SKODA Karoq 2018, Kodiaq 2017, Kodiaq 2019, Octavia III 2013, Octavia III 2014 Workshop Manual

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Service

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Workshop Manual

Karoq 2018 ➤ , Kodiaq 2017 ➤ ,

K Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 2014 ➤ , Superb III 2015 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤

odiaq 2019 ➤ , Octavia III 2013 ➤ ,

Fuel system - Petrol engines

Engine ID

CJZA CJZB CJZC CJZD

CZCACZDACZEACYVACYVBDADADKRCDKLDDKR

CJSA CJSB CJSC CJXA

DKZ

DLBA

DNU

CHZBCHZCCHZ

CHHACHHBCZPACZPBDKT

CHZJ

CHP

Edition 12.2018

Service Department. Technical Information

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List of Workshop Manual Repair Groups

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epa i r G r o u p

00 - Technical data 20 - Fuel supply system

Service

Technical information should always be available to the foremen and mechanics, because their careful safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

and constant adherence to the instructions is essential to ensure vehicle road-worthiness and

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Contents

00 - Technical data

1 Denomination

1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 5

2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 5

3 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system . . . . . . . . 6

4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.3 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

20 - Fuel supply system

1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1 Assembly overview - fuel tank

1.2 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.3 Drain the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.1 Assembly overview - fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.2 Removing and installing cover of assembly opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.3 Removing and installing fuel pump/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2.4 Removing and installing the fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

2.5 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3 Quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

3.1 Separating push-on couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.1 Summary of components - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

5.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

5.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

5.3 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

6.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 137

7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

7.1 Checking the fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

7.2 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

7.3 Check the suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

7.4 Removing and installing suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

8 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

8.1 Removing and installing fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

8.2 Removing and installing the fuel line for the auxiliary heating . . . . . . . . . . . . . . . . . . . . . . 177

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Contents i

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ii Contents

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Fuel system - Petrol engines - Edition 12.2018

00 – Technical data

1 Denomination

(SRL001337; Edition 12.2018)

⇒ “1.1 Engine number, engine data”, page 1

1.1 Engine number, engine data

Engine codes CZCA CZDA CZEA CHPA CJSA CJSB Superb III 06.2015 ► 10.2015 ► 03.2015 ► ----- 08.2015 ► -----

Kodiaq 01.2017 ► 10.2016 ► 01.2017 ► ----- ----- ----Karoq ----- ----- ----- ----- ----- ----Yeti 05.2015 ►

09.2017

Octavia III ----- 05/2015 ► ----- 11.2012 ►

Rapid NH 05/2015 ► ----- ----- ----- ----- ----Emission stand‐

ards Dis‐

place‐ ment

Out‐ put

Tor‐ que

Fuel RON

kW at rpm 92/5000-6000110/5000-6

Nm at rpm 200/1400-4000250/1500-3

min. 95 unleaded 95 unlea‐

EU6 EU6 EU6 EU6 EU6 / BS4 EU5 / EU6

1395 1395 1395 1395 1798 1798

05.2015 ►

09.2017

000

500

ded

----- ----- ----- -----

11.2012 ► 05.2013 ►

05.2015

110/5000-6

000

250/1500-3

500

95 unlea‐

ded

110/5000-6

000

250/1500-3

500

95 unlea‐

ded

132/5100-6200132/5100-62

250/1250-5000280/1350-45

95 1 unlea‐

ded

95 1 unlea‐

ded

At least 91 RON in exceptional cases, although engine output

is reduced.

Engine codes CJSC CJXA CHHA CHHB CHZJ DADA Superb III 08.2015 ► 08.2015 ► ----- 06.2015 ► ----- 07.2018 ►

Kodiaq ----- ----- ----- ----- ----- ----Karoq ----- ----- ----- ----- 07.2017 ► 08.2017 ► Yeti ----- ----- ----- ----- ----- ----Octavia III ----- ----- 05/2015 ► ----- ----- ----Rapid NH ----- ----- ----- ----- ----- ----Emission stand‐

ards Dis‐

place ment

Out‐

kW at rpm 132/4000-6200206/5600-6500169/4700-6

put Tor‐

que Fuel

RON

Nm at

EU6 / BS4 EU6 EU6 EU4 / EU6 EU6 EU6

rpm

min. 95 unleaded 95 unleaded 95 unlea‐

1798 1984 1984 1984 999 1495

200

320/1450-3900350/1700-5600350/1500-4

600

ded

162/4500-6

200

350/1500-4

400

95 unlea‐

ded

85/5000-5500110- 5000

200/2000-3500250/1500-3

95 unleaded 95 unlea‐

500

ded

1. Denomination 1

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Engine codes CHZB CHZC CHZD DKRC DKLD Superb III ----- ----- ----- ----- -----

Kodiaq ----- ----- ----- ----- ----Karoq ----- ----- ----- ----- ----Yeti ----- ----- ----- ----- ----Octavia III ----- ----- 05.2016 ► ----- ----Rapid NH 06.2017 ► 06.2017 ► ----- 07.2018 ► 07.2018 ► Emission standards EU6 EU6 EU6 EU6 EU6 Dis‐

999 999 999 999 999 place‐ ment

Output kW at rpm 70/5000 - 5500 81/5000 - 5500 85/5000-5500 81/5000 - 5500 70/5000 - 5500 Torque Nm at rpm 160/1500-3500 200/2000-3500 200/2000-3500 200/2000-3500 160/1500-3500 Fuel -

min. 95 unleaded 95 unleaded 95 unleaded 95 unleaded 95 unleaded

RON

Engine codes DKRF DKZA DKTB DLBA CZPB DNUA CZPA Superb III ----- 11.2018 ► ----- ----- 11.2018 ► 08.2018 ► -----

Kodiaq ----- 08.2018 ► ----- ----- ----- ----- 10.2016 ► Karoq ----- 11.2018 ► ----- ----- ----- ----- ----Yeti ----- ----- ----- ----- ----- ----- ----Octavia III ----- 08.2018 ► 08.2018 ► 05/2017 ► 12.2018 ► ----- ----Rapid NH 07.2018 ► ----- ----- ----- ----- ----- ----Emission

EU6 EU6 EU6 EU6 EU6 EU6 EU4 / EU6

standards Dis‐

999 1984 1984 1984 1984 1984 1984 place ment

Out‐ put

Tor‐ que

Fuel

kW at

85/5000-5500140/4200-6

rpm

Nm at

rpm

200/2000-3

500

min. 95 unlea‐

ded

000

320/1450-4

200

95 unlea‐

ded

180/5000-

6200

370/1600-

4300

95 unlea‐

ded

180/5000-6

200

370/1600-4

300

95 unlea‐

ded

140/4200-6

000

320/1450-4

200

95 unlea‐

ded

200/5600-6

500

350/1700-5

600

95 unlea‐

ded

132/3900-

6000

320/1500-

3940

95 unlea‐

ded

RON

Engine codes CJZA CJZB CJZC CJZD CYVA CYVB Superb III ----- ----- ----- ----- ----- -----

Kodiaq ----- ----- ----- ----- ----- ----Karoq ----- ----- ----- ----- ----- ----Yeti ----- ----- ----- ----- ----- 05.2014 ►

Octavia III 11.2012 ►

05.2015

Rapid NH ----- ----- 05.2015 ►

Emission stand‐

EU5 EU5 EU6 EU6 EU6 EU6

ards Dis‐

1197 1197 1197 1197 1197 1197 place ment

2 Rep. gr.00 - Technical data

11.2012 ►

05.2015

----- ----- 05.2015 ►

07.2018

05.2017

05.2015 ►

05.2017

----- -----

09.2017

05.2015 ►

05.2016

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Engine codes CJZA CJZB CJZC CJZD CYVA CYVB Out‐

kW at rpm 77/4500-550063/4300-530066- 4400 81- 4600 63/4300-530081/4600-56

put Tor‐

que Fuel

Nm at

175/1400-4000160/1400-3500160/1400-3500175/1400-4000160/1400-3500175/1400-4

rpm

min. 95 unleaded 95 unleaded 95 unleaded 95 unleaded 95 unleaded 95 unlea‐

000

ded

RON

1. Denomination 3

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Fuel system - Petrol engines - Edition 12.2018

2 Safety instructions

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4

⇒ “2.2 Safety precautions when working on vehicles with startstop system”, page 5

⇒ “2.3 Safety precautions during road tests in which testing and measuring equipment is used”, page 5

2.1 Safety precautions when working on fuel supply system

Fuel under very high pressure creates a risk of injury. – Wear protective gloves. – Wear safety goggles! ♦ The injection system consists of a high pressure part (max.

pressure sure of approx. 0.7 MPa = 7 bar).

♦ The fuel system is under pressure. Before opening the injec‐

tion system high-pressure system, the fuel pressure must be reduced to residual pressure ⇒ Rep. gr. 24 ; Injection system; reducing fuel pressure .

of 25 MPa = 250 bar) and a low pressure part (pres‐

Note

This function does not have to be available for all motor code let‐ ters.

♦ After the pressure has been reduced to residual pressure (ap‐

prox. 0.7 MPa = 7 bar), the connection point must be opened »immediately«. To do this place a clean cloth around the con‐

nection point. Leaking fuel creates a fire hazard. Fuel pump is activated by switching on ignition and via driver door

contact switch. For reasons of safety, the power supply to the fuel pump must be interrupted

Disconnect the voltage supply to the fuel pump

• Only disconnect the battery when the ignition is switched off

Electrical system ; Rep. gr. 27 ; Battery; Disconnecting and

⇒

connecting battery . ♦ By disconnecting the battery ⇒ Electrical system; Rep. gr.

27 ; Battery; Disconnecting and connecting battery . ♦ By removing the fuse for the control unit for the fuel pump -

J538- ⇒ Current flow diagrams, Electrical fault finding and

Fitting locations. ♦ By disconnecting the connector from the flange of the fuel

pump.

⇒ page 4 .

NOTICE

Risk of damage to fuel pump.

The fuel pump must not run »dry«.

4 Rep. gr.00 - Technical data

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2.2 Safety precautions when working on ve‐ hicles with start-stop system

Risk of injury as a result of automatic engine start in vehicles with start/stop system.

In vehicles with the start/stop system activated (identifiable by an indication ically if required.

– Ensure that the start-stop system is deactivated when carrying

out work on the vehicle (switch ignition off, if required switch ignition on again).

in the dash panel insert) the engine can start automat‐

2.3 Safety precautions during road tests in which

testing and measuring equipment

is used

Risk of accident from distraction Using testers and measuring instruments during driving operation

causes distraction. There is a risk of injury if testers and measuring instruments are

not secured adequately. Increased risk of injury from unsecured testers and measuring

instruments must be prevented. Measuring instruments can turn into dangerous projectiles on air‐

bag activation. Testers and measuring instruments must always be secured on

the

rear seat using a seat belt and operated by a 2nd person from

there.

2. Safety instructions 5

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3 General points

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6

3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system

Carefully observe the following “rules” for cleanliness when work‐ ing 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.

♦ When the system is opened: do no use compressed air. Do

not move the vehicle.

♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean

the hoses immediately.

♦ Protect electrical plug connections from dirt and moisture and

only connect them when dry.

6 Rep. gr.00 - Technical data

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Fuel system - Petrol engines - Edition 12.2018

4 Repair instructions

⇒ “4.1 General repair instructions”, page 7 ⇒ “4.2 Contact corrosion”, page 7 ⇒ “4.3 Cable routing and securing”, page 7

4.1 General repair instructions

When removing and installing the parts from a partly filled fuel tank, pay attention to the following:

•

The fuel tank must not be more than 3/4 tract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

• The extraction hose of an exhaust extraction system which is switched on, must be positioned close to the assembly open‐ ing

of the fuel tank in order to extract the released fuel vapours,

even before the work is commenced.

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 m3/

h must be used.

full. If necessary, ex‐

4.2 Contact corrosion

The use of unsuitable connection elements (screws, nuts, wash‐ ers, etc.) can cause contact corrosion.

This is why only connection elements with a special surface coat‐ ings are fitted.

Therefore, the rubber or plastic parts and the adhesives are made from electrically non-conductive materials.

If there is a question mark about the suitability of parts, generally use new parts ⇒ ETKA - Electronic Catalogue of Original Parts .

4.3 Cable routing and securing

Install lines of all kinds so that the original routing can be restored. To rule out mix ups and ensure the original fitting position, mark

the lines before disassembly. Make photos or sketches where necessary. To avoid damage to lines, ensure sufficient clearance from all

moving or hot components. Insulation or heat shield mats must be installed again in their

original position.

