D4B8078C002-1 - 5 - 110 - KW - TSI - EVO - Engine 08.2019

Service
Workshop Manual
Karoq 2018 ➤
Kodiaq 2017 ➤
Kodiaq 2019 ➤
Superb III 2015 ➤
1,5/110 kW TSI EVO Engine
Engine ID
DAD DPC
A A
Edition 08.2019
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
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.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information
unless authorised by should
ŠKODA AUTO always be AUTO
A. S. ŠKODA available
A. S. does to the foremen
not guarantee or accept anyand
liabilitymechanics, because their
careful and constant adherence

with respect to toinformation
the correctness of the instructions
in this document.is essential
Copyright by ŠKODAto AUTO
ensure A. S. vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2020 ŠKODA AUTO a. s. D4B8078C002

Karoq 2018 ➤ , Kodiaq 2017 ➤ , Kodiaq 2019 ➤ , Superb III 2015 ➤
1,5/110 kW TSI EVO Engine - Edition 08.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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 measures for working on vehicles with start-stop system . . . . . . . . . . . . . . . . . . . . 4
2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 4
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Assembly of radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Checking the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Disconnecting engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3 Attach engine attached to engine and gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Support the engine in its installed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.6 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.7 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Assembly overview - V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Removing and installing tensioning pulley for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 48
1.4 Removing and installing vibration dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.6 Replacing crankshaft sealing ring on the belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Summary of components - cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2 Replace the needle bearing in the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.4 Removing and installing oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.5 Check piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.6 Check radial clearance of connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.7 Position piston to TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Summary of components - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.6 Checking the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.3 Overview of components - Timing tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.6 Pre-installing and fitting the timing tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.7 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.8 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.9 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.2 Removing and installing bracket for radial shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.3 Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.4 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.5 Removing and installing cam adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.6 Removing and installing camshaft control valve 1 in the inlet N727 . . . . . . . . . . . . . . . . . . 145
3.7 Removing and installing camshaft control valve 1 in the exhaust N318 . . . . . . . . . . . . . . 145
3.8 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.1 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Assembly overview - pan/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.3 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 168
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.1 Summary of components - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.1 Summary of components - crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4 Oil filter, oil pressure switch . . . . . . .unless . . . authorised
. . . . . .by. ŠKODA
. . . . .AUTO
. . .A.. S.
. .ŠKODA
. . . . AUTO
. . . .A..S.. does
. . . not
. .guarantee
. . . . . or176
accept any liability
ii Contents
4.1 Summary of components - oil pressure switch/oil pressure control . . . . . . . . . . . . . . . . . . 176

4.2 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.4 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 177
4.5 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.2 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.1 Summary of components - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.3 Summary of components - coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . 189
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.6 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 194
2.7 Removing and installing coolant temperature transmitter G62 . . . . . . . . . . . . . . . . . . . . . . 197
2.8 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 198
2.9 Removing and installing coolant temperature sender at engine outlet G82 . . . . . . . . . . . . 199
2.10 Removing and installing element for engine temperature control GX33 . . . . . . . . . . . . . . 200
2.11 Testing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.1 Summary of components - coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4 Coolers, radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.1 Assemblyunless
overview
authorised- by
radiator/radiator
ŠKODA AUTO A. S. ŠKODA fan AUTO . . . .A..S.. does
. . . not
. . guarantee
. . . . . .or.accept
. . . .any
. .liability
.............. 214
4.2 Summary ofwithcomponents - fan shroud and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . .
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
215
4.3 Removing and installing radiator with charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.4 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.6 Removing and installing radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.3 Removing and installing the exhaust gas turbocharger connection fitting . . . . . . . . . . . . . . 234
1.4 Removing and installing element for load pressure control GX34 . . . . . . . . . . . . . . . . . . 235
2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.4 Installing and removing the air guide pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.5 Checking the charge-air system for leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2.6 Leak testing the charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.1 Installation location overview - fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.1 Summary of components - fuel distributor with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Contents iii
2.4 Clean injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.3 Removing and installing the throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . 281
4.4 Cleaning throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
5.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
5.2 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.3 Removing and installing intake manifold pressure sender GX9 . . . . . . . . . . . . . . . . . . . . 287
5.4 Removing and installing pressure sensor for exhaust gas 1 G450 . . . . . . . . . . . . . . . . . . 289
5.5 Removing and installing valve for air mass meter GX35 . . . . . . . . . . . . . . . . . . . . . . . . . . 289
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
6.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
7 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
7.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
7.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
7.3 Removing and installing high pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.2 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.4 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.5 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2 Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
2.1 Summary of components - exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
2.3 Removing and installing the exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . 333
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.4 Removing and installing position transmitter for inlet camshaft G1002 . . . . . . . . . . . . . . . . 338
1.5 Removing and installing position transmitter for exhaust camshaft G1003 . . . . . . . . . . . . 339
1.6 Removing and installing the engine speed transmitter G28 . . . . . . . . . . . . . . . . . . . . . . . . 340
iv Contents
00 – Technical data
1 Identification
(SRL001444; Edition 08.2019)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data

Type plate on upper toothed belt guard
The engine code letters and the engine number are located on
the type plate, which is affixed to the sticker on the upper toothed
belt guard.
Each engine has its unique type plate, which can not be used for
any other engine. This type plate may not be replaced by any
other.
The new engine is also supplied with a new type plate on the new
toothed belt guard.
On the new engine, the data on the type plate and on the accom‐
panying card for the engine must be checked. The information
given must be the same.
1 - Information about the construction of the crankshaft.
2 - Engine number
3 - Engine codes
Information about the construction of the crankshaft.
♦ Used to document the construction and commissioning.
♦ After replacing certain components, the construction data
must be transferred to the engine control unit ⇒ Vehicle diag‐
nostic tester.
♦ Components that require this step are described in the work‐
flows.
Engine number
♦ The engine number consists of up to nine digits (numbers and
letters).
♦ The first 3 characters represent
unless authorised by ŠKODAthe AUTO“Engine
A. S. ŠKODAcode”
AUTO.A. S. does not guarantee or accept any liability
♦ The second six -digit part represents the “current number” .
♦ If more than 999,999 engines were produced with the same
code letters, the first of the 6 digits is replaced by a letter.
1. Identification 1
Engine codes
The “engine identification characters” and “serial number” are lo‐
cated on the cylinder block -arrow-.
♦ The engine identification characters are also indicated on the
vehicle data sticker and the type plate.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine - J623- control unit.
Fitting locations for vehicle data stickers:
♦ ⇒ Maintenance ; Booklet Superb III
♦ ⇒ Maintenance ; Booklet Karoq
♦ ⇒ Maintenance ; Booklet Kodiaq
Vehicle data carrier on the camshaft housing

♦ Used to document the construction and commissioning.
♦ After replacing the components, the construction data must be
transferred to the engine control unit ⇒ Vehicle diagnostic
tester.
♦ Components that require this step are described in the work‐
flows.
♦ Each engine has its own unique vehicle data carrier. The data
can not be used for any other engine.
♦ On the left side of the plate can be found the »Data Matrix
Code«. This information is read ⇒ Vehicle diagnostic tester.
♦ On the right side is alphanumeric information about of the
construction. This form is used for the manual entry of the data
relating to construction for commissioning ⇒ Vehicle diagnos‐
tic tester.
♦ The listed data are the measured values of the components.
XN1 - Cam on cylinder 1
XW1 - Sensing wheel for inlet camshaft
XW2 - Encoder wheel for exhaust camshaft
Engine codes DADA DPCA

Karoq 08.2017 ► 07/2019 ►
Superb III 07.2018 ► 08.2019 08/2019 ►
Kodiaq 07.2018 ► 07.2019 07/2019 ►
Emission standards EU6 EU6
Displace‐ cm3 1495 1495
ment Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Output kW at rpm 110- 5000 110- 5000
Torque Nm at rpm 250/1500-3500 250/1500-3500
Bore ∅ mm 74.5 74.5
2 Rep. gr.00 - Technical data

Engine codes DADA DPCA

Stroke mm 85.7 85.7
Compression ratio 10.5 10.5
Number of cylinders/valves 4- 4 4- 4
per cylinder
Fuel - RON min. 95 unleaded 95 unleaded
Ignition system/fuel injection Motronic MG 1 Motronic MG 1
Firing order 1-3-4-2 1-3-4-2
Exhaust gas recirculation no no
Balancing shaft module no no
Intake manifold change-over no no
Camshaft control valve, in‐ yes / yes yes / yes
let / exhaust
ACT yes yes
Exhaust gas turbocharger yes yes
1. Identification 3
2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 4
⇒ “2.2 Safety measures for working on vehicles with start-stop
system”, page 4
⇒ “2.3 Safety precautions during road tests in which testing and
measuring equipment is used”, page 4
⇒ “2.4 Safety precautions when working on cooling system”, page
5
⇒ “2.5 General safety instructions”, page 5
⇒ “2.6 Safety precautions when working on ignition system”, page
6
2.1 Safety precautions when working on fu‐

el supply system
Fuel under very high pressure creates a risk of injury.
– Wear protective gloves.
– Wear safety goggles!
Leaking fuel creates a fire hazard.
Fuel pump is activated by switching on ignition and via driver door
contact switch. Therefore, if the battery power hasn't been dis‐
connected, for safety reasons the plug of the fuel delivery unit
must be disconnected, or the fuel pump fuse must be removed
before opening the fuel system.
– Disconnect fuse for fuel pump control unit - J538- ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
Risk of damage to the electronic components when disconnecting
the battery.
Only disconnect the battery when the ignition is switched off ⇒
Electrical system ; Rep. gr. 27 ; Battery; Disconnecting
Protected by copyright. Copyingand con‐or commercial purposes, in part or in whole, is not permitted
for private
necting battery . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
2.2 Safety measures for working on vehi‐

cles 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 in the dash panel insert) the engine can start automat‐
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).
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
airbag 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.
2.4 Safety precautions when working on

cooling system
Risk of injury due to hot steams.
– Wear protective gloves.
– Wear safety goggles!
Relieve any possible pressure prior to the repair.
When the engine is warm, the cooling system is under overpres‐
sure.
Hot steam may escape when the expansion reservoir is opened.
– Cover the cap unless
ofwith
the coolant
authorised expansion
by ŠKODA AUTO A.tank with
S. ŠKODA a cloth
AUTO and
A. S. does not guarantee or accept any liability
open carefully.
2.5 General safety instructions

The safety measures for the pressure reduction in the high pres‐
sure system must be observed.
Place a clean cleaning cloth around the connection point before
detaching hose connections. Reduce pressure by carefully re‐
moving the hose.
– Do not touch or disconnect ignition leads with the engine run‐
ning or at start speed.
Ignition must be switched off before disconnecting and re-con‐
necting the cables of the fuel injection and the ignition system as
well as of the test equipment.
If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure, re‐
move the fuse for the voltage supply of the injection valves and
the ignition coils from the fuse holder ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Danger of poisoning by chemical substances.
Exhaust gas temperature sensors can contain chemical sub‐
stances. Risk of injury to the respiratory tract and poisoning.
The exhaust gas temperature encoder must not be cut or opened.
Risk of injury due to hot condensate and particles in the exhaust
system
The exhaust system may contain hot condensate and/or particles.
Risk of injury to the eyes, skin and the respiratory tract as well as
danger of poisoning.
Wear protective gloves and safety goggles when disconnecting
the exhaust system.
When disconnecting, use a suction device or provide adequate
ventilation.
2. Safety instructions 5
2.6 Safety precautions when working on ig‐

nition system
Risk of injury due to high voltage.
– Do not touch the ignition system with the engine running or at
start speed.
Risk of damage to injection and ignition system
– Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition sys‐
tem as well as of the test equipment.
Switch off ignition before an engine wash.

3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 7
⇒ “3.2 Foreign bodies in the engine”, page 7
⇒ “3.3 Contact corrosion”, page 7
⇒ “3.4 Cable routing and securing”, page 7
⇒ “3.5 Assembly of radiators and condensers”, page 8
⇒ “3.6 General repair instructions”, page 8
⇒ “3.7 Checking the vacuum system”, page 10
3.1 Rules of cleanliness

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 open, do not work with compressed air
and 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.
3.2 Foreign bodies in the engine

To prevent the penetration of foreign bodies, open channels of
the inlet connection and exhaust tract must be sealed with suit‐
able plugs during assembly works on the engine, for example
from the screw plug set for engine - VAS 6122- .
3.3 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 .
3.4 Cable
Protected byrouting andfor securing
copyright. Copying private or commercial purposes, in part or in whole, is not permitted
Install lines of allwith
kinds so that the original routing can be restored.
♦ Fuel feed lines

♦ Hydraulic lines
♦ Brake fluid lines
♦ Coolant lines
3. Repair instructions 7
♦ Vacuum lines
♦ Activated charcoal filter system lines
♦ Electrical lines
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.
Secure all hose connections with hose clamps, assignment ⇒
Electronic Catalogue of Original Parts .
When installing fit the coolant hoses free of stress, without them
touching any other components (pay attention to the marking on
the coolant connection and hose).
3.5 Assembly of radiators and condensers

The radiator, capacitor and the radiator for charge air coolant cir‐
culation may have minor indentations on the fins, even if assem‐
bled correctly. This does not constitute damage. Radiators,
capacitors and the radiator for charge air coolant circulation must
not be replaced because of these indentations.
3.6 General repair instructions

⇒ “3.6.1 Additional instructions when undertaking assembly work
on the air-conditioning system”, page 8
⇒ “3.6.2 General instructions for charge air system”, page
9
⇒ “3.6.3 General notes on the ignition system”, page 9
⇒ “3.6.4 General notes on the injection system”, page 10
⇒ “3.6.5 General Instructions ”, page 10
3.6.1 Additional instructions when undertak‐

ing assembly work onwiththe
unless air-condition‐
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ing system
CAUTION
Risk of frost due to refrigerant.
Do not open the refrigerant circuit of the air conditioning system.

To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or bent.
Steps which should be taken in order to remove and install the
engine without opening the refrigerant circuit
– Remove the holding clamp(s) of the refrigerant lines.
– Removing AC compressor ⇒ Heating, Air Conditioning ; Rep.
gr. 87 ; AC compressor; installing and removing AC compres‐
sor .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

3.6.2 General instructions for charge air sys‐

tem
When undertaking all installation work, particularly in the engine
compartment because of its cramped construction, please ob‐
serve the following:
♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,
cooling fluid and refrigerant, brake fluid, vacuum) and electri‐
cal lines in such a way that the original line guide is re-
established.
♦ Ensure that there is adequate free access to all moving or hot
components.
In case a mechanical damage to the exhaust gas turbocharger is
found, for example, damage to the compressor wheel, it is not
sufficient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ InspectProtected
the airbyfilter housing, the air filter element and the in‐
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
take hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air cooler
for foreign bodies.
♦ The charge-air system must be tight.
♦ Replace self-locking nuts.
♦ Hose connections and hoses for the charge air system must
be free of oil and grease before being installed.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ ETKA - Electronic Catalogue of Original Parts .
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Before connecting the oil feed line, fill the exhaust turbocharg‐
er via the connection fitting with engine oil.
♦ To ensure the oil supply to the exhaust gas turbocharger,
leave the engine running for about 1 minute after installing the
exhaust gas turbocharger.
3.6.3 General notes on the ignition system

♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the engine control unit.
♦ The engine control unit and further components are equipped
with self-diagnosis; inspect ⇒ Vehicle diagnostic tester.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to query the event mem‐
ory after having completed all inspections and repairs, and if
necessary, delete the entries ⇒ Vehicle diagnostic tester.
Safety measures ⇒ “2.6 Safety precautions when working on ig‐
nition system”, page 6 .
Setting data, spark plugs:
3.6.4 General notes on the injection system

♦ The engine control unit is equipped with a self-diagnosis sys‐
tem. Before repairs and also for fault finding, first of all inter‐
rogate the event memory. Also check the vacuum hoses and
connections (unmetered air).
♦ Fuel hoses in the engine compartment may only be secured
with spring-type clips ⇒ ETKA - Electronic Catalogue of Orig‐
inal Parts . The use of clamp-type or screw-type clips is not
allowed.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to query the event mem‐
ory after having completed all inspections and repairs, and if
necessary, delete the entries ⇒ Vehicle diagnostic tester.
Safety precautions when working on the injection system ⇒
“2.5 General safety instructions”, page 5 .
3.6.5 General Instructions

♦ The engine control unit is equipped with a self-diagnosis sys‐
tem. Before repairs and also for fault finding, first of all inter‐
rogate the event memory. Also check the vacuum hoses and
connections (unmetered air).
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ The vehicles are fitted with a fuel cut-off system for impacts.
The fuel cut reduces the risk of ignition on impact by shutting
off the fuel pump via the fuel pump relay.
♦ When opening the driver door the fuel pump starts up for ap‐
prox. 2 seconds in order to build up the pressure in the fuel
system. Observe safety measures ⇒ “2.1 Safety precautions
when working on fuel supply system”, page 4 .
Fuel pump is activated by switching on ignition and via driver door
contact switch. Therefore, if the battery power hasn't been dis‐
connected, for safety reasons the plug of the fuel delivery unit
must be disconnected, or the fuel pump fuse must be removed
before opening the fuel system.
♦ When removing the high-pressure line, mark the line and at‐
tach it in the same place.
♦ The high pressure line mustbynever
Protected beCopying
copyright. bent.for private or commercial purposes, in part or in whole, is not permitted
♦ The high pressure line with
must be installed free from stress.
Tighten all connections hand-tight, and then tighten with the

appropriate tightening torque.
3.7 Checking the vacuum system

Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-
– Check all the vacuum lines in the complete system for:

♦ tears
♦ marten bites
♦ pinching
♦ porous points and other leaks
In the event of an event memory entry, check the vacuum lines
to the mentioned component and also to the other components.
If no vacuum can be created or the vacuum drops immediately
with the hand vacuum pump - VAS 6213- , check the hand vac‐
uum pump - VAS 6213- and connecting hoses for leaks.
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 12
⇒ “1.2 Disconnecting engine and gearbox”, page 22
⇒ “1.3 Attach engine attached to engine and gearbox mount”,
page 23
⇒ “1.4 Installing engine”, page 23
1.1 Removing engine

♦ Removal tool for inner lining of the door panel - T10236-
♦ Extension - 2024A/1- of lifting device - MP9-201 (2024A)-
♦ Engine and gearbox jack - V.A.G 1383A-
♦ Engine mount - T10497-
♦ Catch pan , e.g. -VAS 6208-
♦ Hose strap pliers , e.g. -VAS 6362-
♦ Locking pin - T10060A-
♦ Double ladder
♦ Radiator protection mat - VAS 531 003-
♦ Protective goggles and gloves
Note
The engine is removed downwards together with the gearbox.
• Fit all cable straps on again in the same place when installing.
– Remove both front wheels ⇒ Chassis, axles, steering; Rep.
gr. 44 ; Wheels, tyres .
– Remove the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Summary of components -
noise insulation . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove the front left and right wheelhouse liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheelhouse liner; remov‐
ing and installing front wheelhouse liner .
– Remove air filter housing ⇒ “3.2 Removing and installing air
filter housing”, page 274 .
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page
183 .
– Removing fan shroud ⇒ “4.4 Removing and installing fan
shroud”, page 224 .
12 Rep. gr.10 - Removing and installing engine

– Cover radiator with radiator protection mat - VAS 531 003- .

– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
For vehicles with air conditioning
– Remove the ribbed V-belt ⇒ “1.2.2 Removing and installing V-
ribbed belt on vehicles with air conditioning system”, page
47 .
CAUTION
– Disconnect plug connection -1- on the control valve for the air
conditioning system compressor - N280- .
– Release screws -arrows- for AC compressor.
NOTICE
Risk of damaging AC compressor, refrigerant lines and hoses.
♦ Do not over-tension, buckle and bend refrigerant lines and

hoses.
– Remove AC compressor with connected refrigerant hoses and
strap up to the right side.
Continued for all vehicles

– Unlock catch -arrow- and remove vacuum hose -1-.
– Expose vacuum hose on the air guide pipe -2-.
– Remove the vacuum hose -1- from the brake vacuum pump -
V192- -A-.
– Remove vacuum hose from the engine mounting.
– Remove the heat shield on top of the catalyst ⇒ page 232 .
1. Removing and installing engine 13

– Mark the position of the clamp.
Note
♦ Before loosening the coupling point between catalytic con‐

verter and turbocharger, mark the position of the clamp!
♦ Re-establish the position of the clamp when assembling.
– Unscrew screw -2- and remove screw clamp.

– Remove screw -1-, remove nuts -arrows- and strap up cat‐
alytic converter to the bodyshell so as not to damage the
decoupling element.
Note
do not twist decoupling element in the exhaust pipe more than

10° - risk of damage
– Unscrew screws -arrows- and remove holder.
CAUTION
Risk of injury from fuel under pressure.
♦ To relieve the fuel pressure, place a clean cloth around the

connection point and loosen the connection point carefully be‐
fore opening the fuel system.
NOTICE
Risk of malfunctions caused by soiling.
Observe safety measures and rules for cleanliness ⇒ “3.1 Rules

of cleanliness”, page 7 .
– Disconnect the fuel feed line -1- and vent line -2- to the acti‐
vated charcoal filter.

– Unscrew retaining clip -2- from hoses from the coolant tank.
– Loosen hose clamp -3- and remove coolant hose.
For vehicles without auxiliary heating

– Raise holding clamps -arrows- and remove coolant hoses
from heat exchanger for heating.
Vehicles fitted with auxiliary heating

– Loosen holding clamp and holding clamps and pull off both
coolant hoses -arrows-.
– Place a cloth below to absorb leaking coolant.
– Loosen hose clamp -1- and remove coolant hose.

– Raise holding clamp -arrow- and disconnect top right coolant

hose from charge air cooling circuit radiator.
– Raise holding clamp -arrow- and remove top left coolant hose
from radiator.
Note
For the following clip unclipping procedure, use the removal tool
for door panel - T10236- .
– Disconnect plug -1- from the engine control unit - J623- ⇒

“6.1 Removing and installing engine control unit J623 ”,
page 290 .
– Take electrical plug connections -2- and -3- out of the holder
and disconnect.
– Open the cable guide -2- upwards in -direction of arrow-.

– Expose electric cables.

– Disconnect plug connection -2-.

– Remove B+-pole protection -1- and unscrew B+-cable from
the starter magnet switch.
– Unscrew the earth cable on the body.
– Unlock catches -arrows-, remove cover -1- for E-box in the

engine compartment.
– Unlock catch with a screwdriver -arrow- and pull cover -1- for
E-box in the engine compartment upwards.
– Unscrew nut -arrow-, remove and expose electric cable.

For vehicles with manual gearbox

– Disconnect connectors -1- and -2-.
– Remove shift mechanism from the gearbox ⇒ Rep. gr. 34 ;
Shift mechanism; removing and installing shift mechanism .
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch slave
cylinder; Removing and installing clutch slave cylinder .
For vehicles with automatic gearbox
– Unlock and disconnect connectors for automatic gearbox ⇒
Rep. gr. 34 ; Removing and installing the gearbox; remove
gearbox .
– Remove selector lever linkage, disconnect mechatronics con‐
nector and remove all holders from the gearbox ⇒ Rep. gr.
37 ; Shift mechanism; installing and removing shift mecha‐
nism .

– Disconnect electrical plug connection -1- at the oil level and
oil temperature sender - G266- .
– Unscrew nut arrow on left and right -1- for coupling rod -3- on
anti-roll bar -2-.
– Undo screws -1-, -2-, -3- and remove the pendulum support.

– Unscrew screws -arrows- and remove heat shield for right

cardan shaft, if present.
– Remove left and right cardan shaft from gearbox ⇒ Chassis,
axles, steering; Rep. gr. 40 ; Cardan shaft; removing and in‐
stalling cardan shaft and tie up.
Note
Ensure that the surface protection of the cardan shaft is not dam‐
aged.
For vehicles with four-wheel drive

– Remove angle gearbox ⇒ Rep. gr. 34 ; Angle gearbox; Re‐
move angle gearbox .
For the Karoq vehicles
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Move to service position
and reset .

If the encoder for front left vehicle level - G78- -3- is installed.
– Remove nut -4- and screw -1- and put front left vehicle level
sensor - G78- aside.
– Unscrew nuts -arrows- on right and left steering joint.
– Unhook swivel hub from track control arm on left and right.

– Swivel suspension strut left towards the outside and support

with extension -2024A/1- , as shown in the illustration.
CAUTION
There is a risk of accident from loose parts of the support.
– Secure locking pin and swivel hub with plug-in lock -arrow- and
nut -1-.
– Bolt swivel hub -2- on the right to the track control arm -1- with
the nut -arrow-, as shown in the illustration.
– Screw out screws -arrows- on engine mount by approximately

2 turns.
Gearbox mount with 2 screws

– Screw out screws -arrows- on gearbox mount by approxi‐
mately 2 turns.


– Screw out screws -arrows- on gearbox mount by approxi‐
mately 2 turns.

– Position clamping piece T10497/2 on the housing fin of the
cylinder block, as shown in the illustration.
– Position engine mount - T10497- with bolts T10497/1 at the
cylinder block.
– Screw clamping piece T10497/2 with screw -1- onto the en‐
gine mount T10497 and tighten it to 20 Nm.
– Fit the adapter - T10497/3- to the engine mount - T10497- and

tighten screw -1- to 20 Nm.
– Insert engine mount - T10497- onto the engine and gearbox
jack - V.A.G 1383A- and lift engine/gearbox unit a little.
Note
Use commercially available double ladder to release the screws

for the assembly bracket.
– Screw out engine mount screws -arrows- fully.


– Screw out gearbox mount screws -arrows- fully.

– Screw out gearbox mount screws -arrows- fully.
NOTICE
Risk of damaging vacuum lines or electric cables and the engine
compartment.
– Check that all vacuum lines and electric cables between en‐
gine, gearbox, assembly mountings and body have been loos‐
ened.
– Drain engine/gearbox unit a little.
– Push the gearbox side of the engine/gearbox unit forwards
and drain it slowly and carefully.
1.2 Disconnecting engine and gearbox

♦ Workshop crane , e.g. -VAS 6100-
♦ Shackle - 10-222A/12-
• Engine/gearbox unit removed and attached to engine mount -
T10497- .
– Remove the starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Install shackle - 10-222A/12- on gearbox.
– Hook gearbox to shackle - 10-222A/12- on the workshop crane
- VAS 6100- .
Note
Pre-load the workshop crane - VAS 6100- slightly, but do not raise
the gearbox.
– Unscrew engine/gearbox connecting screws ⇒ Rep. gr. 34 ;

Removing and installing gearbox .
– Remove the gearbox from the engine.

1.3 Attach engine attached to engine and

gearbox mount
♦ Supporting device - MP9-201 (2024A)-
♦ Engine and gearbox mount - VAS 6095-
♦ Workshop crane , e.g. -VAS 6100-
• Gearbox disconnected from engine ⇒ “1.2 Disconnecting en‐
gine and gearbox”, page 22 .
– Suspend lifting device - MP9-201 (2024A)- -A- from the engine
and workshop crane - VAS 6100- -B- as shown in the illustra‐
tion.
– For coordination with the unit centre of gravity position the
perforated rails must be placed as shown in the illustration.
CAUTION
There is a risk of accident from loose parts of the lifting device.
– The suspension hooks and locking pins on the lifting device

must be secured with plug-in locks -arrows-.
– Remove engine from engine mounting - VAS 6100- using
workshop crane - T10497- .
– Secure engine using bolts -arrows- to the engine and gearbox

mount - VAS 6095- .
1.4 Installing engine

♦ Extension - 2024A/1- of lifting device - MP9-201 (2024A)-
♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931-
♦ Engine mount - T10497-
♦ Hose strap pliers , e.g. -VAS 6362-
♦ Double ladder
♦ Grease - G 000 100-

Note
♦ When installing a new engine, make sure that the supplied

toothed belt guard is installed at the top.
♦ The type plate for the new engine is attached to the toothed
belt guard at the top.
♦ Only this type plate contains the correct information about the
engine.

– Clean the serration of the drive shaft and if the clutch disc has
been used clean the hub serration, remove any corrosion
present and only apply a very thin layer of grease - G 000 100-
to the serration of the drive shaft.
– Then move clutch plate to and fro on input shaft until hub
moves freely on shaft. Always remove excess grease.
– Check centring of driven plate assembly ⇒ Rep. gr. 30 ;
Clutch; removing and installing clutch .
– Check the clutch release bearing for wear. Replace release
bearing when worn ⇒ Rep. gr. 30 ; Clutch control; Summary
of components- Clutch release mechanism .
– Replace the needle bearing -arrow- in the crankshaft ⇒
“3.2 Replace the needle bearing in the crankshaft”, page
68 .
Continued for byallcopyright.
Protected vehicles Copying for private or commercial purposes, in part or in whole, is not permitted
Installation
with is carried
respect out in the
to the correctness reverseinorder.
of information When
this document. installing,
Copyright by ŠKODA AUTO A. S.
observe the following:
– Screws which have been tightened firmly to a torquing angle
must be replaced.
– Replace self-locking nuts, sealing rings, gaskets and O-rings.
• Secure all hose connection ends with spring-type clips that
comply with the series design ⇒ ETKA - Electronic Catalogue
of Original Parts .
– Install intermediate plate ⇒ Fig. ““Install intermediate plate”“ ,
page 57 .
– Installing gearbox ⇒ Rep. gr. 34 ; Removing and installing the

gearbox; installing gearbox .
Note
♦ The new engine is delivered with dowel sleeves -A- to replace

the engine.
♦ Depending on the gearbox variant, the dowel sleeves have
different lengths.
♦ For dowel sleeve assignment, see ⇒ ETKA - Electronic Cat‐
alogue of Original Parts .
– Attach engine/gearbox unit to engine mount - T10497- .

– Insert engine/gearbox assembly in the body.

– Initially insert screws -arrows- for engine mount by hand as far

as the stop.

– Initially insert screws -arrows- for gearbox mount by hand as
far as the stop.

– Initially insert screws -arrows- for gearbox mount by hand as far as the stop.
Note
The screws must not be permanently tightened until the assembly bracket is adjusted ⇒
“2.6 Adjusting the unit mounting”, page 37 .
– Remove engine mount T10497 from engine.

– Install the starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and installing starter .
– Remove clutch slave cylinder: ⇒ Rep. gr. 30 ; Clutch slave cylinder; Removing and in‐
stalling clutch slave cylinder .
– Install linkages with cable support ⇒ Rep. gr. 34 ; Shift mechanism; installing and removing
shift mechanism .
– Install selector lever linkage, install mechatronics connector and install holders to the gear‐
box ⇒ Rep. gr. 37 ; Shift mechanism; installing and removing shift mechanism .
– Install angle gearbox ⇒ Rep. gr. 34 ; Angle gearbox; Remove angle gearbox .
– Install pendulum support ⇒ “2.4 Removing and installing pendulum support”, page 32 .
– Install exhaust pipe with catalytic converter ⇒ “2.2 Removing and installing catalytic con‐
verter”, page 328 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing
and installing drive shaft .

– Install nuts for axle joint/ left and right wheelhouse ⇒ Chassis, Axles, steering; Rep. gr. 40 ;
Bottom track control arm, steering joint; Removing and installing the bottom track control
arm .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; Removing
and installing AC compressor .
– Install the V-ribbed belt ⇒ “1.2 Removing and installing V-ribbed belt”, page 46 .
Electrical connections and proper routing ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– Connect plug of the engine wiring harness to engine control unit ⇒ “6.1 Removing and in‐
stalling engine control unit J623 ”, page 290 .
– Connect the remaining electric cables to the engine and gearbox.
– Connect coolant hoses.
– Install the front left and right wheelhouse liner ⇒ Exterior body work ; Rep. gr. 66 ; Wheel‐
house liner; Removing and installing the front wheelhouse liner .
– Install the front wheels ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels, tyres .
– Adjust the assembly bracket ⇒ “2.6 Adjusting the unit mounting”, page 37 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
installing battery .
– Install air filter housing ⇒ “3.2 Removing and installing air filter housing”, page 274 .
– Checking the oil level:
– Top up and bleed cooling system ⇒ “1.3 Draining and filling coolant”, page 183 .
– Interrogate all event memories and delete all event entries which are caused by removing
and installing the engine
Protected ⇒ Vehicle
by copyright. diagnostic
Copying for tester.purposes, in part or in whole, is not permitted
private or commercial
NOTICE
Risk of damaging control units as a result of overvoltage.
♦ Do not use charger for jump starting!

In the event that a new complete engine has been installed:
Comply with the information given in the type plate ⇒ page 1 .
– Check the information on the vehicle type plate with the accompanying engine identity card.
The information given must be the same.
– Carry out 0001 - Adaptation after the encoder wheel change function ⇒ Vehicle
diagnostic tester.
– Carry out 0001 - Reset the injection valve learning values function ⇒ Vehicle
diagnostic tester.
– Carry out 0001 - Correction values of crankshaft position function ⇒ Vehicle di‐
agnostic tester.
– Carry out 0001 - camshaft position correction values (intake and exhaust
camshafts) function ⇒ Vehicle diagnostic tester.
– Carry out 0001 - Adaptation charge pressure plate -V465 function ⇒ Vehicle diag‐
nostic tester.

– Carry out 0001 - Adaptation of the lambda probes function ⇒ Vehicle diagnostic
tester.
Specified torques
Note
♦ Tightening torques apply only for lightly greased, oiled, phosphatized or blackened nuts and
screws.
♦ Other lubricants such as engine and gearbox oil are allowed, but no lubricants containing
graphite.
♦ Do not use degreased parts.
Component Specified torque

Screws/nuts M6 9 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm
deviations:
Connecting screws for engine to gearbox ⇒ Rep. gr. 34 ; Installing and removing gearbox;
tightening torques for gearbox .
♦ Cardan shaft guard ⇒ Chassis, axles, steering ; Rep. gr. 40 ; Cardan shaft; Removing
and installing cardan shaft.
Screws for assembly bracket ⇒ “2.1 Assembly overview - assembly mountings”, page
28 .

