Skoda Workshop Service and Repair Manuals

Removing and installing cylinder head cover (Fabia II, Roomster, Rapid)   Note Observe the safety precautions when working on the diesel direct injection system → Chapter. Removing Observe all safety measures and notes for assembly work on the fuel and injection system as well as the rules for cleanliness → Chapter. –  Remove engine cover → Chapter. –  If present, remove the noise insulation at the injection units.   Caution t  Carefully disconnect the plug from the glow plugs. t  If the plug is damaged when disconnecting it, the complete wiring loom including the plugs must be replaced (plugs cannot be replaced separately).

–  Carefully disconnect the plug from the glow plugs. To do so use an open-end wrench, SW 12, for help.

–  Disconnect the plug of the position sender for charge pressure regulator -G581--arrow- at the vacuum unit from the exhaust turbocharger and guide the line out of the brackets.

–  Unscrew bolt -3-. –  Remove suspension - engine mount -grey-.

–  Remove the fuel high pressure line between the high pressure pump -1- and the fuel distributor -3-.   Note t  Preferred loosening sequence of the high pressure lines cylinders 4-3-2-1. t  Counterhold at the injection units when loosening the high pressure connection piece. –  Remove high pressure line between fuel distributor and injection units.

–  Slacken spring strap clamp -arrow- and detach the line from the fuel distributor.

–  Disconnect the plug at the fuel pressure regulating valve -N276--arrow-. –  Remove the cable guide from the rail and lay it to the side.

–  Disconnect plug at fuel pressure sender -G247--B-. –  Detach the vacuum line at the cylinder head cover -A-.

–  Screw out screws -arrows- and remove fuel distributor.

–  Unscrew the fixing screws at the intake manifold -arrows- and lay the fuel return-flow line to the side.

–  Disconnect the plug from the injection units -A-.

–  Unlock the connections of the fuel return-flow line using a screwdriver and a set of pointed pliers.   Note Always replace clamps.

–  Disconnect the connections of the fuel return-flow line at the injectors in -direction of arrow-. –  Remove the complete return-flow line and place it down at the intake manifold. –  Remove the remaining vacuum lines from the bracket at the cylinder head cover. –  Remove top toothed belt guard. –  Remove the vent line between the cylinder head cover and the intake hose. To do so, press together the quick-release fittings. –  Remove the injection units → Chapter. –  Unscrew the fixing screws of the cylinder head cover. –  Remove cylinder head cover.

–  To do so, unclip the cylinder head cover at the catch pegs -arrows- of the rear toothed belt guard. Install Installation is performed in the reverse order, pay attention to the following points: Tightening torques t  Cylinder head cover - Summary of components: → Chapter. t  Fuel system - Summary of components: → Chapter.   Note Replace gasket for cylinder head cover if damaged or leaking. –  Screw on the cylinder head cover by hand in the sequence -1 ... 6-.

–  Tighten the bolts in the sequence -1…6- to 10 Nm. –  Make sure that the cylinder head cover is correctly clipped with the toothed belt guard.   Note To provide a clearer illustration, the camshaft sprocket is removed.

–  To do so, if necessary use a screwdriver to press the toothed belt guard in the area of the clips -arrows- against the cylinder head cover until they lock audibly into each other. –  Check the clearance between the hub and the toothed belt guard. –  Install the injection units → Chapter. Connect the → Vehicle diagnostic tester and carry out the function „bleeding the fuel system“ in the „targeted functions“.