1999 SKODA OCTAVIA 1.9TDi 66kw Engine Workshop Manual

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Edition 08.96


Fuel Supply System20
Safety precautions when carrying out work on fuel supply system
Pay attention to the following points when removing and installing the fuel gauge sender or the fuel pump (fuel delivery unit) from the fuel tank: The extraction hose of an exhaust extraction system should be placed close to the assembly opening of the fuel tank and the extraction system switched on before commencing work in order to extract the fuel vapours which are released. If no exhaust extraction system is available, it is possible to use a radial fan with a delivery volume of more than 15 m
3/h (motor not
positioned in the air flow).
Avoid skin contact with fuel! Wear fuel- resistant gloves!
Rules for cleanliness
Pay careful attention to the following rules for cleanliness when carrying out work on the fuel supply/fuel injection system: Thoroughly clean connection points and the surrounding area before disconnecting.
Place removed parts down on a clean sur-
face and cover over. Do not use fluffing cloths!
Carefully cover over or seal opened compo- nents if repairs are not carried out imme-
diately.
Install only clean parts: Do not remove replacement parts from their wrapping until just before installing. Do not use parts which have been stored unwrapped (e.g. in tool boxes etc.).
If the system is open:
Avoid working with compressed air, if possible.
Avoid moving the vehicle, if possible.
In addition, ensure that no diesel fuel flows onto the coolant hoses. If this happens, the
hoses should be cleaned again immediately.
Replace any hoses which have suffered da- mage.

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Edition 08.96


Fuel Supply System20
- Unbolt cover (below rear seat).
- Unplug multi-pin connector for fuel gauge.
- Open fuel filler cap and lever out tensioning ring in rubber bowl (around filler neck).
- Push rubber bowl through to the inside.
- Remove rear right wheelhouse liner.
- Slacken 2 screws for fuel filler neck working from the wheelhouse.
- Remove cover below the fuel tank -arrows-
(not fitted to all models).
- Separate 2 fuel pipes at the front right of the fuel tank:
- Press buttons on the hose connections
for this purpose -arrows-.
black = feed pipe
blue = return flow pipe
- Position engine/gearbox jack (e.g. V.A.G 1383 A) below the fuel tank for supporting it.
- Slacken the bolted connections -arrows- at
the front left and at the retaining straps.
- Lower fuel tank.Installing
- Take heat shield from the old fuel tank and fit onto the new one.

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