2 Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”, page 28
⇒ “2.2 Removing and installing engine mount”, page 30
⇒ “2.3 Removing and installing gearbox mount”, page 31
⇒ “2.4 Removing and installing pendulum support”, page 32
⇒ “2.5 Support the engine in its installed position”, page 33
⇒ “2.6 Adjusting the unit mounting”, page 37
⇒ “2.7 Check assembly bracket setting”, page 39
2.1 Assembly overview - assembly mount‐

ings
Note
Replace bolts / nuts that are tightened at an angle of rotation, as

well as replacement components after removal.
1 - Screw
❑ Replace after disas‐
sembly
❑ Tightening torque and
tightening order ⇒ Fig.
““Engine support brack‐
et - tightening torque
and tightening order”“ ,
page 29
2 - Engine support bracket
““Engine support brack‐
et - tightening torque
and tightening order”“ ,
page 29
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling engine support”,
page 50
3 - Engine mounting
❑ with supporting arm
stalling engine mount”,
page 30
4 - Screw
sembly
❑ with40respect
Nm to+the 90°
correctness of information in this document. Copyright by ŠKODA AUTO A. S.
5 - Screw
sembly
❑ 20 Nm + 90°

6 - Screw
❑ 8 Nm
7 - Mounting bracket
❑ Does not need to be installed in all vehicles
8 - Screw
❑ Replace after disassembly
❑ 60 Nm + 90°
9 - Pendulum support
❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 32
10 - Screw
❑ Tightening torque and tightening order ⇒ Fig. ““Pendulum support - tightening torque and tightening
order”“ , page 30
11 - Screw
❑ Tightening torque and tightening order ⇒ Fig. ““Pendulum support - tightening torque and tightening
12 - Screw
❑ byReplace
Protected afterfordisassembly
copyright. Copying private or commercial purposes, in part or in whole, is not permitted
with❑ Tightening
respect torque
to the correctness and tightening
of information order
in this document. ⇒ Fig.
Copyright ““Pendulum
by ŠKODA AUTO A. S. support - tightening torque and tightening
13 - Screw
❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Summary of components - assembly mountings
14 - Screw
❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Summary of components - assembly mountings
15 - Screw
❑ 50 Nm + 90°
16 - Gearbox mount
❑ with supporting arm
❑ Removing and installing ⇒ “2.3 Removing and installing gearbox mount”, page 31
Engine support bracket - tightening torque and tightening order
Note
Screws which have been tightened firmly to a torquing angle must

be replaced.
– Tighten screws gradually in the given sequence:

Stage Bolts Tightening torque/torque angle
1. -1- to -3- 7 Nm
2. -1- to -3- 40 Nm
3. -1- to -3- 90°
2. Assembly bracket 29
Pendulum support - tightening torque and tightening order
Note

be replaced.

1. -2-, -3- 50 Nm
2. -1- 130 Nm
3. -1- to -3- Turn 90° further
2.2 Removing and installing engine mount

Removing
– Unscrew the vacuum pump for brake - V192- together with the
bracket from the motor bearing ⇒ Braking systems; Rep. gr.
47 ; Vacuum system; Removing and installing electric vacuum
pump .
– Unlock catches using a screwdriver -arrow- and lay coolant
expansion tank to the side.
– Suspend engine into the installation position ⇒ “2.5 Support
the engine in its installed position”, page 33 .
– Unscrew screws -arrows- and remove engine mount -1-.

Installing
Installation is carried out in the reverse order. When installing,
Note

be replaced.
– Check assembly mounting adjustment ⇒ “2.7 Check assembly

bracket setting”, page 39 .
Tightening torques - summaries of components Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note

• Assembly bracket ⇒ “2.1 Assembly overview - assembly

mountings”, page 28 .

2.3 Removing and installing gearbox mount

Removing
– Remove the engine control unit ⇒ “6.1 Removing and installing
engine control unit J623 ”, page 290 .
– Unscrew the nuts -arrows- and remove holder -1-.
Note
Holders are installed differently according to build version.
– Unscrew screw -1-, unclip upwards -arrows- and push slightly

to the side.

– Unscrew screws -arrows- and remove the gearbox mount
-1-.

– Unscrew screws -2- and then screws -arrow-.
– Remove gearbox mount -1-.
Installing
Note

be replaced.
NOTICE
There is a risk of damaging the thread in the gearbox support
bracket by positioning the bolts obliquely.
♦ Before screwing in the screws -arrows- the gearbox support

bracket and supporting arm of the gearbox mount must be
absolutely parallel to each other. If necessary, push up gear‐
box at the rear using a hydraulic trolley jack.
♦ Do not remove supporting device - MP9–200 (10-222A)- until
the bolts securing the gearbox mount have been tightened to
specified torque.
– Lift gearbox with the support bracket spindle until the gearbox
support bracket is touching the supporting arm of the gearbox
mount.
– Remove supporting device - MP9–200 (10-222A)- .
Tightening torques - summaries of components
Note
Replace bolts / nuts unless

that are tightened at an angle of rotation, as
well as replacement components
with respect to theafter removal.
correctness of information in this document. Copyright by ŠKODA AUTO A. S.
♦ Assembly bracket ⇒ “2.1 Assembly overview - assembly

2.4 Removing and installing pendulum sup‐

port
noise insulation .
– Remove screws -1-, -2- and -3-.
– Remove pendulum support -4- from assembly carrier -5-.
Installing
Installation is carried out in the reverse order.

Note

♦ Screws for pendulum support ⇒ “2.1 Assembly overview - as‐

sembly mountings”, page 28 .
2.5 Support the engine in its installed posi‐

tion
⇒ “2.5.1 Support the engine in installation position, Superb III”,
page 33
⇒ “2.5.2 Support the engine in its installed position, Karoq”, page
34
⇒ “2.5.3 Support the engine in its installed position, Kodiaq”, page
35
2.5.1 Support the engine in installation posi‐

tion, Superb III
♦ Supporting plate - T30119-
♦ Support - 10-222A/31–3-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hook - MP9-200/10 (10-222A/10)-
♦ Supporting device - T30099-
♦ Adapter - T40091/3-
– Remove engine cover ⇒ “3.1 Removing and installing engine
trim panel”, page 41 .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr.by50
Protected ; Dash
copyright. panel;
Copying installing
for private andpurposes,
or commercial removingin part or in whole, is not permitted
plenumunless
chamber cover
authorised .
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove caps of screwed connections for front suspension
strut domes.
– Install adapter -3- with hook -4- and support -2-.
– Place support bracket -5- with support -2- and base -1- on the
screwed connections of the front suspension strut domes.
1- Supporting plate - T30119-
2- Support - 10-222A/31–3-
3- Adapter - MP9-200/18 (10-222A/18)-
4- Hook - MP9-200/10 (10-222A/10)-
5- Supporting device - T30099-
6- Adapter - T40091/3-
– Attach snap hook to the engine suspension eyes.
– Slightly pre-tension the engine/gearbox assembly via the
hooks - MP9-200/10 (10-222A/10)- (but do not raise).
♦ Battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐

moving and installing battery
♦ Windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wiper system; Removing and installing wind‐
screen wiper arms .
2.5.2 Support the engine in its installed posi‐

tion, Karoq
♦ Hook - MP9-200/10 (10-222A/10)-
♦ Supporting device - MP9–200 (10-222A)-
♦ Adapter - 10-222A/13-
♦ Shackle - 10-222A/12-
– Fit the supporting device as shown and place on the vehicle.
• Adapter - 10-222A/13- with the inscription L located on the

right side of the vehicle.

• Adapter - 10-222A/13- with the inscription R located on the left

side of the vehicle.
• Arrows on the adapters - 10-222A/13- point forwards in the
direction of travel.
– Insert hook - MP9-200/10 (10-222A/10)- with shackles -
10-222A/12- into the engine suspension lugs.
– Secure support bracket - MP9–200 (10-222A)- -A- to the bon‐
net hinges on both sides with the aid of the tensioning strap -
T10038- -B-.
2.5.3 Support the engine in its installed posi‐

tion, Kodiaq
♦ Supporting device - MP9–200 (10-222A)-
♦ Adapter - 10-222A/29-
♦ Adapter - T40091/3- - 2x
♦ Support part - T40091/1- - 2x
♦ Spindle - T40093/3- - 2x
♦ Adapter - T40093/3-6- or -T40093/3-6A- 2x
♦ Hook - MP9-200/10 (10-222A/10)- - 2x
♦ Shackles - 10-222A/12- - 2x
• For attaching the spindle - T40093/3- with adapter -
T40093/3-6- or -T40093/3-6A-with the interception
respect device
to the correctness to thein this document. Copyright by ŠKODA AUTO A. S.
of information
right side member, the cross member on the right side of the
vehicle must be loosened.
The member is located in the area underneath the right wheel‐
house liner.
Detaching the cross member creates a space to fit the spindle -
T40093/3- with adapter - T40093/3-6- or -T40093/3-6A- for the
supporting device.
– Remove the front right wheelhouse liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; Removing and
installing the front wheelhouse liner .
– Unscrew the screws -arrows- and detach the cross member

from the front wall.
– If present, remove electrical cables in the front bar area from

the right longitudinal member -arrow-.
– Open holding clamps on the air conditioning system pipes.
• Before installing the actual interceptor device, the adapters
are to be positioned on the side rails - T40093/3-6- or -
T40093/3-6A- .
– Position the adapter - T40093/3-6- or -T40093/3-6A- on the
frame side rail as shown.
• The adapter must be secured by the bolt -A- to the flange of
the frame side rail -arrow-.
– Disconnect plastic holder with electrical lead from left side

member and place laterally, so that a second adapter -
T40093/3-6- or -T40093/3-6A- can be positioned.
– Position adapter - T40093/3-6- or -T40093/3-6A- on the left
side member, just behind the windscreen washer tank filler
pipe, as shown in the figure.
• The adapter must be secured by the bolt -A- to the flange of
the frame side rail -arrow-.
– Screw spindles - T40093/3- on both adapters - T40093/3-6- or
-T40093/3-6A- .
Both spindles - T40093/3- are subsequently connected with
straps - T40091/1- (see further workflow).

– Fit the adapter - 10-222A/29- -1- to the body under the mud‐
guard edge on both sides of the vehicle, at the points shown.
• Adapter with symbol “L” is installed on the “right” side of the
vehicle.
• Adapter with symbol “R” is installed on the “left” side of the
vehicle.
• The arrow shows the direction of travel on each side.
– Fit supporting device - MP9–200 (10-222A)- together with the

other elements, as shown.
A - Adapter - 10-222A/29-
B - Supporting device - MP9–200 (10-222A)-
C - Spindle - T40093/3-
D - Carrier part - T40091/1-
E - Adapter - T40091/3-
F - Hook - MP9-200/10 (10-222A/10)-
G - Shackle - 10-222A/12-
– Using spindles - T40093/3- -C- align the carriers -
T40091/1- -D- horizontally on the right and left sides and tight‐
en all interlocking elements with locking screws.
2.6 Adjusting the unit mounting

– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Removing and installing battery .
Engine mounting
– Unscrew screws -arrows- for engine mount one after another
and replace (if not already done during engine installation).
– Firstly, loosely insert the screws.

– Unscrew screws -arrows- for gearbox mount one after another

– Unscrew screws -arrows- for gearbox mount one after another
Engine mounting
– Move engine/gearbox unit with an assembly lever until the fol‐
lowing dimensions are set:
A distance of -a- = 10 mm must be present between engine sup‐
port -2- and engine mount -1-.
The cast edge on the engine support -2- must be parallel with the
engine mount supporting arm -1-.
Dimension -b- = -b-.
Note
The distance -a- = 10 mm can be checked, for example with suit‐

able round bars.
– Tighten engine mount screws.

Make sure that the edges of the supporting arm of the gearbox
sides -2- and the gearbox support -1- are parallel.
• Dimension -x- = -x-.
– Tighten gearbox mount screws.


sides and the gearbox bearing are parallel.
– Tighten gearbox mount screws.
Further installation occurs in reverse order.
Note

♦ Assembly bracket ⇒ “2.1 Assembly overview - assembly

2.7 Check assembly bracket setting

Engine mounting
The following dimensions must be reached:
• A distance of -a- = 10 mm must be present between engine
support -2- and engine mount -1-.
• The cast edge on the engine support -2- must be parallel with
the engine mount supporting arm -1-.
• Dimension -b- = -b-.
Note
The distance -a- = 10 mm can be checked, for example with suit‐

able round bars.
If the measured distance is too great or too small, adjust the as‐
sembly mountings ⇒ “2.6 Adjusting the unit mounting”, page 37 .

Make sure that the edges of theunless
supporting
Protected armCopying
by copyright. of theforgearbox
private or commercial purposes, in part or in whole, is not permitted
sides -2- and the gearbox supportwith
-1-respect
are toparallel.
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

If the measured distances are not correct, then adjust the unit
mount ⇒ “2.6 Adjusting the unit mounting”, page 37 .

sides and the gearbox bearing are parallel.
If the measured distances are not correct, then adjust the unit
mount ⇒ “2.6 Adjusting the unit mounting”, page 37 .

3 Engine trim panel

⇒ “3.1 Removing and installing engine trim panel”, page 41
3.1 Removing and installing engine trim

panel
Removing
– Remove engine cover -1- upwards from the ball studs in the
following order:
– Remove engine cover -1- first from the ball studs -a-.
– Remove engine cover -1- then from the ball studs -b-.
Installing
– Pre-moisten the ball studs with water before installation.
– Check the rubber buffer for correct fit and correct if necessary.
Note
Maintain the sequence when installing!
– Press down engine cover -1- to the ball studs -b-.

– Then press down engine cover -1- to the ball studs -a-.
3. Engine trim panel 41

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - V-ribbed belt drive”, page 42
⇒ “1.2 Removing and installing V-ribbed belt”, page 46
⇒ “1.3 Removing and installing tensioning pulley for V-ribbed
belt”, page 48
⇒ “1.4 Removing and installing vibration dampener”, page
49
⇒ “1.5 Removing and installing engine support”, page 50
⇒ “1.6 Replacing crankshaft sealing ring on the belt pulley side”,
page 54
1.1 Assembly overview - V-ribbed belt drive

⇒ “1.1.1 Summary of components - V-ribbed belt drive for vehi‐
cles without air conditioning system”, page 42
⇒ “1.1.2 Summary of components - V-ribbed belt drive for vehi‐
cles with air conditioning system”, page 44
1.1.1 Summary of components -unless

V-ribbed
Protected belt
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
drive for vehicles without air condition‐
ing system
Note

42 Rep. gr.13 - Crankshaft group

1 - Screw
sembly
❑ to release and tighten
use counterholder -
T10475-
❑ 150 Nm + 180°
2 - Crankshaft V-ribbed belt
pulley
❑ with vibration damper
stalling vibration damp‐
ener”, page 49
3 - V-ribbed belt
❑ check for wear
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ do not kink
❑ Routing of the ribbed V-
belt ⇒ page 47
stalling V-ribbed belt”,
page 46
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it
4 - Screw
sembly
❑ 20 Nm + 90°
5 - Tensioning pulley for V-ribbed belt
❑ Swivel tensioning device for V-ribbed belt with socket insert to slacken the V-ribbed belt
❑ lock with locking pin - T10060A-
❑ Removing and installing ⇒ “1.3 Removing and installing tensioning pulley for V-ribbed belt”, page
48
6 - Screw
❑ 23 Nm
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator .
❑ Depending on the model of the AC generator, different separation V-ribbed belt pulleys can be fitted with
freewheel -A- and -B- ⇒ Fig. ““Version of V-ribbed belt pulley with freewheel”“ , page 44
❑ Depending on the model of the belt pulley for AC generator, the correct length of the V-ribbed belt must
be assigned ⇒ ETKA - Electronic Catalogue of Original Parts
43
1. Cylinder block (pulley end)
Version of V-ribbed belt pulley with freewheel
1.1.2 Summary of components - V-ribbed belt

drive for vehicles with air conditioning
system
Note


1 - V-ribbed belt
❑ check for wear
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ do not kink
❑ Routing of the ribbed V-
belt ⇒ page 48
⇒ “1.2.1 Removing and
installing V-ribbed belt
on vehicles without air
conditioning system”,
page 46
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it
2 - Screw
sembly
❑ to release and tighten
use counterholder -
T10475-
❑ 150 Nm + 180°
3 - Crankshaft V-ribbed belt
pulley
❑ with vibration damper
stalling vibration damp‐
ener”, page 49
4 - Tensioning pulley for V-
ribbed belt
❑ Swivel tensioning de‐
vice for V-ribbed belt with socket insert to slacken the V-ribbed belt
❑ lock with locking pin - T10060A-
❑ Removing and installing ⇒ “1.3 Removing and installing tensioning pulley for V-ribbed belt”, page
48
5 - Screw
❑ 20 Nm + 90°
6 - Screw
❑ 23 Nm
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator .
❑ Depending on the model of the AC generator, different separation V-ribbed belt pulleys can be fitted with
freewheel -A- and -B- ⇒ Fig. ““Version of V-ribbed belt pulley with freewheel”“ , page 46
❑ Depending on the model of the belt pulley for AC generator, the correct length of the V-ribbed belt must
be assigned ⇒ ETKA - Electronic Catalogue of Original Parts
8 - Fitting sleeve
❑by copyright.
Protected for theCopying
AC compressor
for private or commercial purposes, in part or in whole, is not permitted
9 -respect
with AC compressor
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
❑ Do not unscrew or disconnect refrigerant lines
1. Cylinder block (pulley end) 45

❑ installing and removing ⇒ Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; installing and re‐
moving AC compressor
10 - Screw
❑ 23 Nm
Version of V-ribbed belt pulley with freewheel
1.2 Removing and installing V-ribbed belt

⇒ “1.2.1 Removing and installing V-ribbed belt on vehicles with‐
out air conditioning system”, page 46
⇒ “1.2.2 Removing and installing V-ribbed belt on vehicles with
air conditioning system”, page 47
1.2.1 Removing and installing V-ribbed belt

on vehicles without air conditioning sys‐
tem
NOTICE
Risk of damage by reversing the direction of rotation of a V-
ribbed belt that has already been used.
– Mark the direction of rotation with chalk or a felt-tip pen for the
re-installation before removing the V-ribbed belt.
Removing
– Swing the tensioning pulley in -direction
Protected of arrow-
by copyright. to private
Copying for detension
or commercial purposes, in part or in whole, is not permitted
the V-ribbed belt. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Lock tensioning pulley with locking pin - T10060A- .
– Remove the V-ribbed belt.

Installing
– Position the V-ribbed belt as shown in the illustration.
1- V-ribbed belt pulley.
2- Tensioning roller for V-ribbed belt.
3- Belt pulley-AC generator.
– Turn the tensioning pulley in -direction of arrow- and pull out

the locking pin - T10060A- .
– Release tension on tensioning pulley.
– Check the correct fit of the tensioning pulley.
– Start engine and check that the V-ribbed belt is running cor‐
rectly.
1.2.2 Removing and installing V-ribbed belt

on vehicles with air conditioning system
Removing
NOTICE
Risk of damage by reversing the direction of rotation of a V-
ribbed belt that has already been used.
re-installation before removing the V-ribbed belt.
– Loosen the V-ribbed belt by turning the tensioning pulley in the
-direction of the arrow-.
– Lock tensioning pulley with locking pin - T10060A- .
– Remove the V-ribbed belt.

Installing
– Lay the V-ribbed belt in stages as shown in the illustration:
1- V-ribbed belt pulley.
2- Tensioning roller for V-ribbed belt.
3- Belt pulley-AC generator.
4- Belt pulley-AC compressor
– Turn the tensioning pulley in -direction of arrow- and pull out

the locking pin - T10060A- .
– Release tension on tensioning pulley.
– Check the correct fit of the tensioning pulley.
– Start engine and check the that the V-ribbed belt is running
correctly.
1.3 Removing and installing tensioning pul‐

ley for V-ribbed belt
Removing
– Remove the V-ribbed belt from the tensioning roller:
♦ Vehicles without air conditioning system ⇒ “1.2.1 Removing
and installing V-ribbed belt on vehicles without air conditioning
system”, page 46 .
♦ Vehicles with air conditioning system ⇒ “1.2.2 Removing and
installing V-ribbed belt on vehicles with air conditioning sys‐
tem”, page 47 .
Version 1
– Unscrew screws -arrows- and pull off tensioning pulley -1- for
V-ribbed belt.

Version 2
– Unscrew screws -arrows- and pull off tensioning pulley -1- for
V-ribbed belt.
Installing
– Install the V-ribbed belt:
♦ Vehicles without air conditioning system ⇒ “1.2.1 Removing
and installing V-ribbed belt on vehicles without air conditioning
♦ Vehicles with air conditioning system ⇒ “1.2.2 Removing and
installing V-ribbed belt on vehicles with air conditioning sys‐
tem”, page 47 .
Note

wellunless
as authorised
replacement components after removal.
♦ Tensioning roller - vehicles without air conditioning ⇒
“1.1.1 Summary of components - V-ribbed belt drive for vehi‐
cles without air conditioning system”, page 42 .
♦ Tensioning roller - vehicles with air conditioning ⇒ “1.1.2 Sum‐
mary of components - V-ribbed belt drive for vehicles with air
conditioning system”, page 44 .
1.4 Removing and installing vibration damp‐

ener
♦ Counterholder - T10475-
Note
♦ Different vibration damper variants can be installed.

♦ The counterholder - T10475- must be adapted to the holes on
the vibration damper.
Version 1
– Complete the counterholder - T10475- -1- with the catch bolt
- T10475/2- -2-.

Version 2
– Complete counterholder - T10475- with support bolt -
T10475/1- and catch bolt - T10475/2- , as shown.
Note
After the vibration damper variant, use the bore -A- or -B- on the
counterholder - T10475- -1-.
Removing
noise insulation .
– Remove V-ribbed belt ⇒ “1.2 Removing and installing V-ribbed
belt”, page 46 .
– Position piston of the cylinder 1 on TDC ⇒ “4.7 Position piston
to TDC”, page 77 .
– Loosen screw -arrow- for vibration damper; to do so, use

counterholder - unless
T10475- .
– Unscrew screw and remove the vibration damper.
NOTICE
Risk of destruction of the engine.
♦ In order not to adjust the timing, the crankshaft must not be

turned from the TDC position on removed vibration damper.
Installing
Note
♦ Screws which have been tightened firmly to a torquing angle

must be replaced.
♦ All contact surfaces between screw, vibration damper and
crankshaft toothed belt sprocket must be free of oil and
grease.

note the following:
– Install the V-ribbed belt ⇒ “1.2 Removing and installing V-
ribbed belt”, page 46 .
Note

♦ Screw for vibration damper ⇒ “1.1 Assembly overview - V-

ribbed belt drive”, page 42 .
1.5 Removing and installing engine support

Removing


– Remove tensioning pulley for V-ribbed belt ⇒ “1.3 Removing
and installing tensioning pulley for V-ribbed belt”, page 48 .
– Remove top toothed belt guard ⇒ “2.4.1 Removing and in‐
stalling top toothed belt guard”, page 98 .
– Unscrew bolt -1-.
– Remove holder for cable harness -arrow- from the engine
support.
Note
Open closed lines and connections immediately with suitable

screen caps.


– Unscrew the screws -1- and remove the bracket -2- for the
catalytic converter.
– Open holding clamps on the air conditioning system pipes.

– Loosen screw -1-, but do not remove it.
– Swivel generator -3- forward in -direction of the arrow-.
– Unscrew screws -arrows- from bracket of the pre-exhaust

pipe. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Remove pendulum support
with ⇒ “2.4
respect to the Removing
correctness and
of information installing
in this document. Copyright by ŠKODA AUTO A. S.
pendulum support”, page 32 .
– Remove engine mounts ⇒ “2.2 Removing and installing en‐
gine mount”, page 30 .
– Remove screws -arrows-.

– Unscrew screws -1-, -2- and -3-.


– Remove screws -arrows-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Press engine/gearbox unit slightly to the left and remove en‐
gine support.
Installing
Note

♦ Assembly bracket ⇒ “2 Assembly bracket”, page 28 .

♦ Tensioning pulley for V-ribbed belt ⇒ “1.1 Assembly overview
- V-ribbed belt drive”, page 42 .
♦ Toothed belt guard ⇒ “2.1 Summary of components - toothed
belt guard”, page 94 .
♦ Coolant pipes ⇒ “3.1 Summary of components - coolant pipe”,
page 207 .
♦ Charge-air system ⇒ “2.1 Summary of components - charge
air system”, page 237 .
♦ Air filter ⇒ “3.1 Assembly overview - air filter housing”, page
273 .

♦ Removing and installing parts of the exhaust system ⇒

“2.1 Summary of components - exhaust gas cleaning”, page
321 .
1.6 Replacing crankshaft sealing ring on the

belt pulley side
♦ Assembly tool - T10485/1,2 and 3-
♦ Extractor tool - T20143-
– Remove toothed belt ⇒ “2.5 Removing and installing toothed
belt”, page 99 .
– Remove crankshaft toothed belt sprocket -1- -arrow-.
NOTICE
♦ In order not to adjust the timing, the crankshaft must not be

turned from the TDC position on removed vibration damper.
– Pry sealing ring off with the extractor tool -T20143/2- -arrow-.
– Clean the contact and sealing surfaces.
Note
Do not oil new sealing ring.
– Push new sealing ring in -direction of the arrow- over the as‐
sembly sleeve - T10485/3- onto the guide bushing -
T10485/2- .
• Fitting position: closed side of sealing ring points to the thrust
piece - T10485/1- .

– Pull off assembly sleeve - T10485/3- in -direction of arrow-.
– Fit guide bushing - T10485/2- with seal -1- onto crankshaft

journal.
– Pull sealing ring -2- up to the stop using the thrust piece -
T10485/1- and the belt pulley screw -1-.
– Fit crankshaft toothed belt sprocket onto the crankshaft.

• The contact surface between the V-ribbed belt pulley and the
grease.
• Milled surface -arrow- on the crankshaft toothed belt must be
positioned on the crankshaft stub.
– install (set the timing) ⇒ “2.5 Removing and installing toothed
belt”, page 99 .

2 Cylinder block on gearbox side

⇒ “2.1 Summary of components - cylinder block on gearbox side”,
page 56
⇒ “2.2 Removing and installing flywheel”, page 58
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 59
2.1 Summary of components - cylinder

block on gearbox side
Note

1 - Flywheel
stalling flywheel”, page
58
❑ can be installed only in
one position
2 - Screw
sembly
❑ 60 Nm + 90°
3 - Fitting sleeve
❑ Qty. 2
4 - Engine speed transmitter -
G28-
stalling the engine
speed transmitter G28 ”,
page 340
5 - Screw
❑ Tightening torque ⇒
“1.1 Assembly overview
- ignition system”,
page 334
6 - Gasket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
7 - Intermediate plate with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
❑ do not damage/bend
during assembly work
❑ installing ⇒ Fig. ““Install
intermediate plate”“ ,
page 57
8 - Intermediate plate
❑ Removing and installing ⇒ Fig. ““Installing intermediate plate”“ , page 57
9 - Screw
❑ Qty. 2

❑ for intermediate plate
❑ 25 Nm
10 - Fitting sleeve
❑ Qty. 2
11 - Sealing flange with rotor and sealing ring
❑ Replace sealing flange completely with oil seal, sensing wheel and engine speed sensor - G28- only
❑ Do not reuse a used sealing flange
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 59
12 - Screw
❑ Tightening torque and tightening order ⇒ Fig. ““Sealing flange on the gearbox side - tightening torque
and tightening order”“ , page 57
13 - Screw
❑ Screw plug for “TDC” bore .
❑ with integrated sealing ring
❑ Tightening torque ⇒ Fig. ““Screw plug for TDC bore in the cylinder block behind - tightening torque”“ ,
page 58
Sealing flange on the gearbox side - tightening torque and tight‐

ening order
– Tighten screws gradually as follows:
Step Bolts Specified torque
1. -1-6- by hand as far as the stop
2. -1-6- tighten crosswise in steps up to
10 Nm
Install intermediate plate

– Mount intermediate plate -1- on sealing flange arrow -B- and
push onto the dowel sleeves arrows -A-.
Installing intermediate plate

– Unscrew the screws before removing the screws -arrows-.
– Push
Protectedthe intermediate
by copyright. Copying forplate
private onto the adapter
or commercial sleeves
purposes, in ⇒ Fig.
part or in whole, is not permitted
““Install intermediate plate”“ , page 57 ,

Bolts 25 Nm
2. Cylinder block on gearbox side 57

Screw plug for “TDC” bore in the cylinder block behind - tightening
torque
Note
♦ Screw -arrow- onto inner sealing ring.

♦ Replace if damaged

Screw for “TDC”- 30 Nm
drilling
2.2 Removing and installing flywheel

⇒ “2.2.1 Removing and installing flywheel”, page 58
⇒ “2.2.2 Pre-tension gearing in the flywheel - vehicles with auto‐
matic dual-clutch gearbox”, page 59
2.2.1 Removing and installing flywheel

♦ Rig tool - MP1-223 (3067)-
Removing
• Gearbox removed
– Remove clutch in vehicles with manual gearbox ⇒ Rep. gr.
30 ; Clutch; removing and installing clutch .
• Fitting position of the tool:
A - for tightening
B - for slackening
– Insert the counterholder - MP1-223 (3067)- into the hole on
the cylinder block -B-.
– Loosen and remove all flywheel bolts.
Installing
Note
Assembly of flywheel with rotor is only possible in one position.
– Insert the counterholder - MP1-223 (3067)- into the hole on

the cylinder block -A-.
Note
In vehicles with automatic dual-clutch

Protected by copyright. Copying gearbox, the gearing
for private or commercial of the
purposes, in part or in whole, is not permitted
dual-clutch gearbox
unless in the flywheel
authorised by ŠKODA must
AUTO A.be pre-tensioned
S. ŠKODA and
AUTO A. S. does not guarantee or accept any liability
secured. Pre-tensioning is initiated when the engine is started for
the first time and the gearing engages between flywheel and dual
clutch. ⇒ “2.2.2 Pre-tension gearing in the flywheel - vehicles with
automatic dual-clutch gearbox”, page 59 .

Note

♦ Screws for flywheel ⇒ “2.1 Summary of components - cylinder

block on gearbox side”, page 56 .
2.2.2 Pre-tension gearing in the flywheel - ve‐

hicles with automatic dual-clutch gear‐
box
In vehicles with automatic dual-clutch gearbox, the gearing of the
dual-clutch gearbox in the flywheel must be pre-tensioned and
secured. Pre-tensioning is initiated when the engine is started for
the first time and the gearing engages between flywheel and dual
clutch.
– Insert a suitable screwdriver (6.5 mm wide lip) into the recess
and turn by 90° in direction of arrow -A- so that the safety clutch
-1- is exposed above the recess.
– Press the locking clutch inwards with a suitable tool in the di‐
rection of the arrow -B-, detach the inverted screwdriver again.
– Repeat the procedure for the other safety clutch.
The gearing in the flywheel is now pre-tensioned and ready for
gearbox installation.
2.3 Removing and installing sealing flange

on gearbox side
♦ Depth gauges , e.g. -VAS 6082-
♦ Assembly tool - T10134-
♦ Guide bolt - T10578-
♦ Locating screw - T10340-
♦ 3x screw M6 x 35
Note
♦ After replacing the sealing flange, the new values must be

transferred to the engine control unit.
♦ The work sequence must be absolutely observed.

Touch-up assembly device - T10134- with guide pins - T10578- .

Rework assemble device - T10134- -1-.
– Expand guide pin for diesel engine (black button) -G-. Then
unscrew the knob.
– Install guide pins - T10578- -2- at this point. Unscrew the knob
and screw in again.
• Removed gearbox ⇒ Rep. gr. 34 ; Removing and installing
the gearbox; remove gearbox .
Note
♦ For reasons of clarity, the work was performed with the engine
removed.
♦ The work sequences are identical with the engine installed and
gearbox removed.
– Remove flywheel or driver disc ⇒ “2.2 Removing and installing

flywheel”, page 58 .
– Remove intermediate plate -1- from the dowel sleeves arrows

-A-.
– Move intermediate plate -1- upwards.
– At the same time, pull the retaining lug arrow -B- of the inter‐
mediate plate -1- out of the recess behind the sealing flange.
– Position piston of the cylinder 1 on TDC ⇒ “4.7 Position piston
to TDC”, page 77 .
– Removing the oil pan ⇒ “1.3 Removing and installing oil pan”,
page 163 .
– Remove the engine speed sender - G28- -arrow- ⇒ “1.6 Re‐

moving and installing the engine speed transmitter G28 ”,
page 340 .
– Unscrew screws -arrows- on sealing flange -1-.

– Sealing flange and rotor are pressed together with 3 M6x35

mm screws from the crankshaft.
– Alternating, screw in three screws -arrows- (max. 1/2 turn
(180°) per screw) into the threaded holes of the sealing flange
-1- and remove the sealing flange together with the rotor -2-
from the crankshaft -3-.
Sealing flange with rotor
Note
♦ Do not reuse the used sealing flange!

♦ The sealing flange with PTFE sealing ring is provided with
sealing lip supporting ring -2-. This support ring serves as a
fitting sleeve and must not be removed prior to installation.
♦ Do not separate the sealing flange and rotor -1- after removing
them from the spare part package.
♦ The rotor gets its fitting location by fixing by fixing to the posi‐
tioning pin of the assembly tool - T10134- ⇒ page 61 .
♦ Sealing flange and sealing ring form one unit and must only
be renewed together with the transmitter wheel.
♦ The assembly device - T10134- is given its fitting location to
the crankshaft by means of a guide bolt, which is guided into
the threaded bore of the crankshaft ⇒ page 61 .
Assembly tool - T10134-

A - Clamping surface
B - Hexagon nut
C - Assembly housing
D-
Locating pin
E - Allan screws (2 pieces)
F - Guide bolts for petrol engines
G-
Guide bolt - T10578-
H - Knurled screws (3 pieces)
I - Inner part

A - Attach sealing flange with rotor to the assembly tool - T10134-

– Screw on nut -B- until just before it touches the clamping sur‐
face -A- of the threaded spindle.
– Grip assembly tool - T10134- at clamping surface -A- of the

threaded spindle in a vice.
– Press assembly housing -C- downwards until it lies on
hexagon nut -B-.
– Screw nut onto threaded spindle until inner part of assembly
tool and assembly housing are at same height.
– Remove the securing clip -arrow- from the new sealing flange.
Note
Do not remove the rotor from the sealing flange.
• The locating hole -A- on the rotor -C- must be flush with the
marking -B- on the sealing flange.

– Place sealing flange with front side facing down on a clean

level surface.
– Press down sealing lip supporting ring -1- in
-direction of arrow-, until it rests on the level surface.
• The upper edge of the sealing lip supporting ring -1- and front
edge of the sealing flange -2- must align -arrows-.
– Lay the sealing flange -1- with the front side on the assembly
tool - T10134- so that the positioning pin -D- engages into the
hole -3- of the rotor -2-.
When the position of the hole -3- opposite the fixing pin -D- is not
correct, carefully turn the encoderunless
wheel -2- with
authorised the support
by ŠKODA AUTO A. S.ring.
ŠKODA AUTO A. S. does not guarantee or accept any liability
• Sealing flange must lie straight on the assembly tool.
– Press on the sealing flange -1- and sealing lip supporting ring
-2- by tightening the 3 knurled screws -H- onto the surface of
the assembly tool - T10134- .
Note
This prevents locating pin from slipping out of sender wheel hole.
When installing the sealing flange, ensure that the sender wheel
remains fixed in the assembly device.