4. Repair instructions 7

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Fuel system - Petrol engines - Edition 12.2018

20 – Fuel supply system

1 Fuel tank

⇒ “1.1 Assembly overview - fuel tank”, page 8 ⇒ “1.2 Removing and installing the fuel tank”, page 24 ⇒ “1.3 Drain the fuel tank”, page 64

1.1 Assembly overview - fuel tank

⇒ “1.1.1 Summary of components - fuel tank, Rapid NH”, page 8

⇒ “1.1.2 Summary of components - fuel tank, Octavia III, vehicles with front-wheel drive”, page 11

⇒ “1.1.3 Summary of components -fuel tank, Yeti, front-wheel drive vehicles”, page 13

⇒ “1.1.4 Summary of components - fuel tank, Superb III, vehicles with front-wheel drive”, page 15

⇒ “1.1.5 Summary of components -fuel tank, Kodiaq, front-wheel drive vehicles”, page 17

⇒ “1.1.6 Summary of components -fuel tank, Karoq, vehicles with front-wheel drive”, page 18

⇒ “1.1.7 Assembly overview - fuel tank, Octavia III, Superb III, Kodiaq, Karoq, four-wheel drive vehicles”, page 20

⇒ “1.1.8 Summary of components -fuel tank, Yeti, four-wheel drive vehicles”, page 22

1.1.1 Summary of components - fuel tank, Rapid NH

8 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

1 - Fuel tank

❑

support with engine/ gearbox jack V.A.G 1383A- when re‐ moving

❑ Removing and installing

⇒ “1.2.1 Removing and installing the fuel tank, Rapid NH”, page 24

2 - Sealing ring

❑

replace if damaged

3 - Fuel pump - G6-

❑ In the event of a fuel

pump with integrated fuel filter, the fuel filter cannot be replaced indi‐ vidually

❑ Checking fuel pump

electrics ⇒ Vehicle diag‐ nostic tester

❑ Fitting position

⇒ Fig. ““Fitting location of the fuel delivery unit”“ , page 10

❑

Summary of compo‐ nents

⇒ “2.1 Assembly over‐ view - fuel delivery unit, fuel gauge sender”, page 81

❑ Removing

and installing

⇒ “2.3.2 Removing and installing fuel pump for pre-delivery G6 G6, Rapid NH”, page 97

❑

inspecting fuel pump

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

4 - Lock ring

❑

110 Nm

5 - Return-flow line

❑ not in vehicles with fuel filter in flange of the fuel delivery unit

6 - Feed line

❑ black 7 - Overflow hose 8 - Screw cap 9 - Fuel tank lid unit

❑ with rubber bowl 10 - Earth connection 11 - O-ring

❑ Replace after disassembly 12 - Vent valve

❑ Check

⇒ Fig. ““Inspect vent valve”“ , page 11

13 - Gravity valve

❑

to remove, unclip valve and lift up and out of the filler neck

1. Fuel tank 9

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Fuel system - Petrol engines - Edition 12.2018

❑ inspect valve for blockage: ❑

Valve open vertically

❑ Valve tilted 45°: closed

14 - Activated charcoal filter

❑ Summary of components of activated charcoal filter system

⇒ “5.1.3 Summary of components - activated charcoal filter system, Rapid NH”, page 125

❑

Checking the fuel tank venting

15 - Vent line 16 - O-ring

❑

Replace after disassembly

17 - Screw

❑ 10 Nm 18 - Circlip 19 - Heat shield

❑ for fuel tank 20 - Screw

❑ Replace after disassembly

❑ 25 Nm 21 - Straps

❑ pay attention to different lengths 22 - fuel feed line

❑ black 23 - Fuel filter

❑ not in vehicles with fuel filter in flange of the fuel delivery unit

❑ Summary of components 24 - Screw clamp

❑

not in vehicles with fuel filter in flange of the fuel delivery unit

25 - Vent line

❑ to solenoid valve 1 for activated charcoal filter in engine compartment 26 - Vent line

❑ between activated charcoal filter Pos. 14 and vent line Pos. 25

⇒ “5.3.3 Checking the fuel tank venting, Rapid NH”, page 132

⇒ “4.1 Summary of components - fuel filter”, page 121

Fitting location of the fuel delivery unit

• Clutch -2- on the fuel delivery unit closing flange must point to

opening -arrow- and be between tabs -3- and -4- on the fuel tank locking ring.

10 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

Inspect vent valve If the lever is in the rest position, the air bleed valve must be

closed. If the lever is pressed in the -direction

is then opened.

Note

of arrow-, the air bleed valve

Before installation of the vent valve unscrew the cap from the filler neck.

1.1.2 Summary of components - fuel tank, Octavia III, vehicles with front-wheel drive

1 - Screw cap

❑ screw

❑ attached to the fuel tank

2 - Earth connection

❑ for fuel filler neck ❑ for discharging the elec‐

3 - Screw

❑

❑ 8 Nm + 90°

4 - Lock ring

❑ 110 Nm

5 - Sealing ring

❑ Replace after disas‐

❑ install when dry

6 - Fuel pump - G6-

❑ with integrated fuel filter,

❑ Checking fuel pump

❑ Fitting position

❑

in until there is an

audible click

lid unit with anti-loss washer

trostatic charge

⇒ Fig. ““Earth connec‐ tion for fuel filler neck”“ , page 31

Replace after disas‐ sembly

sembly

the fuel filter cannot be replaced individually

electrics ⇒ Vehicle diag‐ nostic tester

⇒ Fig. ““Fitting location of the fuel delivery unit”“ , page 12

Summary of components

⇒ “2.1.1 Assembly overview - Fuel pump for pre- feed G6 , Vehicles with front-wheel drive and with fuel filter in the flange of the fuel delivery unit”, page 81

Removing and installing

⇒ “2.3.1 Fuel pump for pre-delivery G6 Removing and installing front-wheel drive vehicles, Octavia III, Yeti”, page 93

1. Fuel tank 11

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Fuel system - Petrol engines - Edition 12.2018

❑ inspecting fuel pump ⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

7 - Fuel tank

❑

Removing and installing

⇒ “1.2.2 Removing and installing fuel tank Octavia III, vehicles with front-wheel drive”, page 27

8 - Heat shield

❑

for fuel tank

9 - Shield locking mechanism

❑ for heat shield ❑ Qty. 4

10 - Tensioning strap

❑ mark installed position before removing ❑ check correct fitting

11 - Screw

❑ Replace after disassembly ❑ 20 Nm + 90°

12 - Mounting bracket

❑ For fuel pump control unit -J538-

13 - Mounting bracket

❑ for vehicles with auxiliary heating ❑ for dosing pump -V54❑ pay attention to correct fit of the dosing pump in the holder

14 - Fuel line

❑ to the engine ❑ pushed into the fuel tank ❑ do not kink ❑ disconnect and connect

15 - Fuel line

❑

for vehicles with auxiliary heating ❑ to the dosing pump -V54❑ do not kink ❑ disconnect and connect

16 - Dosing pump -V54-

❑

for vehicles with auxiliary heating

⇒ “3.1 Separating push-on couplings”, page 117

Fitting location of the fuel delivery unit

• The marking -2- on the closing flange of the fuel pump -1- must be located opposite to the arrow -3- on the fuel tank.

12 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

1.1.3 Summary of components -fuel tank, Yeti, front-wheel drive vehicles

1 - Screw cap

❑ screw

❑ attached to the fuel tank

2 - Earth connection

❑ for fuel filler neck ❑ check for firm seating

3 - Screw

❑ Replace after disas‐

❑ 11 Nm 4 - Wiring 5 - Screw

❑ Replace after disas‐

❑ 25 Nm 6 - Fuel tank

❑ Removing and installing

7 - Circlip 8

- Bracket for the exhaust sys‐

tem 9 - Tensioning strap

❑ mark installed position

❑ check correct fitting 10 - Heat shield

❑ for fuel tank 11 - fuel feed line

❑ to the engine

❑ pushed into the fuel tank

❑ do not kink

❑ disconnect and connect 12 - Fuel filter

❑

❑ Summary of components 13 - Vent line

❑

❑ check for firm seating 14 - Sealing ring

❑ Replace after disassembly

❑ install when dry

in until there is an

audible click

lid unit with anti-loss washer

sembly

⇒ “1.2.3 Removing and installing the fuel tank, Yeti - vehicles with frontwheel drive”, page 31

before removing

⇒ “3.1 Separating push-on couplings”, page 117

Fitting position: arrow points in direction of flow

⇒ “4.1 Summary of components - fuel filter”, page 121

pushed into the fuel tank

1. Fuel tank 13

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Fuel system - Petrol engines - Edition 12.2018

15 - Fuel pump - G6-

❑

with fuel gauge sender - G-

❑ Removing and installing

⇒ “2.3.1 Fuel pump for pre-delivery G6 Removing and installing front-wheel drive vehicles, Octavia III, Yeti”, page 93

❑

inspecting fuel pump

❑

Summary of components

❑

Fitting position

❑

Removing and installing the fuel gauge sender - G-

⇒ “2.4.1 Removing and installing the fuel gauge sender display G , vehicles with front-wheel drive”, page 113

❑

disconnect and connect

❑

Clean strainer if dirty

16 - Lock ring

❑ 110 Nm

17 - fuel feed line

❑ black ❑ pushed into the fuel tank ❑ check for firm seating

18 - Fuel return-flow line

❑ blue ❑ pushed into the fuel tank ❑ check for firm seating

19 - Fuel tank lid unit

❑ removing and installing ⇒ general body repairs, exterior; Rep. gr. 55 ; Fuel tank lid unit; installing and

removing fuel tank lid unit.

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge sender”, page 81

⇒ Fig. ““Fitting location of the fuel delivery unit”“ , page 14

⇒ “3.1 Separating push-on couplings”, page 117

Fitting location of the fuel delivery unit

• The peg -2- on the fuel delivery unit must be between the pegs

-1- and -3-.

Note

♦

The -arrow- shows the direction of travel.

♦

The fuel delivery unit can only be installed in this position.

14 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

1.1.4 Summary of components - fuel tank, Superb III, vehicles with front-wheel

drive

1 - Screw cap

❑ screw

❑ attached to the fuel tank

2 - Filler neck 3 - Screw

❑ Replace after disas‐

❑ 8 Nm + 90° 4 - Rubber buffer

❑ Qty. 4

❑ between fuel tank and

❑ check correct fitting 5 - Guide 6 - Screw

❑ Replace after disas‐

❑ 20 Nm + 90° 7 - Fuel tank

❑ Removing and installing

8 - Heat shield

❑ 9 - Clamping system

❑ for heat shield

❑ Qty. 4 10 - Tensioning strap

❑ mark installed position before removing

❑ check correct fitting

❑ Fitting position 11 - Tensioning strap

❑

❑ check correct fitting

❑ Fitting position 12 - Connected fuel hoses

❑

❑ disconnect and connect 13 - Fuel pump control unit - J538-

❑

in until there is an

audible click

lid unit with anti-loss washer

sembly

bodyshell

sembly

⇒ “1.2.4 Removing and installing fuel tank Su‐ perb III, vehicles with front-wheel drive”, page 34

for fuel tank

⇒ Fig. ““Attaching the fuel tank”“ , page 16

mark installed position before removing

⇒ Fig. ““Attaching the fuel tank”“ , page 16

do not kink

⇒ “3.1 Separating push-on couplings”, page 117

Removing and installing

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170

1. Fuel tank 15

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Fuel system - Petrol engines - Edition 12.2018

14 - Fuel pump - G6-

❑

with integrated fuel filter, the fuel filter cannot be replaced individually

❑ Removing and installing

⇒ “2.3.3 Fuel pump for pre-delivery G6 Removing and installing front-wheel drive vehicles, Superb III, Karoq, Kodiaq”, page 100

❑

Summary of components

⇒ “2.1.1 Assembly overview - Fuel pump for pre- feed G6 , Vehicles with front-wheel drive and with fuel filter in the flange of the fuel delivery unit”, page 81

15 - Earth connection

❑

for fuel filler neck

❑ for discharging the electrostatic charge

Attaching the fuel tank 1 - Tensioning strap for fuel tank 2 - Screw with washer 3 - Rubber holder 4 - guide bushing

⇒ Fig. ““Earth connection for fuel filler neck”“ , page 40

16 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

1.1.5 Summary of components -fuel tank, Kodiaq, front-wheel drive vehicles

1 - Screw cap

❑ screw

❑ attached to the fuel tank

2 - Filler neck 3 - Earth connection

❑ for fuel filler neck

❑ for discharging the elec‐

4 - Screw

❑

❑ 8 Nm + 90° 5 - Vent line

❑ to activated charcoal fil‐

❑ pushed into the fuel tank

❑ do not kink 6 - Rubber buffer

❑ Qty. 4

❑ between fuel tank and

❑ check correct fitting 7 - Fuel pump - G6-

❑ with integrated fuel filter,

❑ Removing and installing

❑

8 - Fuel tank

❑

9 - Clamping system

❑ 10 - Heat shield

❑ for fuel tank 11 - Tensioning strap

❑ check correct fitting 12 - Screw

❑ Replace after disassembly

in until there is an

audible click

lid unit with anti-loss washer

trostatic charge

⇒ Fig. ““Earth connec‐ tion for fuel filler neck”“ , page 47

Replace after disas‐ sembly

ter solenoid valve 1 N80- and to activated charcoal filter

bodyshell

the fuel filter cannot be replaced individually

⇒ “2.3.3 Fuel pump for pre-delivery G6 Removing and installing front-wheel drive vehicles, Superb III, Karoq, Kodiaq”, page 100

Summary of components

⇒ “2.1.1 Assembly overview - Fuel pump for pre- feed G6 , Vehicles with front-wheel drive and with fuel filter in the flange of the fuel delivery unit”, page 81

Removing and installing

⇒ “1.2.5 Removing and installing the fuel tank, Kodiaq - vehicles with front-wheel drive”, page 40

for heat shield

1. Fuel tank 17

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Fuel system - Petrol engines - Edition 12.2018

❑ 20 Nm + 90°

13 - Screw

❑

Replace after disassembly

❑ 20 Nm + 90°

14 - Mounting bracket

❑ Fuel pump control unit - J538❑ Removing and installing fuel pump control unit - J538-

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170

15 - Fuel line

❑

Vehicles fitted with auxiliary heating

❑ for dosing pump - V54❑ do not kink

16 - Fuel line

❑ to the engine ❑ pushed into the fuel tank ❑ do not kink

1.1.6 Summary of components -fuel tank, Karoq, vehicles with front-wheel drive

1 - Screw cap

❑ screw in until there is an

audible click

❑ attached to the fuel tank

lid unit with anti-loss washer

2 - Earth connection

❑ for fuel filler neck ❑ for discharging the elec‐

trostatic charge

⇒ Fig. ““Earth connec‐ tion for fuel filler neck”“ , page 52

3 - Screw

❑

Replace after disas‐ sembly

❑ 8 Nm + 90°

4 - Lock ring

❑ use wrench - T10202- or

-T30101 (3087)- for loosening and tighten‐ ing

❑ 110 Nm

5 - Sealing ring

❑ Replace after disas‐

sembly

❑ install when dry

6 - Fuel pump - G6-

❑ with integrated fuel filter,

the fuel filter cannot be replaced individually

❑ Removing and installing

⇒ “2.3.3 Fuel pump for

18 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

pre-delivery G6 Removing and installing front-wheel drive vehicles, Superb III, Karoq, Kodiaq”, page 100

❑

Summary of components

⇒ “2.1.1 Assembly overview - Fuel pump for pre- feed G6 , Vehicles with front-wheel drive and with fuel filter in the flange of the fuel delivery unit”, page 81

7 - Fuel tank

❑

Removing and installing

⇒ “1.2.6 Removing and installing the fuel tank, Karoq - vehicles with front-wheel drive”, page 47

8 - Heat shield

❑

for fuel tank

9 - Clamping system

❑ for heat shield 10 - Tensioning strap

❑ check correct fitting 11 - Screw

❑ Replace after disassembly

❑ 20 Nm + 90° 12 - Fuel pump control unit - J538-

❑ Removing and installing

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170

13 - Fuel line

❑

to the engine ❑ do not kink ❑ disconnect and connect

⇒ “3.1 Separating push-on couplings”, page 117

14 - Vent line

❑

to activated charcoal filter solenoid valve 1 - N80- and to activated charcoal filter ❑ do not kink

15 - Vent line

❑ to the activated charcoal filter system ❑ do not kink

1. Fuel tank 19

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Fuel system - Petrol engines - Edition 12.2018

