed connections at the high pressure pump and at the bottom part of intake manifold/fuel distributor when unscrewing the union nuts with a wrench.

–  Unscrew union nuts -arrows- and screw -1- and remove high pressure line.   Note t  The bracket for the fuel lines must on no account be bent up. t  If the bracket is bent up or the fuel line is replaced, the bracket must also be replaced.

–  Disconnect the plug -1- from the fuel pressure regulating valve -N276- and the fuel feed line -2- from the high pressure pump.   Note Collect the fuel which flows out with a cloth.

–  Screw out the fixing screws -1- evenly.

–  Pull the high pressure pump -3- and the roller tappet -1- out of the camshaft housing. Install   Note t  Moisten the roller tappet of the high pressure pump with clean engine oil. t  Always replace the O-ring of the high pressure pump.

–  Slide the roller tappet -1- into the camshaft housing. –  Insert a new, oiled O-ring -2- into the slot of the high pressure pump -3-. –  Turn the crankshaft until the roller tappet is in the lowest position. –  Position the high pressure pump -3- onto the camshaft housing.

–  First of all screw in the fixing screws -1- sufficiently until the bolt heads are positioned on the flange. –  Then tighten the fixing screws -1- evenly.    Tightening torque: 20 Nm

–  Screw on the union nuts of the high pressure line -3- by hand. –  Install the bracket for the fuel lines and tighten the fixing screw -1- to 8 Nm.   Note Hold the screwed connections at the high pressure pump and at the bottom part of intake manifold/fuel distributor when tightening the union nuts with a wrench. –  Tighten the union nuts of the high pressure line -arrows- to 18 Nm. Further installation occurs in reverse order.