B - secure assembly tool - T10134- with sealing flange -1- onto

the crankshaft flange and cylinder block
• Crankshaft flange free from oil and grease.
• Engine is at “TDC” ⇒ “4.7 Position piston to TDC”, page
77 .
– Screw nut -B- on until it reaches end of threaded spindle.
– Press the threaded spindle of the assembly tool - T10134-
in -direction of arrow- until the nut -B- rests against the as‐
sembly cup -C-.
– Align flat side of assembly housing to the cylinder block sealing
surface on the oil sump side.
– Secure the assembly tool - T10134- and the sealing flange

-1- with Allan screws -E- to the crankshaft flange.
Note
Screw in Allan screws -E- into the crankshaft flange by approx.

five thread turns.
– Slide the guide pin -G- into the crankshaft flange.
– Screw in two M6x35 mm screws -2- by about 3 turns for sealing

flange guide -1- into the cylinder block.
Screw C - attach assembly tool - T10134- onto crankshaft flange

– Push the assembly cup -C- by hand in the
-direction of the arrow- until the sealing lip supporting ring -1-
rests on the crankshaft flange -2-.
– Slide the guide pin -G- into the crankshaft bore. This gives the
rotor its final installation position. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note
The second guide pin must not be inserted in the threaded hole
of the crankshaft.
– Tighten the two Allan screws hand-tight.

– Screw nut -B- onto threaded spindle by hand until it lies against
assembly housing -C-.

Press D - press rotor with assembly tool - T10134- onto crankshaft

flange
– Tighten nuts -B- on the assembly tool - T10134- with torque
wrench to 35 Nm.
• After tightening the nut to 35 Nm there must still be a narrow
air gap between the cylinder block and the sealing flange.
E - Inspect the installation position of the rotor on the crankshaft

– Screw nut -B- on until it reaches end of threaded spindle.
– Unscrew bolts-2- from the intake manifold.
– Remove the guide bolt -G- from the crankshaft flange.
– Remove knurled screws -H- from the sealing flange -1-.
– Unscrew the Allan screws -E- from the crankshaft flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
– Place caliper gauge on crankshaft flange.
– Measure distance -a- between crankshaft flange -2- and rotor

-1-.
• Set value: Dimension -a- = 0.5 mm.
If dimension »a« is too small:
– Press down rotor ⇒ page 66 .
If dimension »a« is achieved:
– Complete the remaining installation ⇒ page 66 .

F - Pressing down the rotor

– Secure the assembly tool - T10134- and with Allan screws
-E- to the crankshaft flange.
Make sure the positioning pin of the assembly tool - T10134- en‐
gages in the bore of the rotor.
– Tighten the two Allan screws -E- hand-tight.
– Press the assembly tool - T10134- against the sealing
flange -1- by hand.
– Screw nut -B- onto threaded spindle by hand until it lies against
the assembly housing.
– Slide the guide pin -G- into the crankshaft bore.
– Screw the knurled screws -H- into the flange -1-.
– Screw in two M6x35 mm screws -2- by about 3 turns for sealing
flange guide -1- into the cylinder block.
– Tighten nut -B- of the assembly tool - T10134- to 40 Nm.

– Check the fitting position of the rotor on the crankshaft
again ⇒ page 65 .
If the dimension »a« is too small again:
– Tighten nut -B- of the assembly tool - T10134- to 45 Nm.
– Check the fitting position of the rotor on the crankshaft
again ⇒ page 65 .
Installing
– Tighten screws for sealing flange crosswise.
– Installing the oil pan ⇒ “1.3 Removing and
with respect installing
to the correctness oil pan”, in this document. Copyright by ŠKODA AUTO A. S.
of information
page 163 .
– Install intermediate plate / intermediate plate ⇒ “2.1 Summary
of components - cylinder block on gearbox side”, page 56 .
– Install the flywheel ⇒ “2.2 Removing and installing flywheel”,
page 58 .
NOTICE
Risk of engine damage if the locating screw - T10340- would
not be removed.
♦ After completing work, make sure that the positioning screw -

T10340- has been removed.
– Reset the correction values in the engine control unit ⇒ Vehi‐
cle diagnostic tester.
♦ 0001 - Engine electronics - Petrol engine 1.5 l
♦ 0001 - Repair groups
♦ 15 - Cylinder head, valve gear
♦ 15 - Correction values of crankshaft position
Note
The function is independent until the end.

Process the type plate on the toothed belt guard
Note
♦ The crankshaft drive has many mechanical and electronic tol‐

erances.
♦ These tolerance values are already determined on the factory
side and are stored on the type plate on the upper toothed belt
guard.
♦ The tolerances are changed by replacing the sealing flange.
♦ Production value -a- »XK-1 code« Is no longer valid.
♦ Value -a- »XK-1 code« on the sticker -1- must be destroyed
by scratching after replacing the flange on the shield.
♦ Scratch out value -a- with a sharp tool so that it can not be
seen.
Note

♦ Sealing flange on the gearbox side ⇒ “2.1 Summary of com‐

ponents - cylinder block on gearbox side”, page 56 .
♦ Engine speed sender - G28- ⇒ “2.1 Summary of components
- cylinder block on gearbox side”, page 56 .
♦ Screw plug for bore in the cylinder block ⇒ Fig. ““Screw plug
for TDC bore in the cylinder block behind - tightening torque”“ ,
page 58 .

3 Crankshaft
⇒ “3.1 Measuring axial play of crankshaft”, page 68
⇒ “3.2 Replace the needle bearing in the crankshaft”, page
68
⇒ “3.3 Crankshaft dimensions”, page 69
3.1 Measuring axial play of crankshaft

♦ Universal dial gauge bracket - MP3-447 (VW 387)-
♦ Dial gauge , e.g. -VAS 6079-
NOTICE
There is a risk of bearing seat deformation.
Newer loosen the screws of the crankshaft bearing cover.
♦ The crankshaft must not be removed. Merely releasing the

screws of the crankshaft bearing cover will result in deforma‐
tions of the bearing seats of the cylinder block.
♦ If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
♦ Measuring the crankshaft bearing clearance is not possible
with normal workshop equipment.
– Secure dial gauge - VAS 6079- with the universal dial gauge
bracket to the camshaft housing - VW 387- , as shown in the
illustration.
– Place dial gauge against the crankshaft cheek.
– Press crankshaft against the dial gauge and set dial gauge to
“0”.
– Press the crankshaft off the dial gauge and read the measured
value.
• Axial clearance: 0.066 - 0.233 mm.
3.2 Replace the needle bearing in the

crankshaft
Only for vehicles with automatic gearbox Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Centering mandrel -T30029 (3176)-
♦ Interior extractor - Kukko 21/2- or e.g. -VAS 251 635-
♦ Counter support - Kukko 22/1- or e.g. -VAS 251 621-
Removing
• If the engine and transmission were separated, always replace
the needle bearing -arrow-.

Pulling out the needle bearing

– Remove needle bearing -1- with internal extractor -Kukko
21/2- -A- and countersupport -Kukko 22/1- -B- from crankshaft
-2-.
Fit the internal extractor -Kukko 21/2- behind the needle rim
-arrow-.
Installing
Fitting position of the needle bearing:
♦ The marked side of the needle bearing should be visible when
in its installed condition.
– Clean the bearing in the crankshaft.
– Press the eedle bearing with centring mandrel -T30029

(3176)- into the installation depth in the crankshaft.
Assembly depth: dimension a = 2.0 mm.
Note
If the bearing has been pressed in too deeply, it must be replaced.

The bearing is damaged if it is removed again.
3.3 Crankshaft dimensions

NOTICE
There is a risk of bearing seat deformation.
Newer loosen the screws of the crankshaft bearing cover.
3. Crankshaft 69
♦ The crankshaft must not be removed. Merely releasing the

screws of the crankshaft bearing cover will result in deforma‐
tions of the bearing seats of the cylinder block.
♦ If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
♦ Measuring the crankshaft bearing clearance is not possible
with normal workshop equipment.
Grinding dimension ∅ conrod journal
mm
Basic dimension 47.80 -0.022
-0.037

4 Pistons and conrods

⇒ “4.1 Assembly overview - piston and conrod”, page 71
⇒ “4.2 Removing and installing the piston”, page 72
⇒ “4.3 Separating new connecting rod”, page 73
⇒ “4.4 Removing and installing oil injection nozzles”, page
74
⇒ “4.5 Check piston and cylinder bore”, page 75
⇒ “4.6 Check radial clearance of connecting rods”, page 76
⇒ “4.7 Position piston to TDC”, page 77
4.1 Assembly overview - piston and conrod
1 - Screw
sembly
❑ Oil threads and contact
surface
❑ 30 Nm + 90°
2 - Connecting rod bearing cap
❑ as a result of the con‐
rods separated in the
cracking process, the
conrod bearing cap fits
only in one position and
only to the relevant con‐
rod
❑ Mark assignment to the
cylinder and to the con‐
rod in colour -B-
3 - Bearing shells
❑ Fitting position ⇒ Fig.
““Bearing shell installa‐
tion position”“ , page
72
❑ replace used bearing
shells
❑ check for firm seating
4 - Connecting rod
❑ with cracked conrod
bearing cap
❑ Renew as set only.
❑ Mark assignment to the
cylinder and to the con‐
rod bearing cap in
colourCopying
Protected by copyright. -B- for private or commercial purposes, in part or in whole, is not permitted
❑ separate newof conrod
with respect to the correctness information ⇒
“4.3 Separating new connecting rod”, page 73
5 - Circlip
❑ Qty. 2
6 - Piston pin
❑ Removing and installing ⇒ “4.2 Removing and installing the piston”, page 72
4. Pistons and conrods 71

7 - Piston
❑ Mark the installation position and the assignment to cylinder ⇒ Fig. ““Fitting position of piston and as‐
signment of piston to cylinder”“ , page 72
❑ Removing and installing ⇒ “4.2 Removing and installing the piston”, page 72
❑ Check piston and cylinder bore ⇒ “4.5 Check piston and cylinder bore”, page 75
8 - Piston rings
❑ Compression rings
❑ Measure end gap ⇒ Fig. ““Measure piston ring end gap”“ , page 75
❑ Measure vertical gap ⇒ Fig. ““Measure piston ring vertical gap”“ , page 76
❑ use commercially available piston ring pliers for removing and installing
❑ Installation position: Identification “TOP” or labelled side towards piston crown
❑ Offset gaps by 120°
9 - Piston ring
❑ Oil scraper ring
❑ Measure end gap ⇒ Fig. ““Measure piston ring end gap”“ , page 75
❑ Measure vertical gap ⇒ Fig. ““Measure piston ring vertical gap”“ , page 76
❑ use piston ring pliers for removing and installing
❑ Installation position: Identification “TOP” or labelled side towards piston crown
❑ Offset joint 120° to bottom compression ring
Fitting position of piston and assignment of piston to cylinder
NOTICE
Risk of damaging the piston crown.
♦ For re-installation, mark the assignment in colour on the piston

crown of cylinders that have already been used. Do not mark
piston crown not using centre punch, scratch, nick or similar.
• Arrow on the piston crown to the belt pulley side -arrow-.
Bearing shell installation position

– Insert bearing shells centrally in the
with respect conrod
to the and
correctness conrod inbear‐
of information this document. Copyright by ŠKODA AUTO A. S.
ing cap.
• Dimension -a- = 2.5 mm
4.2 Removing and installing the piston


♦ Drift , e.g. -T10046-

♦ Commercially available piston ring tensioning strap
Removing
– Remove cylinder head ⇒ “1.3 Removing and installing cylinder
head”, page 84 .
page 163 .
– Mark installation position and assignment of the piston to the
cylinder ⇒ “4.1 Assembly overview - piston and conrod”, page
71 .
– Mark the installation position and assignment of the conrod to
the cylinder and to the conrod bearing cap ⇒ “4.1 Assembly
overview - piston and conrod”, page 71 .
– Remove conrod bearing cap and pull out piston with conrod
upwards.
Note
If the piston pin is stiff, heat the piston to approximately 60 °C.
– Remove circlips from the piston pin eye.

– Drive off piston pin with a drift , e.g. -T10046- .
Installing
Note

be replaced.
– Oil the contact surfaces of the bearing shells.

– Install pistonunless
with commercially available piston ring tension‐
ing strap, check installation position ⇒ Fig. ““Fitting position of
piston and assignment of piston to cylinder”“ , page 72 .
– Install conrod bearing cap, check installation position ⇒
“4.1 Assembly overview - piston and conrod”, page 71 .
– Install cylinder head ⇒ “1.3 Removing and installing cylinder
head”, page 84 .
– Installing the oil pan ⇒ “1.3 Removing and installing oil pan”,
page 163 .
Note

♦ Conrod bearing cap screws ⇒ “4.1 Assembly overview - piston

and conrod”, page 71 .
4.3 Separating new connecting rod

On new conrods it is possible that the target breaking point is not

fully broken through. If the connecting rod bearing cap cannot be
removed by hand, then proceed as follows:
– Mark the assignment of the connecting rod to the cylinder.
– Tension the conrod in a vice equipped with protective alumini‐
um jaws.
Note
Only tension the conrod slightly in order to avoid damage.
– Tension the conrod below the dotted line.

– Unscrew both screws -arrows- by approx. 5 turns.
– Carefully knock against the conrod bearing cap with a rubber

hammer in -direction of arrow- in order to loosen it.
4.4 Removing and installing oil injection

nozzles
♦ Torx insert T40 - T10545-
Removing
page 163 .
• The crankshaft must be turned so that the Torx insert T40 -
T10545- can be inserted into the applicable pressure relief
valve.
• The teeth of Torx insert T40 - T10545- and the pressure relief
valve must engage correctly.
– Turn the crankshaft using the locating screw of the vibration
damper in direction of rotation of engine until the pressure re‐
lief valve is accessible.

– Unscrew and remove the pressure relief valves -1- with Torx
insert T40 - T10545- .
– Remove oil spray nozzles -2-.
Installing
NOTICE
Risk of damaging the oil injection nozzles.
Do not bend oil injection nozzles.
♦ Replace the oil injection nozzles if they are bent.

♦ Check clearance of pistons from oil injection nozzles after re‐
installing the piston and nozzles.
• Fitting position: Align the guide edge of the oil injection nozzle
to the area of the cylinder block being worked on.
1- Pressure relief valve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
2- Oil spray nozzle (for cooling piston) with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
– Installing the oil pan ⇒ “1.3 Removing and installing oil pan”,
page 163 .
Specified torques
Pressure relief valve 27 Nm
4.5 Check piston and cylinder bore

Inspecting piston
– Using an external micrometer, measure pistons approx.
10 mm from the lower edge of skirt, at 90° to the piston pin
axis.
∅ piston in mm
Nominal value without coating 74.450 +0,009 -0,009
Nominal value with coating 74.472 +0,017 -0,017
• Manufacturer of Kolbenschmidt piston company (thickness
0.014 mm 0.005 -0,005 per side)
Measure piston ring end gap

– Push the piston ring into the bottom cylinder opening at right
angles to the cylinder wall from above to about 15 mm from
the cylinder edge.
– To insert, use a piston without piston ring.
Piston ring New Wear limit
mm mm
1st compression ring 0.20 +0.10 0.6
2nd compression ring 0.50 +0.20 1.0
3-part oil scraper ring 0.20 +0.50 1.5

Measure piston ring vertical gap

– Clean before inspecting the annular groove of the piston.
Piston ring New Wear limit
mm mm
1st compression ring 0.04 … 0.08 0.15
2nd compression ring 0.030 … 0.070 0.15
3-part oil scraper ring cannot be measured
Measure cylinder bore
NOTICE
There is risk of damaging the cylinder bore surface.
♦ Do not use normal workshop equipment to work on cylinder

bore (boring, honing, grinding).
– Using the internal precision instrument - VAS 6078- , measure
crosswise at 3 points in the transverse direction -A- and lon‐
gitudinal direction -B-.
Cylinder bore ∅ mm
Nominal dimension 74.5 + 0.015 1)
+0.005
Note
Cylinder bores must not be measured when cylinder block is

mounted on engine and gearbox support - VAS 6095- , as mea‐
surements may be incorrect.
4.6 Check radial clearance of connecting

rods
♦ Plastigage
Work procedure
– Remove conrod bearing cap.
– Clean the connecting rod bearing cap and connecting rod
bearing pin.
– Place plastigage of the bearing width according to the con‐
necting rod bearing pin or into the bearing shell.
– Fit connecting rod bearing cap and tighten to 30 Nm and turn
a further 90°.
Note
Do not twist the crankshaft.
– Remove conrod bearing cap.

– Measure the thickness of the plastigage.

• Axial clearance: 0.023 - 0.061 mm.

– Replace screws for conrod.
Note

♦ Conrod bearing screw ⇒ “4.1 Assembly overview - piston and

conrod”, page 71 .
4.7 Position piston to TDC

Position piston of the cylinder 1 on »TDC« ⇒ page 77
Place piston of cylinder 1 for working on the toothed belt drive and
for the control timing adjustment on »TDC« ⇒ page 78
Position piston of the cylinder 1 on »TDC« .
noise insulation .
– Undo locking screw behind for “TDC” bore -arrow- on the
cylinder block.
– Place a clean cloth below to absorb leaking engine oil.
NOTICE
Risk of damage to the engine if the locating screw - T10340- is
screwed in at the wrong position.
– Screw in the locating screw - T10340- up to the stop into the

cylinder block and tighten.
• The head of the fixing screw - T10340- must be in contact with
the cylinder block.
If the locating screw - T10340- cannot be screwed in up to the
stop, the crankshaft is not in the correct position!
In this case, proceed as follows:
– Unscrew locating screw - T10340- .
– Turn the crankshaft 90° in the running direction of the engine.
– Screw in the locating screw - T10340- again up to the stop into
the cylinder block and tighten.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft sprocket is now in contact with the fixing screw -
T10340- and the “TDC” position is set.
Note

The locating screw - T10340- only locks the crankshaft in direction

of rotation of the engine.
Place piston of cylinder 1 for working on the toothed belt drive and
for the control timing adjustment on »TDC«
– Remove the pulley for coolant pump drive ⇒ “2.6 Removing
and installing toothed belt pulley for coolant pump”, page
194 .
– Position piston of the cylinder 1 on »TDC« ⇒ page 77 .
– Unscrew screw -a- at the closure -1- of the intake camshaft on

the gearbox side.
– Remove closure -1- and check the position of the intake
camshaft.
• Edge -e-, machined surfaces on the intake camshaft, must

point upwards.
When the edge -e- does not point upwards:
– Turn the crankshaft in direction of rotation of engine by 1 turns
⇒ page 77 .
• Edge -e- of the intake camshaft and edge -a- of the exhaust
camshaft must point upwards.
• Edge -e- of the intake camshaft and edge -a- of the exhaust
camshaft must be parallel to line -c-.
♦ Screw plug for bore in the cylinder block ⇒ “2.1 Summary of
components - cylinder block on gearbox side”, page 56 .
Locating screw - T10340- 30 Nm

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 79
⇒ “1.2 Summary of components - camshaft housing”, page
81
⇒ “1.3 Removing and installing cylinder head”, page 84
⇒ “1.4 Removing and installing camshaft housing”, page 87
⇒ “1.5 Checking compression”, page 91
⇒ “1.6 Checking the combustion chamber for tightness”, page
92
1.1 Summary of components - cylinder

head
Note

1. Cylinder head 79
1 - Cylinder head
stalling cylinder head”,
page 84
❑ check for distortion ⇒
Fig. ““Checking cylinder
head for distortion”“ ,
page 81
2 - Dowel pins
❑ Qty. 2
3 - Camshaft housing
❑ The camshafts cannot
be removed individually
❑ Summary of compo‐
nents ⇒ “1.2 Summary
of components -
camshaft housing”,
page 81
stalling camshaft hous‐
ing”, page 87
4 - Gasket
sembly
❑ Different versions ⇒
ETKA - Electronic Cata‐
logue of Original Parts
5 - Cylinder head bolt
sembly
❑ pay attention to order for
slackening ⇒ page
85
❑ Tightening torque and tightening order ⇒ Fig. ““Cylinder head - tightening torque and tightening order”“ ,
page 81
7 - Screw
❑ 20 Nm
8 - Cylinder head gasket
❑ replace after removal ⇒ “1.3 Removing and installing cylinder head”, page 84
❑ Observe fitting position: Part number points to cylinder head.
9 - Screw for camshaft housing
❑ Tightening torque and tightening order ⇒ Fig. ““Camshaft housing - tightening torque and tightening
80 Rep. gr.15 - Cylinder head, valve gear

Cylinder head - tightening torque and tightening order

Tighten screws gradually in the given sequence:
– Insert cylinder head bolts and tighten by hand.
Step Bolts Tightening torque / torquing angle
1. -1-10- 40 Nm
2. -1-10- Turn 90° further
Checking cylinder head for distortion

– Inspect cylinder head at several points for distortion using a
500 mm knife-edge straightedge - VAS 6075- and feeler
gauge.
• Max. permissible distortion: 0.05 mm
1.2 Summary of components - camshaft

housing
ProtectedNote
1. Cylinder head 81
1 - O-ring
❑ Check the O-ring for
damage and replace if
necessary.
2 - Exhaust cam adjuster for
cylinder 3 - N595-
stalling cam adjuster”,
page 143
3 - O-ring
❑ Check the O-ring for
damage and replace if
necessary.
4 - Inlet cam adjuster for cylin‐
der 3 - N591-
page 143
5 - Screw
❑ 4 Nm
6 - Inlet cam adjuster for cylin‐
der 2 - N583-
page 143
7 - Screw
❑ 4 Nm
8 - Exhaust cam adjuster for
cylinder 2 - N587-
⇒ “3.5 Removing and installing cam adjuster”, page 143
9 - Screw
❑ Tightening torque and tightening order ⇒ Fig. ““Camshaft housing - tightening torque and tightening
10 - Screw
❑ 8 Nm
11 - Screw
❑ 8 Nm
12 - Camshaft adjustment valve 1 in the outlet - N318-
❑ Removing and installing ⇒ “3.7 Removing and installing camshaft control valve 1 in the exhaust N318
”, page 145
13 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Check O-ring for damagewith respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
❑ O-ring is not available separately; in the event of damage, replace together with exhaust camshaft control
valve 1 - N318- .
14 - Position sensor for exhaust camshaft - G1003-
❑ Removing and installing ⇒ “1.5 Removing and installing position transmitter for exhaust camshaft G1003
”, page 339
❑ Summary of components ⇒ “1.1 Assembly overview - ignition system”, page 334

15 - O-ring
❑ Check O-ring for damage
❑ O-ring is not available separately; in the event of damage, replace together with position transmitter for
exhaust camshaft - G1003- .
16 - Sealing ring
❑ for inlet camshaft on the belt pulley side
❑ Removing and installing ⇒ “3.3.2 Removing and installing the inlet camshaft on the belt pulley side”, page
132
17 - Sealing ring
❑ for exhaust camshaft on the belt pulley side
❑ Removing and installing ⇒ “3.3.3 Removing and installing the exhaust camshaft on the belt pulley side”,
page 134
18 - Exhaust gas pressure sensor 1 - G450-
❑ Removing and installing ⇒ “5.4 Removing and installing pressure sensor for exhaust gas 1 G450 ”, page
289
❑ 25 Nm
19 - Sealing ring
❑ O-ring is not available separately; in the event of damage, replace together with pressure sensor 1 fr
exhaust gas - G450- .
20 - Gasket
21 - O-ring
22 - Sealing ring
❑ for exhaust camshaft on the gearbox side
❑ Removing and installing ⇒ “3.3.4 Removing and installing the exhaust camshaft on the gearbox side”,
page 135
23 - Pulley
❑ For coolant pump drive
❑ Removing and installing ⇒ “2.6 Removing and installing toothed belt pulley for coolant pump”, page
194
24 - Screw
❑ Tightening torque Pos. -3- ⇒ “2.1 Summary of components - coolant pump/thermostat”, page 187
25 - Screw
❑ 8 Nm
26 - Screw
❑ 8 Nm
27 - Position sensor
unless authorised for intake
by ŠKODA AUTO A.camshaft
S. ŠKODA AUTO - G1002-
❑ Removing and installing ⇒ “1.4 Removing and installing position transmitter for inlet camshaft G1002 ”,
page 338
28 - O-ring
❑ O-ring is not available separately; in the event of damage, replace together with inlet camshaft 1 -
G1002- .
29 - Screw cap
30 - O-ring
1. Cylinder head 83
Camshaft housing - tightening torque and tightening order
Note
Replace screws which have been tightened to specified torquing

angle.

1. -1- to -17- by hand as far as the stop
2. -1- to -17- 10 Nm
3. -1- to -17- Turn 120° further
1.3 Removing and installing cylinder head

♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Screw plug set for engine , e.g. -VAS 6122-
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Commercially available scraper (blade width at least 40 mm)
Removing
Note
♦ All heat protection sleeves and cable straps should be fas‐

tened again in the same place when installing.
♦ Seal open channels using suitable screw plugs from the screw
plug set for engine - VAS 6122- .
♦ Cover openings on gearbox with cleaning cloths so that no
fluids can run into the coupling housing.
– Remove camshaft housing ⇒ “1.4 Removing and installing

camshaft housing”, page 87 .
– Removing the intake manifold ⇒ “4.2 Removing and installing
intake manifold”, page 278 .
– Remove exhaust turbocharger
Protected ⇒ “1.2 Removing
by copyright. and installing
Copying for private or commercial purposes, in part or in whole, is not permitted
exhaust gas turbocharger”,
unlesspage 231
authorised .
– Remove the roller towing lever and balancing elements ⇒
page 89 .

– Disconnect plug connections -1-, -2- and -3-.
– Unscrew screw -1- at the engine support.
– Loosen and unscrew the screws for the cylinder head in the
sequence -1- to -10-.
NOTICE
Danger of damage to cylinder head and valves.
– Remove cylinder head and place it on a clean base (foam).

Note
Apply coolant to the pistons and the cylinders of the cylinder block
immediately with a cloth.
1. Cylinder head 85
Installing
Make sure that when cleaning the cylinder head and cylinder
block no foreign particles can get into the cylinder or into the oil
and coolant galleries.
– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.
NOTICE
Risk of damaging sealing surfaces.
– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.
– Carefully remove any residual gas from the cylinder head and
cylinder block using a standard scraper with a blade. Sealing
surfaces must not be damaged!
Make sure this does not cause any extended scoring or scratch‐
ing.
NOTICE
Risk of damaging the cylinder block.
♦ There must be no oil or coolant in the blind holes for the cylin‐
der head screws in the cylinder block.
NOTICE
Risk of damage to the cylinder head gasket.
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ To prevent the silicon layer and the area of the bead from being
damaged, handle the gasket with the utmost care.
Note
♦ Replace self-locking nuts, sealing rings, gaskets and O-rings.

♦ If a replacement cylinder head must be installed, the contact
surfaces between hydraulic balancing elements, roller rocker
fingers and camshaft slideways must be oiled before the
camshaft housing is installed.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts“ETKA” .
♦ When the cylinder
unless authorised by ŠKODA head
AUTO orA. S.the cylinder
ŠKODA AUTO A.head
S. doesgasket is re‐
not guarantee or accept any liability
placed, thetoengine
with respect oil must
the correctness be replaced.
of information in this document. Copyright by ŠKODA AUTO A. S.
CAUTION
Risk of injury to eyes and skin.
Wear safety gloves and safety goggles.
– Carefully remove old sealant residue from the cylinder head

and cylinder block using a chemical sealant remover.

– Fit on cylinder head gasket -1-.

♦ Pay attention to dowel sleeves in cylinder block -arrows-.
♦ Observe fitting location of cylinder head gasket, identification:
part number must be legible from the inlet side.
If the crankshaft has rotated in the meantime: Position piston of
cylinder 1 at TDC ⇒ “4.7 Position piston to TDC”, page 77 .
– Turn crankshaft slightly back.
– Insert the cylinder head.
– Insert cylinder head bolts and tighten by hand.
– Tighten cylinder head bolts ⇒ Fig. ““Cylinder head - tightening
torque and tightening order”“ , page 81 .
Note
Tightening up the cylinder head bolts after doing repair work is

not necessary.

note the following:
– Change engine oil:
– Top up coolant ⇒ “1.3 Draining and filling coolant”, page
183 .
Note

♦ Engine support bracket ⇒ Fig. ““Engine support bracket - tight‐

ening torque and tightening order”“ , page 29 .
♦ Cylinder head ⇒ “1.1 Summary of components - cylinder
head”, page 79 .
1.4 Removing and installing camshaft hous‐

ing
Removing
– Remove the air guide pipe between the charge air cooler and
the exhaust turbocharger ⇒ “2.4.1 Removingwithand installing
respect the of information in this document. Copyright by ŠKODA AUTO A. S.
to the correctness
air guide pipe between the charge air cooler and the exhaust
gas turbocharger”, page 242 .
1. Cylinder head 87
– Push release buttons -b- on hose for crankcase ventilation

-1- and remove the hose.
– Unscrew screw -a- and remove the hose from the exhaust gas
turbocharger -2-.
– Disconnect the plug -3- on the position sender for inlet

camshaft - G1002- -1-.
– Remove connector of wiring harness -1-.

The number of connections may vary.
– Unscrew screw -2- and expose the wiring loom and lay it to
the side.
– Pull out oil dipstick -3-.
– Removing ignition coils ⇒ “1.2 Removing and installing ignition
coils with output stage”, page 336 .
– Remove connection fitting on exhaust gas turbocharger ⇒
“1.3 Removing and installing the exhaust gas turbocharger
connection fitting”, page 234 .
– Remove the oil separator at the top ⇒ “3.2.2 Removing and
installing oil separator”, page 174 .
– Remove coolant pump ⇒ “2.5 Removing and installing coolant
pump”, page 191 .
194 .
– Disconnect the fuel line -5- from the high pressure pump ⇒
“7.1 Summary of components - high pressure pump”, page
293 . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
– Remove high pressure pump ⇒ “7.2 Removing and installing

the high pressure pump”, page 294 .

– Unscrew the fixing screw -b- for the coolant pipe.

– Remove the toothed belt from the camshafts ⇒ “2.9 Remove
the toothed belt from the camshaft”, page 123 .
– Remove bracket -1-.

– Screw in screws -arrows- , unclip the pipe from the intake
manifold ⇒ “4.2 Removing and installing intake manifold”,
page 278 .
If the camshaft housing is to be replaced:
– If necessary, remove components that have remained on the
camshaft
Protected housing
by copyright. ⇒ for
Copying “1.2 Summary
private or commercial ofpurposes,
components
in part or in- whole,
camshaft
is not permitted
housing”, page 81 .
– If necessary, remove outlet camshaft control ⇒ “3.4 Removing
and installing camshaft control”, page 137 .
Remove camshaft housing

– Unscrew screws for camshaft housing in the sequence -17- to
-1-.
– Lift the camshaft housing and detach it from the locating pins.
– Run the camshaft housing forward and out of the coolant pipes
of the exhaust gas turbocharger.
– Press the coolant pipe to the turbocharger on the camshaft
housing to the side.
If roller toe levers and balancing elements are to be removed:

– Assignment of the roller towing levers -1-, Compensating ele‐
ments -4- and valves -3- for reintegration.
– Remove the roller rocker finger together with the balancing
elements and lay aside on a clean surface.
Installing
Note
1. Cylinder head 89

be replaced.
NOTICE
Risk of damaging the valve gear.
♦ When turning, the camshafts must not be moved axially.
• Locating screw - T10340- screwed up to the stop into the

cylinder block and tightened to 30 Nm.
• Crankshaft in direction of rotation of engine in contact with the
locating screw - T10340- = “TDC” position. ⇒ page 77
– Check if all roller towing levers -1- are resting correctly on the
valve end -3-.
– Check if all roller towing levers -1- are pressed on the corre‐
sponding compensating element -4-.
– Check that the camshafts are on »TDC« for work on the
toothed belt ⇒ page 78 ,
– Replace seal -4-.

– Fit gasket -4- onto dowel pins -2-.
– Carefully set the camshaft housing -3- onto the dowel pins
-2-.
Note
Makewith
sure that
respect the
to the camshaft
correctness housing
of information does
in this notCopyright
document. tilt. by ŠKODA AUTO A. S.
– Tighten camshaft housing screws ⇒ “1.2 Summary of compo‐

nents - camshaft housing”, page 81 .
– Install the toothed belt ⇒ “2.9 Remove the toothed belt from
the camshaft”, page 123 .
NOTICE
Risk of damaging valves and piston crowns after work on the
valve gear.
To ensure that no valve is set during starting, turn the engine

carefully by at least 2 turns.
Electrical connections and proper routing ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.

If the camshaft housing has been replaced:

– Adjust position transmitter with the ⇒ Vehicle diagnostic tester.
♦ 0001 - Basic setting
♦ 0001 - Adapt camshaft position
Note

♦ Cylinder head ⇒ “1.1 Summary of components - cylinder

head”, page 79 .
♦ Camshaft housing ⇒ “1.2 Summary of components - camshaft
page 207 .
♦ Exhaust gas turbocharger ⇒ “1.1 Summary of components -
exhaust gas turbocharger”, page 227 .
♦ High pressure tube ⇒ “7.1 Summary of components - high
pressure pump”, page 293 .
1.5 Checking compression

♦ Spark plug wrench - 3122B-
♦ Compression tester - V.A.G 1763-
♦ Adapter - V.A.G 1381/1-
♦ Adapter - V.A.G 1381/5A-
Test condition
• Engine oil temperature at least 30 °C.
• Battery voltage at least 12.5 V
– Remove fuse for fuel pump control unit from the fuse holder.
Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
Note
Removing fuse interrupts the voltage supply of the fuel pump

control unit.
– Start engine and allow to run until it has cut out.