1.1.7 Assembly overview - fuel tank, Octavia III, Superb III, Kodiaq, Karoq, fourwheel drive vehicles

1 - Screw cap

❑ screw

❑ attached to the fuel tank

2 - Screw

❑ Replace after disas‐

❑ 8 Nm + 90°

3 - Earth connection

❑ for fuel filler neck ❑ for discharging the elec‐

♦ For Superb III, Kodiaq ve‐

hicles

⇒ Fig. ““Earth connection for fuel filler support for Oc‐ tavia III, Superb III, Kodiaq vehicles”“ , page 58

♦

For the Karoq vehicles

⇒ Fig. ““Ground connection for fuel filler neck vehicles Karoq”“ , page 59

4 - Rubber buffer

❑ ❑ between fuel tank and

❑ check correct fitting

5 - Fuel tank

❑ Removing and installing

6 - Fuel pump - G6-

❑ ❑ Summary of components

❑

7 - Left fuel pump

❑ ❑ for fuel gauge transmitter 2 - G169❑ Summary of components ❑

❑ ❑

in until there is an

audible click

lid unit with anti-loss washer

sembly

trostatic charge:

Qty. 6

bodyshell

⇒ “1.2.7 Removing and installing fuel tank, Oc‐ tavia III, Superb III, Kodiaq, Karoq, four-wheel drive vehicles”, page 52

with integrated fuel filter, the fuel filter cannot be replaced individually

⇒ “2.1.3 Summary of components - fuel system pressurisation pump G6 , vehicles with four-wheel drive”, page 85

Removing and installing

⇒ “2.3.4 Fuel pump for pre-delivery G6 Removing and installing, all-wheel drive vehicles, Superb III, Karoq, Kodiaq”, page 104

with suction spray pump

Removing and installing

⇒ “2.3.6 Removing and installing the fuel pump closing flange on the left”, page 111

Removing and installing suction jet pump Removing and installing fuel gauge sender 2 - G169-

⇒ “2.5 Removing and installing fuel gauge sender 2 G169 ”, page 116

⇒ “2.1.5 Summary of components - left fuel pump”, page 89

⇒ “7.4 Removing and installing suction jet pump”, page 172

20 Rep. gr.20 - Fuel supply system

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8 - Rubber buffer 9 - Screw

❑

Replace after disassembly

❑ 20 Nm + 90°

10 - Tensioning strap

❑ mark installed position before removing ❑ check correct fitting ❑ Securing the fuel tank

⇒ Fig. ““Attaching the fuel tank”“ , page 16

11 - Guides 12 - Heat shield

❑

for fuel tank 13 - Vent line 14 - Dosing pump - V54-

❑ fir auxiliary heating

15 - Mounting bracket

❑ Fuel pump control unit - J538❑ Removing and installing

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170

Fuel system - Petrol engines - Edition 12.2018

1. Fuel tank 21

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Fuel system - Petrol engines - Edition 12.2018

1.1.8 Summary of components -fuel tank, Yeti, four-wheel drive vehicles

1 - fuel feed line

❑

black

❑ check for firm seating

2 - Fuel return-flow line

❑ blue ❑ check for firm seating

3 - Sealing ring

❑ replace ❑ insert dry into the open‐

ing of the fuel tank

❑ only moisten the inner

seal of the flange with fuel for fitting purposes

4 - Fuel pump

❑ Removing and installing

⇒ “2.3.5 Removing and installing fuel system pressurisation pump G6 , vehicles with fourwheel drive, Yeti”, page 107

❑

inspecting fuel pump

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

❑ note

❑ with

❑ Summary of components ❑

❑

5 - Lock ring

❑ 110 Nm

6 - Fuel pump control unit - J538-

❑ after replacing, adapt the engine control unit - J623- to the fuel pump control unit - J538- ⇒ Vehicle

7 - Screw cap

❑ replace if damaged 8 - Fixing screw 9 - Fuel tank lid unit

❑ with rubber bowl

❑ removing and installing ⇒ general body repairs, exterior; Rep. gr. 55 ; Fuel tank lid unit; installing and

the correct installa‐ tion position in the fuel tank

⇒ Fig. ““Fitting position of the fuel delivery unit and the fuel gauge sender 2 -G169- ”“ , page 24

fuel gauge sender -

G-

Removing and installing the fuel gauge sender - G-

⇒ “2.4.1 Removing and installing the fuel gauge sender display G , vehicles with front-wheel drive”, page 113

Clean strainer if dirty

diagnostic tester

removing fuel tank lid unit.

⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge sender”, page 81

22 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

10 - Earth connection

❑

check for firm seating

11 - Screw

❑ 11 Nm 12 - Tank ventilation 13 - Plug connection

❑ Fuel gauge transmitter 2 - G16914 - Fuel gauge transmitter 2 - G169-

❑ with suction jet pump integrated in the left fuel pump

❑ Removing and installing

❑

note the correct installation position in the fuel tank

⇒ “2.5 Removing and installing fuel gauge sender 2 G169 ”, page 116

⇒ Fig. ““Fitting position of the fuel delivery unit and the fuel gauge sender 2 -G169- ”“ , page 24

❑

Summary of components

⇒ “2.1.5 Summary of components - left fuel pump”, page 89

15 - Suction spray pump

❑

with fuel gauge transmitter 2 - G169- integrated into the fuel pump on the left

❑ Removing and installing

⇒ “2.3.6 Removing and installing the fuel pump closing flange on the left”, page 111

❑

Summary of components

⇒ “2.1.5 Summary of components - left fuel pump”, page 89

16 - Tank ventilation 17 - Vent line 18 - Fuel tank

❑

Removing and installing

⇒ “1.2.8 Removing and installing the fuel tank, Yeti - vehicles with four-wheel drive”, page 59

19 - Tensioning strap

❑

Check fitting position

20 - Screw

❑ Replace after disassembly ❑ 25 Nm

21 - Screw

❑ 23 Nm

22 - Cover plate

❑ riveted together with hanger of exhaust system

23 - Screw

❑ 3 Nm

24 - Fuel filter

❑ Summary of components

⇒ “4.1 Summary of components - fuel filter”, page 121

25 - Vent line

❑

Clipped onto side of fuel tank.

❑ check for firm seating

1. Fuel tank 23

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Fuel system - Petrol engines - Edition 12.2018

Fitting position of the fuel delivery unit and the fuel gauge sender 2 - G169-

Marking on the flange must be aligned with marking on the fuel tank -arrows-.

Note

The arrows on the fuel tank are hardly visible because of the floor panel.

1.2 Removing and installing the fuel tank

⇒ “1.2.1 Removing and installing the fuel tank, Rapid NH”, page 24

⇒ “1.2.2 Removing and installing fuel tank Octavia III, vehicles with front-wheel drive”, page 27

⇒ “1.2.3 Removing and installing the fuel tank, Yeti - vehicles with front-wheel drive”, page 31

⇒ “1.2.4 Removing and installing fuel tank Superb III, vehicles with front-wheel drive”, page 34

⇒ “1.2.5 Removing and installing the fuel tank, Kodiaq - vehicles with front-wheel drive”, page 40

⇒ “1.2.6 Removing and installing the fuel tank, Karoq - vehicles with front-wheel drive”, page 47

⇒ “1.2.7 Removing and installing fuel tank, Octavia III, Superb III, Kodiaq, Karoq, four-wheel drive vehicles”, page 52

⇒ “1.2.8 Removing and installing the fuel tank, Yeti - vehicles with four-wheel drive”, page 59

1.2.1 Removing and installing the fuel tank, Rapid NH

Special tools and workshop equipment required ♦ Engine/gearbox jack , e.g. -V.A.G 1383A-

• The fuel tank must be empty for weight reasons when remov‐

ing it. If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

Removing Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Switch

key. – Remove cover for fuel pump assembly opening

⇒ “2.2.1 Removing and installing cover of assembly opening,

Rapid NH, Yeti”, page 90 .

off ignition and all electrical loads, and pull out ignition

24 Rep. gr.20 - Fuel supply system

Page 29

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– Disconnect plug connection -arrow- at the closing flange.

– Open the fuel tank cap and clean around the fuel filler neck

-2-.

– Unscrew the cap -1- for the fuel filler neck.

Note

Close the opening of the fuel filler neck with a clean cloth so that no dirt can penetrate.

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing rear wheelhouse liner .

– Unscrew fixing screws on tank filler neck -arrows-. – Remove both ventilation lines from activated charcoal filter

⇒ “5.1.3 Summary of components - activated charcoal filter system, Rapid NH”, page 125 , Pos. 6 and 7.

– Remove rear axle ⇒ Chassis, axles, steering; Rep. gr. 42 ;

Rear axle; removing and installing rear axle .

– Remove centre and rear of exhaust system ⇒ Rep. gr. 26 ;

Exhaust pipes / exhaust; Remove and install centre and rear section

of the exhaust system . ⇒ Rep. gr. 26 ; Exhaust pipes /

exhaust; Removing and installing rear silencer .

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐

the connection point in order to relieve the pressure in the fuel

en system.

Wear protective spectacles and protective gloves.

For vehicles with fuel filter outside the fuel tank – Disconnect the feed line -1- and the vent line -2-

⇒ “3.1 Separating push-on couplings”, page 117 .

1. Fuel tank 25

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For vehicles with fuel filter in the flange of the fuel delivery unit – Disconnect

of the fuel tank. Continued for all vehicles – Support the fuel tank using the engine and gearbox jack -

V.A.G 1383A- . – Remove left underfloor trim panel ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underfloor trim panel; removing and

installing underfloor trim panels .

CAUTION

Risk of accident due to the fuel tank weight.

♦ The aid of a 2nd mechanic is required to remove the fuel tank

-1-.

– Unscrew tensioning straps and fixing screw of the fuel tank

-arrows-.

– Carefully lower the engine/gearbox jack -V.A.G 1383A- and

remove

ic. Fitting – Check both earth connections for corrosion, if necessary re‐

move corrosion.

the feed line -1-and the vent line on the front right

the fuel tank with the assistance of a second mechan‐

– Check fitting position of the earth lead -1-.

• The plug -1- on the metal plate ring -2- must be pushed on

firmly.

• The contact tab -4- must be hung on the fuel tank -3- and se‐

cured with the spacer bush -5-.

26 Rep. gr.20 - Fuel supply system

Page 31

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Further installation occurs in reverse order. Pay attention to the following:

Make sure that the heat shield for fuel tank -1- does not collide with the tunnel-heat shield

– Lay the vent and fuel lines without any kinks.

• The tunnel-heat shield -2- must slightly overlap with the fuel tank tunnel-heat shield in direction of travel -C-.

♦ Do not mix-up the feed line and the return-flow line (the return-

flow line is blue, the feed line is black).

♦ Make sure the line connections fit tightly. ♦ After installing the fuel tank, check whether the lines are also

clipped in place on the fuel tank.

CAUTION

Risk of electrostatic charge.

♦ After installation, check electrical connection using an ohm‐

meter.

♦ Check the connection of the metal ring on the fuel filler neck

with a bare metal part of the body.

• Specified value approx. 0 ohm.

If the specified value is not correct, there is a risk of explosion due to electrostatic charge.

-2- when installing the fuel tank.

WARNING

Risk of fuel container explosion on fuel pump start-up!

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.1 Summary of components - fuel tank, Rapid NH”, page 8 .

1.2.2 Removing and installing fuel tank Octa‐

via III, vehicles with front-wheel drive

Special tools and workshop equipment required ♦ Engine/gearbox jack , e.g. -V.A.G 1383A♦ Disassembly wedge - 3409-

• The fuel tank must be empty for weight reasons when remov‐ ing it. If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

1. Fuel tank 27

Page 32

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Removing Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Switch

key.

– Remove cover for fuel pump assembly opening

⇒ “2.2.2 Removing and installing cover of assembly opening -

Superb III, Octavia III, Karoq”, page 91 .

– Separate electrical plug connection -1-. – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

⇒ “7.2 Removing and installing fuel pump control unit J538 ”,

page 170 .

Vehicles fitted with auxiliary heating – Disconnect plug connection -2- of dosing pump - V54- .

off ignition and all electrical loads, and pull out ignition

-1-

Continued for all vehicles – Open the fuel tank cap and clean around the fuel filler neck

-2-.

– Unscrew the cap -1- for the fuel filler neck.

Note

Close the opening of the fuel filler neck with a clean cloth so that no dirt can penetrate.

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and

installing rear wheelhouse liner . – Remove rear right brake caliper and place sideways ⇒ Brak‐

ing systems; Rep. gr. 45 ; Sensors; Overview of components

- Speed sensor on the rear axle .

Note

Do not open the brake line when removing the brake calliper.

– Disconnect the plug connection at the ABS speed sensor and

undo the line from the brackets at the rear axle ⇒ Braking

systems; Rep. gr. 46 ; Rear wheel brake; overview of com‐

ponents - Rear wheel brake .

28 Rep. gr.20 - Fuel supply system

Page 33

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– Unscrew screws -1- and -2- for fuel filler neck.

Fuel system - Petrol engines - Edition 12.2018

– Remove

the vent lines -1- and -2- from the activated charcoal filter, do so by disconnecting the push-fit couplings

⇒ “3.1 Separating push-on couplings”, page 117 .

– Loosen ventilation lines from fasteners on the holder

-arrows-.

– Loosen ventilation line -1- from fastener on the holder

-arrow-.

– Remove centre and rear of exhaust system ⇒ Rep. gr. 26 ;

Exhaust pipes / exhaust; Remove and install centre and rear section

of the exhaust system . ⇒ Rep. gr. 26 ; Exhaust pipes /

exhaust; Removing and installing rear silencer .

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system.

– Disconnect vent line -3- and fuel line -2-

⇒ “3.1 Separating push-on couplings”, page 117 .

Note

For vehicles with auxiliary heating, the fuel line -1- for the dosing pump - V54- must also be disconnected

⇒ “3.1 Separating push-on couplings”, page 117 .

CAUTION

Risk of accident due to the fuel tank weight.

The fuel tank must be empty for removal

⇒ “1.3 Drain the fuel tank”, page 64 .

1. Fuel tank 29

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– Release screw -5-. – Remove holder for exhaust system retaining strap -arrow-. – Unscrew securing bolt -3- and remove tensioning strap -7-.

– Support the fuel tank using the engine/gearbox jack - V.A.G

1383A- .

– Unscrew locating screws -2-, -4- and -6-. – Remove

protection plate.

– Slightly lower the fuel tank using the engine and gearbox jack

- V.A.G 1383A- .

♦

The aid of a 2nd mechanic is required to remove the fuel tank.

