Skoda Workshop Service and Repair Manuals

Removing and installing the high pressure pump Special tools and workshop equipment required t  Counterholder -T10051- t  Counterholder -T10172- with bolts -T10172/9- t  Extractor -T40064- t  Thrust piece -T40064/1- t  Bolt -T40064/2- Removing Observe safety measures and rules of cleanliness when undertaking all work on the fuel system → Chapter. Observe the instructions for the fuel hose in the engine compartment → Chapter. –  Remove engine cover → Chapter. –  Remove the sound dampening system → Body Work; Rep. gr.50.   Caution Make sure that no cable connection is damaged when disconnecting the plugs. Otherwise, the complete wiring loom must be replaced.

–  Disconnect plugs -10, 11 and 12-. 10 -  Hall sender -G40- 11 -  Fuel dosage valve -N290- 12 -  Fuel temperature sender -G81- in the fuel feed line

–  Release screws of coolant return-flow line -arrows-. –  Lay coolant return-flow line to the side. Way of proceeding if the high pressure pump is not replaced –  Collect the fuel which flows out with a cloth.

–  Detach the fuel hoses -1 and 6- at the quick couplings. To do so, push the quick couplings onto the nozzles, press in the securing elements (hold pressed) and detach the quick couplings.    If the fuel hoses are not detached from the high pressure pump, they must not be replaced. Way of proceeding if the high pressure pump is replaced    Observe the instructions for the fuel hose in the engine compartment → Chapter.

–  Detach the fuel hoses -arrows- at the high pressure pump. Continue as follows for both procedures

–  Carefully unlock the fuel return-flow line -arrow- at the high pressure pump. –  Carefully remove the fuel return-flow line from the high pressure pump.

–  Unscrew high pressure line -2- between fuel distributor and high pressure pump. –  Remove right charge air pipe → Chapter. –  Remove the toothed belts from the toothed belt sprockets of the camshaft and the high pressure pump → Chapter. –  Hold the toothed belt sprocket on the high pressure pump using the counterholder -T10172- with bolts -T10172/9-.

–  Release screws -1- and remove timing belt gear from the high pressure pump.

–  Hold the hub of the high pressure pump with the counterholder -T10051- and unscrew the securing nut -1-.   Note Replace the basic pressure plate with the pressure plate -T40064/1- on the extractor -T40064-.

–  Position extractor -T40064- with pressure plate -T40064/1- and bolt -T40064/2- as shown. –  Detach the hub from the high pressure pump. If necessary counterhold with an open-end wrench 24 mm.

–  Release the fixing screws -arrows- of the high pressure pump. –  Remove the high pressure pump. Install   Caution Risk of damage to the high pressure pump through running dry. If the high pressure pump is removed or replaced, the initial fuel filling of the high pressure pump must be carried out before the first engine start. For this purpose, connect vehicle diagnosis, measurement and information system -VAS 505x- and carry out the targeted function „filling/bleeding the high pressure pump and the fuel system“. During this function, the fuel pump is actuated for 180 seconds.   Note t  When installing the high pressure pump, ensure that no dirt penetrates the fuel system. t  Only remove the screw plug immediately before installing the fuel lines. Installation occurs in reverse order for removal, while paying attention to the following: t  The screws for the high pressure pump must be replaced. t  Tightening torques of fuel system → Chapter. t  Tightening torques of toothed belt drive → Chapter.

t  If the fuel hoses -arrows- were removed at the high pressure pump, they must be replaced → Chapter. –  install toothed belt and set the timing → Chapter.   Note If the high pressure pump was replaced, the initialisation values of the fuel pressure regulating valve -N276- must be reset → Vehicle diagnostic tester, „Targeted functions“; „Reset initialisation values of the regulating valve for the fuel pressure“. –  Filling and bleeding the fuel system. For this purpose, connect vehicle diagnosis, measurement and information system -VAS 505X- and carry out the targeted function „filling/bleeding the high pressure pump and the fuel system“. During this function, the fuel pump is actuated for 180 seconds. –  Check fuel system for tightness → Chapter.