– Switch off ignition.
– authorised
unless Pull out ignition
by ŠKODA coils
AUTO A. S. at power
ŠKODA AUTOoutput stage
A. S. does ⇒ “1.2
not guarantee Removing
or accept any liability
and installing ignition coils with output stage”, page 336 .
1. Cylinder head 91
– Remove the spark plugs with spark plug wrench - 3122B- .
– Check compression pressure with the Compression tester de‐

vice - V.A.G 1763- with adapter - V.A.G 1381/1- and adapter
- V.A.G 1381/5A- ; Operation ⇒ Owner's Manual ,
– 2nd mechanic depresses the accelerator pedal fully and at the
same time actuates the starter until the tester shows no further
pressure rise.
– Repeat the work procedure for each cylinder.
Compression readings
Engine new 1.0 - 1.5 MPa
(10.0 - 15.0 bar)
Wear limit 0.7 MPa (7.0
bar)
Maximum difference between cylinders 0.3 MPa (3.0
bar)
– Install spark plugs:
♦ ⇒ Maintenance ; unless
Booklet Karoq

– Install ignition coils at power output stage ⇒ “1.2 Removing
and installing ignition coils with output stage”, page 336 .
Because the electrical plug connections were disconnected and
the engine started, faults are stored in the event memory of the
engine control unit.
– Erase the event memory.
♦ Screw for ignition coil with power output stage ⇒ “1.1 Assem‐
bly overview - ignition system”, page 334 .
♦ Spark plugs ⇒ “1.1 Assembly overview - ignition system”, page
334 .
1.6 Checking the combustion chamber for

tightness
♦ Spark plug wrench , e.g. -3122B-
♦ Adapter - T40012- or -VAS 5161A/35-

– Remove ignition coils with power output stages ⇒ “1.2 Re‐

moving and installing ignition coils with output stage”, page
336 .
– Unscrew the spark plugs with the spark plug wrench - 3122B- .
– Carefully insert a screwdriver into the opening of the ignition
plug of the appropriate cylinder, minimum length of shaft 250
mm, in -direction of arrow- so that it touches the piston head.
– Turn the crankshaft until the piston is at “TDC”.
– Screw the adapter - T40012- or -VAS 5161A/35- into the plug
connector thread.
– With the assistance of a second mechanic, lock the screw on
the crankshaft at “TDC” position in order to avoid displacement
of the piston after pressure build-up.
♦ Vehicles without air conditioning system Pos. -1- ⇒
“1.1.1 Summary of components - V-ribbed belt drive for vehi‐
cles without air conditioning system”, page 42 .
♦ Vehicles with air conditioning Pos. -2- ⇒ “1.1.2 Summary of
components - V-ribbed belt drive for vehicles with air condi‐
tioning system”, page 44 .
– Install adapter on the pressure hose of the compressed air
distribution.
Note
Perform a pressure build-up in the “TDC” position when the in‐

duction and outlet valves are closed.
– Build up a pressure of 0.3 MPa (3 bar) in the combustion

chamber.
– Repeat the test for the remaining cylinder.
– Determine how the pressure escapes:
1- Via the inlet valve(s) - the pressure enters the throttle valve.
2- Via the outlet valve(s) - the pressure enters the exhaust
system.
3- Via the piston rings - the pressure enters the cylinder block.
♦ Spark plugs ⇒ “1.1 Assembly overview - ignition system”, page
334 .
1. Cylinder head 93
2 Toothed belt drive

⇒ “2.1 Summary of components - toothed belt guard”, page
94
⇒ “2.2 Summary of components - toothed belt”, page 95
⇒ “2.3 Overview of components - Timing tool”, page 97
⇒ “2.4 Removing and installing toothed belt guard”, page 98
⇒ “2.5 Removing and installing toothed belt”, page 99
⇒ “2.6 Pre-installing and fitting the timing tool”, page 104
⇒ “2.7 Checking valve timing”, page 112
⇒ “2.8 Setting the timing”, page 114
⇒ “2.9 Remove the toothed belt from the camshaft”, page 123
2.1 Summary of components - toothed belt

guard
Note


1 - Top toothed belt guard

installing top toothed
belt guard”, page 98
❑ Note the vehicle type
plate ⇒ page 1
2 - Screw
❑ captive
❑ 8 Nm
3 - Storage
4 - Screw
❑ for coolant pipe
❑ 8 Nm
5 - Bottom toothed belt guard
installing bottom
toothed belt guard”,
page 99
6 - Screw
❑ 8 Nm
7 - Screw
tightening order ⇒
“2.1 Assembly overview
- assembly mountings”,
page 28
8 - Engine support bracket
2.2 Summary of components - toothed belt
Note
Replace bolts / correctness
to the nuts thatof are tightened
information at an angle
in this document. Copyrightof
by rotation,
ŠKODA AUTO asA. S.
with respect
2. Toothed belt drive 95

1 - Screw
❑ 7 Nm
2 - Screw cap
3 - O-ring
sembly
4 - Screw
sembly
❑ 50 Nm + 135°
5 - Toothed belt pulley, ex‐
haust camshaft
❑ With camshaft control
camshaft control ⇒
“3.4 Removing and in‐
stalling camshaft con‐
trol”, page 137
6 - guide bushing
7 - Toothed belt pulley, inlet
camshaft
❑ With camshaft control
camshaft control ⇒
stalling camshaft con‐
trol”, page 137
8 - Control valve
❑ Check the operating
valve ⇒ Fig. ““Check the
control valve”“ , page
97 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ 140 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
9 - Tensioning pulley
❑ for removing and installing, remove engine support ⇒ “1.5 Removing and installing engine support”, page
50
10 - Screw
❑ Tightening torque and tightening order ⇒ “2.9 Remove the toothed belt from the camshaft”, page
123
11 - Guide pulley
❑ for removing and installing, remove engine support ⇒ “1.5 Removing and installing engine support”, page
50
12 - Screw
❑ 8 Nm
13 - Screw
❑ Component part of the guide pulley
❑ 40 Nm
14 - Crankshaft toothed belt sprocket
❑ there must not be any oil present on the contact surface between the pulley and the crankshaft
❑ can be installed only in one position
15 - Toothed belt

❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
❑ Removing and installing ⇒ “2.5 Removing and installing toothed belt”, page 99
❑ Set the timing ⇒ “2.8 Setting the timing”, page 114 .
16 - Holder for radial shaft seal
❑ Removing and installing ⇒ “3.2 Removing and installing bracket for radial shaft seal”, page 128
17 - Sealing ring
18 - Camshaft adjustment valve 1 in the inlet - N727-
❑ Removing and installing ⇒ “3.6 Removing and installing camshaft control valve 1 in the inlet N727 ”,
page 145
19 - Screw
❑ 8 Nm
20 - Screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note
When tightening with working tool -

T10572- at the torque wrench -
V.A.G 1783- apply the tightening
torque of 4.2 Nm.
21 - Sealing ring
❑ Removing and installing ⇒ “3.3.1 Removing and installing oil seal for camshaft for holder Valve 1 for
camshaft adjustment in the inlet N727 ”, page 130
Check the control valve

• The piston -arrow- must be pressed about 3 mm against the
spring force. The piston must not become jammed.
– Carefully press piston -arrow-.
– Inspect control valve -1- for dirt and clean if necessary.
If the sealing ring is damaged -2- the control valve has to be re‐
placed ⇒ Electronic parts catalogue (ETKA) .
Ensure that the gasket is seated properly -2-.
2.3 Overview of components - Timing tool

A - Angle sensor - VAS 611

007/1-
B - Locking - VAS 611 007/2-
C - Clamping ring - VAS 611
007/3-
D - Adapter for camshaft hous‐
ing - VAS 611 007/4- for 1.5 l
TSI EVO engine
E - Adapter for angle sensor -
VAS 611 007/5- for 1.5 l TSI
EVO engine
F - Adapter for camshaft - VAS
611 007/6- for 1.5 l TSI EVO
engine, intake camshaft, blue
marking
G - Adapter for camshaft - VAS
611 007/7- for 1.5 l TSI EVO
engine, exhaust camshaft, red
marking
2.4 Removing and installing toothed belt

guard
⇒ “2.4.1 Removing and installing top toothed belt guard”, page
98
⇒ “2.4.2 Removing and installing bottom toothed belt guard”,
page 99
2.4.1 Removing and installing top toothed belt

guard
Removing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove camshaft control valve 1 - N727- ⇒ “3.6 Removing
and installing camshaft control valve 1 in the inlet N727 ”, page
145 .

– Expose vacuum hose on the holder -3-.

– Unscrew screws -2-.
– Remove top toothed belt guard -1-.
Installing
Note the vehicle type plate ⇒ page 1
♦ Top toothed belt guard ⇒ “2.1 Summary of components -
toothed belt guard”, page 94 .
2.4.2 Removing and installing bottom toothed

belt guard
Removing
– Remove V-ribbed belt pulley from crankshaft ⇒ “1.4 Removing
and installing vibration dampener”, page 49 .
– Remove bottom toothed belt guard.
Installing
♦ Bottom toothed belt guard ⇒ “2.1 Summary of components -
toothed belt guard”, page 94 .

♦ Wrench - T10499A-
♦ Insertion tool - T10500-
♦ Torque wrench - V.A.G 1410- or -VAS 6583-
Removing
– Remove V-ribbed
Protectedbelt pulleyCopying
by copyright. from crankshaft ⇒ “1.4purposes,
for private or commercial Removingin part or in whole, is not permitted
and installing with
vibration dampener”, page 49 .
– Remove bottom toothed belt guard ⇒ “2.4.2 Removing and in‐

stalling bottom toothed belt guard”, page 99 .

re-installation before removing the toothed belt pulley.
Bending radius of the toothed belt
NOTICE
Risk of damage to the toothed belt.
♦ The bending radius -r- of the toothed belt -2- must not be al‐
lowed to drop below the minimum of 25 mm (approx. half the
Ø of the crankshaft-belt pulley).
♦ If the bending radius falls below the minimum of 25 mm, this
will affect the lifetime of the belt.
NOTICE
♦ So as not to adjust the timing the crankshaft must not be

turned.
– Remove timing belt.
– Remove crankshaft toothed belt sprocket -1- -arrow-.

Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note

be replaced.
• Locating screw - T10340- screwed up to the stop into the

cylinder block and tightened to 30 Nm.
• Piston for cylinder 1 on “TDC” for working on the toothed
belt ⇒ “4.7 Position piston to TDC”, page 77 .

– Replace screw -4- and loosely insert a new screw ⇒ “3.4.2 Re‐
moving and installing camshaft control, outlet side”, page
140 .
– Take the control valve -3- and loosely screw it in ⇒ “3.4.1 Re‐
moving and installing camshaft control, inlet side”, page
137 .
• It must still be possible to turn the camshaft sprockets on the
camshafts, however they must not hang loose.
• The sheet peg -arrow- of the tensioning pulley must engage

in the cast iron recess of the cylinder head.
– Fit crankshaft toothed belt sprocket onto the crankshaft.

• The contact surface between the V-ribbed belt pulley and the
grease.
• Milled surface -arrow- on the crankshaft toothed belt must be
positioned on the crankshaft stub.

NOTICE
– Start by fitting the toothed belt -1- from below onto the
crankshaft toothed belt sprocket -2-.
– Install bottom toothed belt guard ⇒ “2.4.2 Removing and in‐
stalling bottom toothed belt guard”, page 99
– Installing the V-ribbed belt pulley ⇒ “1.4 Removing and in‐
stalling vibration dampener”, page 49 .
Place toothed belt

– Pull toothed belt upwards, then fit the tensioning pulley -2- and
camshaft sprockets -3- and -4- onto the guide roller -1-.

Tensioning toothed belt

– Rotate the eccentric -2- of the tensioning pulley with the
wrench - T10499A- in -direction of arrow- until the adjustment
pointer -3- is located approx. 10 mm to the right from the ad‐
justment window.
– Push eccentric so far back that the adjustment pointer is po‐
sitioned exactly in the adjustment window.
NOTICE
Risk of damage to the engine when tightening to incorrect light‐
ening torque!
To tighten, the torque wrench - VAS 6583- or torque wrench -

V.A.G 1410- must be used!
• To tighten the reduced torque, no other torque wrench may be
used!
Tighten with torque wrench VAS 6583
• Only use the torque wrench together with insertion tool -
T10500- !
• When setting the
unless tightening
authorised by ŠKODAtorque
AUTO onA. S.the torque
ŠKODA AUTO wrench - VAS
6583- the actual dimension
with respect specified
to the correctness on the
of information tool
in this insertCopyright
document. - by ŠKODA AUTO A. S.
T10500- must be put into the torque wrench!
– Keep eccentric in this position and tighten screw -1- to 25 Nm.
Use tool insert - T10500- with torque wrench - VAS 6583- to
do this.
Tighten with torque wrench VAG 1410
• Only use the torque wrench together with insertion tool -
T10500- !
• Set the reduced tightening torque of 12 Nm on the torque
wrench - V.A.G 1410-
• The required tightening torque of 25 Nm is achieved by the
extending the torque wrench - V.A.G 1410- around the tool
insert - T10500- !
– Keep eccentric in this position and tighten screw -1- to 12 Nm.
Use tool insert - T10500- with torque wrench - V.A.G 1410- to
do this.
Continued
Note
If the engine continued to turn or has run, there may be slight

deviations of the adjustment pointer -3- setting in the adjustment
window. This has no influence on the toothed belt tensioning.
– Adjusting valve timing ⇒ “2.8 Setting the timing”, page

114 .
Note


♦ V-ribbed belt drive ⇒ “1.1 Assembly overview - V-ribbed belt

drive”, page 42 .
♦ Toothed belt guard ⇒ “2.1 Summary of components - toothed
belt guard”, page 94 .
♦ Toothed belt drive ⇒ “2.2 Summary of components - toothed
belt”, page 95 .
♦ Screw plug for bore in the cylinder block ⇒ Fig. ““Screw plug
for TDC bore in the cylinder block behind - tightening torque”“ ,
page 58 .
♦ Camshaft housing ⇒ “1.2 Summary of components - camshaft
2.6 Pre-installing and fitting the timing tool

⇒ “2.6.1 Pre-assembly of the adjustment tool VAS 611 007 ”,
page 104
⇒ “2.6.2 Electronically teach the adjustment tool VAS 611 007
and Adjust the basic settings”, page 107
⇒ “2.6.3 Install Adjustment tool VAS 611 007 ”, page 109
2.6.1 Pre-assembly of the adjustment tool -

VAS 611 007-
♦ Adjustment tool - VAS 611 007-
Adjustment tool - VAS 611 007-

A - Angle sensor - VAS 611

007/1-
B - Locking - VAS 611 007/2-
C - Clamping ring - VAS 611
007/3-
D - Adapter for camshaft hous‐
ing - VAS 611 007/4- for 1.5 l
TSI EVO engine
E - Adapter for angle sensor -
VAS 611 007/5- for 1.5 l TSI
EVO engine
F - Adapter for camshaft - VAS
611 007/6- for 1.5 l TSI EVO
engine, intake camshaft, blue
colour code marking
G - Adapter for camshaft - VAS
611 007/7- for 1.5 l TSI EVO
engine, exhaust camshaft, red
colour code marking
Pre-assembly of the adjustment tool - VAS 611 007-

– Before installing the adapter for the angle encoder - VAS 611
007/5- -E- in the angle encoder - VAS 611 007/1- -A-, check
the correct affiliation depending on the colour coding -A-.
– Insert adapter for angle encoder - VAS 611 007/5- -E- in angle
encoder - VAS 611 007/1- -A-.

Take note when mounting on the position of the locating pins

-a-.
Adapter for angle encoder - VAS 611 007/5- -E- fits only in one
position.
– Check whether the brake -b- Is detached. Do not use force.
– Use adapter for angle encoder - VAS 611 007/5- -E- in angle
encoder - VAS 611 007/1- -A- until it stops.
– Insert clamping ring - VAS 611 007/3- -C- In the groove -a- of
the adapter for angle sensor - VAS 611 007/5- -E- and audibly
press it in.
– Position angle encoder - VAS 611 007/1- -A- with the red
colour marking in the red side -arrows- -a- of the adapter for
camshaft housing - VAS 611 007/4- -D- .
– Thereby unlock the fixing bolt -c- by lifting.
– Slide angle encoder - VAS 611 007/1- -A- until the fixing pin
clicks into place.
– Repeat the operation with the blue marked angle encoder -
VAS 611 007/1- -A- -arrows- -b-.
– Screw on colour-coordinated lock rings - VAS 611 007/2- -B-

by about 2 turns.
Note the colour coding -arrows- -a- and -arrow-Protected
-b-. by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

• The lock ring - VAS 611 007/2- -B- may be screwed in by max.
2 turns.
– Check shaft can move freely.

• The adapter for the angle encoder - VAS 611 007/5- -e- must
be easily rotatable.
2.6.2 Electronically teach the adjustment tool

- VAS 611 007- and Adjust the basic
settings
– Pre-assemble adjustment tool - VAS 611 007- ⇒ page 105 .
– Connect electronic measurement to the adjustment tool - VAS
611 007- ⇒ Owner’s Manual ,
– Install software for adjustment tool - VAS 611 007- .⇒ Owner’s
Manual .
– unless
Start the test
authorised sequence
by ŠKODA AUTO A.⇒ Owner's
S. ŠKODA AUTOManual . guarantee or accept any liability
A. S. does not
If the angle encoder - VAS 611 007/1- is not connected, this mes‐
sage appears.
– Connect angle encoder - VAS 611 007/1- and press CON-
NECT .

If the angle encoder - VAS 611 007/1- is connected, this message

appears.
ANW - Exhaust camshaft - red
ENW - Intake camshaft - blue
– Rotate adapter for angle encoder - VAS 611 007/5- -E- for
exhaust camshaft.
Exhaust camshaft is relearned when »OK« appears.
– Rotate adapter for angle encoder - VAS 611 007/5- -E- for
intake camshaft.
The intake camshaft is relearned when OK appears.
– Select MEASURE function.
When this angle display appears, the control times can be

checked or set ⇒ “2.7 Checking valve timing”, page 112 .

– In this display, check that the brake symbol is »green«.

• The symbol should not be »yellow« or »red«.
A - »green« symbol - brake released
B - »yellow« symbol - brake applied
C - »red« symbol - apply brake with final tightening torque
Note
After electronic relearning of the adjustment tool - VAS 611 007-

do not disconnect the diagnostic device.
2.6.3 Install Adjustment tool - VAS 611 007-

– Pre-assemble adjustment tool - VAS 611 007- ⇒ page 105 .
– Electronically teach the adjustment tool - VAS 611 007- and
carry out basic settings ⇒ page 107 .
Check adapter for camshaft - VAS 611 007/6- and -VAS 611
007/7- .
Note
♦ There is a tightening torque specification on camshaft

adapters. This information must be checked. If the tightening
torque »2 Nm« is given here, this information shall be uniden‐
tifiable by appropriate means.
♦ The adapters must not be tightened with »2 Nm«.
♦ Only tighten the adapters with »1 Nm«.
– Rotate both adapters for angle encoder - VAS 611 007/5- so

that the display is approx. »0 °«.
– unless
Carry out preliminary
authorised by ŠKODA AUTOwork to check
A. S. ŠKODA AUTO the
A. S. control timings
does not guarantee ⇒ any liability
or accept
“2.7 Checking valve timing”, page 112 .
– Check that the piston for cylinder 1 for working on the toothed
belt is at “TDC” ⇒ “4.7 Position piston to TDC”, page 77 .

– Check the edges of the camshafts -1- for damage.

– Check the edges -arrows- of both camshaft adapters - VAS
611 007/6- -F- and -VAS 611 007/7- -G- for damage.
• The edges of the camshaft adapters - VAS 611 007/6- -F- and
-VAS 611 007/7- -G- and the edges on the camshafts must lie
flush.
Note
With damaged edges, no exact measurement can be made.
– Place adapter for camshaft - VAS 611 007/6- -F- and adapter
for camshaft - VAS 611 007/7- -G- on camshafts -1-.
Note the orientation of the edges of the adapters for the camshafts
-arrows- with the edges on camshaft -1-.
– Check that both locking screws -arrows- -b- are loose.

Check colour coding
F - Adapter for camshaft - VAS 611 007/6- for intake camshaft -
blue colour coding -a-
G - Adapter for camshaft - VAS 611 007/7- for exhaust camshaft
- red colour coding -a-
– Place the adapters as far as they will go on camshafts.
– Tighten locking screws -arrows- -b- with 1 Nm.
– Check that the brakes are detached on both sides of the angle
encoder - VAS 611 007/1- ⇒ page 106 .
– Turn the adapter for angle encoder - VAS

Protected 611 Copying
by copyright. 007/5-for-E- byor commercial purposes, in part or in whole, is not permitted
private
hand until the lugs are againstunless
the grooves
authorised byof the adapter
ŠKODA for AUTO A. S. does not guarantee or accept any liability
AUTO A. S. ŠKODA
camshaft - VAS 611 007/6- or thewithadapter for camshaft - VAS
611 007/7- -arrows-.
• The position of the lugs at adapter for angle encoder - VAS

611 007/5- -e- must exactly line up with the groove -arrow- of
the adapter for the camshaft - VAS 611 007/6- or the adapter
for camshaft - VAS 611 007/7- to match.
Note
Check the position through the spyhole and if necessary, rotate

the Adapter for angle encoder - VAS 611 007/5- -E-.

– Place Adapter for camshaft housing - VAS 611 007/4- -D- on

the camshaft housing.
– Alternatively tighten by hand the screws -arrows- -and-.
Note the correct positioning of the Adapter for camshaft housing
- VAS 611 007/4- -D-.
• The adjustment tool - VAS 611 007- must be positioned so as
to fit the camshaft housing -1- in one line.
– Check that the brakes are detached on both sides of the angle
encoder - VAS 611 007/1- ⇒ page 106 .
– Tighten the locking rings - VAS 611 007/2- -B- hand-tight by

hand.
– In doing so, check if the Adapter for camshaft housing - VAS
611 007/4- -D- rests over the entire surface of the camshaft
housing -1-.
• The Adapter for camshaft housing - VAS 611 007/4- -D- may
not be lifted from the camshaft housing -1-.
Note
♦ The correct preload is achieved when the Adapter for

camshaft housing - VAS 611 007/4- -D- rests over the entire
surface of the camshaft housing -1-.
♦ If the lock ring - VAS 611 007/2- -B- is tightened too tight, the
Adapter for camshaft housing - VAS 611 007/4- -D- is lifted
from the camshaft housing -1-. Thus, the result of the mea‐
surement will be incorrect.
If the Adapter for camshaft housing - VAS 611 007/4- -D- is lifted,
the lock rings - VAS 611 007/2- -B- are detached again.
Put on the lock rings - VAS 611 007/2- -B- in such a way that the
adapter for camshaft housing - VAS 611 007/4- -D- rests over the
entire surface and is not raised.

– Check if the brakes -a- at the adjustment tool - VAS 611 007-
are released at both sides.
2.7 Checking valve timing

• Timing belt is installed ⇒ “2.5 Removing and installing toothed
belt”, page 99 .
– Remove the noise
unless authorised insulation
by ŠKODA AUTO A. S. ⇒ŠKODA
General AUTO body repairs,
A. S. does exterior;
Rep.with
gr.respect
66 to
; Noise insulation;
the correctness Summary
of information of components
in this document. - AUTO A. S.
Copyright by ŠKODA
noise insulation .
– Remove the front right wheelhouse liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; Removing and
installing the front wheelhouse liner .
– Remove air guide pipe ⇒ “2.4 Installing and removing the air
guide pipe”, page 242 .
pump”, page 191 .
194 .

– Unscrew screw -arrow- and remove lock -1- of the intake

camshaft on the transmission side.
– Install piston for cylinder 1 on “TDC” for working on the toothed
belt ⇒ page 77 .
– Install Adjustment tool - VAS 611 007- ⇒ “2.6.3 Install Adjust‐
ment tool VAS 611 007 ”, page 109 .
– Check if the brakes -a- at the adjustment tool - VAS 611 007-
are released at both sides.
– In this display, check that the brake symbol is »green« -A-.


– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Screw in fixing screw - T10340- .
belt ⇒ page 77 .

– Display the angle for control times in the display and compare
them with the setpoints.
Setpoint for angle in ° Inlet camshaft Exhaust camshaft

-0.3°±1.2° +1.1°±1.2°
If the control times are not OK, set the control times ⇒ “2.8 Setting
the timing”, page 114 .
NOTICE
Set control times as precisely as possible. Setting values must
be as close as possible to the setpoint.
Control times must not be outside the tolerance limit. by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
must be replaced.
– Replace O-rings and seal after disassembly
Note

♦ Screw plug for “TDC” bore ⇒ Fig. ““Screw plug for TDC bore
in the cylinder block behind - tightening torque”“ , page 58 .
♦ Locking screw for camshaft ⇒ “1.2 Summary of components -
camshaft housing”, page 81 ,
2.8 Setting the timing

NOTICE
Control times must not be outside the tolerance limit.
• Timing belt is installed ⇒ “2.5 Removing and installing toothed

belt”, page 99 .

Note
♦ When adjusting the control times, leave the toothed belt ten‐
sioned. Only loosen the camshaft adjusters.
♦ If the exhaust camshaft adjuster mounting bolt was not tight‐
ened with forward rotation, then do not carry out the screw
replacement in the rest of the procedure.

belt ⇒ page 78 .
If the timing belt has been removed and reinstalled due to another
repair:
Camshaft adjusters are not tightened ⇒ “2.5 Removing and in‐
stalling toothed belt”, page 99 .
If the timing belt has not been removed:
– Release the camshaft adjuster at the inlet side ⇒ page
138 .
– Release the camshaft adjuster at the outlet side ⇒ page
141 .
Continued
NOTICE
Risk of damaging the engine by means of adjusted control
times.
♦ So as not to adjust the timing the crankshaft must not be turned

to the TDC position.
Note
♦ To collect engine oil, place a cloth under the camshaft ad‐

justers and over tensioning roller.
♦ Contact points of the toothed belt, camshaft sprocket,
crankshaft pulley, tensioning pulley and guide pulley are to be
kept free of oil.
♦ Immediately collect or remove the spilled oil.
♦ Remove the engine oil, which unless
runs authorised
out when the engine
by ŠKODA AUTO A. S. isŠKODA AUTO A. S. does not guarantee or accept any liability
turned, from the camshaft adjuster.
– Place a cloth below the camshaft control and over the ten‐
sioning roller to collect any oil.
belt is at “TDC” ⇒ page 78 .

– Replace the screw -4- if it has already been tightened with a

further angle of rotation and loosely insert a new screw ⇒
“3.4 Removing and installing camshaft control”, page 137 .
– Take the control valve -3- and loosely screw it in ⇒ “3.4 Re‐
moving and installing camshaft control”, page 137 .
Camshaft adjusters must still be able to rotate on the camshafts.
– Install Adjustment tool - VAS 611 007- ⇒ “2.6.3 Install Adjust‐
ment tool VAS 611 007 ”, page 109 .
Set camshaft adjuster to »0 °«

– Check if the screws -a- for brakes on adjustment tool - VAS
611 007- are released on both sides.

• The symbol should not
unless be »yellow«
authorised or »red«.
– The two camshafts are set to »0.0 °«.

– For this purpose, turn the camshafts with the adapters for an‐
gle encoders - VAS 611 007/5- -e-.
– Stop camshafts using the adapter for angle sensors - VAS 611
007/5- -e- with the key in the »0.0 °«position.
– After setting to »0.0 °« tighten the brakes.
– Tighten screws -a- for brakes on adjustment tool - VAS 611
007- on both sides using 10 Nm.
– In this display, check that the brake symbol is »red« -A-.

• The symbol should not be »yellow« or »green«.

– Pre-torque intake camshaft adjuster with torque ⇒ page
139 .
– Pre-torque outlet camshaft adjuster with torque ⇒ page
143 .
– Protected
Release brakesCopying
by copyright. -a- atforthe adjustment
private tool - VAS
or commercial purposes, in part611 007-is on
or in whole, not permitted
both sides.


– Seal phaser -1- and -2- with stopper -A- from the sealing plug
set for engine - VAS 6122- .
Note
♦ Use plugs with outer diameter ∅ 45 - 50 mm.

♦ On the camshaft adjuster on the outlet side -1- the plug must
be pressed in slightly before insertion.
– Place a piece of paper in the stoppers to collect the engine oil.

– Place the plug in the camshaft adjusters as shown.
Determine the inclination angle
– Install piston for cylinder 1 on »TDC« for working on the
toothed belt ⇒ page 78 .
– Read out and note the control times in the display.
1. Example of measurement: read value

Note
♦ The inclination angle is determined individually for each vehi‐

cle.
♦ The value read after the engine is turned is used to determine
the angle of inclination.
♦ Note the signs of the values.
♦ The pitch angle results from the difference between the nom‐
inal value and the actual value read after double cranking of
the crankshaft.
♦ The pitch angle is used to set the control times.
♦ The pitch angle must be set with the corresponding sign / di‐
rection of rotation.
♦ The inclination angle is determined individually for each vehi‐
cle.
♦ The value read after the engine is turned is used to determine
the angle of inclination.
♦ Note the signs of the values.
♦ The pitch angle results from the difference between the nom‐
inal value and the actual value read after double cranking of
the crankshaft.
♦ The pitch angle is used to set the control times.
♦ The pitch angle must be set with the corresponding sign / di‐
rection of rotation.
Index Description
e Actual value of intake camshaft after spinning the
crankshaft twice.
f Intake camshaft setpoint (tolerance +/-) ⇒ page
119 .
c Direction adjustment (+/-).
d Determined slope angle (correction value).
a Actual value of exhaust camshaft after spinning
the crankshaft twice.
b Exhaust camshaft setpoint (tolerance +/-) ⇒ page
119 .

-0.3°±1.2° +1.1°±1.2°
– Set the determined angle of inclination

Protected for camshafts
by copyright. Copying for private or ⇒
commercial purposes, in part or in whole, is not permitted
page 119 . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Set the control times with the angle of inclination
– Place a cloth below the camshaft control to collect any oil.
– Remove plugs from the sealing plug set for engine - VAS 6122-
from the camshaft adjusters.
– Remove paper from the plugs and camshaft adjusters.
– Remove the oil from the camshaft adjusters.


138 .
– Release the camshaft adjuster at the outlet side ⇒ page
141 .
NOTICE
times.

belt is at “TDC” ⇒ page 78 .
– Check if the screws -a- for brakes on adjustment tool - VAS
611 007- are released on both sides.

– Adjust the two camshafts to the determined inclination angle
⇒ page 118 .
– For this purpose, turn the camshafts with the adapters for an‐
gle encoders - VAS 611 007/5- -e-.

If the two camshafts are set to the determined inclination angle:

– Tighten screws -a- for brakes on adjustment tool - VAS 611
007- on both sides using 10 Nm.
– In this display, check that the brake symbol is »red« -A-.

• The symbol should not be »yellow« or »green«.

– Pre-torque intake camshaft adjuster with torque ⇒ page
139 .
– Pre-torque outlet camshaft adjuster with torque ⇒ page
143 .
– Release brakes -a- at the adjustment tool - VAS 611 007- on

both sides.


– Seal phaser -1- and -2- with stopper -A- from the sealing plug
set for engine - VAS 6122- .
Note
♦ Use plugs with outer diameter ∅ 45 - 50 mm.

♦ On the camshaft adjuster on the outlet side -1- the plug must
be pressed in slightly before insertion.
– Place a piece of paper in the stoppers to collect the engine oil.

– Place the plug in the camshaft adjusters as shown.
– Install piston for cylinder 1 on »TDC« for working on the
toothed belt ⇒ page 78 .
– Test timing ⇒ “2.7 Checking valve
unless timing”,
authorised page
by ŠKODA 112
AUTO A. S..ŠKODA AUTO A. S. does not guarantee or accept any liability
NOTICE
Control times must not be outside the tolerance limit.
– Read control times and compare with setpoints.

-0.3°±1.2° +1.1°±1.2°
If the control times are not OK, set the control times ⇒ “2.8 Setting
the timing”, page 114 .
– Tighten inlet camshaft adjuster with final tightening torque ⇒
page 140 .

– Tighten outlet camshaft adjuster with final tightening torque ⇒

page 143 .
Note

♦ Camshaft control ⇒ “2.2 Summary of components - toothed

belt”, page 95 .
♦ Screw plug for “TDC” bore ⇒ Fig. ““Screw plug for TDC bore
in the cylinder block behind - tightening torque”“ , page 58 .
2.9 Remove the toothed belt from the

camshaft
♦ Wrench - T10499A-
noise insulation .
– Remove holder for radial shaft seal ⇒ “3.2 Removing and in‐
stalling bracket for radial shaft seal”, page 128 .
– Place engine on “TDC for cylinder 1” for work on the toothed
belt drive ⇒ page 78 .
138 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Release the camshaft
with respect adjuster at the
to the correctness outlet side
of information ⇒ pageCopyright by ŠKODA AUTO A. S.
in this document.
141 .

– Position wrench - T10499A- .-C- on eccentric -4- of the ten‐

sioning pulley -6-.
– Release screw -5- using insertion tool - T10500- -B-.
– Slacken the tensioning pulley -6- at the eccentric -4- using the
wrench - T10499A- -C-.
NOTICE
– Remove the toothed belt from the camshaft sprockets.
NOTICE
times.

Installing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Replace screw -4- and loosely insert a new screw ⇒ “3.4 Re‐
– Take the control valve -3- and loosely screw it in ⇒ “3.4 Re‐
– Fit on the toothed belt ⇒ page 102 .
– Tension timing belt ⇒ page 103 .
– Adjusting valve timing ⇒ “2.8 Setting the timing”, page 114 .
Note


♦ Tensioning pulley ⇒ “2.2 Summary of components - toothed

belt”, page 95 .

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 126
⇒ “3.2 Removing and installing bracket for radial shaft seal”, page
128
⇒ “3.3 Removing and installing gasket ring for camshaft”, page
130
⇒ “3.4 Removing and installing camshaft control”, page 137
⇒ “3.5 Removing and installing cam adjuster”, page 143
⇒ “3.6 Removing and installing camshaft control valve 1 in the
inlet N727 ”, page 145
⇒ “3.7 Removing and installing camshaft control valve 1 in the
exhaust N318 ”, page 145
⇒ “3.8 Removing and installing valve stem seals”, page 146
3.1 Assembly overview - valve gear
1 - Valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ Inlet or outlet valve
❑ See also ⇒ Electronic
parts catalogue
❑ Valve dimensions ⇒
“4.3 Valve dimensions”,
page 158
❑ inspecting valve
guides ⇒ “4.1 inspecting
valve guides”, page
158
2 - Hydraulic balancing ele‐
ment
❑ Do not interchange
❑ Oil contact surface
3 - Locking clip
❑ for hydraulic balancing
element
4 - Roller rocker finger
stalling camshaft hous‐
ing”, page 87
❑ Fitting position ⇒ Fig.
““Mounting roller towing
lever”“ , page 127
❑ mark the fitting position
for re-installation
❑ inspect roller bearings
for smooth operation Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ oil the contact surfaces with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
before installing
5 - Valve collets

❑ Removing and installing ⇒ “3.8 Removing and installing valve stem seals”, page 146
6 - Valve spring plate
7 - Valve spring
❑ Fitting position ⇒ Fig. ““Fitting position of the valve spring”“ , page 127
❑ See also ⇒ Electronic parts catalogue
8 - Valve stem gasket
❑ Fitting position ⇒ Fig. ““Mounting valve stem seal”“ , page 127
❑ pay attention to different version
❑ See also ⇒ Electronic parts catalogue
9 - Cylinder head
❑ Summary of components ⇒ “1.1 Summary of components - cylinder head”, page 79
❑ Removing and installing ⇒ “1.3 Removing and installing cylinder head”, page 84
Fitting position of the valve spring

• The small ∅ -a- points to the valve spring plate.
• The small ∅ -b- points to the cylinder head.
Mounting roller towing lever

1 - Roller rocker finger
2 - Hydraulic balancing element
3 - Valve
4 - Cylinder head
Šipka - Locking clip
Mounting valve stem seal

Please take care during mounting that the spring -arrow- is above,
as shown.
1 - Valve
8 - Valve stem gasket
9 - Cylinder head
Šipka - Spring
3. Valve gear 127

3.2 Removing and installing bracket for ra‐

dial shaft seal
♦ Centering mandrel - T10576-
♦ Torx Bit T30 - T10584-
♦ Torque wrench , e.g. -V.A.G 1783-
Removing
– Remove camshaft control valve 1 - N727- ⇒ “3.6 Removing
and installing camshaft control valve 1 in the inlet N727 ”, page
145 .
NOTICE
Risk of damage to the toothed belt due to leaking engine oil.
Contact points of the toothed belt, camshaft sprocket, crankshaft

pulley, tensioning pulley and guide pulley are to be kept free of
oil.
– Screw out screws -1- and remove the bracket for radial shaft
seal -2-.
To unscrew use Working tool - T10572- with Torx Bit 30 -
T10584- .
Pay attention that the fastening screws -1- do not fall into the
toothed belt drive. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Installing
– Check the radial shaft seal for damage and if necessary re‐
place it ⇒ “3.3.1 Removing and installing oil seal for camshaft
for holder Valve 1 for camshaft adjustment in the inlet N727 ”,
page 130 .
In order to insert the radial shaft seal onto the camshaft adjuster
without damage, the holder must be centred.
Always use the centring mandrel - T10576- for centring the hold‐
er.