♦

Make sure that the individual cables are not damaged.

– With the aid of a second mechanic, turn the fuel tank to one

side, and lower.

– Pull the filler tube through between the rear axle and body‐

shell.

Installing

securing nuts for heat shield of fuel tank and remove

Note

For vehicles with auxiliary heating and additional heating the dos‐ ing pump - V54- must also be tested for firm seating on the holder.

– Check both earth connections for corrosion, if necessary re‐

move corrosion.

– Check the fitting position of the earth lead.

30 Rep. gr.20 - Fuel supply system

Page 35

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Earth connection for fuel filler neck – Connect earth connection as shown in the illustration. Ensure proper seating of plug connection. ♦ Plug -2-

fuel filler neck.

– Hook the contact peg -1- of the earth connection into the

mounting hole on the fuel tank -4- and push in the distance sleeve -5-.

– Guide the filler neck between rear axle and structure with the

assistance of a 2nd mechanic. Then position the fuel tank onto the engine/gearbox jack - V.A.G 1383A- .

Further installation occurs in reverse order. However, pay atten‐ tion to the following:

♦ Vent and fuel lines must be laid without any kinks. ♦ Do not mix-up the feed line and the return-flow line (the return-

flow line is blue, the feed line is black).

♦ Make sure the line connections fit tightly. ♦ After installing the fuel tank, check whether the lines are also

clipped in place on the fuel tank.

of the earth connection on the threaded ring -3- of the

CAUTION

Risk of electrostatic charge.

♦ After installation, check electrical connection using an ohm‐

meter.

♦ Check the connection of the metal ring on the fuel filler neck

with a bare metal part of the body.

• Specified value approx. 0 ohm. If the specified value is not correct, there is a risk of explosion due

to electrostatic charge.

WARNING

Risk of fuel container explosion on fuel pump start-up!

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.2 Summary of components - fuel tank, Octavia III, ve‐ hicles with front-wheel drive”, page 11 .

1.2.3 Removing and installing the fuel tank, Yeti - vehicles with front-wheel drive

Special tools and workshop equipment required

1. Fuel tank 31

Page 36

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Fuel system - Petrol engines - Edition 12.2018

♦ Engine/gearbox jack , e.g. -V.A.G 1383A♦ Disassembly wedge - 3409-

• The fuel tank must be empty for weight reasons when remov‐ ing it. If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

Removing Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Switch

key.

– Remove cover for fuel pump assembly opening

⇒ “2.2.1 Removing and installing cover of assembly opening, Rapid NH, Yeti”, page 90 .

– Unlock and disconnect the connectors -1- from the fuel deliv‐

ery unit.

off ignition and all electrical loads, and pull out ignition

For vehicles with auxiliary heating – Disconnect plug connection -2- of dosing pump - V54- . – Remove

unit and pull out the wiring.

Continued for all vehicles – Open fuel tank cap. – Clean the area around the fuel filler neck. – Remove rear right wheel ⇒ Chassis, axles, steering; Rep. gr.

44 ; Wheels, tyres .

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing rear wheelhouse liner .

the rubber grommet from the cover of the fuel delivery

32 Rep. gr.20 - Fuel supply system

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– Unscrew screws -1- for fuel filler neck.

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system.

– Disconnect

push-fit couplings on the ventilation line -1- (white) and fuel feed line -2- (black)

⇒ “3.1 Separating push-on couplings”, page 117 .

For vehicles with auxiliary heating – Disconnect the fuel line from the dosing pump - V54- . Continued for all vehicles – Remove the central and rear part of the exhaust system ⇒

Rep.

gr. 26 ; Silencer/muffler; Remove and install central part

of exhaust system .

CAUTION

Risk of accident due to the fuel tank weight.

♦ The aid of a 2nd mechanic is required to remove the fuel tank.

– Unscrew securing bolts -2- and -4- and remove tensioning

strap.

– Remove

securing nuts for heat shield of fuel tank and remove

protection plate.

– Support the fuel tank using the engine/gearbox jack - V.A.G

1383A- .

– Unscrew securing bolts -1- and -3-. – Slightly lower the fuel tank using the engine and gearbox jack

- V.A.G 1383A- .

Make sure that the individual cables are not damaged. – Turn the fuel tank to one side and lower. – Pull the filler tube through between the rear axle and body‐

shell.

Installing – Check both earth connections for corrosion, if necessary re‐

move corrosion.

1. Fuel tank 33

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– Check fitting position of the earth lead -1-.

• The plug -1- must be firmly fitted to the metal plate ring -2-.

• The contact tab -4- must be hung on the fuel tank -3- and se‐ cured with the spacer bush

– With the aid of a second mechanic, pull the filler tube through

between the rear axle and bodyshell and support fuel tank with the engine/gearbox jack - V.A.G 1383A- .

Further installation occurs in reverse order. However, pay atten‐ tion to the following:

♦ Vent and fuel lines must be laid without any kinks. ♦ Do not mix-up the feed line and the air bleed valve (the air

bleed valve is white, the feed line is black).

♦ Make sure the line connections fit tightly. ♦ After installing the fuel tank, check whether the lines are also

clipped in place on the fuel tank.

CAUTION

Risk of electrostatic charge.

-5-.

♦ After installation, check electrical connection using an ohm‐

meter.

♦ Check the connection of the metal ring on the fuel filler neck

with a bare metal part of the body.

• Specified value approx. 0 ohm.

If the specified value is not correct, there is a risk of explosion due to electrostatic charge.

WARNING

Risk of fuel container explosion on fuel pump start-up!

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.3 Summary of components -fuel tank, Yeti, front-wheel drive vehicles”, page 13 .

1.2.4 Removing and installing fuel tank Su‐

Special tools and workshop equipment required ♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931-

• The fuel tank must be empty for weight reasons when remov‐ ing it. If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

perb III, vehicles with front-wheel drive

34 Rep. gr.20 - Fuel supply system

Page 39

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Removing Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Move front seats all the way forward. – Switch

off ignition and all electrical loads, and pull out ignition

key.

– Remove cover for fuel pump assembly opening

⇒ “2.2.2 Removing and installing cover of assembly opening -

Superb III, Octavia III, Karoq”, page 91 .

– Separate electrical plug connection -1-. – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

-1-

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170 .

Vehicles fitted with auxiliary heating – Disconnect plug connection -2- from auxiliary heating dosing

pump - V54- .

Continued for all vehicles – Open the fuel tank cap and clean around the fuel filler neck

-2-.

– Unscrew the cap -1- for the fuel filler neck. – Close the opening of the fuel filler neck with a clean plug, so

that no dirt can penetrate.

– Remove

rear right wheel ⇒ Chassis, axles, steering; Rep. gr.

44 ; Wheels, tyres; wheel change .

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing rear wheelhouse liner .

– Unscrew screws -1- and -2- for fuel filler neck.

1. Fuel tank 35

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Fuel system - Petrol engines - Edition 12.2018

– Remove

filter, do so by disconnecting the push-fit couplings

⇒ “3.1 Separating push-on couplings”, page 117 .

– Loosen ventilation lines from fasteners on the holder

-arrows-.

– Undo the vent line -1- from the fastening on the mounting

bracket -arrows-.

– Remove rear right underfloor trim panel ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Underfloor trim panel; installing and removing underfloor trim panels .

– Remove

ing ; Rep. gr. 42 ; Rear axle; Remove and install rear axle .

Risk of injury caused by fuel which is under high pressure.

the vent lines -1- and -2- from the activated charcoal

the rear axle trim panel ⇒ Running gear, axles, steer‐

CAUTION

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

Vehicles without auxiliary heating – Disconnect

⇒ “3.1 Separating push-on couplings”, page 117 .

Vehicles fitted with auxiliary heating – Disconnect the fuel line -1- to the auxiliary heating, fuel line

-2- to the engine and vent line

⇒ “3.1 Separating push-on couplings”, page 117 .

the fuel line -1- and vent line -2- on the underbody

-3- on the underbody

36 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

Continued for all vehicles – Mark the installation position -arrow- between wheel bearing

housing -1- and trailing arm

-2- rear right.

– Mark in the area indicated -arrow- on the trailing arm.

Vehicles with electronically controlled damping (ECD) – Disconnect the plug connection -1- at the shock absorber

-2-.

– Disconnect line -3- from the shock absorber -2- -arrow-.

Note

If there are signs of moisture blow out the contacts on the shock absorber and connector with compressed air.

Continued for all vehicles – Disconnect electrical plug connection -1- on the right side of

the vehicle from the ABS speed sensor and place it on the side.

– Disconnect electrical plug connection -2- on the right side of

the vehicle from the electromechanical parking brake motor.

– Remove the electric wiring harness from the holders

-arrows- and expose.

– Support the wheel bearing unit with the engine and gearbox

jack -1-.

– Unscrew screws -2- and -3-. – Remove engine and gearbox jack .

1. Fuel tank 37

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Fuel system - Petrol engines - Edition 12.2018

– Swing trailing arm -2- downwards.

– Support the fuel tank -1- using the engine and gearbox jack -

V.A.G 1383A- -2-.

CAUTION

Risk of accident due to the fuel tank weight.

♦ The aid of a 2nd mechanic is required to remove the fuel tank

-1-.

– Remove screws -arrows-.

Note

To improve the visualisation, the fuel tank -1- is shown without the engine and gearbox jack - V.A.G 1383 A- .

– Lower the fuel tank slightly and pull the fuel filler neck out of

the sealing grommet of the fuel tank lid unit. – Lower fuel tank by pivoting it to one side and downwards. – Pull the filler tube through between the rear axle and body‐

shell. Installing The installation occurs in reverse order. Pay attention to the fol‐

lowing: – Pull through between the rear axle and the fixture. – If present, check for firm seating of the dosing pump - V54- on

the bracket. – Lay the vent and fuel lines without any kinks. Make sure the rubber buffer Pos. 4 is seated correctly

⇒ Item 4 (page 15) .

– If present, clip the lines for the auxiliary heating onto the fuel

tank. – Use engine and gearbox jack to position fuel tank on under‐

body.

38 Rep. gr.20 - Fuel supply system

Page 43

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Make sure that the filler neck of the fuel tank is correctly inserted into the opening of the fuel tank lid unit

-2-.

Make sure that the sealing grommet of the fuel tank lid unit -2- is seated correctly on the fuel filler neck.

– Tighten screws -arrows- hand-tight.

Note

To provide a clearer illustration, the fuel tank is shown without the engine/gearbox jack .

Note the position of the straps. – Lower engine and gearbox jack . Make sure the line connections fit tightly

⇒ “3.1 Separating push-on couplings”, page 117 .

– Check they are firm by pulling!

– Align

wheel bearing housing -1- and steering gear -2- to each

other.

– Use the marks you have already made -arrow- for this pur‐

pose. – Tighten screws -3-. – Check if the earth lead shows traces of oxidation on the plugs,

remove if necessary.

1. Fuel tank 39

Page 44

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

Earth connection for fuel filler neck – Check the fitting position of the earth joint.

• The plug -2- must be firmly fitted to the metal plate ring -3-.

• The contact peg -1- must be hung in the fuel tank -4- and se‐ cured with the spacer bush

CAUTION

Risk of electrostatic charge.

– Check the connection of the metal ring on the fuel filler neck

by measuring between the ring and a bare metal part of the body using an ohmmeter.

• Specified value approx. 0 ohm.

If the specified value is not correct, there is a risk of explosion due to electrostatic charge.

WARNING

Risk of fuel container explosion on fuel pump start-up!

-5-.

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.4 Summary of components - fuel tank, Superb III, ve‐ hicles with front-wheel drive”, page 15 .

♦ Wheel bolts ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels,

tyres; wheel change.

♦ Underfloor trim panel ⇒ General body repairs, exterior; Rep.

gr. 66 ; Underfloor trim panel .

1.2.5 Removing and installing the fuel tank,

Kodiaq - vehicles with front-wheel drive

Special tools and workshop equipment required ♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-

• The fuel tank must be empty for weight reasons when remov‐ ing it. If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

Removing Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Move front seats all the way forward.

40 Rep. gr.20 - Fuel supply system

Page 45

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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– Switch

off ignition and all electrical loads, and pull out ignition

key.

– Remove cover for fuel pump assembly opening

⇒ “2.2.3 Removing and installing cover of assembly opening,

Kodiaq”, page 92 .

– Separate electrical plug connection -1-. – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

-1-

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170 .

Vehicles fitted with auxiliary heating – Disconnect plug connection -2- from auxiliary heating dosing

pump - V54- .

Continued for all vehicles – Open the fuel tank cap and clean around the fuel filler neck

-2-.

– Unscrew the cap -1- for the fuel filler neck. – Close the opening of the fuel filler neck with a clean plug, so

that no dirt can penetrate.

– Guide the sealing grommet -1- out of the filler neck -arrows-. – Remove rear right wheel ⇒ Chassis, axles, steering; Rep. gr.

44 ; Wheels, tyres; wheel change .

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing rear wheelhouse liner .

– Unscrew screws -1- and -2- for fuel filler neck.

1. Fuel tank 41

Page 46

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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– Remove

filter, do so by disconnecting the push-fit couplings

⇒ “3.1 Separating push-on couplings”, page 117 .

– Loosen ventilation lines from fasteners on the holder

-arrows-.

– Loosen ventilation line -1- from fastener on the holder

-arrow-.

– Remove rear right underfloor trim panel ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Underfloor trim panel; installing and removing underfloor trim panels .

– Remove heat shield of fuel tank ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Underfloor trim panel; installing and removing underfloor trim panels .

– Remove

ing ; Rep. gr. 42 ; Rear axle; Remove and install rear axle .

– Remove the rear silencer of the exhaust system ⇒ Rep. gr.

26 ; Exhaust pipes/silencer; removing and installing silencer .

the vent lines -1- and -2- from the activated charcoal

the rear axle trim panel ⇒ Running gear, axles, steer‐

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

Vehicles without auxiliary heating – Disconnect

⇒ “3.1 Separating push-on couplings”, page 117 .

the fuel line -1- and vent line -2- on the underbody

42 Rep. gr.20 - Fuel supply system

Page 47

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

Vehicles fitted with auxiliary heating – Disconnect the fuel line -1- to the auxiliary heating, fuel line

-2- to the engine and vent line

-3- on the underbody

⇒ “3.1 Separating push-on couplings”, page 117 .

Continued for all vehicles – Mark the installation position -arrow- between wheel bearing

housing -1- and trailing arm

-2- rear right.

– Mark in the area indicated -arrow- on the trailing arm.

Vehicles with electronically controlled damping (ECD) – Disconnect the plug connection -1- at the shock absorber

-2-.

