Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � Workshop Manual Karoq 2018 ➤ Kodiaq 2017 ➤ Superb III 2015 ➤ Fuel system for diesel engines Engine ID DCX A CRL B DDA A DFC A DFE A DCZ A CRG A DFG A DFH A CRG B DBG C DDY A DFFA Edition 06.2017 Service Service Department. Technical Information GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � List of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 20 - Fuel supply system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. Service All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2017 ŠKODA AUTO a. s. D4B8052B83C GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.2 Safety precautions for working on vehicles with start-stop system . . . . . . . . . . . . . . . . . . 3 2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 3 2.4 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system . . . . . . . . 4 4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4.5 Assembly of radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4.6 Adjusting the learnt value for the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 Procedure in case of misfuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.1 Step 1, engine started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Step 2, the engine was not started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.3 Step 3, metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . . . 10 1.4 Step 4, no metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . 11 1.5 Step 5, metal swarfs are present in the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . 12 1.6 Step 6: no metal swarfs are present in the high pressure pump . . . . . . . . . . . . . . . . . . . . 12 2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.2 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.3 Drain the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 2.4 Removing and installing misfuelling protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2.5 Deactivate misfuelling protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 3.1 Assembly overview - fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 66 3.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 77 3.3 Removing and installing cover of assembly opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 4 Quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 4.1 Separating push-on couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.1 Summary of components - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5.3 Fuel hoses in the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 5.4 Drain fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 6 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 6.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 105 7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 7.1 Checking the fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 7.2 Check the suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 7.3 Removing and installing suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 7.4 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 Contents i GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 8 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 8.1 Removing and installing the fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 8.2 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 8.3 Removing and installing the moisture trap sender G63 . . . . . . . . . . . . . . . . . . . . . . . . . . 129 9 Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 9.1 Removing and installing fuel line for auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 ii Contents GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 00 – Technical data 1 Denomination (SRL001095; Edition 06.2017) ⇒ “1.1 Engine number, engine data”, page 1 1.1 Engine number, engine data Superb III Engine codes DCXA CRLB DFEA DDAA DFCA DCZA CRGA DFGA DFHA Emission stand‐ ards EU6 EU6 EU6 EU6 EU6 EU6 EU4 EU6 EU6 Displacement l 1.598 1.968 1.968 1.968 1.968 1.598 1.968 1.968 1.968 Output kW 88 110 110 140 140 88 130 110 140 Kodiaq Engine codes DFGA DFHA DBGC CRGB Emission standards EU6 EU6 EU5 EU3 / EU4 Displacement l 1.968 1.968 1.968 1.968 Output kW 110 140 110 130 Karoq Engine codes DDYA DFFA Emission standards EU6 plus EU6 plus Displacement l 1.598 1.968 Output kW 85 110 Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 1. Denomination 1 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 2 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 