– Lightly oil centring mandrel - T10576- -A- around the entire

circumference -4-.
Note
Also lightly oil the area of the holder for the radial shaft seal ring
into which the centring pin engages.
– Place centring mandrel - T10576- -A-, from the side of Valve

1 for camshaft adjustment in the inlet - N727- , into the holder
-2-.
Make sure that the centring mandrel - T10576- -A- is completely
on the holder -2-, -arrow-.
Part of the centring mandrel - T10576- -A- with the smaller diam‐
eter -arrow- -a- is inserted into the sensor wheel inside -arrow-
-b- of the camshaft adjuster -1- plugged.
3. Valve gear 129

– Place holder -2- with centring - T10576- -A- into the camshaft
housing -3-.
– Set 4.2 Nm on the torque wrench - V.A.G 1783- .
– Tighten mounting screws -arrows- with Working tool - T10572-
and Torx Bit 30 - T10584- .
Pay attention that the fastening screws -1- do not fall into the
toothed belt drive.
– Remove centring mandrel - T10576- -A- from the holder -2-.
– Install top toothed belt guard ⇒ “2.4.1 Removing and installing
top toothed belt guard”, page 98 .
– Install camshaft control valve 1 - N727- ⇒ “3.6 Removing and
installing camshaft control valve 1 in the inlet N727 ”, page
145 .
– Install the engine cover ⇒ “3.1 Removing and installing engine
♦ Holder for radial shaft seal ⇒ “2.2 Summary of components -
toothed belt”, page 95 .
3.3 Removing and installing gasket ring for

camshaft
⇒ “3.3.1 Removing and installing oil seal for camshaft for holder
Valve 1 for camshaft adjustment in the inlet N727 ”, page 130
⇒ “3.3.2 Removing and installing the inlet camshaft on the belt
pulley side”, page 132
⇒ “3.3.3 Removing and installing the exhaust camshaft on the belt
pulley side”, page 134
⇒ “3.3.4 Removing and installing the exhaust camshaft on the
gearbox side”, page 135
3.3.1 Removing and installing oil seal for

camshaft for holder Valve 1 for camshaft
adjustment in the inlet - N727-
♦ Extractor tool - T20143/2-
♦ Centering mandrel - T10576-
Removing
– Holder for sealing ring ⇒ “3.2 Removing and installing bracket
for radial shaft seal”, page 128 .
– Insert the vice with protective jaws.
Note
♦ The holder is a component made of cast aluminium. High

pressure can lead to damage or breakage.
♦ Do not clamp the holder without the centring mandrel for this
very reason.

– Place centring mandrel - T10576- -A-, from the side of Valve

1 for camshaft adjustment in the inlet - N727- , into the holder
-2-.
The centring mandrel - T10576- -A- reaches its position when the
shoulder is completely at the holder -2- -arrow-.
– Tighten centring mandrel - T10576- -A- with holder for radial

shaft seal -1- at the point -arrows- in the vice -3-.
– Take hold of the seal -1- with the top of the extraction tool -
T20143/2- -B- In position -b-.
– The end of the extraction tool - T20143/2- -B- is supported in
the position -a- on the holder -2-.
– Remove seal -1- using extractor tool - T20143/2- -B-.
Replace gasket rings
• The sealing and bearing surfaces of the holder for the sealing
ring must not be scratched!
Note
3. Valve gear 131

– Place a new sealing ring -1- on the holder -2-.

Fitting position:
• The closed side -d- of the gasket points outwards.
Apply sealing ring

– Shoulder -e- of the mounter - T10582- -C- must be inserted
between the sealing ring -1- and centring mandrel - T10576-
-A-.
– Carefully, with a hammer and mounter - T10582- insert -C-
seal -1- In the holder -2- so that it aligns.
Installing
– Insert holder for radial shaft seal ⇒ “3.2 Removing and in‐
3.3.2 Removing and installing the inlet

camshaft on the belt pulley side
♦ Assembly tool - T10478B-
♦ Spindle - T10585-
Removing
– Remove inlet camshaft control ⇒ “3.4.1 Removing and in‐
stalling camshaft control, inlet side”, page 137 .
– Remove seal -1- using extractor hook - T20143/1- .
Installing
Note

– Push sealing ring -1- over the receiver tube -T10478/3- onto
the guide bushing -T10478/2- .
Fitting position:
• Closed side of sealing ring points to the receiver tube.
– Disconnect receiver tube - T10478/3- and guide bushing -
T10478/2- .
– Tightly screw in spindle - T10585- -A- by hand into the

camshaft -2-.
– Fit guide sleeve - T10478/2- -B- with seal -3- on camshaft.
– Place thrust piece - T10478/1A- -C- up to the sealing ring

-3-.
– Screw nuts -D- on spindle - T10585- -A-.
3. Valve gear 133

– Tighten nuts -D- until the thrust piece - T10478/1A- -C- is fitted
on the camshaft housing -1-.
– Check whether the sealing ring with thrust piece - T10478/1A-
-C- is correctly pressed into the camshaft housing.
– If necessary, using the hexagon bolt -arrow- loosen the spindle

- T10585- -A-.
– Insert inlet camshaft control ⇒ “3.4.1 Removing and installing
camshaft control, inlet side”, page 137 .
3.3.3 Removing and installing the exhaust

camshaft on the belt pulley side
♦ Assembly device - T10478B- with screw -T10478/5-
Removing
– Remove engine support ⇒ “1.5 Removing and installing en‐
gine support”, page 50 .
– Remove outlet camshaft control ⇒ “3.4.2 Removing and in‐
stalling camshaft control, outlet side”, page 140 .
– Remove seal -1- using extractor hook - T20143/1- .
Installing
Note

– Push sealing ring -1- over the receiver tube -T10478/3- onto
the guide bushing -T10478/2- .
• Installation position: Closed side of sealing ring points to the
receiver tube.
– Disconnect receiver tube and guide bushing.
– Fit guide bushing -T10478/2- with seal -1- onto camshaft.
– Pull sealing ring in to the stop using the thrust piece -

T10478/1A- and the camshaft sprocket screw -1-.
– Install camshaft control with new screw and tighten by hand
⇒ “3.4.2 Removing and installing camshaft control, outlet
side”, page 140 .
– install (set the timing) ⇒ “2.9 Remove the toothed belt from the
camshaft”, page 123 .
– Install engine support ⇒ “1.5 Removing and installing engine
support”, page 50 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
3.3.4 Removing and installing the exhaust

camshaft on the gearbox side
Removing
194 .
3. Valve gear 135

– Carefully fit extractor hook - T20143/2- -A- between camshaft

-1- and seal -2-.
– Support the extractor hook - T20143/2- -A- in the area of the
-arrow- on the camshaft housing -3-.
– Remove sealing ring.
Installing
Note
– Push the seal -2- via the receiver tube - T10579/2- -B- on the
guide sleeve - T10579/1- -C- in -arrow-.
• Installation: The open side of the sealing ring -2- points to the
mounting cone -B-.
• Installation: The open side of the sealing ring -2- points to the
camshaft housing -3-.
– Separate mounting cone -B- and guide sleeve -C-.
– Fit guide sleeve - T10579/1- -C- with seal -2- on camshaft
-1-.
– Slide thrust piece - T10579/3- -e- via guide sleeve - T10579/1-

-C- in -arrow-.
– Screw in screw - T10579/4- -D- until the thrust piece -
T10579/3- -E- is on the sealing ring.

– Screw in screw - T10579/4- -D- in the direction of the -arrow-

until the thrust piece - T10579/3- -E- is on the camshaft hous‐
ing -3-.
– Remove assembly device - T10579- .
– Install the pulley for coolant pump drive ⇒ “2.6 Removing and
installing toothed belt pulley for coolant pump”, page 194 .
3.4 Removing and installing camshaft con‐

trol
⇒ “3.4.1 Removing and installing camshaft control, inlet side”,
page 137
⇒ “3.4.2 Removing and installing camshaft control, outlet side”,
page 140
3.4.1 Removing and installing camshaft con‐

trol, inlet side
♦ Mounting bracket - T10575-
♦ Counterholder - T10172A-
♦ Extension No. 24 - T10580-
♦ Torque wrench - V.A.G 1331-
♦ Ratchet adapter - V.A.G 1331/1-
Prepare the tools
– Screw the counterholder - T10172A- -A- and holder - T10575-
-B- with knurled screws -arrows-.
Removing
3. Valve gear 137

Remove inlet camshaft control

– Expose hoses on bracket -2- and place to one side.
CAUTION

– Lay the fuel hoses to the side.
belt ⇒ page 78 .
NOTICE

oil.
– Remove holder forunless
radial shaftbyseal
authorised ŠKODA ⇒ AUTO
“3.2 A.Removing
S. ŠKODA AUTO and in‐does not guarantee or accept any liability
A. S.
– Clean the camshaft adjuster of oil.
– Place holder - T10575- -B- with backstop - T10172A- -A- on

camshaft adjuster -1- as shown in the figure.
The bolts of the holder - T10575- -B- are not evenly spaced.
The distances are equal to the hole spacings in the camshaft
control.
• The bolts must properly engage the holes -arrows-.

– Place holder - T10575- -B- over the full surface of the camshaft
adjuster -1-.
– Secure camshaft adjuster »clockwise« with holder -
T10575- -B- and backstop - T10172A- -A- in this position.
– Release control valve -2- with Extension No 24 - T10580- .
– Remove outlet camshaft control ⇒ page 141 .
– Unscrew control valve -2- and remove camshaft control.
– Remove oil from camshaft and camshaft housing.
Installing
• Camshafts are in the “OT”Position for working on the toothed
• Crankshaft is in the “TDC” position.
must be replaced.
– Remove oil from camshaft adjuster with cloth.
– Check control valve -3- before installation ⇒ Fig. ““Check the

control valve”“ , page 97 .
– Tighten control valve -3- by hand as far as the stop
– Tighten screw -4- by hand as far as the stop
– Place the timing belt onto the camshaft ⇒ “2.5 Removing and
installing toothed belt”, page 99 .
Pre-torque intake camshaft adjuster with tightening torque .

– Hold the camshaft control with the holder - T10575- -B- and
counterholder - T10172A- -A-.
– Pre-tighten control valve -2- with torque wrench.
Stage Control valve for intake Specified torque
camshaft adjuster
1. -2- 18 Nm
Note
For level 1 use the torque wrench - V.A.G 1331- with insert tool -
V.A.G 1331/1- .
3. Valve gear 139

Tighten inlet camshaft adjuster with final tightening torque.

– Tighten control valve -2- for camshaft adjuster in 2 stages with
final tightening torque.
Stage Control valve for intake Specified torque
camshaft adjuster
2. -2- 50 Nm
3. -2- 140 Nm
Note
For level 2 and 3 use the torque wrench - V.A.G 1332- with insert
tool - V.A.G 1332/1- .

Note

♦ Summary of components - toothed belt ⇒ “2.2 Summary of

components - toothed belt”, page 95 .
3.4.2 Removing and installing camshaft con‐

trol, outlet side
♦ unless
Mounting bracket
authorised - AUTO
by ŠKODA T10554-
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Counterholder - T10172A-
♦ Socket insert XZN 12 - T10586-
Prepare the tools
– Screw the counterholder - T10172A- and holder - T10554- with
knurled screws -arrows-.

Insert support - T10554-

The row spacings -1- and -2- of the holder - T10554- are arranged
unevenly.
They are equal to the hole spacings in the camshaft control.
Removing
Remove outlet camshaft control

– Expose hoses on bracket -2- and place to one side.
CAUTION

– Disconnect the fuel feed line -1- and vent line
with -2- totothe
respect acti‐
– Lay the fuel hoses to the side.
NOTICE

oil.
Note
Turn the camshaft further to ensure access to all screws.
– Remove cover for exhaust camshaft adjuster.

– Clean the camshaft adjuster of oil.
belt ⇒ page 78 .
3. Valve gear 141

– Place holder - T10554- on camshaft adjuster -1- as shown in

the figure.
The bolts of the holder - T10554- are not evenly spaced.
The distances are equal to the hole spacings in the camshaft
control.
• The bolts must properly engage the holes -arrows-.
– Hold the outlet camshaft control -2- with the holder - T10554-
and counterholder - T10172A- .
– Loosen screw -1- with plug connector XZN 12 - T10586- by
approximately one revolution.
– Remove inlet camshaft control ⇒ page 138 .
– Unscrew securing bolt -1- and remove camshaft control -2-.
– Remove oil from camshaft and camshaft housing.
Installing
• Camshafts are in the “OT”Position for working on the toothed
• Crankshaft is in the “TDC” position.
must be replaced.
– Remove oil from camshaft adjuster with cloth.
– Before installing the camshaft adjuster, place the guide sleeve
Pos. -6- ⇒ Protected
“2.2 Summary
by copyright.of components
Copying - toothed
for private or commercial belt”,inpage
purposes, part or in whole, is not permitted
95 . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Tighten screw -4- by hand as far as the stop

– Tighten control valve -3- by hand as far as the stop
– Place the timing belt onto the camshaft ⇒ “2.5 Removing and
installing toothed belt”, page 99 .

Pre-torque outlet camshaft adjuster with tightening torque .

– Hold the camshaft control with the holder - T10554- and coun‐
terholder - T10172A- .
– Pre-tighten screws -1- with torque wrench.
Stage Fitting screw for exhaust Specified torque
camshaft adjuster
1. -1- 18 Nm
Note
For level 1 use the torque wrench - V.A.G 1331- with insert tool -
V.A.G 1331/1- .
Tighten exhaust camshaft adjuster with final tightening torque.

– Tighten screw -1- to the final tightening torque.
Stage Fitting screw for exhaust Further turning angle
camshaft adjuster
2. -1- 50 Nm
3. -1- 135°
Note
For level 2 and 3 use the torque wrench - V.A.G 1332- with insert
tool - V.A.G 1332/1- .

note the following:
– Replace seal in cover for exhaust camshaft.
Note

♦ Summary of components - toothed belt ⇒ “2.2 Summary of

components - toothed belt”, page 95 .
3.5 Removing and installing cam adjuster

Installation overview - cam adjuster
1 - Exhaust cam adjuster for cylinder 2 - N587-
3 - Inlet cam adjuster for cylinder 2 - N583-
Removing
3. Valve gear 143

Cam adjuster for cylinder 3

the exhaust turbocharger ⇒ “2.4.1 Removing and installing the
– Unscrew screw -a- and remove the hose -1- from the exhaust
gas turbocharger -2-.

– Unclip and move clear the electric wiring loom -4- -arrow-.
Continued for all cylinders

– Disconnect electrical plug connections -1-:
– Unscrew screws -arrows- and remove cam adjuster.
Installing
– Check the O-rings for damage and replace if necessary.
– Before installing, moisten O-ring with engine oil.
– Check pins for cam adjuster for damage. The pins must not
be kinked or worn.
If damage to the cam follower is detected, replace the camshaft
housing.
– Bring pins of the control element for the cam adjuster into in‐
stallation position.
• The pins of the control element must be fully inserted
-arrows-.
Note

♦ Summary of components - camshaft housing ⇒ “1.2 Summary

of components - camshaft housing”, page 81 .
♦ Summary of components - exhaust gas turbocharger ⇒
“1.1 Summary of components - exhaust gas turbocharger”,
page 227 .


trol valve 1 in the inlet - N727-
Removing
NOTICE

oil.
– Unscrew screws -1- and remove camshaft control valve 1 in
the exhaust - N727- .
Note
♦ The screws-1- are to be guided through pipes in Valve 1 for

camshaft adjustment in the inlet - N727- .
♦ If the pipe is also unscrewed when the screw is unscrewed,
the screw with the pipe can nevertheless still be used.
Installing
Installation is carried
Protected outCopying
by copyright. in theforreverse order. When
private or commercial purposes,installing,
in part or in whole, is not permitted
observeunless
the following:
– Replace sealant ring Pos. -17- ⇒ “2.2 Summary of compo‐
nents - toothed belt”, page 95 .
Note

♦ Camshaft control valve 1 in the inlet - N727- ⇒ “2.2 Summary

of components - toothed belt”, page 95 .

trol valve 1 in the exhaust - N318-
Removing
3. Valve gear 145


– Release screws -arrows- and remove camshaft adjustment
valve 1 in the outlet - N318- -1-.
Installing
– Check O-ring for damage.
If the O-ring is damaged, replace together with camshaft control
valve 1 in the outlet - N318- .
♦ Camshaft control valve 1 in the exhaust - N318- ⇒ “1.2 Sum‐
mary of components - camshaft housing”, page 81 .
3.8 Removing and installing valve stem

seals
⇒ “3.8.1 Removing and installing valve stem seal with cylinder
head installed”, page 146
⇒ “3.8.2 Removing and installing valve stem seal with cylinder
head removed”, page 152
3.8.1 Removing and installing valve stem seal

with cylinder head installed
♦ Spark plug wrench , e.g. -3122B-
♦ Disassembly and assembly device for valve collets - VAS
5161A- with set - VAS 5161A/32- and set - VAS 5161A/40-
♦ Adapter - VAS 5161A/35- or -T40012-
♦ valve stem seal insertion tool - MP1-233 (3365)-
♦ Valve shaft pliers , e.g. -VAS 6770-
Removing
– Unscrew the spark plugs with the spark plug wrench - 3122B- .

– Unscrew the fixing screw for the coolant pipe -c-.

– If necessary, unscrew the coolant pipe fixing screw -b-.
– Loosen hose clamps -arrows- and remove coolant hoses.
– Remove the coolant line -1- from the exhaust gas turbocharger
-2-.
– Unscrew screws -arrows- and remove coolant line.
– Assignment of the roller towing levers -1-, Compensating ele‐

ments -4- and valves -3- for reintegration.
– Remove the roller rocker finger together with the balancing
elements and lay aside on a clean surface.
– Put the piston of the relevant cylinder at “bottom dead centre”.
Note
♦ Pistons for cylinder 1 and for cylinder 4 are located on the

»TDC« after removal of the camshaft housing .
♦ Pistons for cylinder 2 and for cylinder 3 are located on the
»UT« after removal of the camshaft housing .
♦ After rotating the engine by half a revolution in the directional
direction of the engine, the pistons for cylinder 1 and for cylin‐
der 4 are positioned on the »UT«.
♦ When rotating the engine, guide the toothed belt by hand so
that it is not damaged.
Disassembly and assembly tool for valve collets - VAS 5161A-
3. Valve gear 147

A - Guide plate - VAS 5161A/

40-
B - Knurled screws -
VAS 5161/12-
C - Drift - VAS 5161/3A-
D - Support fork - VAS 5161/5-
E - Grid part - VAS 5161/6-
F - Mounting cartridge -
VAS 5161A/32-1-
G - Bushing - VAS 5161A/
40-1-
H - Pressure fork -
VAS 5161/2-
I - Adapter - VAS 5161A/35-
– Place guide plate - VAS 5161A/40- -A- on the cylinder head

-1- and screw on using the knurled screws - VAS 5161/12-
-B-.
– Screw in the compressed air adapter - VAS 5161A/35- -I-
hand-tight into the respective spark plug thread.
– Connect the air adapter - VAS 5161A/35- -I- to the com‐
pressed air with a commercially available intermediate piece
and apply constant pressure.
• Minimum pressure: 0.6 MPa (6 bar)
– In guide plate - VAS 5161A/40- -A- , place punch spike -
VAS 5161/3A- -C- and detach the fixed valve cone pieces with
a plastic hammer.

Inlet side
– In guide plate - VAS 5161A/40- -A- screw in support fork -
VAS 5161/5- -D- with grid part - VAS 5161/6- -e-.
– In the guide plate - VAS 5161A/40- -A- place the mounting
cartridge - VAS 5161A/32-1- -F- complete with the pushed on
shell - VAS 5161A/40-1- -G-.
– Place pressure fork - VAS 5161/2- -H- in the grid part -
VAS 5161/6- -e- and attach to the mounting cartridge -
VAS 5161A/32-1- -F-.
– Position the pressure fork - VAS 5161/2- -H- In a suitable
working position and lock with bolts.
Note
Place pressure fork - VAS 5161/2- -H- so that the mounting car‐
tridge - VAS 5161A/32-1- -F-, can be pressed downwards with a
minimum force effort up to the stop.
Outlet side
– Insert the mounting cartridge - VAS 5161A/32-1- -F- with
pushed on shell - VAS 5161A/40-1- -G- in the guide plate -
VAS 5161A/40- -A-.
VAS 5161A/32-1- -F-.
Note
Continue for both sides

– Press down mounting cartridge - VAS 5161A/32-1- -F- with
pressure fork - VAS 5161/2- unless
-H-.
– Turn the knurled screw of the assembly cartridge -
VAS 5161A/32-1- -F- to the right, until the tips engage in the
valve collets.
– Turn the knurled screws to the left and the right- as a result,
the valve collets are pushed away from each other and latch
into the assembly cartridge - VAS 5161A/32-1- -F-
– Release the pressure fork - VAS 5161/2- -H-.
– Remove mounting cartridge - VAS 5161A/32-1- -F-.
– Unscrew guide plate - VAS 5161A/40- -A- and turn it to the
side.
• T compressed air hose remains connected.
– Remove the valve spring with the valve spring retainer.
3. Valve gear 149

– Use valve shaft pliers - VAS 6770- to pull off valve stem seal.
Installing
NOTICE
Risk of damage to valve stem seals during installation.
Install the valve stem seal

– Lightly oilauthorised
unless sealingbylip of the
ŠKODA valve
AUTO stemAUTO
A. S. ŠKODA sealA.-8-.
S. does not guarantee or accept any liability
– Install valve stem seal ⇒ Fig. ““Mounting valve stem seal”“ ,
page 127 .
– Carefully slide valve stem seals -8- with suppressor for valve
stem seal - MP1-233 (3365)- -A- on the valve -1-.
– Carefully push valve stem seals -8- with suppressor for valve
stem seal - MP1-233 (3365)- -A- on to the valve guide up to
the contact at the cylinder head -9-.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ Fig. ““Fitting position of the valve
spring”“ , page 127 .
If the valve collets were removed from the assemble cartridge -

VAS 5161A/32-1- -F- they must be inserted into the insertion de‐
vice - VAS 5161A/32-3- .
– Press the spring washer downwards until three grooves are
visible.
– Insert the valve cones into the grooves.
• The large diameter of the valve collets points to the top.
– Remove disc. The spring pressure pushes the disc back up‐
wards and holds the valve cone pieces.
– Press the assembly cartridge - VAS 5161A/32-1- -F-from
above onto the insertion device and pick up the valve collets.
the valve collets are pushed towards each other and latch into
the assembly cartridge - VAS 5161A/32-1- -F-
Install the valve cones
– Rescrew guide plate - VAS 5161A/40- -A- to the cylinder head
with screws - VAS 5161/12- -B-.

Inlet side
Outlet side
Continue for both sides
– Place mounting cartridge - VAS 5161A/32-1- -F- with shell -
VAS 5161A/40-1- -G- into the guide plate.
– Screw in grid part - VAS 5161/6- -e- with support fork -
VAS 5161/5- -D- in the guide plate - VAS 5161A/40- -A-.
VAS 5161A/32-1- -F-.
pressure fork - VAS 5161/2- -H-.
– At the same time as tractioning the knurled screw of the
mounting cartridge - VAS 5161A/32-1- -F- clockwise and anti-
clockwise, thereby inserting the valve cone pieces.
Note
By pulling out the knurled screw of the mounting cartridge -

VAS 5161A/32-1- -F- the pressure fork - VAS 5161/2- -H- is re‐
lieved
– Repeat the procedure for each valve.

Installing
– Replace seal item -18- between coolant lines and exhaust gas
turbocharger ⇒ “1.1.2 Assembly overview - Piping on the ex‐
haust gas turbocharger”, page 229 .
– Install coolant
unlessline itemby-15-
authorised ŠKODA onAUTO
exhaust gas AUTO
A. S. ŠKODA turbocharger
A. S. does not⇒
guarantee or accept any liability
“1.1.2 Assembly overview - Piping on the exhaust gas tur‐
bocharger”, page 229 .

– Install spark plugs:
– Install camshaft housing ⇒ “1.4 Removing and installing
3. Valve gear 151

Note

♦ Coolant line for exhaust gas turbocharger ⇒ “1.1.2 Assembly

overview - Piping on the exhaust gas turbocharger”, page
229 .
3.8.2 Removing and installing valve stem seal

with cylinder head removed
♦ Disassembly and assembly device for valve collets - VAS
5161A- with set - VAS 5161A/32- and set - VAS 5161A/40-
♦ Engine and gearbox mount - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Valve shaft pliers - VAS 6770-
♦ valve stem seal insertion tool - MP1-233 (3365)-
Cylinder head tensioning device - VAS 6419-

A - Clip - VAS 6419-

B - Adjustment link - VAS
6419/2-
C - Adjustment link - VAS
6419/1-
a - Lever for moving the air
cushion
b - Air cushion
c - Button »on« for filling with
compressed air
d - Button »off« for discharging
the compressed air

– Remove the roller towing lever and balancing elements ⇒
page 89 .
– Remove cylinder head ⇒ “1.3 Removing and installing cylinder
head”, page 84 .
Affix cylinder
Protected head
by copyright. cylinder
Copying head
for private tensioning
or commercial device
purposes, in part or-inVAS
whole, 6419-
is not permitted
– with
Insert the
respect cylinder
to the head
correctness tensioning
of information deviceCopyright
in this document. - VAS by
6419-
ŠKODAinto
AUTOthe
A. S.
engine and gearbox jack - VAS 6095- .
– Rescrew tensioning bow -VAS 6419/1- -C- and -VAS 6419/2-
-B- To T-nut receptacle -A-.
– To do this, screw in the 15 mm threaded rods.
– Tension the cylinder head in the cylinder head tensioning de‐
vice, as shown in the illustration.
– Fasten cylinder head with tensioner.
– Connect cylinder head tensioning device to compressed air.
Pressure is 2.0 bar.
3. Valve gear 153

– Adjust the air bellows with the lever -arrow- below the com‐
bustion chamber on which the valve stem seals should be
removed.
Note
The marking on the lever is then in the middle in front of the re‐
spective cylinder.
– Fill the air cushion by pressing button item -C- ⇒ Item c (page
153) .
– Allow just enough air to flow into the air bag so that it applied
to the valve disc.
Disassembly and assembly tool for valve collets - VAS 5161A-
A - Guide plate - VAS 5161A/

40-
B - Knurled screws -
VAS 5161/12-
C - Drift - VAS 5161/3A-
D - Support fork - VAS 5161/5-
E - Grid part - VAS 5161/6-
F - Mounting cartridge -
VAS 5161A/32-1-
G - Bushing - VAS 5161A/
40-1-
H - Pressure fork -
VAS 5161/2-
I - Adapter - VAS 5161A/35-

– Place guide plate - VAS 5161A/40- -A- on the cylinder head

-1- and screw on using the knurled screws - VAS 5161/12-
-B-.
– In guide plate - VAS 5161A/40- -A- , place punch spike -
VAS 5161/3A- -C- and detach the fixed valve cone pieces with
a plastic hammer.

Note
In addition, select for this purpose a suitable area for screwing in

the guide plate - VAS 5161A/40- -A-.
– In the guide plate - VAS 5161A/40- -A- place the mounting

cartridge - VAS 5161A/32-1- -F- complete with the pushed on
shell - VAS 5161A/40-1- -G-.
VAS 5161A/32-1- -F-.
Note

– Turn the knurled screw of the assembly cartridge -
VAS 5161A/32-1- -F- to the right, until the tips engage in the
valve collets.
the valve collets are pushed away from each other and latch
into the assembly cartridge - VAS 5161A/32-1- -F-
– Release the pressure fork - VAS 5161/2- -H-.
– Remove mounting cartridge - VAS 5161A/32-1- -F-.
– Unscrew guide plate - VAS 5161A/40- -A- and turn it to the
side.
– Remove the valve spring with the valve spring retainer.
3. Valve gear 155

– Use valve shaft pliers - VAS 6770- to pull off valve stem seal.
Remove the valves
– Rotate Cylinder head tensioning device - VAS 6419- by 90°.
– Discharge compressed air from the air cushion of the cylinder
head tensioning device - VAS 6419- using the button -d-.
– Slide away the air cushion -b- and remove the valves.
Installing
NOTICE
Risk of damage to valve stem seals during installation.
Install the valve stem seal

– Lightly oil sealing lip of the valve stem seal -8-.
– Install valve stem seal ⇒ Fig. ““Mounting valve stem seal”“ ,
page 127 .
– Carefully slide valve stem seals -8- with suppressor for valve
stem seal - MP1-233 (3365)- -A- on the valve -1-.
– Carefully push valve stem seals -8- with suppressor for valve
stem seal - MP1-233 (3365)- -A- on to the valve guide up to
the contact at the cylinder head -9-.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ Fig. ““Fitting position of the valve
spring”“ , page 127 .
If the valve collets were removed from the assemble cartridge -

VAS 5161A/32-1- -F- they must be inserted into the insertion de‐
vice - VAS 5161A/32-3- .
– Press the spring washer downwards until three grooves are
visible.
– Insert the valve cones into the grooves.
• The large diameter of the valve collets points to the top.
– Remove disc. The spring pressure pushes the disc back up‐
wards and holds the valve cone pieces.
– Press the assembly cartridge - VAS 5161A/32-1- -F-from
above onto the insertion device and pick up the valve collets.
the valve collets are pushed towards each other and latch into
the assembly cartridge - VAS 5161A/32-1- -F-

Install the valve cones

– Rescrew guide plate - VAS 5161A/40- -A- to the cylinder head
-1- with screws - VAS 5161/12- -B-.
– Place mounting cartridge - VAS 5161A/32-1- -F- with shell -
VAS 5161A/40-1- -G- into the guide plate.
– Screw in grid part - VAS 5161/6- -e- with support fork -
VAS 5161/5- -D- in the guide plate - VAS 5161A/40- -A- ⇒
page 149 ,
VAS 5161A/32-1- -F-.
– At the same time as tractioning the knurled screw of the
mounting cartridge - VAS 5161A/32-1- -F- clockwise and anti-
clockwise, thereby inserting the valve cone pieces.
Note
By pulling out the knurled screw of the mounting cartridge -

VAS 5161A/32-1- -F- the pressure fork - VAS 5161/2- -H- is re‐
lieved
– Repeat the procedure for each valve.

Installing
– Install cylinder head ⇒ “1.3 Removing and installing cylinder
head”, page 84 .
3. Valve gear 157

4 Inlet and exhaust valves

⇒ “4.1 inspecting valve guides”, page 158
⇒ “4.2 Testing valves”, page 158
⇒ “4.3 Valve dimensions”, page 158
4.1 inspecting valve guides

♦ Universal dial gauge bracket - MP3-447 (VW 387)-
♦ Dial gauge , e.g. -VAS 6079-
– Insert valve into guide. End of valve stem must be flush with
guide. On account of differing stem diameters, only use inlet
valve in inlet valve guide and exhaust valve in exhaust valve
guide.
– Determine valve rock.
• Wear limit: 0,5 mm
– If the wear limit is exceeded, repeat measurement with new
valves.
– If the wear limit is again exceeded, replace cylinder head.
Note
The valve guides cannot be changed.
4.2 Testing valves

– Check valves on the shank and seat surface for scoring.
– If scoring is clearly visible, change valve.
4.3 Valve dimensions
Note
Inlet and exhaust valves must not be reworked. Only lapping-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 29.0 25.0
∅b mm 4.973 4.953
c mm 112.6 110.09
α ∠° 45 by ŠKODA AUTO A. S. ŠKODA30
unless authorised AUTO A. S. does not guarantee or accept any liability

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - pan/oil pump”, page 159
⇒ “1.2 Engine oil”, page 163
⇒ “1.3 Removing and installing oil pan”, page 163
⇒ “1.4 Removing and installing oil pump”, page 167
⇒ “1.5 Removing and installing oil level and oil temperature
sender G266 ”, page 168
1.1 Assembly overview - pan/oil pump
Note
♦ If considerable quantities of metal swarf or abrasion is found when carrying out an engine repair, this can
be subject to damage to the crankshaft and conrod bearings. In order to prevent secondary damage, perform
the following tasks after the repair: clean oil channels carefully; change oil injection nozzles, engine oil cooler
and oil filter.
♦ Oil spray nozzle and pressure relief valve ⇒ “4.4 Removing and installing oil injection nozzles”, page 74 .
1. Sump, oil pump 159

1 - Oil pan
stalling oil pan”, page
163
2 - Screw
sembly
❑ Tightening sequence ⇒
Fig. ““Oil sump - tighten‐
ing torque and tighten‐
ing order”“ , page
162
3 - Sealing ring
sembly
❑ for oil drain plug with re‐
placeable gasket ring ⇒
page 163
4 - Oil drain plug
Note
♦ Replace the oil drain plug when

it has an integrated sealing ring.
♦ Always replace the gasket ring.
❑ For vehicles with cap‐
tive sealing ring ⇒
page 162 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ for vehicles with re‐unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
placeable gasket ringwith⇒ respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
page 163
❑ 30 Nm
5 - Baffle
❑ with oil suction pipe
6 - Gasket
7 - Screw
❑ Tightening torque and tightening order ⇒ Fig. ““Oil pump - tightening torque and tightening order”“ , page
162
8 - Sealing ring
❑ Replace ⇒ “1.6 Replacing crankshaft sealing ring on the belt pulley side”, page 54
9 - Screw
❑ Tightening torque and tightening order ⇒ Fig. ““Oil pump - tightening torque and tightening order”“ , page
162
10 - Oil pump
❑ Removing and installing ⇒ “1.4 Removing and installing oil pump”, page 167
11 - Fitting sleeve
❑ Qty. 2
12 - Gasket
13 - Dipstick
14 - Sealing ring
160 Rep. gr.17 - Lubrication

❑ Qty. 2
❑ Check for damage and replace if necessary
15 - Sealing ring
16 - Fit pin
17 - Oil filter
❑ pay attention to the notes ⇒ page 159
❑ Before installing, lightly coat sealing ring with clean engine oil
❑ Removing and installing ⇒ “4.3 Removing and installing oil filter housing”, page 177
❑ 20 Nm
18 - Supports
❑ for the oil filter
❑ Tighten loosened screw connector ⇒ Fig. ““Secure the oil filter screw connector”“ , page 161
19 - Plugs
20 - Screw
❑ 9 Nm
21 - Oil level and oil temperature transmitter - G266-
❑ Removing and installing ⇒ “1.5 Removing and installing oil level and oil temperature sender G266 ”, page
168
22 - Sealing ring
Secure the oil filter screw connector

If the screw connector -2- was released from the oil pan -1-, attach
it as follows:
For this purpose, use:
♦ 2 x hexagon nuts 068 115 723 ⇒ Electronic Catalogue of
Original Parts “ETKA” .
– Screw on nuts -3- and -4- onto the screw connector -2- and
tighten against each other.
– Retighten the screw connectors -2- by tighten the nuts -3-.
– Undo nuts -3- and -4- in a way that prevents the screw con‐
nector from undoing.
Specified torques
Screw connector -2- 50 Nm

Oil sump - tightening torque and tightening order

Step Bolts Tightening torque / torquing angle
1. -1 … 19- by hand as far as the stop
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further
4. -Arrows- ⇒ Rep. gr. 34 ; Removing and in‐
stalling the gearbox
Oil pump - tightening torque and tightening order

St Bolts Tightening torque / torquing angle
ep
1. -1- 5 Nm
2. -2- 10 Nm
3. -1- 8 Nm
4. -2- 20 Nm
5. -1- and -2- Turn 90° further
Oil drain plug with captive gasket ring (factory-fitted)

– Unscrew and dispose of oil drain plug with captive gasket ring
-1-.
– Install new oil drain plug -3- with replaceable sealing ring -2-.