– Disconnect line -3- from the shock absorber -2- -arrow-.

Note

If there are signs of moisture blow out the contacts on the shock absorber and connector with compressed air.

Continued for all vehicles – Disconnect electrical plug connection -1- on the right side of

the vehicle from the ABS speed sensor and place it on the side.

– Disconnect electrical plug connection -2- on the right side of

the vehicle at the engine on the electromechanical parking brake on the brake caliper.

– Remove the electric wiring harness from the holders

-arrows- and expose.

1. Fuel tank 43

Page 48

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

– Support the wheel bearing unit with the engine and gearbox

jack -1-. – Unscrew screws -2- and -3-. – Remove engine and gearbox jack .

– Swing trailing arm -2- downwards.

– Unscrew screws arrows -A-. – Remove tensioning strap -2-.

– Remove heat shield for fuel tank -1-. – To do so, remove the lock washers -arrows-. – Remove heat shield on fuel tank.

44 Rep. gr.20 - Fuel supply system

Page 49

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

– Support the fuel tank -1- using the engine and gearbox jack -

V.A.G 1383A- -2-.

CAUTION

Risk of accident due to the fuel tank weight.

♦ The aid of a 2nd mechanic is required to remove the fuel tank

-1-.

– Remove screws -arrow B-.

Note

To improve the visualisation, the fuel tank -1- is shown without the engine and gearbox jack - V.A.G 1383 A- .

– Lower fuel tank by pivoting it to one side and downwards. – Pull the filler tube through between the rear axle and body‐

shell. Installing The installation occurs in reverse order. Pay attention to the fol‐

lowing: – Pull through between the rear axle and the fixture. – If present, check for firm seating of the dosing pump - V54- on

the bracket. – Lay the vent and fuel lines without any kinks. Make sure the rubber buffer Pos. 6 is seated correctly

⇒ Item 6 (page 17) .

– If present, clip the lines for the auxiliary heating onto the fuel

tank. – Use engine and gearbox jack to position fuel tank on under‐

body.

Make sure that the filler neck of the fuel tank is correctly inserted into the opening of the fuel tank lid unit.

Make sure that the sealing grommet -1-

is seated correctly on the

filler neck of the fuel tank.

1. Fuel tank 45

Page 50

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

– Tighten screws -arrows B- by hand.

Note

To provide a clearer illustration, the fuel tank is shown without the engine/gearbox jack .

– Lower engine and gearbox jack . – Install the heat shield. – Install tensioning strap and tighten screws -arrows A- hand-

tight.

Make sure that the brackets for the exhaust system are correctly seated ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Summary of components - silencers .

Make sure the line connections fit tightly

⇒ “3.1 Separating push-on couplings”, page 117 .

– Check they are firm by pulling!

– Align

– Use the marks you have already made -arrow- for this pur‐

– Tighten screws -3-. – Check if the earth lead shows traces of oxidation on the plugs,

wheel bearing housing -1- and steering gear -2- to each

other.

pose.

remove if necessary.

46 Rep. gr.20 - Fuel supply system

Page 51

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

Earth connection for fuel filler neck – Check the fitting position of the earth joint.

• The plug -2- must be firmly fitted to the metal plate ring -3-.

• The contact peg -1- must be hung in the fuel tank -4- and se‐

cured with the spacer bush

CAUTION

Risk of electrostatic charge.

– Check the connection of the metal ring on the fuel filler neck

by measuring between the ring and a bare metal part of the

body using an ohmmeter.

• Specified value approx. 0 ohm. If the specified value is not correct, there is a risk of explosion due

to electrostatic charge.

WARNING

Risk of fuel container explosion on fuel pump start-up!

-5-.

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.5 Summary of components -fuel tank, Kodiaq, front-

wheel drive vehicles”, page 17 .

♦ Wheel bolts ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels,

tyres; wheel change. ♦ Exhaust pipes ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Sum‐

mary of components- silencers ♦ Underfloor trim panel ⇒ General body repairs, exterior; Rep.

gr. 66 ; Underfloor trim panel .

1.2.6 Removing and installing the fuel tank,

Karoq - vehicles with front-wheel drive

Special tools and workshop equipment required ♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931-

• The fuel tank must be empty for weight reasons when remov‐

ing it. If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

Removing Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

1. Fuel tank 47

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Move front seats all the way forward. – Switch

key.

– Remove cover for fuel pump assembly opening

⇒ “2.2.2 Removing and installing cover of assembly opening -

Superb III, Octavia III, Karoq”, page 91 .

– Separate electrical plug connection -1-. – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

⇒ “7.2 Removing and installing fuel pump control unit J538 ”,

page 170 .

Vehicles fitted with auxiliary heating – Disconnect plug connection -2- from auxiliary heating dosing

pump - V54- .

off ignition and all electrical loads, and pull out ignition

-1-

Continued for all vehicles – Open the fuel tank cap and clean around the fuel filler neck

-2-. – Unscrew the cap -1- for the fuel filler neck. – Close the opening of the fuel filler neck with a clean plug, so

that no dirt can penetrate.

– Remove

44 ; Wheels, tyres; wheel change .

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing rear wheelhouse liner .

– Unscrew screws -1- and -2- for fuel filler neck.

rear right wheel ⇒ Chassis, axles, steering; Rep. gr.

48 Rep. gr.20 - Fuel supply system

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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– Remove

the vent lines -1- and -2- from the activated charcoal filter, do so by disconnecting the push-fit couplings

⇒ “3.1 Separating push-on couplings”, page 117 .

– Loosen ventilation lines from fasteners on the holder

-arrows-.

– Undo the vent line -1- from the fastening on the mounting

bracket -arrows-.

– Remove rear axle ⇒ Chassis, axles, steering; Rep. gr. 42 ;

Rear axle; removing and installing rear axle .

– Remove the rear silencer of the exhaust system ⇒ Rep. gr.

; Exhaust pipes/silencer; removing and installing silencer .

– Remove heat shield for fuel tank.

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

Vehicles without auxiliary heating – Disconnect

the fuel line -1- and vent line -2- on the underbody

⇒ “3.1 Separating push-on couplings”, page 117 .

Vehicles fitted with auxiliary heating – Disconnect the fuel line -1- to the auxiliary heating, fuel line

-2- to the engine and vent line

-3- on the underbody

⇒ “3.1 Separating push-on couplings”, page 117 .

1. Fuel tank 49

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Continued for all vehicles – Unscrew screws -3- and -5-. – Remove tensioning strap -7-.

– Support the fuel tank -1- using the engine and gearbox jack -

VAS 6931- .

– Remove screws -2-, -4- and -6-.

CAUTION

Risk of accident due to the fuel tank weight.

♦ The aid of a 2nd mechanic is required to remove the fuel tank

-1-.

♦ To improve the visualisation, the fuel tank -1- is shown without

the engine and gearbox jack - VAS 6931- .

– Lower the fuel tank slightly and pull the fuel filler neck out of

the sealing grommet of the fuel tank lid unit. – Lower fuel tank by pivoting it to one side and downwards. Installing The installation occurs in reverse order. Pay attention to the fol‐

lowing: – If present, check for firm seating of the dosing pump - V54- on

the bracket. – Lay the vent and fuel lines without any kinks. – If present, clip the lines for the auxiliary heating onto the fuel

tank. – Use engine and gearbox jack to position fuel tank on under‐

body.

50 Rep. gr.20 - Fuel supply system

Page 55

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Fuel system - Petrol engines - Edition 12.2018

Make sure that the filler neck of the fuel tank is correctly inserted into the opening of the fuel tank lid unit

-2-.

Make sure that the sealing grommet of the fuel tank lid unit -2- is seated correctly on the fuel filler neck.

– Tighten screws -2- -4- and -6- hand-tight.

Note

To provide a clearer illustration, the fuel tank is shown without the engine/gearbox jack .

– Lower engine and gearbox jack . – Install tensioning strap -7- and tighten screws-3- and -5- by

hand.

Make sure the line connections fit tightly

⇒ “3.1 Separating push-on couplings”, page 117 .

– Check they are firm by pulling! – Check

if the earth lead shows traces of oxidation on the plugs,

remove if necessary.

1. Fuel tank 51

Page 56

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

Earth connection for fuel filler neck – Check the fitting position of the earth joint.

• The plug -2- must be firmly fitted to the metal plate ring -1-.

• The contact lug -4-

CAUTION

Risk of electrostatic charge.

– Check the connection of the metal ring on the fuel filler neck

by measuring between the ring and a bare metal part of the

body using an ohmmeter.

• Specified value approx. 0 ohm. If the specified value is not correct, there is a risk of explosion due

to electrostatic charge.

WARNING

Risk of fuel container explosion on fuel pump start-up!

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

must be hung in the fuel tank and secured.

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.6 Summary of components -fuel tank, Karoq, vehicles

with front-wheel drive”, page 18 .

♦ Rear axle ⇒ Chassis, axles, steering; Rep. gr. 42 ; Rear axle;

removing and installing rear axle. ♦ Wheel bolts ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels,

tyres; wheel change. ♦ Exhaust pipes ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Sum‐

mary of components- silencers

1.2.7 Removing

and installing fuel tank, Octa‐ via III, Superb III, Kodiaq, Karoq, fourwheel drive vehicles

Special tools and workshop equipment required ♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-

• The fuel tank must be empty for weight reasons when remov‐ ing it. If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

Removing Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

52 Rep. gr.20 - Fuel supply system

Page 57

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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Fuel system - Petrol engines - Edition 12.2018

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Move front seats all the way forward. – Switch

off ignition and all electrical loads, and pull out ignition

key.

– Remove cover of right assembly opening

⇒ “2.2 Removing and installing cover of assembly opening”,

page 90 .

– Disconnect plug connections -1- and -2-. – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

-1-

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170 .

Vehicles fitted with auxiliary heating – Disconnect plug connection -3- from auxiliary heating dosing

pump - V54- .

Continued for all vehicles – Remove cover of assembly opening on left

⇒ “2.2 Removing and installing cover of assembly opening”, page 90 .

– Separate electrical plug connection -1-. – Separate electrical plug connection -2-. – If present, disconnect electrical plug connection -3-.

– Open the fuel tank cap and clean around the fuel filler neck

-2-.

– Unscrew the cap -1- for the fuel filler neck. – Close the opening of the fuel filler neck with a clean plug, so

that no dirt can penetrate.

– Remove rear right wheel ⇒ Chassis, axles, steering; Rep. gr.

44 ; Wheels, tyres; wheel change .

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing rear wheelhouse liner .

1. Fuel tank 53

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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– Unscrew screws -1- and -2- for fuel filler neck.

– Remove

filter, do so by disconnecting the push-fit couplings

⇒ “3.1 Separating push-on couplings”, page 117 .

– Loosen ventilation lines from fasteners on the holder

-arrows-.

– Loosen ventilation line -1- from fastener on the holder

-arrow-.

– Remove rear right underfloor trim panel ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Underfloor trim panel; installing and removing underfloor trim panels .

– Remove heat shield of fuel tank ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Underfloor trim panel; installing and removing underfloor trim panels .

– Remove

ing ; Rep. gr. 42 ; Rear axle; Remove and install rear axle .

– Remove the rear silencer of the exhaust system ⇒ Rep. gr.

26 ; Exhaust pipes/silencer; removing and installing silencer .

– Remove propshaft from flange of four-wheel drive clutch ⇒

Propshaft and rear final drive; Rep. gr. 39 ; Final drive; remove and install final drive .

– Unclip wiring harness -2- on the fuel tank.

the vent lines -1- and -2- from the activated charcoal

the rear axle trim panel ⇒ Running gear, axles, steer‐

54 Rep. gr.20 - Fuel supply system

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– Disconnect connector -1- for four-wheel drive clutch.

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

Vehicles without auxiliary heating – Disconnect

the fuel line -1- and vent line -2- on the underbody

⇒ “3.1 Separating push-on couplings”, page 117 .

Vehicles fitted with auxiliary heating – Disconnect the fuel line -1- to the auxiliary heating, fuel line

-2- to the engine and vent line -3- on the underbody

⇒ “3.1 Separating push-on couplings”, page 117 .

For vehicles Octavia III – Remove the rear right brake caliper ⇒ Braking system; Rep.

gr. 46 ; Rear brake; Removing and installing brake caliper .

– Strap brake caliper to the body.

Continued for all vehicles – Mark the installation position -arrow- between wheel bearing

housing -1- and trailing arm -2- rear right.

– Mark in the area indicated -arrow- on the trailing arm.

1. Fuel tank 55

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Vehicles with electronically controlled damping (ECD) – Disconnect the plug connection -1- at the shock absorber

-2-.

– Disconnect line -3- from the shock absorber -2- -arrow-.

Note

If there are signs of moisture blow out the contacts on the shock absorber and connector with compressed air.

Continued for all vehicles – Disconnect electrical plug connection -1- on the right side of

the vehicle from the ABS speed sensor and place it on the side.

– Disconnect electrical plug connection -2- on the right side of

the vehicle from the electromechanical parking brake motor.

– Remove the electric wiring harness from the holders

-arrows- and expose.

– Support the wheel bearing unit with the engine and gearbox

jack -1-. – Unscrew screws -2- and -3-. – Remove engine and gearbox jack .

For the Karoq vehicles – Remove and place on the side electrical wiring harness -2-

from stock -1-. – Mark the installed position of the bearing -1- on the body. – Remove screws -arrows-. – Remove longitudinal guide together with bearing -1- .

56 Rep. gr.20 - Fuel supply system

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For Octavia III, Superb III, Kodiaq vehicles – Swing trailing arm -2- downwards. Continued for all vehicles – Loosen heat shield for fuel tank.

– Support the fuel tank -1- using the engine and gearbox jack -

V.A.G 1383A- -2-.

CAUTION

Risk of accident due to the fuel tank weight.

♦ The aid of a 2nd mechanic is required to remove the fuel tank

-1-.

– Unscrew securing bolts -arrows-.

Note

To improve the visualisation, the fuel tank -1- is shown without the engine and gearbox jack - V.A.G 1383 A- .

– Remove heat shield for fuel tank. – Lower the fuel tank slightly and pull the fuel filler neck out of

the sealing grommet of the fuel tank lid unit. – Lower fuel tank by pivoting it to one side and downwards. – Pull the filler tube through between the rear axle and body‐

shell. Installing The installation occurs in reverse order. Pay attention to the fol‐

lowing: – Pull through between the rear axle and the fixture. – If present, check for firm seating of the dosing pump - V54- on

the bracket. – Lay the vent and fuel lines without any kinks. Make sure the rubber buffer Pos. 4 is seated correctly

⇒ Item 4 (page 20) .