2 ⇒ “2.2 Safety precautions for working on vehicles with start-stop system”, page 3 ⇒ “2.3 Safety precautions during road tests in which testing and measuring equipment is used”, page 3 ⇒ “2.4 Safety precautions when working on the SCR system”, page 3 2.1 Safety precautions when working on fuel supply system Risk of injury caused by fuel which is under high pressure. The fuel system is under high pressure. There is a risk of injury from ejected fuel. Before opening the fuel system: – Wear safety goggles. – Wear protective gloves. – Relieve the pressure: place clean cloths around the connec‐ tion point and carefully open the connecting point. Leaking fuel creates a fire hazard When the battery is connected, the door contact switch activates the fuel pump when the driver door is opened. Escaping fuel can ignite and cause a fire. – Interrupt the supply voltage to the fuel pump before opening the fuel system. Check the filling level of the fuel tank ♦ The fuel tank must only be partially full. Consult the work in‐ structions to see how much fuel can be left in the fuel tank. ♦ Where necessary, drain the fuel tank ⇒ “2.3 Drain the fuel tank”, page 51 ♦ Before starting work, the extraction hose of a switched-on ex‐ haust gas extraction system must be laid near to the assembly opening of the fuel tank. ♦ The exhaust extraction system is used to extract fumes. ♦ If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a delivery volume of more than 15 m 3 /h must be used. ♦ Prevent skin contact with fuel! Wear fuel-resistant gloves! Observe the following points to prevent injury to persons or dam‐ age to the injection and preheating system ♦ Ignition must be switched off before disconnecting and re- connecting the electrical wires of the injection and preheating system as well as of the test equipment. ♦ Do not carry out engine wash unless the ignition is switched off. ♦ If the electrical connectors were disconnected and the engine has been started, entries are stored in the event memory of the engine control unit: Query event memory in Targeted Functions ⇒ Vehicle diagnostic tester. Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 2 Rep. gr.00 - Technical data GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 2.2 Safety precautions for working on vehi‐ cles with start-stop system Risk of injury due to automatic engine start. The engine may start up unexpectedly on vehicles with activated start-stop system. A message in the dash panel insert indicates whether the start-stop system is activated. – Deactivate start/stop system: switch off the ignition. 2.3 Safety precautions during road tests in which testing and measuring equipment is used There is a risk of injury from unsecured testing and measuring instruments. If the front passenger airbag is inflated in an accident, testing and measurement equipment that is insufficiently secured can be‐ come a dangerous projectile. – The testing and measurement equipment must always be at‐ tached to the rear seat. Or – Have a second person operates the testing and measurement equipment on the rear seat. 2.4 Safety precautions when working on the SCR system Please note the following when removing and installing compo‐ nents on the SCR system: ♦ The reduction agent tank must be empty when working on the SCR system. Consult the work instructions for when the re‐ duction agent tank must be emptied. Empty reduction agent tank ⇒ Rep. gr. 26 ; SCR system (Selective Catalytic Reduc‐ tion) . Automatic back-suction of reduction agent • After the ignition is turned off, the reduction agent is sucked back out from the dosage line to the injection valve for reduc‐ tion agent - N474- back into the reduction agent tank. • Before working in this area, you need to wait for the back-suc‐ tion to be completed. This may take up to 10 minutes after turning off the ignition. • The battery can also not be disconnected until this back-suc‐ tion has completed, i.e. 10 minutes after the ignition was turned off ⇒ Electrical system; Rep. gr. 27 ; Battery; discon‐ necting and connecting the battery . Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 2. Safety instructions 3 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 3 General points ⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 4 3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system Carefully observe the following rules for cleanliness when working on the fuel supply/injection system: ♦ Thoroughly clean the connection points and their surroundings before releasing. ♦ Place removed parts on a clean surface and cover. Use lint- free cloths! ♦ Carefully cover or close opened components if the repair is not completed immediately. ♦ Only install clean parts: remove spare parts from their wrap‐ ping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.). ♦ When the system is opened: do no use compressed air. Avoid moving the vehicle. ♦ Also make sure no diesel fuel runs onto the coolant hoses. If this is the case clean the hoses immediately. Replace imme‐ diately any hoses which have suffered damage. ♦ Protect electrical plug connections from dirt and moisture and only connect them when dry. Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 4 Rep. gr.00 - Technical data GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 4 Repair instructions ⇒ “4.1 Rules of cleanliness”, page 5 ⇒ “4.2 Foreign bodies in the engine”, page 5 ⇒ “4.3 Contact corrosion”, page 5 ⇒ “4.4 Cable routing and securing”, page 6 ⇒ “4.5 Assembly of radiators and condensers”, page 6 ⇒ “4.6 Adjusting the learnt value for the SCR system”, page 6 4.1 Rules of cleanliness Even slight contamination can lead to defects. Therefore, when working on the fuel supply system, on the injection system and on the turbocharger, observe the following rules for cleanliness: ♦ Clean connection points and around them thoroughly with en‐ gine or brake cleaner thoroughly before loosening. Dry the cleaned areas thoroughly. ♦ Close any open lines and connections immediately using a clean plug, e.g. from the screw plug set for engine - VAS 6122- . ♦ Place removed parts on a clean surface and cover. Use lint- free cloths! ♦ Carefully cover or close opened components if the repair is not completed immediately. ♦ Only install clean parts: Remove spare parts from their wrap‐ ping immediately before installing. Do not use any parts which have been stored unwrapped (e.g. in tool boxes). ♦ When the system is open, do not use compressed air. Avoid moving the vehicle. ♦ Protect electrical plug connections from dirt and moisture and only connect them when dry. 4.2 Foreign bodies in the engine To prevent foreign bodies entering the system, all open connec‐ tions on the engine must be closed during assembly work. Use suitable plugs, e.g. from the screw plug set for engine - VAS 6122- . 4.3 Contact corrosion The use of unsuitable connection elements causes contact cor‐ rosion (screws, nuts, washers, etc.). This is why only connection elements with a special surface coat‐ ings are fitted. The rubber or plastic parts and the adhesives are also made from electrically non-conductive materials. If there is a doubt about the suitability of parts, generally use new parts ⇒ ETKA - Electronic Catalogue of Original Parts . Please note the following: ♦ Use original spare parts; original spare parts are tested and compatible with aluminium. ♦ Only use Škoda accessories. Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 4. Repair instructions 5 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � ♦ Any damage resulting from contact corrosion is not covered by the terms of the warranty. 4.4 Cable routing and securing Risk of damage to cables Cables may be damaged by moving or hot components. – Install cables in the original cable guide. – Ensure that there is adequate clearance from all moving and hot components. ♦ Avoid mix-ups and maintain the original fitting positions. You must therefore mark the lines for fuel, vacuum, activated char‐ coal filter system and electric cables before removal. Make photos or sketches where necessary. 4.5 Assembly of radiators and condensers The radiator, condenser and charge air cooler may have minor indentations on the fins, even if assembled correctly. This is not a case of damage. Radiators, condensers and charge air coolers do not have to be replaced because of these indentations. 4.6 Adjusting the learnt value for the SCR system The learnt value in the engine control unit must be re-adjusted with the vehicle diagnostic tester if reduction agent has been drained off or one of the following components has been replaced: ♦ Reduction agent tank ♦ Pump for reduction agent ♦ Injection valve for reduction agent ♦ Line for reduction agent ♦ Engine control unit Reset learnt values ⇒ Vehicle diagnostic tester. 