Oil drain plug with replaceable gasket ring (all next oil change
service)
– Unscrew oil drain plug -2- and dispose of used sealing ring
-3-.
– Install new oil drain plug -2- with new captive gasket ring -1-.
1.2 Engine oil

– Check oil capacity using the oil dipstick after oil filling.
• The oil level must not be above the max. marking - risk of
damage to catalytic converter!
Oil capacity and engine oil specification:
Engine oil change “Engine oil: drain off”:
1.3 Removing and installing oil pan

♦ Oil filter tool - 3417-
♦ Socket - T10058-
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Silicone sealant ⇒ authorised
unless Electronic Catalogue
by ŠKODA AUTO A. S.of Original
ŠKODA AUTO A.Parts“ET‐
S. does not guarantee or accept any liability
KA” with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Removing
noise insulation .
– Drain engine oil:

– Remove the ribbed V-belt ⇒ “1.2 Removing and installing V-

ribbed belt”, page 46 .
CAUTION

– Disconnect plug connection -1- on the control valve for the air
conditioning system compressor - N280- .
– Release screws -arrows- for AC compressor.
NOTICE
Risk of damaging AC compressor, refrigerant lines and hoses.
♦ Do not over-tension, buckle and bend refrigerant lines and

hoses.
– Remove AC compressor with connected refrigerant hoses and
tie onto the lock carrier.

– Remove the plug -2- from the oil pan -1-.
– Remove plug -1- in oil level and oil temperature sender -

G266- , if present.


– Remove screws -1- for angular gear holders -2- from the oil
pan -3-.

– Remove securing bolts for gearbox -arrows-.
– Remove screw -19- to -1- In the tire sequence with the working
tool - T10058- .
– Unscrew the screws, leaving a securing screw on each side
of the oil pan.
Note
The oil sump is sealed by a liquid seal -2- that is highly adhesive
when hardened.
– Carefully lever the oil pan at the recess -arrow- from the cylin‐
der block.
– Remove the oil pan from the cylinder block.
– Unscrew the remaining two screws.
– Remove oil sump. Loosen sump with light blows of a rubber
headed hammer if necessary.
– Cover
unless authorised openAUTO
by ŠKODA partsA. S.of the engine.
Installing
CAUTION
Risk of injury.
Wear safety gloves and safety goggles.
– Remove the remaining sealant on the cylinder block and on

the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
Note
Pay attention to the use by date on sealant.

– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).
NOTICE
Risk of blockage of the lubrication system through excess
sealant.
– Do not apply a thicker sealant bead than indicated.

The sealant bead must be:
♦ 2-3 mm thick.
♦ Run past the area around the bolt holes on the inside
-arrows-
– Apply sealant to clean sealing surface of sump as shown.

Take particular care when applying sealant in the area of the
sealing flange.
• The oil pan must be installed within 5 minutes after applying
the sealant.
– Position oil sump and tighten unless
screws ⇒ Fig.
authorised ““Oil sump
by ŠKODA AUTO A.-S.tight‐
ening torque and tightening order”“ , page 162 .
– Plug -2- Into the holes and push in.
Note
♦ Do not damage the plug.

♦ Do not press the plug with a pointed tool or with sharp-edged
tools.
– Check that the plug is seated correctly.

• Let sealing compound dry for approx. 30 minutes after in‐
stalling oil sump. Only then fill with engine oil.
– Fill with engine oil and check the oil level:
Note


♦ Oil filter ⇒ “1.1 Assembly overview - pan/oil pump”, page

159 .
♦ Oil pan screws ⇒ “1.1 Assembly overview - pan/oil pump”,
page 159
♦ Gearbox screws⇒ Rep. gr. 34 ; Removing and installing the
gearbox .
♦ Screw for angle gear holder ⇒ Rep. gr. 34 ; Angular gear;
overview of components - angular gear .
1.4 Removing and installing oil pump

Removing
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
page 163 .
– Remove tensioning pulley for V-ribbed belt ⇒ “1.3 Removing
and installing tensioning pulley for V-ribbed belt”, page 48 .
– Remove alternator ⇒ Electrical system ; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove toothed belt ⇒ “2.5 Removing and installing toothed
belt”, page 99 .
– Remove sealing ring. ⇒ “1.6 Replacing crankshaft sealing ring
on the belt pulley side”, page 54
– Unscrew securing bolts -1- and -2- of the oil pump.
– Pull oil pump off dowel pins on cylinder block in a straight line.
– Remove gasket -1- from dowel pins -arrows-.

Installing
– Fit new gasket -1- onto dowel pins -arrows-.
– Check the oil pump for smooth operation, pushing the bearing
-arrows- with a finger.
Note
A sluggish oil pump must be replaced.
– Rotate oil pump gear to a position where 2 opposing

notches -arrows- are aligned vertically, as shown in the illus‐
tration.
– Slide the oil pump onto the locating pins and tighten the screws
⇒ Fig. ““Oil pump - tightening torque and tightening order”“ ,
page 162 ,
– Insert new sealing ring ⇒ “1.6 Replacing crankshaft sealing
ring on the belt pulley side”, page 54 .
Note

♦ Oil pump ⇒ “1.1 Assembly overview - pan/oil pump”, page

159 .
1.5unless Removing
to the correctness ofand installing
information oilCopyright
in this document. levelby and
ŠKODA oil
with respect AUTO A. S.
temperature sender - G266-

Removing
noise insulation .
– Unscrew screws -1- and remove the oil level and oil temper‐
ature sender - G266- Pos. -4-.
Installing
– Replace gasket ring -2- and oil before installing.
Note

♦ Oil level and oil temperature sender - G266- ⇒ “1.1 Assembly

overview - pan/oil pump”, page 159 .

2 Engine oil cooler

⇒ “2.1 Summary of components - engine oil cooler”, page
170
⇒ “2.2 Removing and installing engine oil cooler”, page 170
2.1 Summary of components - engine oil

cooler
Note

1 - Engine oil cooler

❑ pay attention to the
notes ⇒ “1 Sump, oil
pump”, page 159
stalling engine oil cool‐
er”, page 170
2 - Screw
❑ Replace after disas‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
sembly with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
❑ 8 Nm + 90°
3 - Sealing rings
sembly
2.2 Removing and installing engine oil cool‐

er
Removing
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page
183 .


– Remove electrical coolant pump ⇒ “2.4 Removing and in‐
stalling electric coolant pump”, page 190 .
– Remove charge air cooler ⇒ “2.2 Removing and installing
charge air cooler”, page 240 .
– Loosen coolant pipe ⇒ “3.1 Summary of components - coolant
pipe”, page 207 .
– Unscrew bolts -arrows- and remove engine oil cooler -1-.
Installing
– Insert new O-rings.
– Installing the intake manifold ⇒ “4.2 Removing and installing
– Top up coolant ⇒ page 186 .
Note

♦ Engine oil cooler ⇒ “2.1 Summary of components - engine oil

cooler”, page 170 .
2. Engine oil cooler 171

3 Crankcase ventilation
⇒ “3.1 Summary of components - crankcase ventilation”, page
172
⇒ “3.2 Removing and installing oil separator”, page 173
3.1 Summary of components - crankcase

ventilation
Note

1 - Oil separator below

stalling oil separator”,
page 173
““Oil separator below -
tightening torque and
tightening order”“ , page
173
❑ Replace if damaged.
2 - Screw
❑ 9 Nm
3 - Gasket
sembly
4 - Sealing ring
5 - Plug
❑ for vehicles with pres‐
sure sensor for purging
air from the activated
carbon filter - GX44-
6 - Vent line
❑ from fuel tank
❑ for vehicles without
pressure sensor for
purging air from the ac‐
tivated carbon filter -
GX44-
7 - Screw
❑ 9 Nm
8 - Gasket
❑ for cap
9 - Screw cap
10 - Ventilation hose
❑ from exhaust turbocharger
172 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
Rep. gr.17 - Lubrication
11 - Sealing ring
12 - Oil separator above
❑ Removing and installing ⇒ “3.2 Removing and installing oil separator”, page 173
❑ Tightening torque and tightening order ⇒ Fig. ““Oil separator above- tightening torque and tightening
13 - Gasket
Oil separator below - tightening torque and tightening order

– Tighten the bolts in the sequence -1- through -9-to 9 Nm.
Oil separator above- tightening torque and tightening order

– Tighten the bolts in the sequence -1- through -8-to 9 Nm.
3.2 Removing and installing oil separator

⇒ “3.2.1 Removing and installing oil separator”, page 173
⇒ “3.2.2 Removing and installing oil separator”, page 174
3.2.1 Removing and installing oil separator

Removing
– Remove
unlessthe noisebyinsulation
authorised ŠKODA AUTO⇒ A. General
S. ŠKODA AUTO body repairs,
A. S. exterior;
does not guarantee or accept any liability
Rep. gr.with66 ; Noise insulation; Summary of components -
noise insulation .
– Remove the pump for charge air cooling - V188- from the en‐
gine ⇒ “2.4 Removing and installing electric coolant pump”,
page 190 ,
– Unclip the electric wiring harness from oil separator.
3. Crankcase ventilation 173

– Loosen the screws in the sequence -9- to -1- and remove.

– Remove oil separator.
Installing
– Replace gasket.
– Tighten the screws in the sequence -1- to -9- ⇒ page 173 .
Note

♦ Oil separator ⇒ “3.1 Summary of components - crankcase

ventilation”, page 172 .
♦ Electric coolant pump ⇒ “2.2 Summary of components - elec‐
tric coolant pump”, page 188 .
3.2.2 Removing and installing oil separator

– Remove the airunless
guide pipebybetween
authorised ŠKODA AUTO theA. charge
S. ŠKODA airAUTO cooler and
the exhaust turbocharger
with respect to⇒the
“2.4.1 Removing
correctness and
of information installing
in this the by ŠKODA AUTO A. S.
document. Copyright
– Remove the vent line -3- by pressing the release buttons on
both sides.
– If present, remove the vent line -2- by pressing the release
buttons on both sides.
– Unclip and move clear the electric wiring loom -4-.

– Remove oil separator.
Installing
– Replace gasket.
– Tighten the screws in the sequence -1- to -8- ⇒ Fig. ““Oil sep‐
arator above- tightening torque and tightening order”“ , page
173 .
Note


♦ Oil separator ⇒ “3.1 Summary of components - crankcase

ventilation”, page 172 .
3. Crankcase ventilation 175

4 Oil filter, oil pressure switch

⇒ “4.1 Summary of components - oil pressure switch/oil pressure
control”, page 176
⇒ “4.2 Testing oil pressure and oil pressure switch”, page 177
⇒ “4.3 Removing and installing oil filter housing”, page 177
⇒ “4.4 Removing and installing valve for oil pressure control
N428 ”, page 177
⇒ “4.5 Removing and installing oil pressure sender G10 ”, page
178
4.1 Summary of components - oil pressure

switch/oil pressure control
Note

1 - Screw
❑ 8 Nm
2 - Oil pressure control valve -
N428-
⇒ “4.4 Removing and
installing valve for oil
pressure control N428 ”,
page 177
3 - O-ring
❑ is a component part of
position -2-
❑ In case of leaks replace
valve for oil pressure
control - N428- .
4 - Sealing ring
❑ Replaceunless
afterauthorised
disas‐by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
sembly with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
5 - Oil pressure sender - G10-
❑ black insulation
❑ Switching pressure:
0.03 - 0.06 MPa
(0.3 - 0.6 bar)
❑ check in Targeted
fault finding ⇒ Ve‐
hicle diagnostic tester
stalling oil pressure
sender G10 ”, page
178
❑ 10 Nm + 45°

4.2 Testing oil pressure and oil pressure

switch
Note
♦ Oil Pressure Sensor - G10- Is installed on the engine.

♦ The oil pressure sender - G10- can be diagnosed.
♦ Check the oil pressure sender and the oil pressure via ⇒ Ve‐
hicle diagnostic tester.
♦ Abnormalities are saved in the event memory.
4.3 Removing and installing oil filter housing

♦ Oil filter tool - 3417-
Removing
– Remove oil filter -arrow- with oil filter tool - 3417- .
When the screw has been loosened ⇒ Fig. ““Secure the oil filter
screw connector”“ , page 161 .

– Lightly lubricate gasket ring with clean engine oil.
– Tighten oil filter with oil filter wrench - 3417- .
♦ Oil filter ⇒ “1.1 Assembly overview - pan/oil pump”, page
159 .
4.4 Removing and installing valve for oil

pressure control - N428-
Removing
noise insulation .
4. Oil filter, oil pressure switch 177


– Collect any engine oil which flows out with a cloth.
– Remove screw -3- and remove oil pressure control valve -
N428- -1-.
Installing
Note
♦ Sealing ring not replaceable individually.

♦ Valve for oil pressure control - N428- cannot be reused after
expansion.
– Replace oil pressure control valve - N428- .

– Install the noise insulation ⇒ General body repairs, exterior;
noise insulation .
♦ Oil pressure control valve - N428- ⇒ “4.1 Summary of compo‐
nents - oil pressure switch/oil pressure control”, page 176 .
4.5 Removing and installing oil pressure

sender - G10-
Specialunless
tools and workshop equipment required

Removing
the suction pipe ⇒ “2.4.2 Removing and installing the air guide
pipe between the charge air cooler and the suction pipe”, page
245 .
– Unplug connector -arrow-.

– Disconnect connectors -1- and -3-.

– Remove and move clear the electric wiring loom -arrow-.
– Collect any engine oil which flows out with a cloth.
– With the Extension No 24 - T40284- unscrew the oil pressure
sensor - G10- -2-.
Installing
– After removal, replace seal oil pressure switch item -4- ⇒
“4.1 Summary of components - oil pressure switch/oil pres‐
sure control”, page 176 .
Note
Before replacing, cut open the sealing ring.
– Checking the oil level:

♦ Oil pressure sender - G10- ⇒ “4.1 Summary of components -
oil pressure switch/oil pressure control”, page 176 .
4. Oil filter, oil pressure switch 179

19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 180
⇒ “1.2 Check cooling system for leaks”, page 181
⇒ “1.3 Draining and filling coolant”, page 183
1.1 Connection diagram - coolant hoses
Note
♦ The arrows point in the flow direction of the coolant.

♦ The arrows on the coolant pipes and the coolant hose ends must match.
1 - Coolant expansion tank

❑ Check the overpressure
valve in the screw cap ⇒
page 183 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
2 - Cylinder head and cylinder with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
block
of components - cylin‐
der head”, page 79
3 - Charge-air cooler in intake
manifold
of components - charge
air system”, page
237
stalling charge air cool‐
er”, page 240
❑ Leak testing the charge
air cooler ⇒ “2.6 Leak
testing the charge air
cooler”, page 250
4 - Exhaust gas turbocharger
of components - ex‐
haust gas turbocharg‐
er”, page 227
stalling exhaust gas tur‐
bocharger”, page 231
5 - Engine oil cooler
❑ Summary of components ⇒ “2.1 Summary of components - engine oil cooler”, page 170
❑ Removing and installing ⇒ “2.2 Removing and installing engine oil cooler”, page 170
6 - Integrated exhaust manifold
180 Rep. gr.19 - Cooling

7 - Heat exchanger for heating

8 - Coolant pump
❑ with Module for engine temperature control - GX33-
9 - Coolant radiator
❑ Summary of components ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 214
❑ Removing and installing ⇒ “4.3 Removing and installing radiator with charge air cooler”, page 217
10 - Charge air cooling circuit radiator
❑ Summary of components ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 214
11 - Charge air cooler pump - V188-
❑ Summary of components ⇒ “2.2 Summary of components - electric coolant pump”, page 188
❑ Removing and installing ⇒ “2.4 Removing and installing electric coolant pump”, page 190
12 - Auxiliary heating
❑ Additional equipment
1.2 Check cooling system for leaks

♦ Cooling system testing device , e.g. -V.A.G 1274B-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/9-
Note
To ensure that the leaktightness test can be carried out correctly,

first carry out the test (self-test) of the cooling system testing de‐
withvice - V.A.G
respect 1274B-
to the correctness .
Test (self-test) of the cooling system testing device - V.A.G

1274B-
– Use the cooling system testing device - V.A.G 1274B- to build
up the pressure to 0.3 MPa (3.0 bar).
– Monitor the pressure on the pressure manometer of the cool‐
ing system testing device - V.A.G 1274B- 30 seconds long.
Pressure is not established or the pressure drops:
The cooling system testing device - V.A.G 1274B- is not OK and
cannot be used for the test.
Pressure is built up and does not drop:
The cooling system testing device - V.A.G 1274B- is OK and can
be used for the test.
Check cooling system for leaks
• Engine must be warm.
CAUTION
Wear safety goggles, safety gloves and safety clothing.
1. Cooling system, coolant 181


sure.
– Cover the cap -arrow- of the coolant expansion tank with a

cloth and open carefully.
– Connect the cooling system testing device - V.A.G 1274B-

with adapter -V.A.G 1274/8- to the coolant expansion tank.
– Build up a pressure of approximately 0.15 MPa (1.5 bar) using
hand pump on cooling system testing device - V.A.G 1274B- .
• The pressure must not drop below 0.02 MPa (0.2 bar) after 10
minutes.
If the pressure drops by more than 0.02 MPa (0.2 bar), look for
leaks and resolve any errors.
Note
♦ A loss of pressure of 0.02 MPa (0.2 bar) within 10 minutes is

caused by cooling of the coolant. The colder the engine, the
lower the pressure loss.
♦ You may need to repeat the test when the engine is cold.
CAUTION
♦ Before the cooling system testing device - V.A.G 1274B- is

separated from the connecting hose or the connecting piece -
V.A.G 1274B/1- , the existing pressure must absolutely be re‐
leased.
♦ For this step, press the pressure relief valve on the cooling
system testing device - V.A.G 1274B- until the pressure gauge
indicates the value »0«.

Testing the pressure relief valve in the cap

– Screw cap -1- into adapter for cooling system tester - V.A.G
1274/9- -2-.
– Connect the adapter for cooling system tester - V.A.G 1274/9-

via the supplied connecting hose to the cooling system tester
- V.A.G 1274B- .
– Build up overpressure using hand pump on cooling system
testing device - V.A.G 1274B- .
Blue filler cap:
♦ The pressure relief valve must open at a pressure of 0.14 ...
0.16 MPa (1.4 ... 1.6 bar).
Black filler cap:
♦ The pressure relief valve must open at a pressure of 0.16 ...
0.18 MPa (1.6 ... 1.8 bar).
If the pressure relief valve opens too early or too late:
– Renew cap.
1.3 Draining and filling coolant


♦ Pliers for spring-type clips
♦ Cooling system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Refractometer
Note
The drained coolant must not be re-used.
♦ Collect and dispose of drained coolant in a clean container.

♦ Observe the disposal instructions.
Draining
CAUTION

sure.


noise insulation .
– Place a catch pan under the engine.
– Disconnect plug connection -2- on the coolant temperature

sender at radiator outlet - G83- -3-.
– Raise holding clamp -1-, remove bottom left coolant hose from
coolant radiator and allow coolant to drain.
– Raise holding clamp -arrow-, remove coolant hose from

charge-air cooling circuit radiator, allow remaining coolant to
drain.
Filling up
The drained coolant must not be re-used.
Select the appropriate coolant additive from the ⇒ ETKA - Elec‐
tronic catalogue of original parts .
– In a clean reservoir, mix distilled water and coolant additive in
the specified mixing ratio:
– Connect coolant hoses ⇒ Fig. ““Connect coolant hose with
quick coupling”“ , page 215 .
– Select and execute function 0001 - Filling / bleeding
the cooling system ⇒ Vehicle diagnostic tester.

– Fill up the coolant reservoir -VAS 6096- with at least 10 litres

of pre-mixed coolant mixed to the correct ratio:
– Screw the adapter for cooling system testing device -
V.A.G 1274/8- to the coolant expansion tank.
– Mount cooling system charge unit - VAS 6096- onto the
adapter -V.A.G 1274/8- .
– Place the air hose -2- into a small container -3-.
Note
A small amount of coolant, which is entrained with the exhaust

air, must be collected.
– Close the valves -A- and -B-, while doing so turn the lever at
right angles to the direction of flow.
– Connect hose -4- to compressed air.
• Pressure: 0.6-1.0 MPa (6-10 bar)
– Open the valve -B-, while doing so turn the lever in the direction
of flow.
• A vacuum pump is created in the cooling system by the vac‐
uum pump; the display instrument pointer must move into the
green area.
– In addition, briefly open the valve -A- by turning the lever in the
direction of flow, so that the hose of the coolant expansion
bottle is -VAS 6096- filled with coolant.
– Close the valve -A- again.
– Leave the valve -B- open a further 2 minutes.
• A vacuum pump is created in the cooling system by the vac‐
uum pump; the display instrument pointer must remain in the
green area.
– Close the valve -B-.
• If the display instrument pointer remains in the green area the
vacuum in the cooling system is sufficient for subsequent fill‐
ing.
If the pointer is below the green area, repeat the process.
If the vacuum drops, check the cooling system for leak points.
– Disconnect pneumatic hose.
– Open valve -A-.
• The vacuum
Protected pump
by copyright. in for
Copying the cooling
private system
or commercial draws
purposes, theorcoolant
in part in whole, is out
not permitted
of the
unless coolant
authorised reservoir
by ŠKODA AUTO A. -VAS
S. ŠKODA6096-
AUTOand fills not
A. S. does theguarantee
cooling sys‐any liability
or accept
tem.
– Remove the cooling system charge unit - VAS 6096- from the
coolant expansion tank.

– Fill up coolant to “max” marking.

noise insulation .
– Tighten cap for coolant expansion tank tighten until it clicks
into place.
– End function 0001 - Filling/venting the cooling sys-
tem ⇒ Vehicle diagnostic tester.
– Switch off engine and allow it to cool down.

– Check coolant level ⇒ page 186 .
– Fit the cooling system testing device - V.A.G 1274B- with
adapter -V.A.G 1274/8- onto the coolant expansion tank ⇒
“1.2 Check cooling system for leaks”, page 181 .
– Build up a pressure of 0.1 MPa (1 bar) using hand pump on
cooling system testing device - V.A.G 1274B- .
– Then release the pressure on the cooling system tester -
V.A.G 1274B- and remove the tester ⇒ “1.2 Check cooling
system for leaks”, page 181 .
– Top up coolant to approximately 5 mm above the “max” mark‐
ing -arrow-while the engine is running.
Inspecting coolant level

• If the engine is cold the coolant level must be between the
“Min” and “Max” marking.
When the engine is at operating temperature, the coolant level
may be at or above the “max” marking.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Summary of components - coolant pump/thermostat”,
page 187
⇒ “2.2 Summary of components - electric coolant pump”, page
188
⇒ “2.3 Summary of components - coolant temperature transmit‐
ter”, page 189
⇒ “2.4 Removing and installing electric coolant pump”, page
190
⇒ “2.5 Removing and installing coolant pump”, page 191
⇒ “2.6 Removing and installing toothed belt pulley for coolant
pump”, page 194
⇒ “2.7 Removing and installing coolant temperature transmitter
G62 ”, page 197
⇒ “2.8 Removing and installing coolant temperature sender at
radiator outlet G83 ”, page 198
⇒ “2.9 Removing and installing coolant temperature sender at
engine outlet G82 ”, page 199
⇒ “2.10 Removing and installing element for engine temperature
control GX33 ”, page 200
⇒ “2.11 Testing the coolant pump”, page 202
2.1 Summary of components - coolant

pump/thermostat
Note

2. Coolant pump, regulation of cooling system 187

1 - Toothed belt
❑ For coolant pump
sembly
2 - Pulley
❑ For coolant pump drive
stalling toothed belt pul‐
ley for coolant pump”,
page 194
3 - Screw
sembly
❑ 20 Nm + 90°
4 - Toothed belt guard
❑ For coolant pump
toothed belt
5 - Screw
❑ 8 Nm
6 - Coolant pump
stalling coolant pump”,
page 191
❑ replace toothed belt
when changing coolant
pump
7 - Screw
❑ Tightening sequence ⇒
page 194
❑ 12 Nm
8 - Screw
❑ must not be loosened
❑ Module for engine temperature control - GX33-
10 - Module for engine temperature control - GX33-
❑ comprises:
♦ Position sensor for engine temperature control - G1004-
♦ Actuator for engine temperature control - N493-
❑ Removing and installing ⇒ “2.10 Removing and installing element for engine temperature control GX33
”, page 200
11 - Screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Corrected tightening torque for the use of the insertion tool - T10572- and the torque wrench - V.A.G
1783- 4.2 Nm
12 - Gasket
❑ replace
2.2 Summary of components - electric coolant pump

1 - Charge air cooler pump -

V188-
❑ With holder
stalling electric coolant
pump”, page 190
2 - Coolant hose
3 - Screw
❑ 8 Nm
4 - Coolant hose
2.3 Summary of components - coolant tem‐

perature transmitter
Note


1 - O-ring
sembly
2 - Coolant temperature
sender at radiator outlet - G83-
installing coolant tem‐
perature sender at radi‐
ator outlet G83 ”, page
198
3 - O-ring
sembly
4 - Support ring
5 - Coolant temperature trans‐
mitter - G62-
stalling coolant temper‐
ature transmitter G62 ”, by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
page 197 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
6 - O-ring
sembly
7 - Support ring
8 - Screw
❑ 8 Nm
9 - Coolant temperature sen‐
sor at engine output - G82-
perature sender at engine outlet G82 ”, page 199
10 - Screw
❑ 8 Nm
11 - Retaining clip
❑ Check for secure seating
2.4 Removing and installing electric coolant

pump
♦ Hose clamps up to 25 mm - MP7-602 (3094)-
Removing
CAUTION


sure.
noise insulation .

– Place catch pan underneath.
– At the charge air cooler pump - V188- disconnect coolant
hoses with hose clamps -MP7-602 (3094)- .
– Loosen hose clamps -3- and remove coolant hoses.
– Undo screw -2- and remove charge air cooler pump - V188- .
Installing
– Secure all hose connection ends with spring-type clips that
of Original Parts .
noise insulation .
♦ Charge air cooler pump - V188- ⇒ “2.2 Summary of compo‐
nents - electric coolant pump”, page 188
2.5 Removing and installing coolant pump

♦ Release tool -T10527-
♦ Refractometer
♦ Cooling system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
Removing
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page 183 .
191
2. Coolant pump, regulation of cooling system
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Bat‐

tery; Removing and installing battery .
– Remove air guide pipe ⇒ “2.4.1 Removing and installing the
– Cover openings on gearbox with cleaning cloths so that no
fluids can run into the coupling housing.
– Unscrew screws -b- from the coolant pipe -1-.
– Loosen hose clamps -arrows- and screws -a- for holders for
coolant tube.
– Lay coolant pipe to the side.
– Slacken the hose clamps -arrows- and detach the coolant

hoses from the coolant pump -1-.
– Loosen holding clips for cable harness -b- belt guard -3- of the
coolant pump.
– Release screws-arrows- and remove toothed belt protector
-3-.

– Remove connector -c- from the module for engine tempera‐

ture control - GX33- -4-.
– Unscrew screws -d- from the coolant pipe holder under the
coolant pump.

– Remove coolant pump with toothed belt.
Installing
Note
♦ Always replace the toothed belt for the coolant pump drive af‐
ter disassembly. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Secure hose connection ends with hose clamps that comply
with the series design ⇒ ETKA - Electronic Catalogue of Orig‐

inal Parts .
– Replace seal for coolant pump.

Ensure proper seating of gasket.
– Moisten gasket for coolant pump with coolant.
– Hang up toothed belt -2- centrally between the guides on the

toothed belt wheel of the coolant pump -1-.
– Bring cooling pump to installation position.

• The pins -a- on the coolant pump must enter the openings
-b- on the cylinder head.
Note
Thanks to the centring pins of the coolant pump, the toothed belt
is tensioned automatically.
– Mount coolant pump on cylinder head with securing bolts.

– Apply toothed belt on toothed belt wheel camshaft.
order of tightening
– Tighten the bolts in the sequence -1- through -4-to specified
torque.
If the Module for engine temperature control - GX33- has been
dismantled:
– If necessary, turn the coolant pump shaft into the mounting
position ⇒ page 204 ,
note the following:
– Top up coolant ⇒ page 184 .
Note

♦ Toothed belt guard of the coolant pump ⇒ “2.1 Summary of

components - coolant pump/thermostat”, page 187 .
♦ Screws for coolant pump ⇒ “2.1 Summary of components -
coolant pump/thermostat”, page 187

pulley for coolant pump
♦ Assembly sleeve - T10505-
Screw - T10479/4-
Counterholder - T10172- with adapters -T10172/2-
Extractor - T10221A-
Removal tool - T10498- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Removal wedge - 3409- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
Rig pin - T10504/1-

Removing
pump”, page 191 .
• Drilling on the toothed belt wheel for driving the coolant pump
-3- and the bore on the camshaft housing -4- must be in one
axis.
– Rotate crankshaft in engine direction until the holes are in one
axis.
Note
To test use a commercially available metal drill of »4.5 mm« or

locking pin - T10504/1- -a-.
– Unscrew screw -1-, using counterholder - T10172- with

adapter -T10172/2- to do so.
– Screw in the screw - T10479/4- -a- by hand in the crankshaft

up to the stop.
– Position the extractor - T10221A- -3- on the toothed belt pulley
-4-, as shown.
– Tighten hand-tight the screws puller - T10221A- -b-.
• Screw
unlessfor pullerby-ŠKODA
authorised T10221A-AUTO A.-b- mustAUTO
S. ŠKODA be placed
A. S. does in
notthe centre
of thewith
head oftothe
respect screw -ofT10479/4-
the correctness -a-.
information in this document. Copyright by ŠKODA AUTO A. S.
– Rotate screw -b- for puller - T10221A- until the toothed belt is
almost at the top of the screw - T10479/4- -a- is applied.
– Loosen and remove puller - T10221A- -3-.
– Remove screw - T10479/4- -a- by about 20 mm.
– Once more position the extractor - T10221A- -3- on the
toothed belt pulley -4-, as shown.
– Rotate screw -b- for puller - T10221A- until the toothed belt is
almost at the top of the screw - T10479/4- -a- is applied.
Note
If the toothed belt wheel is not completely removed from the

camshaft, repeat the procedure again.
– Check the radial shaft seal for damage, and if necessary re‐
place it ⇒ “3.3.4 Removing and installing the exhaust camshaft
on the gearbox side”, page 135 .
Installing

Note
♦ Do not use any impact tools!

♦ When using an impact device, the toothed belt wheel can be
damaged.
♦ This avoids axial displacement of the camshaft.
– Remove seal -arrow- carefully with Removal tool - T10498- .

– While doing this, do not damage the camshaft -2- or radial
shaft seal.
– Slide the new sealing ring with Removal wedge - 3409- Into
the groove.
– Position the toothed belt -1- on camshaft -2- so that the shoul‐
der on the toothed belt wheel is in an axis with the edge of the
milled surface on the camshaft -arrows-.
– Lightly lubricate the timing belt guide.
– Place toothed belt -1- straight on camshaft -2-.
• Drilling on the toothed belt wheel -3- and the bore on the
camshaft housing -4- must be in one axis.
Note
To centre, use a commercially available metal drill of »4.5 mm«

or locking pin - T10504/1- -a-.
– Replace fixing screw for toothed belt sprocket.

– Tighten the screw for the toothed belt wheel until the toothed
belt wheel -3- is on the camshaft.
– Tighten the screw to the specified tightening torque while hold‐
ing the toothed belt wheel with counterpart - T10172- with
adapter -T10172/2- .
– Install coolant pump ⇒ “2.5 Removing and installing coolant
pump”, page 191 .

Note

♦ Toothed belt pulley ⇒ “2.1 Summary of components - coolant

pump/thermostat”, page 187 .
♦ Summary of components - camshaft housing ⇒ “1.2 Summary
of components - camshaft housing”, page 81 .
2.7 Removing and installing coolant tem‐

perature transmitter - G62-
♦ Removal tool - T10498-
Removing
• Engine cold.
noise insulation .
– Briefly open the cap -arrow- for the coolant expansion reser‐
voir to release residual pressure in the coolant system, then
close again until it clicks into place.
– Place the catch pan , e.g. -VAS 6208- , underneath.

– Unscrew screw -arrow- and pull out coolant temperature
sender - G62- -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Installing with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.


– Replace O-ring -3-.
Note
If the O-ring -3- with support ring -4- remains in the cylinder head,
lift out the O-ring with support ring using a removal tool - T10498- .
– Insert new coolant temperature sender - G62- immediately in‐

to cylinder head in order to avoid loss of coolant.
Note

♦ Coolant temperature sender - G62- ⇒ “2.3 Summary of com‐

ponents - coolant temperature transmitter”, page 189 .

perature sender at radiator outlet - G83-
Removing
• Engine cold.
Briefly open the cap -arrow- for the coolant expansion reservoir
to release residual pressure in the coolant system, then close
again until it clicks into place.
Rep. gr. 66 ; Noise withinsulation; Summary
respect to the correctness of components
of information - Copyright by ŠKODA AUTO A. S.
in this document.
noise insulation .

– Pull out holding clamp -1- and pull coolant temperature sender
at radiator outlet - G83- out of the connection piece -3-.
Installing
– Renew O-ring.
– Insert a new coolant temperature sender at radiator outlet -
G83- immediately into the neck to avoid loss of coolant.

– Install front sound dampening system ⇒ General body repairs,

exterior ; Rep. gr. 66 ; Noise insulation; Summary of compo‐
nents - noise insulation .

perature sender at engine outlet - G82-
Removing
• Engine cold.
noise insulation .
– Briefly open the cap -arrow- for the coolant expansion reser‐
voir to release residual pressure in the coolant system, then
close again until it clicks into place.