– If present, clip the lines for the auxiliary heating onto the fuel

tank. – Use engine and gearbox jack to position fuel tank on under‐

body.

1. Fuel tank 57

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Make sure that the filler neck of the fuel tank is correctly inserted into the opening of the fuel tank lid unit

Make sure that the sealing grommet of the fuel tank lid unit -2- is seated correctly on the fuel filler neck.

– Tighten screws -arrows- hand-tight.

Note

-2-.

To improve the visualisation, the fuel tank -1- is shown without the engine and gearbox jack - V.A.G 1383 A- .

Note the position of the straps. – Install the heat shield. – Lower engine and gearbox jack . Make sure the line connections fit tightly

⇒ “3.1 Separating push-on couplings”, page 117 .

– Check they are firm by pulling! Make sure that the brackets for the exhaust system are correctly

seated ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Summary of components - silencers .

– Align

– Use the marks you have already made -arrow- for this pur‐

– Tighten screws -3-. – Check if the earth lead shows traces of oxidation on the plugs,

Earth connection for fuel filler support for Octavia III, Superb III, Kodiaq vehicles

– Check the fitting position of the earth joint.

• The plug -2- must be firmly fitted to the metal plate ring -3-.

• The contact peg -1- must be hung in the fuel tank -4- and se‐

wheel bearing housing -1- and steering gear -2- to each

other.

pose.

remove if necessary.

cured with the spacer bush

-5-.

58 Rep. gr.20 - Fuel supply system

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Ground connection for fuel filler neck vehicles Karoq – Check the fitting position of the earth joint.

• The plug -2- must be firmly fitted to the metal plate ring -1-.

• The contact lug -4Continued for all vehicles

CAUTION

Risk of electrostatic charge.

– Check the connection of the metal ring on the fuel filler neck

by measuring between the ring and a bare metal part of the

body using an ohmmeter.

• Specified value approx. 0 ohm. If the specified value is not correct, there is a risk of explosion due

to electrostatic charge.

WARNING

Risk of fuel container explosion on fuel pump start-up!

must be hung in the fuel tank and secured.

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.7 Assembly overview - fuel tank, Octavia III, Superb III,

Kodiaq, Karoq, four-wheel drive vehicles”, page 20 .

♦ Wheel bolts ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels,

tyres; wheel change. ♦ Exhaust pipes ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Sum‐

mary of components- silencers ♦ Propshaft ⇒ Propshaft and rear final drive; Rep. gr. 39 ; Prop‐

shaft; Summary of components - propshaft ♦ Underfloor trim panel ⇒ General body repairs, exterior; Rep.

gr. 66 ; Underfloor trim panel .

1.2.8 Removing and installing the fuel tank,

Yeti - vehicles with four-wheel drive

Special tools and workshop equipment required ♦ Engine/gearbox jack , e.g. -V.A.G 1383A-

• The fuel tank must be empty for weight reasons when remov‐

ing it. If necessary, extract fuel from the fuel tank

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”,

page 140 .

1. Fuel tank 59

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Removing Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Switch

nition lock.

– Remove cover for fuel pump assembly opening

⇒ “2.2.1 Removing and installing cover of assembly opening, Rapid NH, Yeti”, page 90 .

– Unplug connector -1- from fuel temperature sender.

off all electrical components and withdraw key from ig‐

For vehicles with auxiliary heating – Disconnect plug connection -2- of dosing pump - V54- . – Remove

unit and pull out the wiring.

Continued for all vehicles – Remove

on the right) and disconnect the connectors on the right

-arrows-. – Open the fuel tank cap and clean around the fuel filler neck. – Unscrew the cap from the fuel filler neck. – Seal the opening with a clean piece of foam to prevent the

ingress of foreign bodies.

– Remove the rear right wheelhouse liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing rear wheelhouse liner .

the rubber grommet from the cover of the fuel delivery

the cover of fuel gauge sender 2 - G169- (in the figure

60 Rep. gr.20 - Fuel supply system

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– Remove screws -1- for filler neck on the body. – Unclip the electrical cable from the bracket -2- at the top and

bottom of the filler neck.

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system.

– Disconnect

push-fit couplings on the ventilation line -1- (white) and fuel feed line -2- (black)

⇒ “3.1 Separating push-on couplings”, page 117 .

For vehicles with auxiliary heating – Disconnect the fuel line from the dosing pump - V54- .

Continued for all vehicles – Remove rear tunnel bridge -arrows-. – Remove the central and rear part of the exhaust system ⇒

gr. 26 ; Silencer/muffler; Remove and install central part

Rep. of exhaust system .

– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.

39 ; Propshaft; Summary of components - propshaft

– Disconnect plug -arrow- at four-wheel drive control unit -

J492- .

1. Fuel tank 61

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– Unhook the wiring harness -arrows- and place to the side.

– Unscrew screws -2- and -5-.

– Support the fuel tank using the engine and gearbox jack -

V.A.G 1383A- .

CAUTION

Risk of accident due to the fuel tank weight.

♦ The aid of a 2nd mechanic is required to remove the fuel tank. – Unscrew the screws for the tensioning straps -1-, -3-, -4- and

-6-.

– Slightly

- V.A.G 1383A- .

– Then remove the fuel tank from the engine/gearbox jack -

V.A.G 1383A- and pull through the filler neck between the

body and the rear axle with the help of a second mechanic. Make sure that the individual cables are not damaged. Fitting – Check both earth connections for corrosion, if necessary re‐

move corrosion.

lower the fuel tank using the engine and gearbox jack

62 Rep. gr.20 - Fuel supply system

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– Check fitting position of the earth lead -1-.

• The plug -1- must be firmly fitted to the metal plate ring -2-.

• The contact tab -4- must be hung on the fuel tank -3- and se‐ cured with the spacer bush

-5-.

– Pull through the filler neck between the body and the rear axle

with the help of a second mechanic. Then position the fuel tank onto the engine/gearbox jack - V.A.G 1383A- .

Further installation occurs in reverse order. Pay attention to the following:

♦ Lay the vent and fuel lines without any kinks. ♦ Do not mix-up the feed line and the return-flow line (the return-

flow line is blue, the feed line is black).

♦ Make sure the line connections fit tightly. ♦ Check the earth connection of the fuel tank at the body on the

filler neck.

♦ After installing the fuel tank, check whether the lines are also

clipped in place on the fuel tank.

CAUTION

Risk of electrostatic charge.

♦ After installation, check electrical connection using an ohm‐

meter.

♦ Check the connection of the metal ring on the fuel filler neck

with a bare metal part of the body.

• Specified value approx. 0 ohm.

If the specified value is not correct, there is a risk of explosion due to electrostatic charge.

WARNING

Risk of fuel container explosion on fuel pump start-up!

After installing a new or completely emptied fuel tank, you must replenish a minimum of 5 litres of fuel right away.

– Refill at least 5 litres of fuel. Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel tank

⇒ “1.1.8 Summary of components -fuel tank, Yeti, four-wheel drive vehicles”, page 22 .

1. Fuel tank 63

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1.3 Drain the fuel tank

⇒ “1.3.1 Emptying the fuel tank when fuel pump is not damaged, vehicles with front-wheel drive”, page 64

⇒ “1.3.2 Emptying the fuel tank when fuel pump is not damaged, vehicles with four-wheel drive”, page 67

⇒ “1.3.3 Emptying fuel tank when the fuel pump is damaged when more than 3/4 full, Superb III”, page 69

⇒ “1.3.4 Emptying fuel tank when the fuel pump is damaged when more than 3/4 full, Kodiaq, Karoq, Octavia III”, page 71

⇒ “1.3.5 Emptying fuel tank when the fuel pump is damaged when fuel tank is more than 3/4 full, Yeti, Rapid NH”, page 72

⇒ “1.3.6 Emptying fuel tank when the fuel pump is damaged when less than 3/4 full - vehicles with front-wheel drive”, page 73

⇒ “1.3.7 Emptying fuel tank when the fuel pump is damaged when less than 3/4 full - vehicles with four-wheel drive”, page 76

1.3.1 Emptying the fuel tank when fuel pump is not damaged, vehicles with frontwheel drive

Special tools and workshop equipment required ♦ Fuel extraction device , e.g. -VAS 5190♦ Adapter for fuel extraction - VAS 5190/3♦ Remote control - V.A.G 1348/3A♦ Auxiliary measuring set, , e. g. -V.A.G 1594 C♦ Adapter - VAS 5565Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

Note

If the fuel extraction device - VAS 5190- is still fitted with an ex‐ traction hose with a fixed tip, replace it by the version with a screwtype tip.

64 Rep. gr.20 - Fuel supply system

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– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .

– Screw on fuel extraction adapter - VAS 5190/3- to extraction

house.

– Switch

off ignition and all electrical loads, and pull out ignition

key.

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

For vehicles Rapid NH – Pull

off the fuel supply line -2- and catch the fuel that escapes with a cloth. Unlock the quick coupling and disconnect

⇒ “3.1 Separating push-on couplings”, page 117 .

For the vehicles Yeti – Pull

off the fuel supply line -1- and catch the fuel that escapes with a cloth. Unlock the quick coupling and disconnect

⇒ “3.1 Separating push-on couplings”, page 117 .

Continued for other vehicles – Pull

off the fuel supply line -1- and catch the fuel that escapes with a cloth. Unlock the quick coupling and disconnect

⇒ “3.1 Separating push-on couplings”, page 117 .

1. Fuel tank 65

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Continued for all vehicles – Connect

er for the fuel extraction - VAS 5190 /3- to the fuel feed line.

– Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

– Remove cover of assembly opening

⇒ “2.2 Removing and installing cover of assembly opening”, page 90 .

– Disconnect plug connection -1- at fuel pump. Vehicles fitted with auxiliary heating – Disconnect plug connection -2- from auxiliary heating dosing

pump - V54- .

the fuel extraction device - VAS 5190- with the adapt‐

Continued for all vehicles – Connect remote control - V.A.G 1348/3A- to the adapter for

measuring method/DSO (5-pin) - VAS 5565- and to battery

positive (+). – Connect adapter - VAS 5565- to fuel pump -1-. – Connect remote control - V.A.G 1348/3A- to adapter -

VAS

5565- and to battery positive terminal in engine compart‐

ment. – Connect connection -5- (yellow) from the adapter - VAS 5565-

with adapter cables -3- from the adapter set - V.A.G 1594 C-

to the minus pole terminal on the battery.

Note

This step is only intended to ensure that the fuel pump runs when the engine is switched off.

66 Rep. gr.20 - Fuel supply system

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– Open the fuel tank cap and clean around the fuel filler neck

-2-. – Unscrew the cap -1- for the fuel filler neck. – Operate

tap on the fuel extraction device - VAS 5190- until the fuel tank is emptied.

the remote control - V.A.G 1348/3A- and the shut-off

NOTICE

Risk of damage to fuel pump.

The fuel pump must not run »dry«.

1.3.2 Emptying the fuel tank when fuel pump

is not damaged, vehicles with fourwheel drive

Special tools and workshop equipment required ♦ Fuel extraction device , e.g. -VAS 5190♦ Adapter for fuel extraction - VAS 5190/3♦ Remote control - V.A.G 1348/3A♦ Auxiliary measuring set, , e. g. -V.A.G 1594 CObserve safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

Note

If the fuel extraction device - VAS 5190- is still fitted with an ex‐ traction hose with a fixed tip, replace it by the version with a screwtype tip.

– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .

– Screw on fuel extraction adapter - VAS 5190/3- to extraction

house.

– Switch off ignition and all electrical loads, and pull out ignition

key.

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

1. Fuel tank 67

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– Pull

– Collect the fuel which flows out with a cleaning cloth.

– Connect

– Secure the earth cable of the fuel extraction device to a bare

– Remove cover of right assembly opening

off the fuel supply line -1- and catch the fuel that escapes with a cloth. Unlock the quick coupling and disconnect

⇒ “3.1 Separating push-on couplings”, page 117 .

the fuel extraction device - VAS 5190- with the adapt‐

er for the fuel extraction - VAS 5190 /3- to the fuel feed line.

metal part of the body.

⇒ “2.2 Removing and installing cover of assembly opening”, page 90 .

– Disconnect plug connection -1- at fuel pump.

68 Rep. gr.20 - Fuel supply system

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– Connect remote control - V.A.G 1348/3A- with adapter cable

- V.A.G 1348/3–3- and adapter cable from the adapter set V.A.G 1594C- to contact -1-.

– Cover

– Use the adapter cable from the adapter set - V.A.G 1594C- to

– Connect remote control - V.A.G 1348/3A- to the battery posi‐

the second contact of the adapter cable - V.A.G 1348/3–

3- -arrow- with insulating tape to prevent a short circuit.

connect contact -2- to the battery negative terminal -A-.

tive terminal -B-.

Note

This step is only intended to ensure that the fuel pump runs when the engine is switched off.

– Open the fuel tank cap and clean around the fuel filler neck

-2-. – Unscrew the cap -1- for the fuel filler neck. – Operate

tap on the fuel extraction device - VAS 5190- until the fuel tank is emptied.

the remote control - V.A.G 1348/3A- and the shut-off

NOTICE

Risk of damage to fuel pump.

The fuel pump must not run »dry«.

1.3.3 Emptying fuel tank when the fuel pump

damaged when more than 3/4 full, Su‐

is perb III

Special tools and workshop equipment required ♦ Fuel extraction device - VAS 5190Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

1. Fuel tank 69

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– Mark the hose -arrow- at a distance -a- from the end of the

extraction hose for the fuel extraction device - VAS 5190- .

Note

Use insulating tape for this purpose.

Fuel tank Vehicles with front-

wheel drive Vehicles with four-

wheel drive

– Open the fuel tank cap and clean around the fuel filler neck

-2-. – Unscrew the cap -1- for the fuel filler neck. – Unscrew the cap from the fuel filler neck. – Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

– Screw cylinder end piece -1- of the fuel extraction device -

VAS 5190- onto the filler neck of the fuel tank.

– Push

the extraction hose of the fuel extraction device into the fuel tank until the marking -arrow- comes as far as the cylinder end piece.

Distance -a880 mm

980 mm

Note

A ball valve -2- is located at the bottom of the filler neck in the fuel tank -1-; it must not be damaged by the extraction hose -3-. Therefore, the hose must only be pushed in up to the previously made marking -arrow-.

– Drain the fuel tank through the filler neck as much as possible. When no more fuel is extracted, the fuel tank is emptied just

enough for the sender flange to be opened safely. – Carefully pull out the extraction hose.