0001 - Adjusting learnt values for the SCR system Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 6 Rep. gr.00 - Technical data GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 20 – Fuel supply system 1 Procedure in case of misfuelling ⇒ “2 Safety instructions”, page 2 ⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 4 CAUTION Because of insufficient lubrication by diesel fuel, misfuelling can cause irreversible damage to high pressure components, par‐ ticularly the high pressure pump. ♦ Damage can be expected in the form of scoring and particle erosion. ♦ Thus, free metal particles contaminate the fuel system as well as the injection system, whereby further damage can be expected especially to the fuel pressure regulating valve and in the injection units. ♦ If there is uncertainty about the fuel quality, take a sample. Analyse the fuel using the fuel analyser - VAS 6774- ⇒ Owner's Manual . This analyser does not replace laboratory analysis in the event of warranty claims! Note Follow the individual work sequences in this guideline like a flow chart, taking account of the various factors. If the engine was started with incorrect fuel? Yes ⇒ “1.1 Step 1, engine started with incorrect fuel”, page 7 No ⇒ “1.2 Step 2, the engine was not started with incorrect fuel”, page 9 1.1 Step 1, engine started with incorrect fuel Special tools and workshop equipment required ♦ Pressure gauge - VAS 6551- ♦ Adapter set - VAS 6551/5- ♦ Removal wedge - 3409- – Empty fuel tank as far as possible through the filler neck using the fuel extraction device - VAS 5190- : ♦ ⇒ “2.3.2 Emptying the fuel tank when it is more than 3/4 full, Superb III”, page 53 ♦ ⇒ “2.3.3 Emptying the fuel tank when it is more than 3/4 full, Kodiaq, Karoq”, page 54 – Remove cover of assembly opening ⇒ “3.3 Removing and installing cover of assembly opening”, page 90 . Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 1. Procedure in case of misfuelling 7 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � Note Ensure that when the battery is connected the fuel pump cannot be activated by the opening door! Fuel can spill out when the system is open. – Disconnect fuel return-flow line (blue) -2- at the closing flange. Disconnect quick couplings ⇒ “4.1 Separating push-on couplings”, page 93 . CAUTION The fuel system is under pressure. Risk of injury from ejected fuel. – Wear safety goggles. – Wear protective gloves. – Relieve the pressure: place clean cloths around the con‐ nection point and carefully open the connecting point. – Connect the hose line - VAS 6551/1- from the pressure gauge (Diesel) - VAS 6551- to the fuel return-flow lines. – If necessary, extend the hose line - VAS 6551/1- using the connecting nipple - VAS 6551/5-1- and a commercially avail‐ able hose. – Guide the free end of the hose line - VAS 6551/1- into a suit‐ able container. – Connect vehicle diagnosis tester . – Perform Targeted Functions empty fuel tank Note The fuel pump is now activated. – If necessary, repeat this procedure until the fuel tank is com‐ pletely empty. Remove fuel delivery unit ⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐ er”, page 77 . – Check the fuel tank for swarfs. – Empty fuel pump reservoir of the fuel delivery unit. – Carry out a visual inspection for coarse contamination and swarfs in the fuel pump reservoir and on the preliminary stage screen. Are swarfs present? Yes ⇒ “1.3 Step 3, metal swarfs are present in the fuel delivery unit and the fuel tank”, page 10 No ⇒ “1.4 Step 4, no metal swarfs are present in the fuel delivery unit and the fuel tank”, page 11 Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 8 Rep. gr.20 - Fuel supply system GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 1.2 Step 2, the engine was not started with incorrect fuel Special tools and workshop equipment required ♦ Pressure gauge - VAS 6551- ♦ Adapter set - VAS 6551/5- ♦ Removal wedge - 3409- – Empty fuel tank as far as possible through the filler neck using the fuel extraction device - VAS 5190- : ♦ ⇒ “2.3.2 Emptying the fuel tank when it is more than 3/4 full, Superb III”, page 53 ♦ ⇒ “2.3.3 Emptying the fuel tank when it is more than 3/4 full, Kodiaq, Karoq”, page 54 – Remove cover of assembly opening ⇒ “3.3 Removing and installing cover of assembly opening”, page 90 . Note Ensure that when the battery is connected the fuel pump cannot be activated by the opening door! Fuel can spill out when the system is open. Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 1. Procedure in case of misfuelling 9 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � – Disconnect fuel return-flow line (blue) -2- at the closing flange. Disconnect quick couplings ⇒ “4.1 Separating push-on couplings”, page 93 . CAUTION The fuel system is under pressure. Risk of injury from ejected fuel. – Wear safety goggles. – Wear protective gloves. – Relieve the pressure: place clean cloths around the con‐ nection point and carefully open the connecting point. – Connect the hose line - VAS 6551/1- from the pressure gauge (Diesel) - VAS 6551- to the fuel return-flow lines. – If necessary, extend the hose line - VAS 6551/1- using the connecting nipple - VAS 6551/5-1- and a commercially avail‐ able hose. – Guide the free end of the hose line - VAS 6551/1- into a suit‐ able container. – Connect vehicle diagnosis tester . – Perform Targeted Functions empty fuel tank Note The fuel pump is now activated. – If necessary, repeat this procedure until the fuel tank is com‐ pletely empty. – Fill fuel tank with 5 litres of diesel fuel. – Empty fuel tank again fully as described above. – Reconnect the fuel return line (blue) -2-. – Replace the fuel filter ⇒ “5 Fuel filter”, page 97 . – Fill vehicle tank and take it for a test run. End 1.3 Step 3, metal swarfs are present in the fuel delivery unit and the fuel tank Special tools and workshop equipment required ♦ Diesel extractor - VAS 5226- – Clean, for example using fuel delivery unit and fuel tank with diesel suction device - VAS 5226- . Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 10 Rep. gr.20 - Fuel supply system GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � Install fuel delivery unit ⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐ er”, page 77 . – Fill fuel tank with 5 litres of diesel fuel. – Empty fuel tank again fully as described above ⇒ “1.1 Step 1, engine started with incorrect fuel”, page 7 . – Replace the following high pressure components: ♦ High-pressure pump ⇒ Rep. gr. 23 ; High-pressure pump; Remove and install the high-pressure pump . ♦ High-pressure pipes ⇒ Rep. gr. 23 ; Injection units/High- pressure accumulator (rail); Remove and install the high-pres‐ sure pipes . ♦ Removing and installing high-pressure accumulator (rail) in‐ cluding fuel pressure regulating valve - N276- and fuel pres‐ sure sender - G247- ⇒ Rep. gr. 23 ; Injection units/High- pressure accumulator (rail); installing and removing high- pressure accumulator (rail) . ♦ Injector ⇒ Rep. gr. 23 ; Injection units/High-pressure accu‐ mulator (rail); Remove and install the high-pressure pipes . ♦ Fuel return lines (waste fuel lines) ⇒ Rep. gr. 23 ; Injection units/high-pressure accumulator (rail); Assembly overview - injection units (injectors) . ♦ Fuel filter ⇒ “5 Fuel filter”, page 97 . – Fill vehicle tank. – Bleed the fuel system ⇒ Rep. gr. 23 ; injection system; Fill/ bleed the fuel system . – Perform a test drive. End 1.4 Step 4, no metal swarfs are present in the fuel delivery unit and the fuel tank – Fill fuel tank with 5 litres of diesel fuel. – Empty fuel tank again fully as described above ⇒ “1.1 Step 1, engine started with incorrect fuel”, page 7 . CAUTION When removing the fuel dosage valve from the high pressure pump, there is the risk that dirt may get into the pump whereby damage to the pump could occur. Therefore, clean the fuel dosage valve as well as the high pressure pump as thoroughly as possible before removing, while doing so observe the rules of cleanliness when working on the injection system ⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 4 . – Disconnect the plug from the valve. Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 1. Procedure in case of misfuelling 11 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � – Unscrew the screws -arrows- and carefully remove the fuel dosage valve - N290- -A- from the high pressure pump. – Check fuel dosage valve - N290- and high pressure pump for swarfs. Are swarfs present? Yes ⇒ “1.5 Step 5, metal swarfs are present in the high pressure pump”, page 12 No ⇒ “1.6 Step 6: no metal swarfs are present in the high pressure pump”, page 12 1.5 Step 5, metal swarfs are present in the high pressure pump – Replace the following high pressure components: ♦ High-pressure pump ⇒ Rep. gr. 23 ; High-pressure pump; Remove and install the high-pressure pump . ♦ High-pressure pipes ⇒ Rep. gr. 23 ; Injection units/High- pressure accumulator (rail); Remove and install the high-pres‐ sure pipes . ♦ Removing and installing high-pressure accumulator (rail) in‐ cluding fuel pressure regulating valve - N276- and fuel pres‐ sure sender - G247- ⇒ Rep. gr. 23 ; Injection units/High- pressure accumulator (rail); installing and removing high- pressure accumulator (rail) . ♦ Injector ⇒ Rep. gr. 23 ; Injection units/High-pressure