– Unscrew screw -arrow- and pull out coolant temperature
sender at the engine outlet - G82- -2-.
Installing

– Replace O-ring -3-.
Note
If the O-ring -3- with support ring -4- remains in the cylinder head,
lift out the O-ring with support ring using a removal tool - T10498- .
– Insert new coolant temperature sender at the engine outlet -

G82- immediately into cylinder head in order to avoid loss of
coolant.
Note

♦ Coolant temperature sensor at engine output - G82- ⇒

“2.3 Summary of components - coolant temperature transmit‐
ter”, page 189 .
2.10 Removing and installing element for en‐

gine temperature control - GX33-
♦ Torque wrench , e.g. -V.A.G 1783-
♦ Torx Bit T30 - T10573-
Removing
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
– Release holder -a- for cable harness and place it laterally.
– Remove
unless fuel lineby-b-
authorised fromAUTO
ŠKODA theA.holders
S. ŠKODA-1- AUTOat A.the intake
S. does manifold
and place it laterally.

– Unscrew fixing screw for coolant pipe -c- from the charge air
cooler -2- and place the tube laterally.
– Remove coolant pipe -d- from the holders on the intake man‐
ifold -1- and place the tube laterally.
– Release electrical wiring harness -1- from the charge air cooler
-2- -arrow-.
– Remove connector -Arrow- from the module for engine tem‐

perature control - GX33- -3-.
– Push wiring harness -e- to the side so that the lower screw
-4- for the Module for engine temperature control - GX33- -3-
is accessible.
– Unscrew screw -4- with the Working tool - T10572- and Torx
bit T30 - T10573- .
– Unscrew screw -arrow- for Module for engine temperature

control - GX33- -3-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

– Pull the cable harness forward.

– Remove Module for engine temperature control - GX33- -3- in
-arrow- from the shaft -f- for coolant pump.
Installing
– If necessary, check the coolant pump ⇒ page 205 .
Power Control element -1- for Module for engine temperature

control - GX33- only fits the coolant pump shaft -2- in one position.
Module for motor temperature control - GX33- is guided to the

coolant pump via the opening -3- and the knurled pin -4-.
Observe the mounting sequence.
– If necessary, insert the coolant pump shaft into the mounting
position ⇒ page 204 .
– Firstly, position the power control element -1- to the coolant
pump shaft -2-.
– Then position the drill hole on the power control element -3-
on the knurled pin of the coolant pump -4-.
– Screw in screws for Module for engine temperature control -
GX33- .
– Tighten screws with torque wrench - V.A.G 1783- . Working
tool - T10572- and Torx bit T30 - T10573- .
Note with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
When using the torque wrench - V.A.G 1783- and insersion tool
- T10572- , adhere to the corrected torque is 4.2 Nm.

♦ Module for engine temperature control - GX33- ⇒ “2.1 Sum‐
mary of components - coolant pump/thermostat”, page 187 .
2.11 Testing the coolant pump


♦ Testing tool - T10577-
Description of Dial - T10577/2- :
1 - Position »open« Coolant pump -o-
2 - Position »closed« Coolant pump -c-
šipky - End stops
Note
♦ This working step also serves to check that the position of the
coolant pump shaft and the position of the Module for engine
temperature control - GX33- are implemented correctly.
♦ The coolant pump can be mechanically tested in the event of
failures.
♦ During the test, the rotary slide or the shaft is tested for stiff‐
ness.
♦ If it is found during the test that the shaft is too difficult to turn,
replace the coolant pump.
– Remove element for engine temperature control - GX33- ⇒

“2.10 Removing and installing element for engine tempera‐
ture control GX33 ”, page 200 .
Affix Testing tool - T10577- to the coolant pump

– Position Dial - T10577/2- on the pin -4-.
– Screw on Dial - T10577/2- in the two holes -arrows- at the
coolant pump -1-.
– Affix Dial - T10577/2- -A- with the screws -2- from Testing tool
- T10577- and tighten with 5 Nm.

– Position testing tool - T10577/1- -B- on coolant pump -1- as

shown.
Note
Receptacle arrow -b- on the testing tool - T10577/1- -B- only fits
the shaft arrow -a- for the coolant pump -1- in one position.
When positioning, the normal arrow marking must show»O« -1-

for the marking on the testing tool - T10577/1- .
If the arrow does not match the mark, the coolant pump must be
placed in the installation position ⇒ page 204 .
Bring cooling pump to installation position.

• The testing tool - T10577- Is connected to the coolant pump
-1- ⇒ page 203 ,

– Shaft for coolant pump -1- is rotated using the testing tool -
T10577/1- -B- In the mounting position.
• The arrow of mark »O« on Dial - T10577/2- -A- must illustrate,
in the area of the marking arrow, -a- the testing tool - T10577/1-
-B-.
– Install testing tool - T10577- and Module for engine tempera‐
ture control - GX33- .
Testing the coolant pump

• The testing tool - T10577/1- -B- is connected to the coolant
pump -1- ⇒ page 203 .
– Bring cooling pump to installation position ⇒ page 204 .
• The arrow of mark »O« on Dial - T10577/2- -A- must illustrate,

in the area of the marking arrow, -a- the testing tool - T10577/1-
-B-.
– Turn testing tool - T10577/1- In both directions between the
markers arrows -a- In the direction of the arrow -b-.
• The mark on the testing tool - T10577/1- -B- must be between
the markers »O« and »c«.
• The force expenditure cannot be activated thereby with the
overload protection in the testing tool - T10577/1- -B-.
When the overload protection is activated, the shaft for the
coolant pump is too difficult to turn.
The testing tool - T10577/1- can then be rotated without resis‐
tance.
– Replace cooling pump ⇒ “2.5 Removing and installing coolant
pump”, page 191 .

– The testing tool - T10577/1- is rotated in both directions be‐

tween both end stops -arrows-.
– Thereby rotate the marking arrow -a- to both end stops in the
direction of the arrow -b-.
• When the end stops are reached and exceeded, the overload
protection must be activated.
The testing tool - T10577/1- can then be rotated without resis‐
tance.
If the overload protection is not activated, the coolant pump must
be replaced because the end stops are not reached.
– Replace cooling pump ⇒ “2.5 Removing and installing coolant
pump”, page 191 .

3 Coolant pipes
⇒ “3.1 Summary of components - coolant pipe”, page 207
⇒ “3.2 Removing and installing coolant pipes”, page 208
3.1 Summary of components - coolant pipe
1 - Coolant hose
❑ Connection diagram ⇒
“1.1 Connection dia‐
gram - coolant hoses”,
page 180
2 - Clamp
3 - Coolant pipe - front bottom
installing the front bot‐
tom coolant pipe”,
page 212
❑ Connection Protected
diagram ⇒
“1.1 Connection dia‐ by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
gram - coolantwithhoses”,
page 180
4 - Screw
❑ 8 Nm
5 - Front top coolant pipe
installing the front top
coolant pipe”, page
211
page 180
6 - Screw
❑ 3.5 Nm
7 - Clamp
8 - Coolant hose
“1.1 Connection diagram - coolant hoses”, page 180
9 - Coolant tube bottom left
❑ Removing and installing ⇒ “3.2.1 Removing and installing the lower left coolant pipe”, page 208
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 180
10 - Clamp
11 - Coolant hose
12 - Screw
❑ 8 Nm
13 - Coolant hose
14 - Clamp
3. Coolant pipes 207

15 - Screw
❑ 8 Nm
16 - Coolant tube top left
❑ Removing and installing ⇒ “3.2.2 Removing and installing the upper left coolant pipe”, page 210
17 - Screw
❑ 3.5 Nm
18 - Coolant hose
19 - Clamp
3.2 Removing and installing coolant pipes

⇒ “3.2.1 Removing and installing the lower left coolant pipe”, page
208
⇒ “3.2.2 Removing and installing the upper left coolant pipe”,
page 210
⇒ “3.2.3 Removing and installing the front top coolant pipe”, page
211
⇒ “3.2.4 Removing and installing the front bottom coolant pipe”,
page 212
3.2.1 Removing and installing the lower left

coolant pipe
♦ Hose binding claw - VAS 6362-
Removing
noise insulation .
CAUTION

sure.


– Loosen lower hose clamp -arrow- and remove coolant hose

-c-.
– Release screw -d- at bracket for coolant pipe.
– Release clamp -arrow- For coolant hose -2-.

– Detach coolant hose from the charge air cooler -1-.
– Remove the coolant tube and thread it.
– Secure all hose
unless authorised connections
by ŠKODA AUTO A. S. with
ŠKODAhoseAUTO A.clamps which
S. does not comply
withwith
the series
respect to thedesign ⇒of Electronic
correctness Catalogue
information in this of Parts
document. Copyright . AUTO A. S.
by ŠKODA

♦ Summary of components - coolant pipe ⇒ “3.1 Summary of
components - coolant pipe”, page 207 .

3.2.2 Removing and installing the upper left

coolant pipe
Removing
noise insulation .
CAUTION

sure.
– Release hose clamp -arrow- to the right and remove the

coolant hose from the coolant pipe to the turbocharger.
– Remove screw -a- at bracket for coolant pipe.

– Unscrew fixing screw -b- for coolant pipe -1- from the charge
air cooler -2-.
– Release clamp -arrow- For coolant hose -4-.

– Detach coolant hose from the charge air cooler -1-.
– Remove cooling pipe.
– Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Parts .
3.2.3 Removing and installing the front top

coolant pipe
Removing
CAUTION

sure.


– Remove fuel line -b- from the holders -1- at the intake manifold
and place it laterally.
– Unscrew screws -a- from intake manifold -1-.

– Unhook coolant pipe -2- in the points -b-.
– Disconnect coolant hoses to the right and left of the coolant
pipe with hose clamps up to 25 mm - MP7-602 (3094)- .
– Loosen hose clamps on right and left.
– Remove cooling pipe.
Installing
3.2.4 Removing and installing the front bottom

coolant pipe
Removing
CAUTION


sure.
– Remove charge air cooler ⇒ “2.2 Removing and installing
charge air cooler”, page 240 .
– Pinch off coolant hoses at coolant pipe -1- with the hose
clamps up to 25 mm - MP7-602 (3094)- .
– Loosen hose clamps -2- and remove coolant hoses.
– Remove coolant pipe -1-.
Installing

4 Coolers, radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 214
⇒ “4.2 Summary of components - fan shroud and radiator fan”,
page 215
⇒ “4.3 Removing and installing radiator with charge air cooler”,
page 217
⇒ “4.4 Removing and installing fan shroud”, page 224
⇒ “4.5 Removing and installing radiator fan V7 ”, page 225
⇒ “4.6 Removing and installing radiator fan 2 V177 ”, page
226
4.1 Assembly overview - radiator/radiator

fan
Note

1 - Coolant radiator
stalling radiator with
charge air cooler”,
page 217 unless
2 - Coolant hose with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
❑ to remove, raise the

holding clamps
❑ Connect ⇒ Fig. ““Con‐
nect coolant hose with
quick coupling”“ , page
215
3 - Retaining clip
4 - O-ring
sembly
perature sender at radi‐
ator outlet G83 ”, page
198
6 - O-ring
sembly
❑ Moisten with coolant
7 - Coolant hose
❑ to remove, raise the
holding clamps
❑ Connect ⇒ Fig. ““Con‐

nect coolant hose with quick coupling”“ , page 215

8 - O-ring
9 - Coolant hose
❑ to remove, raise the holding clamps
❑ Connect ⇒ Fig. ““Connect coolant hose with quick coupling”“ , page 215
10 - Top radiator bearing
❑ If the fuse latches break, you will not need to replace the top radiator bearing. The fuse is replaced by a
special screw ⇒ Electronic Catalogue of Original Parts“ETKA” .
❑ Screw tightening torque for top radiator bearing, 5 Nm.
11 - Charge air cooling circuit radiator
12 - Condenser
❑ installing and removing ⇒ Heating, Air Conditioning; Rep. gr. 87 ; Refrigerant circuit; installing and
removing condenser .
13 - Bottom radiator bearing
14 - O-ring
❑ No spare part; is part of Pos. -15-
15 - Coolant hose
❑ to remove, raise the holding clamps
❑ Connect ⇒ Fig. ““Connect coolant hose with quick coupling”“ , page 215
16 - O-ring
❑ No spare part; is part of Pos. -9-
Connect coolant hose with quick coupling
Note
Before removing the old O-ring -2-, check that the new part is
available ⇒ Electronic Catalogue of Original Parts “ETKA” .
If the O-ring -2- is available

– Remove old O-ring -2- from the coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
Continued
– Press coolant hose onto connection -1- until there is an audible
click.
– Press coolant hose down again and check by pulling that the
quick coupling is fully engaged.
4.2 Summary of components - fan shroud

and radiator fan Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “4.2.1 Summary of components - fan shroud with a fan”,
page 216
4. Coolers, radiator, radiator fan 215

⇒ “4.2.2 Summary of components - fan shroud with two fans”,

page 216
4.2.1 Summary of components - fan shroud with a fan
1 - Screw
❑ 5 Nm
2 - Fan shroud
stalling fan shroud”,
page 224
3 - Radiator fan - V7-
installing radiator fan V7
”, page 225
4.2.2 Summary of components - fan shroud with two fans

1 - Screw
❑ 5 Nm
2 - Fan shroud
stalling fan shroud”,
page 224
3 - Screw
❑ 5 Nm
4 - Radiator fan - V7-
installing radiator fan V7
”, page 225
5 - Radiator fan 2 - V177-
installing radiator fan 2
V177 ”, page 226
4.3 Removing and installing radiator with

charge air cooler
⇒ “4.3.1 Removing and installing the radiator, Superb III, Kodiaq”,
page 217
⇒ “4.3.2 Removing and installing charge air cooling circuit radia‐
tor, Superb III, Kodiaq”, page 219
⇒ “4.3.3 Removing and installing radiator with charge air cooling
circuit radiator,
with respect Karoq”,of page
to the correctness 221
information in this document. Copyright by ŠKODA AUTO A. S.
4.3.1 Removing and installing the radiator,

Superb III, Kodiaq
Note
The radiator for coolant and radiator for charge air cooling circuit
can be removed together if required ⇒ “4.3.2 Removing and in‐
stalling charge air cooling circuit radiator, Superb III, Kodiaq”,
page 219 .
Removing


– Drain coolant from the radiator ⇒ “1.3 Draining and filling
coolant”, page 183 .
from radiator.

– Press the locking latches for radiator left and right -arrow-, in
the engine compartment at the same time.
– Swivel out coolant radiator towards engine compartment par‐
tially from mounting in radiator for charge air cooling circuit.
– Push radiator for coolant out of the seats below.
– Remove the radiator for the coolant downwards out of the ve‐
hicle.
Installing
Note
Do not replace the cooler when there is light pressure on the fins
⇒ “3.5 Assembly of radiators and condensers”, page 8 .
– Replace O-rings.
– Install fan shroud ⇒ “4.4 Removing and installing fan shroud”,
page 224 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Connect coolant hoses with
with respect quick
to the coupling
correctness ⇒ Fig.
of information ““Connect
coolant hose with quick coupling”“ , page 215 .
183 .

4.3.2 Removing and installing charge air cool‐

ing circuit radiator, Superb III, Kodiaq
Removing
– Remove the front bumper ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; removing and installing bumper .
– Drain coolant from the radiator ⇒ “1.3 Draining and filling
coolant”, page 183 .
from radiator.
For Superb III vehicles

– Unlock expanding rivets -2- on top air guide pipe -3-.
– Unlock catches -4- for air guide -arrows-.
– Press top air guide -3- and bottom air guide -5- off lock carrier.
For Kodiaq vehicles
– Remove the guide profile from the bumper bracket ⇒ General
body repairs, exterior; Rep. gr. 63 ; Front bumper; Summary
of components - bumper .
– Remove top and bottom air guides.
CAUTION


– Press locking tabs -1- on both sides in direction of arrow -A-

and release.
– Pull condenser -3- upwards in direction of arrow -B- and un‐
hook from the radiator -2-.
– Strap condenser to the lock support.
– Press or pinch off the locking latches for the top radiator
mounting -arrows- at the same time, e.g. with screwdrivers,
and unclip the mounting on both sides.
– Press coolant radiator with charge air cooling circuit radiator
towards the engine compartment.
Note
If the fuse latches break or pinched off, you will not need to replace
the top radiator bearing -1-. The fuse is replaced by a special
screw -3- ⇒ Electronic Catalogue of Original Parts ETKA .
– Remove the coolant radiator downwards from the vehicle to‐

gether with the charge air circuit radiator.

– Press left and right radiator locking lugs simultaneously

-arrow- and remove coolant radiator from the charge air cool‐
ing circuit radiator.
Installing
Note
Screw the radiator bearing with screws -arrows- to the lock carrier
after the locking tabs have been pinched off ⇒ ETKA - Electronic
Catalogue of Original Parts .
page 224 .
– Connect coolant hoses with quick coupling ⇒ Fig. ““Connect
– Install front bumper ⇒ General body repairs, exterior ; Rep.
gr. 63 ; Front bumper; Removing and installing bumper .
183 .
Note

♦ Screw for top radiator bearing ⇒ “4.1 Assembly overview - ra‐

diator/radiator fan”, page 214 .
4.3.3 Removing and installing radiator with

charge air cooling circuit radiator, Karoq
Note
The coolant radiator and charge air cooling circuit radiator are
removed
Protected together.
Removing


– Remove the front bumper ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; removing and installing bumper .
from radiator.
– Press or pinch off the locking latches for the top radiator
mounting
Protected-arrows-
by copyright.at the same
Copying time,
for private e.g. with
or commercial screwdrivers,
and unless
unclip the mounting
authorised on both
by ŠKODA AUTO sides.
– Partially tilt cooler into the engine compartment.
Note
If the fuse latches break or pinched off, you will not need to replace
the top radiator bearing -1-. The fuse is replaced by a special
screw -3- ⇒ Electronic Catalogue of Original Parts ETKA .
CAUTION


– Unlock the left and right catches from the radiator -1- arrow
-A- and Unhook the capacitor -2- from the radiator.
– Strap condenser to the lock support.

– Lever out the charge air cooling circuit radiator -1- from the
radiator mountings -arrows-.
– Remove both radiators from the vehicle.
– Press left and right radiator locking lugs simultaneously

-arrow- and remove coolant radiator from the charge air cool‐
ing circuit radiator.
Installing
Note
⇒ “3.5 Assembly of radiators and
Protected by condensers”,
copyright. page
Copying for private 8.

Make sure that the radiator mounting is seated correctly -arrow-.
Note
If the fuse latches break, you will not need to replace the top ra‐
diator bearing -1- . The fuse is replaced by a special screw -3- ⇒
Electronic Catalogue of Original Parts ETKA .
– Install front bumper ⇒ General body repairs, exterior ; Rep.

gr. 63 ; Front bumper; Removing and installing bumper .
page 224 .
– Connect coolant hoses with quick coupling ⇒ Fig. ““Connect
183 .
Note

♦ Screw for top radiator bearing ⇒ “4.1 Assembly overview - ra‐

diator/radiator fan”, page 214 .
4.4 Removing and installing fan shroud

Removing
WARNING
There is risk of injury from radiator fans starting up automati‐
cally.
♦ Before carrying out work in the fan shroud area, remove the
fan plug.
– Unscrew screws -3-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Release catch - 2 -.
– Slide the cover -1- forwards and out of the brackets -arrows-.
– Remove cover -1-.

– Slacken the coolant hose -2- and lay aside.

– Remove air deflector -1-.

– Unlock catches and remove air guide -1-.
– Remove air deflector -1-.
noise insulation .
– Disconnect connector -1- for radiator fan. To do this, detach

screw clamp backwards in direction of arrow -A- and press
release tab.
– Press locking lugs for fan shroud left and right simultaneously
arrow -B- and remove fan shroud upwards from the radiator.
Note
Do not
Protected replace
by copyright. the for
Copying cooler
private when there
or commercial is light
purposes, pressure
in part or in whole,on the
is not fins
permitted
Installing
Electrical connections and proper routing ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
♦ Air guide ⇒ “3.1 Assembly overview - air filter housing”,
page 273 .
4.5 Removing and installing radiator fan -

V7-
Removing


– Unscrew screws -arrow- and remove radiator fan - V7- .
Installing
page 224 .
♦ Fan screw ⇒ “4.2 Summary of components - fan shroud and
radiator fan”, page 215 .
4.6 Removing and installing radiator fan 2 -

V177-
WARNING
There is risk of injury from radiator fans starting up automati‐
cally.
– Before carrying out work in the fan shroud area, disconnect

the electrical plug connections of the fan.
Removing
– Disconnect plug connection -arrow-.
– Remove screws -2- and radiator fan 2 - V177- .
Installing
page 224 .
♦ Fan screw ⇒ “4.2.2
with respect Summary
to the correctness of components
of information - fan
in this document. shroud
Copyright with AUTO A. S.
by ŠKODA
two fans”, page 216 .

21 – Turbocharging/supercharging
1 Exhaust gas turbocharger
⇒ “1.1 Summary of components - exhaust gas turbocharger”,
page 227
⇒ “1.2 Removing and installing exhaust gas turbocharger”, page
231
⇒ “1.4 Removing and installing element for load pressure control
GX34 ”, page 235
⇒ “1.3 Removing and installing the exhaust gas turbocharger
connection fitting”, page 234
1.1 Summary of components - exhaust gas

turbocharger
⇒ “1.1.1 Summary of components - exhaust gas turbocharger”,
page 227
⇒ “1.1.2 Assembly overview - Piping on the exhaust gas tur‐
1.1.1 Summary of components - exhaust gas

turbocharger
Note

1. Exhaust gas turbocharger 227


2 - Sealing ring
sembly
⇒ page 234
3 - Screw clamp
sembly
tightening order ⇒
“2.1 Summary of com‐
ponents - exhaust gas
cleaning”, page 321
4 - Nut
sembly
❑ 14 Nm
5 - Release handle
6 - Locking clip
sembly
7 - Module for charge pressure
regulation - GX34-
❑ consists of:
♦ Charge pressure regulator -
V465-
♦ Position transmitter for
charge pressure regulator - G581-
❑ Removing and installing ⇒ “1.4 Removing and installing element for load pressure control GX34 ”, page
235
8 - Screw
❑ 8 Nm + 45°
❑ Corrected tightening torque for the use of the insertion tool - T10572- and the torque wrench - V.A.G
1783- 4.2 Nm + 45° Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
9 - O-ring with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

10 - Screw
❑ 9 Nm
11 - Supports
❑ Removing and installing ⇒ “1.3 Removing and installing the exhaust gas turbocharger connection fitting”,
page 234
12 - Screw
❑ Pin screw
❑ screwed on in the cylinder head
❑ 16 Nm
228 Rep. gr.21 - Turbocharging/supercharging

13 - Gasket
14 - O-ring
15 - Heat shield
❑ Removing and installing ⇒ page 232
16 - Screw
❑ 25 Nm
17 - Screw
❑ 8 Nm
1.1.2 Assembly overview - Piping on the ex‐

haust gas turbocharger
Note



2 - O-ring
❑ Replace crankcase ven‐
tilation hose Pos. -3- if it
is damaged or leaking
3 - Hose
❑ for crankcase ventila‐
tion
4 - Screw
❑ 5 Nm
5 - Screw
❑ 9 Nm
6 - Oil feed line
7 - O-ring
❑ Replace after disas‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
sembly unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
8 - Screw
❑ 9 Nm
9 - O-ring
sembly
10 - Oil return-flow line
11 - Screw
❑ 9 Nm
12 - Screw
sembly
❑ 9 Nm
13 - O-ring
14 - O-ring
15 - Coolant line
❑ Feed line and return-flow line
16 - Screw
❑ 8 Nm
17 - Screw
❑ 8 Nm
18 - Gasket
19 - Screw
❑ 8 Nm

1.2 Removing and installing exhaust gas

turbocharger
♦ Screw plug set for engine , e.g. -VAS 6122-
Removing
Note
Close any open connections in the airway and in the outlet path
with plugs from closing plug set for engine - VAS 6122- .
Observe rules for cleanliness ⇒ “3.1 Rules of cleanliness”,

page 7 .
In case a mechanical damage to the exhaust gas turbocharger is
found, (e.g. damage to the compressor wheel), it is not sufficient
to only replace the turbocharger. In order to avoid consequential
damage, the following tasks must be performed:
♦ Inspect the air filter housing, the air filter element and air guide
hoses for contamination.
♦ Inspect the whole charge-air routing and charge air cooler for
foreign bodies.
♦ If foreign bodies are found in the charge air system, clean the
charge air duct and replace the charge air cooler if necessary.
– Remove Protected
the airbyguide pipe
copyright. between
Copying for privatethe chargepurposes,
or commercial air cooler
in partand
or in whole, is not permitted
the exhaust
unlessturbocharger
authorised by ŠKODA ⇒ “2.4.1
AUTO A. Removing
S. ŠKODA AUTO and
A. S.installing the or accept any liability
does not guarantee

– Remove module for charge pressure regulation - GX34- ⇒
“1.4 Removing and installing element for load pressure con‐
trol GX34 ”, page 235 .
– Unscrew screw -a- and remove the hose -1- from the exhaust
gas turbocharger -2-.

– Remove the heat shield on top of the exhaust gas turbocharg‐

er and catalyst -5-.
– Also unscrew the screws -d- and -e- and remove baffle -5-.
Note
Right screw (seen in direction of travel) -d- is not installed in all

vehicles.
– Place drip tray underneath, e.g., B. -VAS 6208- for collecting

liquids.

– Unscrew fastening bolts for coolant pipes -b- and -c-.

– Pinch off coolant hoses on coolant pipe with hose clamps up
to 25 mm - MP7-602 (3094)- .
– Loosen hose clamps -arrows- and remove coolant hoses.
– Assignment of installation for screw clamp -2- between ex‐

haust gas turbocharger and catalytic converter ⇒ “2.2 Remov‐
ing and installing catalytic converter”, page 328 .
– Loosen and remove screw clamp -2-.
– Loosen the nuts -arrows-.
– Release the remaining screw connections for the catalytic
converter with the bracket and the engine ⇒ “2.1 Summary of
components - exhaust gas cleaning”, page 321 .
– Strap the catalytic converter to the bodyshell so as not to dam‐
age the wire mesh of the decoupling element.
– Place a cloth under the oil line to collect oil.

– Unscrew bolts -f-.

– Remove oil feed line -3-.
– Unscrew nuts -arrows- and remove exhaust gas turbocharger.

– Remove seal -6- using removal tool - T10498- -A-.

– Remove seal -7- using removal tool - T10498- -A-.
– Replace gaskets, gasket rings, fixing nuts and O-rings.
– Before installing, moisten O-rings with clean engine oil.
– Fit the exhaust gas turbocharger and screw in the nuts.
– Place the oil return line on the engine and on the exhaust gas
turbocharger.
– Compensate oil return line and tighten screws hand-tight.
– Fill exhaust turbocharger with engine oil through the connec‐
tion fitting of the oil feed line.
– Place the oil supply line on the engine and on the exhaust gas
turbocharger.
– Compensate oil feed line and tighten screws hand-tight.
– Tighten nuts and screws.

– Push screwdriver -2- into the recess -arrow- of the exhaust gas
turbocharger and lever out the sealing ring -1-.
– Replace screw clamp between exhaust gas turbocharger and cat‐
alytic converter item -9- ⇒ “2.1 Summary of components - exhaust
gas cleaning”, page 321 .
– Install the screw clamp between the exhaust gas turbocharger and
the catalytic converter in the previously indicated installation posi‐
tion ⇒ Fig. ““Installing catalytic converter - tightening torque and
tightening order”“ , page 324 .
Install all heat protection sleeves back in the same position.
Secure all hose connections with hose clamps which comply with the
series design ⇒ ETKA - Electronic Catalogue of Original Parts . Se‐
cure all hose connections with hose clamps which comply with the
series design ⇒ ETKA - Electronic Catalogue of Original Parts .
– Check coolant level ⇒ “1.3 Draining and filling coolant”, page
183 .
To ensure the oil supply to the exhaust gas turbocharger, leave the
engine running for about 1 minute after installing the exhaust gas tur‐
bocharger; do not rev up immediately.
– Electrical connections and proper routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
If a new exhaust gas turbocharger with built-in pressure regulator has
been installed:
– Adapting the engine control unit - J623- to the charge pressure
regulator - V465- ⇒ Vehicle diagnostic tester.
♦ 0001 - Adaptation of charge pressure regulator - V465
Note
Replace bolts / nuts that are tightened at an angle of rotation, as well

as replacement components after removal.
♦ Exhaust gas turbocharger ⇒ “1.1 Summary of components - ex‐

haust gas turbocharger”, page 227 .
♦ Exhaust pipe with catalytic converter ⇒ “2.1 Summary of compo‐
nents - exhaust gas cleaning”, page 321 .
♦ Cardan shaft guard ⇒ Chassis, axles, steering ; Rep. gr. 40 ; Car‐
dan shaft; Removing and installing cardan shaft.
1.3 Removing and installing the exhaust

gas turbocharger connection fitting
Removing
– Remove air filter housing: ⇒ “3.2 Removing and installing air
filter housing”, page 274

– If present, remove the vent line -2- and -3- from the connection
nozzle -1- by pressing the release buttons on both sides.
– Unscrew screws (non-detachable) -arrows- and remove con‐

nection fittings -1-.
Installing
Secure all hose connections with hose clamps which comply with
the series design ⇒ ETKA - Electronic Catalogue of Original
Parts . Secure all hose connections with hose clamps which com‐
ply with the series design ⇒ ETKA - Electronic Catalogue of
Original Parts .
– Renew O-ring.
Note
Before installing, moisten O-rings with clean engine oil.
Fitting position
– Place connection fitting -1- on exhaust gas turbocharger -2-.
• The bolt on the connecting piece must engage in the opening
-a- on the exhaust gas turbocharger.
– Tighten the screws -arrows- of the connection fitting-1-.


♦ Connection fitting of the exhaust gas turbocharger ⇒

“1.1 Summary of components - exhaust gas turbocharger”,
page 227 .
1.4 Removing and installing element for

load pressure control - GX34-

The Module for charge pressure regulation - GX34- consists of:

♦ Charge pressure regulator - V465-
♦ Position transmitter for charge pressure regulator - G581-
Removing
noise insulation .
– Disconnect plug connection -2- on charge pressure regulator -

V465- .
– Disconnect locking clips -3- and remove actuating lever -4-.
– Remove Module for charge pressure regulation - GX34- -1-.
Installation is carried out in the reverse order. When installing, observe
the following:
– Replace locating screw s and locking clips.
– Adapting the engine control unit - J623- to the charge pressure
regulator - V465- ⇒ Vehicle diagnostic tester.
♦ 0001 - Adaptation of charge pressure regulator - V465
Note

♦ Module for charge pressure regulation - GX34- ⇒ “1.1.1 Summary

of components - exhaust gas turbocharger”, page 227 .
♦ Right cardan shaft guard ⇒ Chassis, axles, steering; Rep. gr. 40 ;
Cardan shaft; Removing and installing cardan shaft .

2 Charge-air system
⇒ “2.1 Summary of components - charge air system”, page
237
⇒ “2.2 Removing and installing charge air cooler”, page 240
⇒ “2.3 Removing and installing charge pressure sender GX26 ”,
page 241
⇒ “2.4 Installing and removing the air guide pipe”, page 242
⇒ “2.5 Checking the charge-air system for leak-tightness”,
page 247
⇒ “2.6 Leak testing the charge air cooler”, page 250
2.1 Summary of components - charge air

system
Note

Before a test or repair,
unless check
authorised all charge
by ŠKODA AUTO A.air pipes,AUTO
S. ŠKODA charge air not
A. S. does hoses
and vacuum lines for tight
with respect to theconnection and leak
correctness of information tightness.
Observe rules for cleanliness ⇒ “3.1 Rules of cleanliness”,

page 7 .
2. Charge-air system 237

1 - Sealing ring
❑ Check for damage and
replace if necessary
❑ moisten with engine oil
2 - Vent line
3 - Vent line
4 - Supports
stalling the exhaust gas
turbocharger connec‐
tion fitting”, page 234
5 - Air guide pipe between the
charge air cooler and the ex‐
haust gas turbocharger.
installing the air guide
pipe between the
charge air cooler and
the exhaust gas tur‐
6 - Mounting bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Replace after disas‐ with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
sembly
7 - Sealing ring
8 - Screw
❑ 7 Nm
9 - Screw
❑ to coolant pipe
❑ 7 Nm
10 - Charge air cooler
❑ Mounting position charge pressure sender - GX26- ⇒ Fig. ““Mounting overview - charge pressure sender
-GX26- ”“ , page 240
❑ Removing and installing ⇒ “2.2 Removing and installing charge air cooler”, page 240
11 - Sealing ring
12 - Throttle valve control unit - GX3-
❑ comprises:
Throttle valve control unit - J338-
Throttle valve drive for electronic power control - G186-

Throttle valve drive angle sensor 1 for electric power control - G187-
Throttle valve drive angle sensor 2 for electric power control - G188-
❑ Removing and installing ⇒ “4.3 Removing and installing the throttle valve control unit GX3 ”, page
281
❑ clean ⇒ “4.4 Cleaning throttle valve control unit GX3 ”, page 282
13 - Screw
❑ 7 Nm
14 - Screw
❑ 3 Nm
15 - Charge pressure transmitter - GX26-
❑ Summary of components ⇒ Fig. ““Mounting overview - charge pressure sender -GX26- ”“ , page 240
❑ Removing and installing ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 241
16 - Sealing ring
17 - Intake manifold
❑ Summary of components ⇒ “4.1 Assembly overview - intake manifold”, page 276
❑ Removing and installing ⇒ “4.2 Removing and installing intake manifold”, page 278
18 - Sealing ring
19 - Air guide pipe between the charge air cooler and the suction pipe.
❑ Removing and installing ⇒ “2.4.2 Removing and installing the air guide pipe between the charge air cooler
and the suction pipe”, page 245
20 - Sealing ring
21 - Intake manifold pressure sender - GX9-
❑ comprises:
♦ Intake manifold temperature encoder - G72-
♦ Intake manifold pressure sender - G71-
❑ Removing and installing ⇒ “5.3 Removing and installing intake manifold pressure sender GX9 ”, page
287
❑ Summary of components ⇒ Fig. ““Assembly overview - Plug for intake manifold sender -GX9- ”“ ,
page 278
22 - Screw
❑ 3unless
Nm authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

Mounting overview - charge pressure sender - GX26-

1 - Charge pressure sender - GX26- ⇒ “2.3 Removing and in‐
stalling charge pressure sender GX26 ”, page 241
2 - Screw, 3 Nm
3 - Check O-ring for damage, no spare part, replace if necessary
with charge pressure sender - GX26-
2.2 Removing and installing charge air cool‐

er
Removing
Rep. gr. 66 ; Noise insulation; Summary of components
unless authorised by ŠKODA AUTO - A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
noise insulation . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Remove electrical coolant pump ⇒ “2.4 Removing and in‐
stalling electric coolant pump”, page 190 .
– Open clamp -5- and remove coolant hose -3-.
– Open clip -4- and pull coolant hose -3- off charge air cooler
-2-.
– Removing the intake manifold -1- ⇒ “4.2 Removing and in‐
stalling intake manifold”, page 278 .
– Release clamps for coolant hoses -arrows- at charge air cool‐

er.
– Detach coolant hose -2- from the charge air cooler -1-.

