Skoda Workshop Service and Repair Manuals

Removing and installing the fuel delivery unit on four-wheel drive vehicles (Octavia II) Special tools and workshop equipment required t  Key -T30101 (3087)-. t  Protective gloves Condition l  The fuel tank must not be more than 1/3 full. Removing   Note t  Drain the fuel tank → Chapter. t  Safety precautions when working on the fuel supply system → Chapter. t  Observe the regulations concerning cleanliness when working on the fuel supply/injection system → Chapter. –  Switch off ignition and withdraw ignition key. –  Removing rear seat bench → Body Work; Rep. Gr.72. –  Remove the cover from the fuel delivery unit.   Note t  For vehicles with auxiliary heating, the plug connection for the dosing pump -V54- must be disconnected additionally. t  Two types of fuel delivery units are installed in the vehicles. They can be recognised on the different flanges. Fuel delivery unit type one

–  Disconnect the plug, the black feed line -1- and the blue return-flow line -2- from the flange.   Note t  Press in the securing ring in order to unlock the lines. t  On vehicles with auxiliary heating the suction line for the dosing pump -V54- must be pulled out additionally (open lower clamp).

–  Open lock ring with the wrench -T30101-. –  Pull out closing flange and gasket ring of the fuel delivery unit from the opening of the fuel tank and place to the side with the connected lines.

–  Separate through the opening of the fuel tank the fuel line -1- to the suction jet pump, to do so press the release button. –  Unhook the fuel delivery line -2- at the fuel delivery unit, to do so pull the fixing clamp upwards -arrow-.   Note t  You must wear protective gloves for removing the fuel delivery unit. t  Take the fuel delivery unit out of the fuel tank in such a way that the electrical cables and the fuel hoses are not damaged and that the float arm of the sender for the fuel gauge display -G- is not bent. t  You must empty the old delivery unit before disposing of it if you wish to replace the fuel delivery unit. –  Pull the fuel delivery unit out of the opening of the fuel tank. Fuel delivery unit type two

–  Disconnect the plug, the black feed line -1- and the blue return-flow line -2- from the flange.   Note t  Press in the securing ring in order to unlock the lines. t  On vehicles with auxiliary heating the suction line for the dosing pump -V54- must be pulled out additionally (open lower clamp).

–  Open lock ring with the wrench -T30101-.

–  Slightly raise the closing flange and check if the spring -2- is still fastened on the flange -1-.    If the spring -2- is loose on the guide pipe -3-, hold it with your fingers while removing the closing flange. –  Pull out closing flange and gasket ring of the fuel delivery unit from the opening of the fuel tank and place to the side with the connected lines.

–  Separate through the opening of the fuel tank the fuel line -1- to the suction jet pump, to do so press the release button. –  Separate the fuel delivery line -2- from the fuel delivery unit.   Note t  You must wear protective gloves for removing the fuel delivery unit. t  Take the fuel delivery unit out of the fuel tank in such a way that the electrical cables and the fuel hoses are not damaged and that the float arm of the sender for the fuel gauge display -G- is not bent. t  You must empty the old delivery unit before disposing of it if you wish to replace the fuel delivery unit. –  Pull the fuel delivery unit out of the opening of the fuel tank. Install The fuel delivery unit is installed in the reverse order. However, pay attention to the following: –  Insert the fuel delivery unit into the fuel tank with the closing flange placed to the side. Thus, do not bend the float arm of the fuel gauge sender unit -G-. –  Install the fuel delivery unit and the fuel line. –  Insert the new dry gasket ring into the opening of the fuel tank and moisten only from the inside with fuel for installing the closing flange. Fuel delivery unit type one

–  Slide the spring -2- into the guide bore -arrow- and fit the cable -1- of the closing flange on the cable -3- of the fuel delivery unit. Fuel delivery unit type two

l  The spring -2- must be fastened to the retaining lugs -1- of the closing flange. –  First of all guide the guide pipe -3- into the guide bore -4-. –  Then lower the closing flange in such a way that the guide pipe -6- locks into the guide bore -5-.   Note

Pay attention that the electrical cables -1- and the fuel feed line -3- are routed according to the illustration and the float arm -2- is not blocked. Continue as follows for both types –  Press the closing flange down and bring it into the installation position.   Note

t  Fitting position of the fuel delivery unit: The peg -2- at the closing flange must be located between the tongues -1- and -3-. The -thick arrow- points in the direction of travel. t  Tighten the lock ring to 110 Nm. t  Do not interchange feed line and return-flow line. t  Make sure the fuel lines fit tightly. t  After installing the fuel delivery unit, check whether the feed line and the return-flow line are still clipped in place on the fuel tank.