accu‐ mulator (rail); Remove and install the high-pressure pipes . ♦ Fuel return lines (waste fuel lines) ⇒ Rep. gr. 23 ; Injection units/high-pressure accumulator (rail); Assembly overview - injection units (injectors) . ♦ Fuel filter ⇒ “5 Fuel filter”, page 97 . – Fill vehicle tank. – Bleed the fuel system ⇒ Rep. gr. 23 ; injection system; Fill/ bleed the fuel system . – Perform a test drive. End 1.6 Step 6: no metal swarfs are present in the high pressure pump Note Make sure the gasket rings of the fuel dosage valve - N290- are free of damage. If a gasket ring is damaged the windscreen must be replaced. – Wet the lower gasket ring for fuel dosage valve - N290- with fuel. – Slide the valve into the high pressure pump with light rotary movements. Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 12 Rep. gr.20 - Fuel supply system GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � – Screw in both screws -arrows- by hand. – Tighten the screws in two stages: Stage Bolts Tightening torque 1. -Arrows- 3 Nm 2. -Arrows- 7 Nm – Replace the fuel filter ⇒ “5 Fuel filter”, page 97 . – Bleed the fuel system ⇒ Rep. gr. 23 ; injection system; Fill/ bleed the fuel system . – Fill vehicle tank and take it for a test run. End Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 1. Procedure in case of misfuelling 13 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 2 Fuel tank ⇒ “2.1 Assembly overview - fuel tank”, page 14 ⇒ “2.2 Removing and installing the fuel tank”, page 24 ⇒ “2.3 Drain the fuel tank”, page 51 ⇒ “2.4 Removing and installing misfuelling protection”, page 60 ⇒ “2.5 Deactivate misfuelling protection”, page 64 2.1 Assembly overview - fuel tank ⇒ “2.1.1 Summary of components - Fuel tank, vehicles with front drive, Superb III”, page 14 ⇒ “2.1.2 Summary of components - Fuel tank, vehicles with front drive, Kodiaq”, page 17 ⇒ “2.1.3 Summary of components - Fuel tank, vehicles with front drive, Karoq”, page 19 ⇒ “2.1.4 Summary of components - Fuel tank, vehicles with four- wheel drive, Superb III, Kodiaq”, page 21 ⇒ “2.1.5 Summary of components - Fuel tank, vehicles with four- wheel drive, Karoq”, page 23 2.1.1 Summary of components - Fuel tank, vehicles with front drive, Superb III Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 14 Rep. gr.20 - Fuel supply system GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 1 - Screw cap ❑ until it locks audibly into place. ❑ attached to the fuel tank lid unit with anti-loss washer 2 - Filler neck 3 - Screw ❑ Replace after disas‐ sembly ❑ 8 Nm + 90° 4 - Rubber buffer ❑ between fuel tank and bodyshell ❑ check correct fitting 5 - Guide 6 - Screw ❑ Replace after disas‐ sembly ❑ 20 Nm + 90° 7 - Fuel tank ❑ Removing and installing ⇒ “2.2.1 Removing and installing fuel tank, vehi‐ cles with front drive, Su‐ perb IIl ”, page 24 8 - Heat shield ❑ for fuel tank 9 - Plate nut ❑ for the heat shield 10 - Tensioning strap ❑ pay attention to correct installation position ❑ mark the direction of travel when removing ❑ Fitting position ⇒ page 16 11 - Tensioning strap ❑ pay attention to correct installation position ❑ mark the direction of travel when removing ❑ Fitting position ⇒ page 16 12 - Fuel line ❑ do not kink ❑ disconnect and connect ⇒ “4.1 Separating push-on couplings”, page 93 ❑ observe the arrow direction (forward or reverse) on the closing flange when installing ❑ clipped in place on fuel tank 13 - Mounting bracket ❑ Fuel pump control unit - J538- ❑ Removing and installing fuel pump control unit - J538- ⇒ “7.4 Removing and installing fuel pump control unit J538 ”, page 122 14 - Fuel delivery unit, fuel gauge sender ❑ Summary of components ⇒ “3.1 Assembly overview - fuel delivery unit, fuel gauge sender”, page 66 Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 2. Fuel tank 15 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � ❑ Removing and installing ⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge sender”, page 77 15 - Earth connection ❑ for fuel filler neck ❑ For diverting static electricity Structure of the fastening of the fuel tank 1 - Tensioning strap/fuel tank 2 - Screw with washer 3 - Rubber holder 4 - Guide bushing Installation location of the vent grommet Before removing the vent grommet, mark the installation position. When installing the fuel tank -2-, note the installation position of the vent grommet -1-. • Angle -α- must be 60°. Karoq 2018 ➤ , Kodiaq 2017 ➤ , Superb III 2015 ➤ Fuel system for diesel engines - Edition 06.2017 16 Rep. gr.20 - Fuel supply system GETtheMANUALS.org