70 Rep. gr.20 - Fuel supply system

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1.3.4 Emptying fuel tank when the fuel pump is damaged when more than 3/4 full, Ko‐

diaq, Karoq, Octavia III

Special tools and workshop equipment required ♦ Fuel extraction device - VAS 5190Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Mark the hose -arrow- at a distance -a- from the end of the

extraction hose for the fuel extraction device - VAS 5190- .

Note

Use insulating tape for this purpose.

♦ Kodiaq, Karoq vehicles: distance -a- = 1100 mm ♦ Octavia III vehicles: distance -a- = 1010 mm

– Open the fuel tank cap and clean around the fuel filler neck

-2-. – Unscrew the cap -1- for the fuel filler neck. – Unscrew the cap from the fuel filler neck. – Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

1. Fuel tank 71

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– Push

the extraction hose of the fuel extraction device into the

fuel tank until the marking -arrow- is up to the filler neck -2-.

Note

There is a flap -1- at the bottom end of the fuel filler neck-2-, which must not get damaged by the extraction hose. Therefore, the hose must only be pushed in up to the previously made marking

-arrow-.

– Drain the fuel tank through the filler neck as much as possible. When no more fuel is extracted, the fuel tank is emptied just

enough for the sender flange to be opened safely. – Carefully pull out the extraction hose. If the extraction hose gets stuck at the check valve while being

pulled out, do not pull it out violently. In this case, proceed as follows:

– Remove the fuel system pressurisation pump - G6-

⇒ “2.3 Removing and installing fuel pump/fuel gauge sender”, page 93 .

– Hold the check valve open by hand. Wear protective gloves

make sure that your arm does not come into contact with

and fuel.

1.3.5 Emptying fuel tank when the fuel pump damaged when fuel tank is more than

/4 full, Yeti, Rapid NH

Special tools and workshop equipment required ♦ Fuel extraction device , e.g. -VAS 5190Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

– Remove cone of valve -2- from the cylinder end piece -1- of

the fuel extraction device , e.g. -VAS 5190- .

72 Rep. gr.20 - Fuel supply system

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– Make a mark -arrow- on hose with insulating tape at distance

-a- = 1180 mm from end of extraction hose. – Open the fuel tank cap and clean around the fuel filler neck. – Unscrew the cap from the fuel filler neck. – Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

– Screw the cylinder end piece -1- of the fuel extraction device

onto the filler neck of the fuel tank.

– Push the extraction hose of the fuel extraction device as far

into the fuel tank holder as necessary until the previously ap‐ plied marking -arrow- terminates with the cylinder end piece

-1-.

A ball valve -2tank; it must not be damaged by the extraction hose -3-. There‐ fore, the hose must only be pushed in up to the marking made earlier -arrow-.

– Drain the fuel tank through the filler neck as much as possible. – Carefully pull out the extraction hose.

is located at the bottom of the filler neck in the fuel

1.3.6 Emptying fuel tank when the fuel pump

is damaged when less than 3/4 full - ve‐ hicles with front-wheel drive

Special tools and workshop equipment required ♦ Fuel extraction device , e.g. -VAS 5190♦ Wrench for union nut - T10202- or -T30101 (3087)- . Observe safety measures when working on the fuel system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

1. Fuel tank 73

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– Remove cover of assembly opening

⇒ “2.2 Removing and installing cover of assembly opening”,

page 90 .

– Disconnect plug connection -1- at the closing flange. For Octavia III, Superb III, Kodiaq, Karoq vehicles – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

⇒ “7.2 Removing and installing fuel pump control unit J538 ”,

page 170 .

Vehicles fitted with auxiliary heating – Disconnect plug connection -2- of dosing pump - V54- . Continued for all vehicles

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel system.

Wear protective spectacles and protective gloves.

-1-

For vehicles with fuel filter in the flange of the fuel delivery unit – Remove fuel line -1- from closing flange

⇒ “3.1 Separating push-on couplings”, page 117 .

For vehicles with fuel filter outside the fuel tank – Disconnect the black feed line -1- and the blue return line -2-

from the flange

⇒ “3.1 Separating push-on couplings”, page 117 .

74 Rep. gr.20 - Fuel supply system

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Vehicles fitted with auxiliary heating – Disconnect

fuel line -2- to dosing pump - V54- for the auxiliary heating from the closing flange

⇒ “8.2 Removing and installing the fuel line for the auxiliary heating”, page 177 .

– To do so, open the bottom clamp. – Carefully pull out fuel line -2-.

Continued for all vehicles – Open

the lock ring with wrench - T10202- or -T30101 (3087)- .

– Carefully raise the flange of the fuel system pressurisation

pump - G6- -3-.

– Remove gasket -1- from the opening of the fuel tank and care‐

fully raise the flange of the fuel pump slightly higher.

– Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

1. Fuel tank 75

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– Insert suction hose of fuel extractor - VAS 5190- as far as

possible into fuel tank. – Extract fuel using the fuel extraction device - VAS 5190- . If the fuel tank only needs to be emptied, re-install the fuel pump

⇒ “2.3 Removing and installing fuel pump/fuel gauge sender”, page 93 .

Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel pump lock ring

⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐

er”, page 81 .

1.3.7 Emptying fuel tank when the fuel pump

is damaged when less than 3/4 full - ve‐ hicles with four-wheel drive

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

– Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary

heater and fuel system”, page 6 .

– Remove cover of right assembly opening

⇒ “2.2 Removing and installing cover of assembly opening”,

page 90 .

76 Rep. gr.20 - Fuel supply system

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– Disconnect the plug connections -1- and -2- on the closing

flange. For Octavia III, Superb III, Kodiaq, Karoq vehicles – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

-1-

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170 .

Vehicles fitted with auxiliary heating – Unhook plug connection -3- for the dosing pump - V54- from

the closing flange.

– Disconnect plug connection -3- of dosing pump - V54- . Continued for all vehicles

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

For vehicles with fuel filter in the flange of the fuel delivery unit – Remove fuel line -1- from closing flange

⇒ “3.1 Separating push-on couplings”, page 117 .

For vehicles with fuel filter outside the fuel tank – Disconnect the black feed line -1- and the blue return line -2-

from the flange

⇒ “3.1 Separating push-on couplings”, page 117 .

1. Fuel tank 77

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Vehicles fitted with auxiliary heating – Disconnect

heating from the closing flange

⇒ “8.2 Removing and installing the fuel line for the auxiliary heating”, page 177 .

Continued for all vehicles – Open

fuel line -2- to dosing pump - V54- for the auxiliary

the lock ring with wrench - T10202- or -T30101 (3087)- .

– Carefully raise the flange of the fuel system pressurisation

pump - G6- -3-.

– Remove gasket -1- and raise the fuel delivery unit flange

slightly higher.

– Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

78 Rep. gr.20 - Fuel supply system

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– Insert suction hose of fuel extractor - VAS 5190- as far as

possible into fuel tank.

– Extract fuel using the fuel extraction device - VAS 5190- .

– Remove cover of assembly opening on left

⇒ “2.2 Removing and installing cover of assembly opening”, page 90 .

– Separate electrical plug connection -1-. – Separate electrical plug connection -2-. – If present, disconnect electrical plug connection -3-. – Loosen

plug connections -1- and -3- from the supports on the

closing flange.

– Open

the lock ring with wrench - T10202- or -T30101 (3087)- .

1. Fuel tank 79

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Fuel system - Petrol engines - Edition 12.2018

– Pull

– Secure the earth cable of the fuel extraction device to a bare

– Insert suction hose of fuel extractor - VAS 5190- as far as

– Extract fuel using the fuel extraction device - VAS 5190- . If the fuel tank only needs to be emptied, re-install the fuel pumps

⇒ “2.3 Removing and installing fuel pump/fuel gauge sender”, page 93 .

Tightening torques - summaries of components

the closing flange -3- with the suction spray pump -1- par‐

tially out of the opening of the fuel tank.

metal part of the body.

possible into fuel tank.

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦ Fuel pump lock ring right

⇒ “2.1.3 Summary of components - fuel system pressurisation pump G6 , vehicles with four-wheel drive”, page 85 .

♦ Fuel pump lock ring left

⇒ “2.1.5 Summary of components - left fuel pump”, page 89 .

80 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

2 Fuel delivery unit, fuel gauge sender

⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge sender”, page 81

⇒ “2.2 Removing and installing cover of assembly opening”, page 90

⇒ “2.3 Removing and installing fuel pump/fuel gauge sender”, page 93

⇒ “2.4 Removing and installing the fuel gauge sender G ”, page 113

⇒ “2.5 Removing and installing fuel gauge sender 2 G169 ”, page 116

2.1 Assembly overview - fuel delivery unit, fuel gauge sender

⇒ “2.1.1 Assembly overview - Fuel pump for pre- feed G6 , Vehi‐ cles with front-wheel drive and with fuel filter in the flange of the fuel delivery unit”, page 81

⇒ “2.1.2 Assembly overview - Fuel pump for pre- feed G6 , Vehi‐ cles with front-wheel drive and with fuel filter external to the fuel delivery unit”, page 83

⇒ “2.1.3 Summary of components - fuel system pressurisation pump G6 , vehicles with four-wheel drive”, page 85

⇒ “2.1.4 Summary of components - fuel system pressurisation pump G6 , vehicles with auxiliary heating”, page 87

⇒ “2.1.5 Summary of components - left fuel pump”, page 89

2.1.1 Assembly overview - Fuel pump for prefeed - G6- , Vehicles with front-wheel drive and with fuel filter in the flange of the fuel delivery unit

For Rapid NH, Octavia III, Superb III, Kodiaq, Karoq vehicles

2. Fuel delivery unit, fuel gauge sender 81

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Fuel system - Petrol engines - Edition 12.2018

1 - Fuel pump - G6-

❑ with

❑ Checking fuel pump

❑ inspecting fuel pump

❑

Removing and installing: ♦

Octavia III

⇒ “2.3.1 Fuel pump for predelivery G6 Removing and installing front-wheel drive vehicles, Octavia III, Yeti”, page 93

♦

Rapid NH

⇒ “2.3.2 Removing and in‐ stalling fuel pump for predelivery G6 G6, Rapid NH”, page 97

♦

Superb III, Kodiaq, Karoq

⇒ “2.3.3 Fuel pump for predelivery G6 Removing and installing front-wheel drive vehicles, Superb III, Karoq, Kodiaq”, page 100

❑

2 - Sealing ring

❑ ❑ install when dry

3 - Lock ring

❑ use wrench - T10202- or -T30101 (3087)- for loosening and tightening ❑ 110 Nm

4 - Fuel pump control unit - J538-

❑ Removing and installing ❑

5 - Plug connection

❑ Ensure safe locking by pulling

6 - Plug connection

❑ Ensure safe locking by pulling

7 - Fuel line

❑ to the engine ❑ do not kink ❑ disconnect and connect

integrated fuel filter, the fuel filter cannot be replaced individually

electrics ⇒ Vehicle diag‐ nostic tester

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

Connect fuel lines

⇒ Fig. ““Connect the fuel lines to the fuel pump.”“ , page 83

Installation position, variant 1

⇒ Fig. ““Installation po‐ sition of the fuel pump, variant 1”“ , page 83

Installation position, variant 2

Replace after disassembly

Check ⇒ Vehicle diagnostic tester

⇒ Fig. ““Installation position of the fuel pump, variant 2”“ , page 83

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170

⇒ “3.1 Separating push-on couplings”, page 117

82 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

8 - Fuel gauge sender - G-

❑

Removing and installing

⇒ “2.4.1 Removing and installing the fuel gauge sender display G , vehicles with front-wheel drive”, page 113

❑

Check with the fuel pump control unit - J538- ⇒ Vehicle diagnostic tester

Installation position of the fuel pump, variant 1

• The marking -2- on the closing flange of the fuel pump -1- must

be located opposite to the arrow -3- on the fuel tank.

Note

arrow points in direction of travel.

Installation position of the fuel pump, variant 2

• The tab -2- on the closing flange of the fuel pump must be

located between tabs -1- and -3- on the fuel tank.

Note

arrow points in direction of travel.

Connect the fuel lines to the fuel pump. 1 - fuel feed line 2 - Fuel line to the dosing pump - V54-

2.1.2 Assembly

overview - Fuel pump for prefeed - G6- , Vehicles with front-wheel drive and with fuel filter external to the fuel delivery unit

For Rapid NK, Yeti vehicles

Note

The fuel pumps of Yeti vehicles with four-wheel drive also have fuel line to the vacuum pump with fuel gauge sender 2 - G169- .

2. Fuel delivery unit, fuel gauge sender 83

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Fuel system - Petrol engines - Edition 12.2018

1 - Lock ring

❑

110 Nm

2 - Fuel line

❑ Black, feed line to en‐

gine ❑ do not kink ❑ disconnect and connect

⇒ “3.1 Separating push-

on couplings”,

page 117

3 - Fuel line

❑

Blue, return line ❑ do not kink ❑ disconnect and connect

⇒ “3.1 Separating push-

on couplings”,

page 117

4 - Flange 5 - Fuel gauge sender - G-

❑ Removing

⇒ “2.4.1 Removing and

installing the fuel gauge

sender display G , vehi‐

cles with front-wheel

drive”, page 113

❑

Check with the fuel

pump control unit -

J538- ⇒ Vehicle diag‐

nostic tester

6 - Fuel pump - G6-

❑ Checking fuel pump

electrics ⇒ Vehicle diag‐

nostic tester ❑ inspecting fuel pump ❑

Removing and installing

♦ Octavia III, Yeti

⇒ “2.3.1 Fuel pump for pre-delivery G6 Removing and installing front-wheel drive vehicles, Octavia III, Yeti”, page 93

♦

Rapid NH

7 - Sealing ring

❑

Replace after disassembly ❑ install when dry

and installing

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

⇒ “2.3.2 Removing and installing fuel pump for pre-delivery G6 G6, Rapid NH”, page 97

84 Rep. gr.20 - Fuel supply system

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Fuel system - Petrol engines - Edition 12.2018

2.1.3 Summary of components - fuel system pressurisation pump - G6- , vehicles with four-wheel drive

1 - Fuel pump - G6-

❑ with

❑ Checking fuel pump

❑ inspecting fuel pump

❑

❑ Removing

❑

2 - Sealing ring

❑

❑ install when dry

3 - Lock ring

❑ use wrench - T10202- or -T30101 (3087)- for loosening and tightening ❑ 110 Nm

4 - Plug connection

❑ Ensure safe locking by pulling

5 - Plug connection

❑ Ensure safe locking by pulling

6 - Fuel pump control unit - J538-

❑ Removing and installing ❑

7 - Fuel line

❑ to the engine ❑ do not kink ❑ disconnect and connect

integrated fuel filter, the fuel filter cannot be replaced individually

electrics ⇒ Vehicle diag‐ nostic tester

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

Connect fuel lines

⇒ Fig. ““Connect the fuel lines to the fuel pump.”“ , page 86

and installing

⇒ “2.3.4 Fuel pump for pre-delivery G6 Remov‐ ing and installing, allwheel drive vehicles, Superb III, Karoq, Ko‐ diaq”, page 104

Installation position, variant 1

⇒ Fig. ““Installation po‐ sition of the fuel pump, variant 1”“ , page 86

Installation position, variant 2

⇒ Fig. ““Installation po‐ sition of the fuel pump, variant 2”“ , page 86

Replace after disas‐ sembly

⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page 170

Check ⇒ Vehicle diagnostic tester

⇒ “3.1 Separating push-on couplings”, page 117

2. Fuel delivery unit, fuel gauge sender 85

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Fuel system - Petrol engines - Edition 12.2018

8 - Fuel gauge sender - G-

❑

Removing and installing

⇒ “2.4.2 Removing and installing the fuel gauge sender display G , vehicles with four-wheel drive”, page 115

❑

Check with the fuel pump control unit - J538- ⇒ Vehicle diagnostic tester

9 - Fuel line

❑ Part of left fuel pump ❑

do not kink

❑ disconnect and connect

Installation position of the fuel pump, variant 1

• The marking -2be located opposite to the arrow -3- on the fuel tank.

Note

on the closing flange of the fuel pump -1- must

⇒ “2.1.5 Summary of components - left fuel pump”, page 89

⇒ “3.1 Separating push-on couplings”, page 117

arrow points in direction of travel.

Installation position of the fuel pump, variant 2

• The tab -2- on the closing flange of the fuel pump must be located between tabs -1- and -3- on the fuel tank.

Note

arrow points in direction of travel.

Connect the fuel lines to the fuel pump. 1 - fuel feed line 2 - Fuel line to the dosing pump - V54-

86 Rep. gr.20 - Fuel supply system

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Plugs for fuel pump 1 - Plug for fuel system pressurisation pump - G62 - Plug for sender for fuel gauge display - G3 - Fuel feed line to the engine

Fuel system - Petrol engines - Edition 12.2018

2.1.4 Summary

of components - fuel system pressurisation pump - G6- , vehicles

with auxiliary heating

1 - Fuel pump - G6-

❑ with

❑ Checking fuel pump

❑ inspecting fuel pump

❑

❑ Removing

❑

2 - Clamp

❑

❑ Secure hose connec‐

3 - Clamp

❑ Replace after disassembly ❑ Secure hose connections with hose clamps that comply with the series design:

4 - Fuel line

❑ to the dosing pump - V54-

integrated fuel filter, the fuel filter cannot be replaced individually

electrics ⇒ Vehicle diag‐ nostic tester

⇒ “7.1 Checking the fuel system pressurisation pump G6 ”, page 140

Connect fuel lines

⇒ Fig. ““Connect the fuel lines to the fuel pump.”“ , page 88

and installing

⇒ “2.3 Removing and in‐ stalling fuel pump/fuel gauge sender”, page 93

Installation position, variant 1

⇒ Fig. ““Installation po‐ sition of the fuel pump, variant 1”“ , page 88

Installation position, variant 2

⇒ Fig. ““Installation po‐ sition of the fuel pump, variant 2”“ , page 88

Replace after disas‐ sembly

tions with hose clamps that comply with the ser‐ ies design:

2. Fuel delivery unit, fuel gauge sender 87

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❑ Removing and installing

⇒ “8.2 Removing and installing the fuel line for the auxiliary heating”, page 177

5 - Sealing grommet

❑

check for damage

❑ Removing and installing

⇒ “8.2 Removing and installing the fuel line for the auxiliary heating”, page 177

6 - Fuel line

❑

to the engine ❑ do not kink ❑ disconnect and connect

Installation position of the fuel pump, variant 1

• The marking -2be located opposite to the arrow -3- on the fuel tank.

Note

on the closing flange of the fuel pump -1- must

⇒ “3.1 Separating push-on couplings”, page 117

arrow points in direction of travel.

Installation position of the fuel pump, variant 2

• The tab -2- on the closing flange of the fuel pump must be located between tabs -1- and -3- on the fuel tank.

Note

arrow points in direction of travel.

Connect the fuel lines to the fuel pump. 1 - fuel feed line 2 - Fuel line to the dosing pump - V54-

88 Rep. gr.20 - Fuel supply system

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2.1.5 Summary of components - left fuel pump

1 - Plug connection

❑

Ensure safe locking by pulling

2 - Lock ring

❑ use wrench - T10202- or

-T30101 (3087)- for loosening and tighten‐ ing

❑ 110 Nm

3 - Sealing ring

❑ Replace after disas‐

sembly

❑ install when dry

4 - Fuel gauge transmitter 2 G169-

❑ Part of fuel pump Pos.

-5-

❑ Removing and installing

⇒ “2.5 Removing and in‐ stalling fuel gauge send‐ er 2 G169 ”, page 116

5 - Fuel pump, flange

❑ Removing

⇒ “2.3.6 Removing and installing the fuel pump closing flange on the left”, page 111

❑

Installation position, variant 1

⇒ Fig. ““Installation po‐ sition of the fuel pump, variant 1”“ , page 90

❑

Installation position, variant 2

⇒ Fig. ““Installation po‐ sition of the fuel pump, variant 2”“ , page 90

6 - Fuel line

❑

with suction spray pump ❑ Part of fuel pump Pos. -5❑ to fuel system pressurisation pump - G6❑ Removing and installing

and installing

⇒ “7.4 Removing and installing suction jet pump”, page 172

2. Fuel delivery unit, fuel gauge sender 89

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Installation position of the fuel pump, variant 1

• The marking -2be located opposite to the arrow -3- on the fuel tank.

Note

on the closing flange of the fuel pump -1- must

arrow points in direction of travel.

Installation position of the fuel pump, variant 2

• The tab -2- on the closing flange of the fuel pump must be located between tabs -1- and -3- on the fuel tank.

Note

arrow points in direction of travel.

2.2 Removing and installing cover of as‐

sembly opening

⇒ “2.2.1 Removing and installing cover of assembly opening, Rapid NH, Yeti”, page 90

⇒ “2.2.2 Removing and installing cover of assembly opening Superb III, Octavia III, Karoq”, page 91

⇒ “2.2.3 Removing and installing cover of assembly opening, Ko‐ diaq”, page 92

2.2.1 Removing and installing cover of as‐

sembly opening, Rapid NH, Yeti

For the vehicles Yeti – Remove

terior; Rep. gr. 72 ; Rear seat; Removing and installing bench seat / individual seats .

– Remove floor covering under the rear seats. For vehicles Rapid NH – Remove rear bench seat ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seat; Removing and installing bench seat / individual seats .

rear seats with brackets ⇒ General body repairs, in‐

90 Rep. gr.20 - Fuel supply system

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Continued for all vehicles – Unclip cover -4- with the fuel pump control unit - J538- -1-.

2.2.2 Removing and installing cover of as‐ sembly

opening - Superb III, Octavia III,

Karoq

Special tools and workshop equipment required ♦ Disassembly wedge - 3409-

Note

♦

On vehicles with four-wheel drive, the assembly openings are on the left and right.

♦

On vehicles with front-wheel drive, the assembly opening is on the right.

– Remove rear bench seat ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seat; Removing and installing bench seat /

individual seats . For Karoq vehicles, VARIOFLEX rear seats – Remove the rear seats and mounting brackets for the rear seat

connectors ⇒ Body - assembly work inside; Rep. gr. 72 ; Rear

seats; Removing and installing rear seat bench / single seat . Continued for all vehicles – Unclip cover -1- for closing flange from holder catches

-arrows- using the disassembly wedge - 3409- .

2. Fuel delivery unit, fuel gauge sender 91

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– Push the sealing grommet -1- downwards out of the cover

-2-.

– Guide cover -2- along the electrical wiring loom -3- in the di‐

rection of the fuel pump.

2.2.3 Removing and installing cover of as‐ sembly opening, Kodiaq

Special tools and workshop equipment required ♦ Disassembly wedge - 3409-

Note

♦

On vehicles with four-wheel drive, the assembly openings are on the left and right.

♦

On vehicles with front-wheel drive, the assembly opening is in the middle.

– Remove rear bench seat ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seat; Removing and installing bench seat / individual seats .

– Unclip cover -1- for closing flange from holder catches

-arrows- using the disassembly wedge - 3409- .

– Push the sealing grommet -2- downwards out of the cover

-1-.

– Guide cover -1- along the electrical wiring loom in the direction

of the fuel pump.

92 Rep. gr.20 - Fuel supply system

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2.3 Removing and installing fuel pump/fuel gauge sender

⇒ “2.3.1 Fuel pump for pre-delivery G6 Removing and installing front-wheel drive vehicles, Octavia III, Yeti”, page 93

⇒ “2.3.2 Removing and installing fuel pump for pre-delivery G6 G6, Rapid NH”, page 97

⇒ “2.3.3 Fuel pump for pre-delivery G6 Removing and installing front-wheel drive vehicles, Superb III, Karoq, Kodiaq”, page 100

⇒ “2.3.4 Fuel pump for pre-delivery G6 Removing and installing, all-wheel drive vehicles, Superb III, Karoq, Kodiaq”, page 104

⇒ “2.3.5 Removing and installing fuel system pressurisation pump G6 , vehicles with four-wheel drive, Yeti”, page 107

⇒ “2.3.6 Removing and installing the fuel pump closing flange on the left”, page 111

2.3.1 Fuel pump for pre-delivery - G6- Re‐ moving and installing front-wheel drive vehicles, Octavia III, Yeti

Special tools and workshop equipment required ♦ Disassembly wedge - 3409♦ Counterholder - T10202- or -T30101 (3087)Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 .

Observe rules for cleanliness

⇒ “3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system”, page 6 .

Follow the repair instructions

⇒ “4.1 General repair instructions”, page 7 .

Removing

•

The fuel tank must not be more than 3/4 full.

If necessary, extract fuel from the fuel tank

⇒ “1.3 Drain the fuel tank”, page 64 .

– Switch

key.

– Remove cover for fuel pump assembly opening

⇒ “2.2 Removing and installing cover of assembly opening”,

page 90 .

For vehicles Octavia III – Pull out and put fuel pump control unit - J538- to one side to‐

gether with the electrical wiring harness

⇒ “7.2 Removing and installing fuel pump control unit J538 ”,

page 170 .

off ignition and all electrical loads, and pull out ignition

-1-

2. Fuel delivery unit, fuel gauge sender 93

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– Separate electrical plug connection -1-.

For the vehicles Yeti – Unlock

closing flange.

and disconnect electrical plug connection -arrow- from

For vehicles with auxiliary heating – Disconnect plug connection -2- of dosing pump - V54- .

– Disconnect fuel line -2- to dosing pump - V54- for the auxiliary

heating from the closing flange

⇒ “8.2 Removing and installing the fuel line for the auxiliary heating”, page 177 .

Continued for all vehicles

CAUTION

Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully slack‐ en

the connection point in order to relieve the pressure in the fuel

system. Wear protective spectacles and protective gloves.

94 Rep. gr.20 - Fuel supply system

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For vehicles Octavia III – Disconnect fuel line -1- from the flange

⇒ “3.1 Separating push-on couplings”, page 117 .

For the vehicles Yeti – Disconnect the black feed line -1- and the blue return line -2-

from the flange

⇒ “3.1 Separating push-on couplings”, page 117 .

Continued for all vehicles – Open

the lock ring with wrench - T10202- or -T30101 (3087)- .

2. Fuel delivery unit, fuel gauge sender 95

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– Carefully raise the closing flange -2-. – Remove sealing ring -1- from fuel tank opening.

CAUTION

Risk of accident due to fuel flowing out of the fuel pump which is still full.

– Place a cloth below to absorb any fuel. – Remove

and fuel hoses are not damaged and the float arm of the send‐ er for fuel gauge display - G- is not bent.

fuel pump from the fuel tank so that the electric cables

Note

You must empty the old delivery unit before disposing of it if you wish to replace the fuel delivery unit.

Fitting – Insert the new dry gasket ring for the flange into the opening

of the fuel tank and moisten only from the inside with fuel for installing the closing flange.

– Insert the fuel pump into the fuel tank in such a way that the

float arm of the sender for the fuel gauge display - G- is not bent.

NOTICE

Risk of leaks if the sealing ring is damaged.

The gasket ring must not get damaged or squashed when insert‐ ing the sealing flange.

• Clutch -2opening -arrow- and be between tabs -3- and -4- on the fuel tank locking ring.

– Press down the closing flange against the spring force and

bring it into the installation position.

– Insert

to tighten.

on the fuel delivery unit closing flange must point to

lock ring and use wrench - T10202- or -T30101 (3087)-

96 Rep. gr.20 - Fuel supply system

SKODA Karoq 2018, Kodiaq 2017, Kodiaq 2019, Octavia III 2013, Octavia III 2014 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Denomination

1.1 Engine number, engine data

2 Safety instructions

2.1 Safety precautions when working on fuel supply system

3 General points

3.1 Cleanliness rules when working on the parking/auxiliary heater and fuel system

4 Repair instructions

4.1 General repair instructions

4.2 Contact corrosion

4.3 Cable routing and securing

20 – Fuel supply system

1 Fuel tank

1.1 Assembly overview - fuel tank

1.1.1 Summary of components - fuel tank, Rapid NH

1.1.2 Summary of components - fuel tank, Octavia III, vehicles with front-wheel drive

1.1.3 Summary of components -fuel tank, Yeti, front-wheel drive vehicles

1.1.5 Summary of components -fuel tank, Kodiaq, front-wheel drive vehicles

1.1.6 Summary of components -fuel tank, Karoq, vehicles with front-wheel drive

1.1.8 Summary of components -fuel tank, Yeti, four-wheel drive vehicles

1.2 Removing and installing the fuel tank

1.2.1 Removing and installing the fuel tank, Rapid NH

1.2.3 Removing and installing the fuel tank, Yeti - vehicles with front-wheel drive

1.3 Drain the fuel tank

2 Fuel delivery unit, fuel gauge sender

2.1 Assembly overview - fuel delivery unit, fuel gauge sender

2.1.3 Summary of components - fuel system pressurisation pump - G6- , vehicles with four-wheel drive

2.1.5 Summary of components - left fuel pump

2.3 Removing and installing fuel pump/fuel gauge sender