– Remove plug -a- also pull out-arrow- slightly.
– Release electrical wiring harness -1- from the charge air cooler
-2- -arrow-.
– Secure charge air cooler -2- upon loosening the fastening

screw -b- to prevent it from falling down.
– Unscrew fixing screw -b- for coolant pipe -1- from the charge
air cooler -2-.
Installing
– Replace sealing rings.
– Install electric coolant pump ⇒ “2.4 Removing and
Protected installing
electric coolant pump”, page 190 , unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
183 .
noise insulation .
Note


2.3 Removing and installing charge pres‐

sure sender - GX26-

The charge pressure sender - GX26- consists:

♦ Charge pressure sender - G31-
♦ Intake air temperature sender - G42-
Removing
– Remove the throttle valve control unit - GX3- ⇒ “4.3 Removing
and installing the throttle valve control unit GX3 ”, page
281 .
– Remove plug -a- also pull out-arrow- slightly.
– Unscrew mounting screws -b-.

– Remove Boost pressure sensor - GX26- -1-.
Installing
Note
♦ O-ring no spare part, replace if necessary with charge pres‐

sure sender - GX26- .
♦ Before positioning, moisten O-ring lightly with oil.
Specified torque
♦ Charge pressure sender - GX26- ⇒ “2.1 Summary of compo‐
nents - charge air system”, page 237 .
2.4 Installing and removing the air guide

pipe
⇒ “2.4.1 Removing and installing the air guide pipe between the
charge air cooler and the exhaust gas turbocharger”, page
242
⇒ “2.4.2 Removing and installing the air guide pipe between the
charge air cooler and the suction pipe”, page 245
2.4.1 Removing and installing the air guide

pipe between the charge air cooler and
the exhaust gas turbocharger
Removing

– Unclip the vacuum line -1- from the receptacle -arrow- on the
air guide pipe -2-.
– Remove vacuum line -1- from the intake manifold, and press
the lock in -arrow-.
– Lay vacuum line to the side.
– If present, remove the vent line -2-
withfrom
respectthe
to theair guide ofpipe
correctness information in this document. Copyright by ŠKODA AUTO A. S.
-1- by pressing the release buttons on both sides.
– Turn lock ring -1- for air guide pipe-2- in -direction of arrow-.

– Unlock mounting bracket -a- at the ends of the two sides -2-
in direction of -arrow-.
– Remove mounting bracket -a- in -direction of arrow-.

– Unhook mounting bracket -a- from the lock -2-.
– Unclip fuel line -A- from air guide pipe-2-.

– Detach the air guide pipe from the charge air cooler.
– Detach the air guide pipe from the exhaust turbocharger.
Installing
– Replace sealing rings.
Note
Before installing, moisten O-rings with engine oil.
Comply with correct setting for O-rings.

– Replace mounting bracket -a- before installation.

– Press the air guide pipe up to the stop on the exhaust gas
turbocharger.
– Press the air guide pipe up to the stop on the charge air cooler.
– Insert the mounting bracket into the grooves for the air guide
pipe.
• The lugs on the mounting bracket -a- must be inserted in the
recesses behind -b- for the air guide pipe-2-.
– Press down air guide pipe -2- In the direction of the arrow -a-
to the turbocharger -3-.
– Rotate lock ring -1- to stop in the direction of the arrow -b-.
2.4.2 Removing and installing the air guide

pipe between the charge air cooler and
the Protected
suction pipe
Removing with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
pump .
– Place vacuum pump for brakes - V192- to the side with con‐
nected cables.
– Pull out tube -b- from the holder -2-.

– Release catches -a- and remove plug -1-.
Note
Intake manifold sender - GX9- -2- does not need to be removed
– Remove the mounting screws -c- for the intake air pipe -3- and
throttle valve control unit - GX3- .
– Unscrew screws -d- from the coolant pipe -5-.

– Release coolant pipe -5- in the points -arrows- from the intake
manifold -4-.
– If present, remove the vent line -2- from the air guide line by
pressing the release buttons on both sides.

– Lift out mounting bracket -b- in the area -arrow- and pull out of
the recesses on the air guide pipe -2-.
– Remove the air guide pipe -2- from the throttle valve control
unit - GX3- and the intake manifold -4- in
-the direction of the arrow-.
Installing
– Replace O-rings and lightly moisten them with engine oil be‐
fore assembly.
Comply with correct setting for O-rings.
Always replace holding bracket -b- before removal.
– Insert the mounting bracket -b- into the grooves -2- for the air
guide pipe.
– Tighten locating screws.
Note

♦ Air guide pipe ⇒ “4.1 Assembly overview - intake manifold”,

page 276 .
♦ Vacuum pump for brake - V192- ⇒ braking systems; Rep. gr.
pump .
2.5 Checking the charge-air system for

leak-tightness
♦ Tester for charge air systems - V.A.G 1687-

– Unlock the locks -e- and remove the vacuum line.
– To do so, press the locks in the -direction of arrow-.

– Close open connections of intake manifold using suitable
plugs from the screw plug set for engine - VAS 6122- .

both sides.
– Close open connections of vent line using suitable plugs from
the screw plug set for engine - VAS 6122- .
– Remove hose clamps -arrows- at the connection piece -1- and

the air filter housing -2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Remove air guide hose -3-. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Vehicles with pressure sensor for purging air from the activated
both sides.
– Use a suitable plug to seal the open channels on the inlet con‐
nection and exhaust gas turbocharger from the screw plug set
for engine - VAS 6122- -A-.

– Connect the adapter - V.A.G 1687/15- -A- with -V.A.G
1687/11- -B- at the exhaust gas turbocharger -1-.
– Check whether the open connections -arrows- are closed with
suitable plugs from the Closing plug set for engine - VAS
6122- .
2 - Crankcase vent line
3 - Intake manifold
– Connect hose -C- of charge air system tester -V.A.G 1687- to
adapter.
Prepare tester for charge air system - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- fully and close the
valves -3- and -4-.
• The rotary switch must be pulled to the top in order to rotate
the pressure control valve -2-.
– Connect tester for charge air systems - V.A.G 1687- to com‐
pressed air using a commercially available intermediate piece
-1-.
If there is water in the inspection glass, drain water via the drain
plug -6-.
– Open valve -3-.
NOTICE
Risk of damage owing to pressure being set too high.
• The pressure must not be greater than 0.05 MPa (0.5 bar)!
– Set the pressure to 0,05 MPa (0,5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 0.05 MPa (0.5 bar).
– Checking the charge-air system for leaktightness:
♦ by listening,

♦ by hand
♦ with commercially available leak search spray
♦ with the ultrasonic tester - V.A.G 1842-
Note
♦ A small amount of air escapes via the valves into the engine.
For this reason no holding pressure test is possible.
♦ Use of ultrasonic measuring device -V.A.G 1842- ⇒ Owner's
Manual .
♦ Before removing the adapter, depressurize the test circuit by
detaching the hose coupling.
Installing
– Replace gaskets and O-rings.
2.6 Leak testing the charge air cooler

♦ Tester for charge air systems - V.A.G 1687-
♦ Screw plug set for engine - VAS 6122-
♦ Y - distributor part - VAS 691 005/1-
♦ Test adapter - VAS 691 005/5-
♦ Turbocharger tester - V.A.G 1397A- or -V.A.G 1397B-
Test condition
• The coolant temperature must be at least 40 °C.
Connect turbocharger tester - V.A.G 1397A-
– Screw the test adapter - VAS 691 005/5- onto the coolant ex‐
pansion tank.
– Mount the Y distributor - VAS 691 005/1- onto the test adapter
- VAS 691 005/5- .
– Connect valve -1- of connection »C« and open valve -2- of
connection »A«.
– Connect connection hose »A« Y distributor to connection »II«
of turbocharger tester - V.A.G 1397A- or -V.A.G 1397B- .
– Put turbocharger tester - V.A.G 1397A- or -V.A.G 1397B- in
switch position »II« (measuring relative pressure) and switch
on.
• The »II« must be visible.
Connect tester for charge air systems - V.A.G 1687-


– Close open connections of intake manifold using suitable
plugs from the screw plug set for engine - VAS 6122- .

both sides.
– Close open connections of vent line using suitable plugs from
the screw plug set for engine - VAS 6122- .
– Remove hose clamps -arrows- at the connection piece -1- and

the air filter housing -2-.
– Remove air guide hose -3-.

– Connect the adapter - V.A.G 1687/15- -A- with -V.A.G

1687/11- -B- at the exhaust gas turbocharger -1-.
– Check whether the open connections -arrows- are closed with
suitable plugs from the Closing plug set for engine - VAS 6122-
-D-.
2 - Vent line for crankcase ventilation
3 - Intake manifold
– Connect hose -C- of charge air system tester -V.A.G 1687- to
adapter.
Prepare tester for charge air system - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- fully and close the
valves -3- and -4-.
• The rotary switch must be pulled to the top in order to rotate
the pressure control valve -2-.
– Connect tester for charge air systems - V.A.G 1687- to com‐
pressed air using a commercially available intermediate piece
-1-.
If there is water in the inspection glass, drain water via the drain
plug -6-.
– Open valve -3-.
NOTICE
Risk of damage owing to pressure being set too high.
• The pressure must not be greater than 0.05 MPa (0.5 bar)!
– Set the pressure to 0,05 MPa (0,5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 0.05 MPa (0.5 bar).
Note
Aunless
small amount
authorised of airAUTO
by ŠKODA escapes via the
A. S. ŠKODA AUTOvalves into
A. S. does the engine
not guarantee and
or accept any liability
the with
exhaust
respect togas system.ofFor
the correctness this reason
information no pressure
in this document. Copyright by test
ŠKODA isAUTO
pos‐A. S.
sible.

Read out from Turbocharger tester - V.A.G 1397A- or -V.A.G

1397B-
– Monitor the turbocharger tester for 5 minutes.
• The pressure displayed on the turbocharger tester must not
exceed 0.025 bar!
If the pressure shown on the turbocharger tester increases con‐
tinuously above 0.025 bar, compressed air is escaping from the
exhaust gas side into the cooling system. The charge air cooler
is not leak-tight and must be replaced.
Note
♦ As a result the subsequent heating of the coolant (reheating

effect), there may be a slight increase in pressure of 0.025 bar.
This slight increase in pressure does not indicate leaking!
♦ There may be a slight vacuum as a result of cooling of the
coolant. A vacuum is indicated on the turbocharger tester by
a »minus« symbol. The »minus« values do not indicate a leak!
♦ If you are uncertain, repeat the test. To do so, briefly open the
shut-off cock -1- and equalise the pressure in the cooling sys‐
tem. If the charge air cooler is not leak-tight, the pressure will
continue to increase with each test.
Clean Y distributor - VAS 691 005/1-
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
After completing the leakage test, the Y distributor - VAS 691
005/1- must be cleaned when necessary to remove any moisture
that has got in.
– Insert washer jet -D- into the hose connection -A- of the Y dis‐
tributor .
– Position test adapter - VAS 691 005/5- on the hose connection
-B-.
– Fit compressed air hose to connection -C-.
– Open the shut-off tap and blow air through the hose for approx.
15 seconds.

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Installation location overview - fuel injection system”, page
254
1.1 Installation location overview - fuel in‐

jection system
⇒ “1.1.1 Installtion location overview - Engine compartment, en‐
gine code DADA”, page 254
⇒ “1.1.2 Installation location overview - Engine compartment, en‐
gine code DPCA”, page 256
⇒ “1.1.3 Installation location overview - engine from top”, page
258
⇒ “1.1.4 Installation overview - engine from front”, page 260
⇒ “1.1.5 Installation overview - engine from rear”, page 262
1.1.1 Installtion location overview - Engine compartment, engine code DADA

Fitting location overview - Engine compartment, vehicles without
Pressure sensor for purging air from the activated carbon filter -
GX44-
254 Rep. gr.24 - Mixture preparation - injection

1 - Lambda probe 1 in front of

the catalytic converter - GX10-
❑ comprises:
♦ Lambda probe - G39-
♦ Lambda probe heater -
Z19-
of components - lambda
probe”, page 297
stalling Lambda probe”,
page 297
2 - Connector
❑ for Lambda probe 1 be‐
fore catalyst - GX10-
and Lambda probe 1 af‐
ter catalyst - GX7-
❑ Overview of the fitting
positions ⇒ Fig. ““Con‐
tactbyassignment
Protected copyright. Copyingatforbulk‐
private or commercial purposes, in part or in whole, is not permitted
unlesshead plenum
authorised by ŠKODA cham‐
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ber”“ , page 256
3 - Plug holder
4 - Ignition coils with a power
output stage
♦ Ignition coil 1 with power
output stage - N70-
output stage - N127-
output stage - N291-
♦ Ignition coil 4 with power output stage - N292-
❑ Removing and installing ⇒ “1.2 Removing and installing ignition coils with output stage”, page 336
❑ When installing new spark plugs, grease the ignition coils with power output stage with lubricating paste
G 052 565 A1.
5 - Position sensor for intake camshaft - G1002-
❑ Summary of components ⇒ “1.2 Summary of components - camshaft housing”, page 81
page 338
6 - Module for air mass measurement - GX35-
❑ not fitted to all engines
❑ comprises:
♦ Air mass meter - G70-
♦ Temperature sensor - G1005-
❑ Summary of components ⇒ “3.1 Assembly overview - air filter housing”, page 273
❑ Removing and installing ⇒ “5.5 Removing and installing valve for air mass meter GX35 ”, page 289
7 - Coolant temperature sender at radiator outlet - G83-
❑ Summary of components ⇒ “2.3 Summary of components - coolant temperature transmitter”, page 189
1. Injection system 255

❑ Removing and installing ⇒ “2.8 Removing and installing coolant temperature sender at radiator outlet
G83 ”, page 198
8 - activated charcoal filter solenoid valve 1 - N80-
❑ comprises:
♦ Charge pressure sender - G31-
♦ Intake air temperature sender - G42-
❑ comprises:
♦ Throttle valve control unit - J338-
♦ Throttle valve drive for electronic power control - G186-
♦ Throttle valve drive angle sensor 1 for electric power control - G187-
281
❑ comprises:
page 278
❑ Removing and installing unless
⇒ “5.3 Removing
authorised by ŠKODAand AUTOinstalling
A. S. ŠKODAintake
AUTO A. manifold pressure
S. does not guarantee sender
or accept GX9 ”, page
any liability
287 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
12 - Vacuum pump for brake - V192-

❑ Summary of components ⇒ Braking systems; Rep. gr. 47 ; Vacuum system; Removing and installing
electric vacuum pump
❑ Summary of components ⇒ “2.2 Summary of components - toothed belt”, page 95
page 145
14 - Engine control unit - J623-
❑ Removing and installing ⇒ “6.1 Removing and installing engine control unit J623 ”, page 290
Contact assignment at bulkhead plenum chamber

1 - Lambda probe 1 in front of the catalytic converter - GX10-
2 - Lambda probe 1 after catalytic converter - GX7-
1.1.2 Installation location overview - Engine compartment, engine code DPCA

Installation location overview - engine compartment, vehicles with

Pressure sensor for purging air from the activated carbon filter -
GX44-
1 - fuel feed line

2 - Vent line
❑ comprises:
Z19-
probe”, page 297
page 297
4 - Connector
❑ for Lambda probe 1 be‐
fore catalyst - GX10-
and Lambda probe 1 af‐
ter catalyst - GX7-
❑ OverviewProtected
of the byfitting
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒with
Fig.
positionsunless ““Con‐
tact assignment at bulk‐
head plenum cham‐
ber”“ , page 258
5 - Engine control unit - J623-
stalling engine control
unit J623 ”, page 290
nents ⇒ “2.3 Summary of components - coolant temperature transmitter”, page 189
❑ Removing and installing ⇒ “2.8 Removing and installing coolant temperature sender at radiator outlet
G83 ”, page 198
7 - Non-return valve
8 - activated charcoal filter solenoid valve 1 - N80-
9 - Pressure sensor for activated charcoal filter air flushing - GX44-
page 338
11 - High pressure pump
❑ with fuel dosage valve - N290-
❑ Summary of components ⇒ “7.1 Summary of components - high pressure pump”, page 293
❑ Removing and installing ⇒ “7.2 Removing and installing the high pressure pump”, page 294
12 - Ignition coil 4 with power output stage - N292-

G 052 565 A1.
G 052 565 A1.
G 052 565 A1.
G 052 565 A1.
16 - Pulsation dampener
❑ Summary of components ⇒ “2.2 Summary of components - toothed belt”, page 95
page 145
❑ comprises:
page 278
287
Contact assignment at bulkhead plenum chamber

1 - Lambda probe 1 in front of the catalytic converter - GX10-
1.1.3 Installation location overview - engine from top


1 - Camshaft adjustment valve

1 in the inlet - N727-
of components - toothed
belt”, page 95
installing camshaft con‐
trol valve 1 in the inlet
N727 ”, page 145
1 in the outlet - N318-
of components -
page 81
installing camshaft con‐
trol valve 1 in the ex‐
haust N318 ”, page 145
3 - Position sensor for exhaust
camshaft - G1003-
of components -
page 81
installing position trans‐
mitter for exhaust
camshaft G1003 ”, page
339
4 - Ignition coil 1 with power
output stage - N70-
❑ Removing and installingunless
⇒with“1.2 Removing
authorised by ŠKODAand AUTOinstalling
A. S. ŠKODA ignition
AUTO A. S.coils with
does not output
guarantee stage”,
or accept page 336
any liability
❑ Removing and installing ⇒ “3.5 Removing and installing cam adjuster”, page 143
8 - Exhaust gas pressure sensor 1 - G450-
❑ Removing and installing ⇒ “5.4 Removing and installing pressure sensor for exhaust gas 1 G450 ”, page
289


❑ with fuel dosage valve - N290-
❑ Summary of components ⇒ “7.1 Summary of components - high pressure pump”, page 293
❑ Removing and installing ⇒ “7.2 Removing and installing the high pressure pump”, page 294
page 338
❑ comprises:
281
❑ comprises:
page 278
287
1.1.4 Installation overview - engine from front


1 - Knock sensor 1 - G61-

nents ⇒ “1.1 Assembly
overview - ignition sys‐
tem”, page 334
installing knock sensor
1 G61 ”, page 338
2 - Oil pressure sender - G10-
of components - oil
pressure switch/oil
pressure control”, page
176
stalling oil pressure
sender G10 ”, page 178
3 - Fuel pressure transmitter -
G247-
of components - fuel dis‐
tributor with injectors”,
page 264
stalling fuel pressure
284
1 in the inlet - N727-
of components - toothed belt”, page 95
page 145
5 - Injection valves
♦ Injection valve for cylinder 1 - N30-
❑ Summary of components ⇒ “2.1 Summary of components - fuel distributor with injectors”, page 264
❑ Removing and installing ⇒ “2.3 Removing and installing injectors”, page 266
page 338
7 - Module
withfor engine
respect temperature
to the correctness control
of information in this-document.
GX33-Copyright by ŠKODA AUTO A. S.
❑ comprises:
♦ Position sensor for engine temperature control - G1004-
♦ Actuator for engine temperature control - N493-
❑ Summary of components ⇒ “2.1 Summary of components - coolant pump/thermostat”, page 187

❑ Removing and installing ⇒ “2.10 Removing and installing element for engine temperature control GX33
”, page 200
8 - Engine speed transmitter - G28-
❑ Removing and installing ⇒ “1.6 Removing and installing the engine speed transmitter G28 ”, page
340
9 - Charge air cooler pump - V188-
❑ Summary of components ⇒ “2.2 Summary of components - electric coolant pump”, page 188
❑ Removing and installing ⇒ “2.4 Removing and installing electric coolant pump”, page 190
1.1.5 Installation overview - engine from rear
1 - Module for charge pressure

regulation - GX34-
Note
Different designs are shown in the

figure.
❑ comprises:
♦ Charge pressure regulator -
V465-
♦ Position transmitter for
charge pressure regulator -
G581-
❑ Summary
with respect of compo‐
haust gas turbocharg‐
er”, page 227
installing element for
load pressure control
GX34 ”, page 235
❑ comprises:
Z19-
probe”, page 297
⇒ page 297
❑ comprises:
♦ Lambda probe downstream of catalytic converter - G130-
♦ Lambda probe heater 1 downstream of catalytic converter - Z29-
❑ Summary of components ⇒ “8.1 Summary of components - lambda probe”, page 297
❑ Removing and installing ⇒ “8.2 Removing and installing Lambda probe”, page 297

4 - Oil pressure control valve - N428-

❑ Summary of components ⇒ “4.1 Summary of components - oil pressure switch/oil pressure control”, page
176
❑ Removing and installing ⇒ “4.4 Removing and installing valve for oil pressure control N428 ”, page
177
5 - Oil level and oil temperature transmitter - G266-
❑ Summary of components ⇒ “1.1 Assembly overview - pan/oil pump”, page 159
❑ Removing and installing ⇒ “1.5 Removing and installing oil level and oil temperature sender G266 ”, page
168
6 - Coolant temperature sensor at engine output - G82-
❑ Removing and installing ⇒ “2.9 Removing and installing coolant temperature sender at engine outlet
G82 ”, page 199
7 - Coolant temperature transmitter - G62-
❑ Removing and installing ⇒ “2.7 Removing and installing coolant temperature transmitter G62 ”, page
197

2 Injection valves
⇒ “2.1 Summary of components - fuel distributor with injectors”,
page 264
⇒ “2.2 Removing and installing the fuel distributor”, page 265
⇒ “2.3 Removing and installing injectors”, page 266
⇒ “2.4 Clean injectors”, page 271
2.1 Summary of components - fuel distribu‐

tor with injectors
Note

1 - Fuel distributor
stalling the fuel distribu‐
tor”, page 265
2 - Screw
sembly
❑ 8 Nm + 90°
3 - Fuel pressure transmitter -
G247- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Replace afterwith disas‐
sembly
❑ Check ⇒ “5.2 Check fuel
pressure sender G247 ”,
page 285 .
stalling fuel pressure
284
❑ 22 Nm + 10°
4 - Injector
stalling injectors”, page
266
5 - O-ring
sembly
❑ moisten with clean en‐
gine oil
6 - Distance ring
7 - Distance ring

8 - Support ring
❑ the fuel distributor exerts force via the support ring that holds the injector in the cylinder head
9 - Sealing cone
10 - Combustion chamber sealing ring
❑ Do not grease or treat using any other lubricant
❑ Replace ⇒ “2.3 Removing and installing injectors”, page 266
11 - High pressure tube
❑ Removing and installing ⇒ “7.3 Removing and installing high pressure pipe”, page 295
❑ Connections must not be damaged
❑ Do not change bending change.
❑ Moisten thread of the union nuts with clean engine oil
❑ 16 Nm + 45°
12 - Screw
❑ can be used several times
❑ 8 Nm + 90°
13 - Clamp
2.2 Removing and installing the fuel distrib‐

utor
Removing
Note
♦ When removing the fuel distributor, the injection valves can be

released from the cylinder head or from the fuel distributor.
♦ Injectors must not be removed while the engine is cold.
♦ After removal,
Protected all Copying
by copyright. seals for
onprivate
the injection
or commercialvalve must
purposes, be
in part replaced
or in whole, is not permitted
because of 35
unless authorised by MPa
ŠKODA (350 bar)
AUTO A. fuel AUTO
S. ŠKODA pressure.
WARNING
♦ Before opening the injection system high-pressure system, the

fuel pressure must be reduced.
– Place a clean cloth below to absorb leaking fuel.
– Remove high pressure pipe ⇒ “7.3 Removing and installing
high pressure pipe”, page 295 .
2. Injection valves 265

– Disconnect the plug connections -arrows-.

– Release the screws -1- and disconnect the fuel distributor from
the high pressure injection valves.
Note
When removing the fuel distributor, the injection valves can be

withdrawn from the cylinder head.
Installing
– Check the fuel distributor and if necessary remove any foreign
particles or old O-rings.
• The sealing surfaces of the fuel distributor must be without
scratches or gauges. If not, replace the component.
– Replacing sealing rings for injection units ⇒ page 266 .
– Position fuel distributor on the injectors.
– Press fuel distributor first to the right, then to the left onto the
injectors up to the stop.
– Press fuel distributor down firmly in the area of the fixing
screws and tighten screws by 2 turns.
– Tighten screws by hand as far as the stop
– Also tighten the screws crosswise to the torque.
– Install high pressure pipe ⇒ “7.3 Removing and installing high
pressure pipe”, page 295 .

♦ Screws for fuel distributor ⇒ “2.1 Summary of components -

fuel distributor with injectors”, page 264 .
2.3 Removing and installing injectors

♦ Removal tool - T10133/16A- from the Tool kit for engines FSI
- T10133C-
♦ Tool kit for high pressure injection valves - T10581-
Tools

A - Pressure element -
T10581/3-
B - Extractor - T10581/4-
C - Removal tool -
T10133/16A-
D - Screw from the Removal
tool - T10133/16A-
E - Baseplate - T10581/1-
F - Knurled screw - T10581/2-
G - Mounting cone - T10581/5-
H - Assembly sleeve -
T10581/6-
I - Calibration sleeve -
T10581/7-
J - Cylinder pin to protect the
mounting cone - T10581/5-
Note
♦ Injectors must not be removed while the engine is cold.

♦ When removing the fuel distributor, the injection valves can be
released from the cylinder head or from the fuel distributor.
♦ In this case, remove the injection valves from the fuel distrib‐
utor.
♦ After removal, all seals on the injection valve must be replaced
because of fuel pressure.
– Remove fuel distributor ⇒ “2.2 Removing and installing the fuel

distributor”, page 265 .

Remove injection valves on cylinder head.

– Disconnect plug -3- at the impact sleeve -1-.
– Sealing ring and spacer rings -2- must be carefully removed
with Removal tool - T10498- .
Note
The two spacer rings have a groove.
– Place pressure element - T10581/3- -A- via injection valve

-1-.
• pressure element - T10581/3- -A- must not be attached to the
support ring -2-.
Gently apply a few knocks to the pressure element - T10581/3-
to loosen the injector.
– Install baseplate - T10581/1- -e- with screws - T10581/2- -F-

as shown.
Use the bores for the fuel distributor to screw to the cylinder head.
– Insert extractor - T10581/4- -B- into the groove at the injec‐

tor-1- .
– Slide in Removal tool - T10133/16A- -C- over the puller -
T10581/4- -B-.
– Screw in screws -D- for Removal tool - T10133/16A- in the
puller - T10581/4- -B-.
– Compensate Removal tool - T10133/16A- -C- and put on the
baseplate - T10581/1- -e-.
• Removal tool - T10133/16A- -C- must be supported at the
baseplate - T10581/1- -e-.
– Rotate Removal tool - T10133/16A- -C- so that at the base‐
plate - T10581/1- -e- covers the largest possible surface area.
– Tighten Protected
screw by -D- slightly
copyright. by hand.
Copying for private or commercial purposes, in part or in whole, is not permitted
Note
Use a torque wrench to pull out the injector.

– Set 5 Nm on the torque wrench.

– Pull the injector out by screwing in the screw -D-.
NOTICE
Risk of injector destruction.
♦ Failure to observe the torque threatens the destruction of the
injector.
If the limit torque of 5 Nm is reached without the injector loosen‐

ing, remove the extractor and begin to loosen the injector again
using the pressure element - T10581/3- ⇒ page 268 .
Repeat the procedure for each injector.
Disassembling the injector

1- Injector
2- Sealing ring
3- Spacer ring (white)
4- Spacer ring (red)
5- Combustion chamber sealing ring
6- Support ring
Replace distance rings and gasket rings.
Replace seal ring -2- and spacer rings -3- and -4- after removal.
– Remove seal -2- carefully with Removal tool - T10498- .
– Remove spacer rings -3- and -4- carefully using Removal tool
- T10498- .
Note
Spacer rings have a groove.
– Clean the shank of the injection valve of combustion residues.

– Install the sealing ring and spacer rings in the specified order.
– Before installing injector, moisten new gasket ring -2- with
clean engine oil.
Replace supporting washer

– Remove the old support disc from the injection valve using a
suitable screwdriver.
– Insert new support disc in the groove -arrow- and slide in.
The open part of the support disc points to the plug.
Replace the combustion chamber sealing ring
– Remove combustion chamber sealing ring with Removal tool

- T10498- .
Ensure that the injector groove is not damaged. If it is damaged,
replace the injection valve.
– When replacing an injection valve, clean the groove for the
combustion chamber sealing ring of combustion residues.

– Push mounting cone - T10581/5- -G- on injection valve -1- to

the stop.
– Push combustion chamber sealing ring -5- on mounting cone
- T10581/5- -G- as shown.
– Push mounting sleeve - T10581/6- -H- on mounting cone -

T10581/5- -G- up to the combustion chamber sealing ring
-5-.
– Slide combustion chamber sealing ring -5- with mounting
sleeve - T10581/6- -H- on to the sealing ring groove ⇒ page
269 .
– Pull of mounting sleeve - T10581/6- -H- from the injection
valve -1-.
Note
When sliding on the injector the combustion chamber sealing ring

is widened. It must therefore be reduced incopyright.
Protected by width in twoforsteps,
Copying ascommercial purposes, in part or in whole, is not permitted
private or
described below. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Press calibrating sleeve - T10581/7- -I-with a gentle rotary

movement (approximately 180°) up to the stop -arrow-onto the
injector-1-.
– Pull off the calibration sleeve - T10581/7- in reverse rotary
movement.
– Press calibrating sleeve - T10581/7- -I-with a gentle rotary
movement (approximately 180°) up to the stop -arrow-onto the
injector-1-.
– Pull off the calibration sleeve - T10581/7- in reverse rotary
movement.
Installing
– Clean hole in the cylinder head using a nylon cylinder brush -
T10133/4- .
– Replace the combustion chamber sealing ring, spacer rings
and sealing ring.
– Before installing injector 2, moisten new O-ring 4 with clean
engine oil.
The combustion chamber sealing ring must not be oiled.
Note
The injectors must fit easily. If necessary, wait until the width of
the combustion chamber sealing ring has reduced sufficiently.

– Press the injection valve -1- by hand up to the stop into the
hole of the cylinder head.
Pay attention to the correct seating and fitting position of the in‐
jectors in the cylinder head.
• The electrical connection of the injector must reach into the
recess provided in the cylinder head.
– Install fuel distributor ⇒ “2.2 Removing and installing the fuel
distributor”, page 265 .
If injection valves have been cleaned or replaced:
– Connect ⇒ Vehicle diagnostic tester.
– Function 0001 - Reset the injection valve learning
values .
2.4 Clean injectors

♦ Ultrasonic cleaning device - VAS 6418-
♦ Feeder plate for injection units - VAS 6418/1-
♦ Cleaning fluid ⇒ ETKA - Electronic Catalogue of Original Parts
• The ultrasound device must be filled with cleaning agent up to
the top of the holes (see inset).
Observe the safety and Owner's Manual of the ultrasound device.
– Place Mounting plate for injection units - VAS 6418/1- on the

cleaning unit.

Cleaning
– Remove injectors ⇒ “2.3 Removing and installing injectors”,
page 266 .
– Remove the combustion chamber sealing ring ⇒ page 269 .
– Insert injectors -1- into the feeder plate for injection units - VAS
6418/1- -2-.
– Immerse injectors with the feeder plate for injection units - VAS
6418/1- into the cleaning fluid - VAS 6418/2- .
– Turn on the cleaning device by pressing the button on / off

-C-.
– On the rotating head -A-, set a cleaning time of 30 minutes.
– On the rotating head -B-, set a temperature of 50 °C.
– Button ► -D- to start cleaning.
Note
Once the cleaning temperature has reached 50 °C the set time

begins to elapse.
– Replace the combustion chamber sealing ring, sealing ring

and spacer rings after cleaning ⇒ “2.3 Removing and installing
injectors”, page 266 .

3 Air filter
⇒ “3.1 Assembly overview - air filter housing”, page 273
⇒ “3.2 Removing and installing air filter housing”, page 274
3.1 Assembly overview - air filter housing
1 - Clamp
2 - Air guide hose
3 - Clamp
❑ 3.5 Nm
4 - Screw
❑ For vehicles with Mod‐
ule for air mass mea‐
surement - GX35-
❑ 1.5 ± 0.2 Nm
5 - Module for air mass mea‐
surement - GX35-
❑ not fitted to all engines
❑ comprises:
Air mass meter - G70-
Temperature sensor -
G1005-
6 - Gasket
surement - GX35-
❑ Check for damage and
replace if necessary
❑ No spare part, compo‐
nent Module
Protected forCopying
by copyright. air for private or commercial purposes, in part or in whole, is not permitted
mass measurement -
GX35-
7 - Air filter top part
surement - GX35-
8 - Air filter top part
❑ For vehicles without Module for air mass measurement - GX35-
9 - Screw
❑ captive
❑ 2 Nm
10 - Air filter element
❑ Change intervals:
11 - Louvre grille
❑ clean to remove dirt and salt residues
3. Air filter 273

12 - Air filter bottom part

❑ remove mechanical foreign particles
13 - Water drain hose
❑ clean
14 - Air guide
15 - Cover
❑ for air guide
16 - Screw
❑ 2 Nm
17 - Screw
❑ captive
❑ 2 Nm
18 - Air guide
❑ on the lock support
3.2 Removing and installing air filter hous‐

ing
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Remove hose clamps -arrows- at the
with respect connection
to the correctness of piece -1-inand
information this document. Copyright by ŠKODA AUTO A. S.
the air filter housing -2-.
– Remove air guide hose -3-.
– Remove -2- For module for air mass measurement - GX35- if

present.
– Remove -1- air filter housing upwards from the rubber guides
-4-.

– Remove the air filter housing -2- in

-the direction of the arrow- from the air guidance -c-.
Installing
Note
♦ Always use an original air filter element.

♦ The hose- and pipe supports and the air guide hoses must be
de-oiled and degreased before installing.
♦ When blowing out the air filter housing using air pressure,
cover air-carrying components with clean cloths.
– Remove the water drain hose -arrow-.

– Remove salt residue and dirt.
– Clean the water drain with compressed air.
– Pre-moisten the ball studs with water before installation.
• It is imperative for the air filter housing to be clean.
• Use a silicone-free lubricant to assemble the air guide hoses.
• Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts“ETKA” .
When
Protected attaching
by copyright. Copying the air guide
for private hose
or commercial to thein air
purposes, part filter housing,
or in whole, pay
is not permitted
attention
with respect to the installation
to the correctness markings
of information in -arrows-.
this document. Copyright by ŠKODA AUTO A. S.

♦ Hose clamp ⇒ “3.1 Assembly overview - air filter housing”,
page 273 .
3. Air filter 275

4 Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 276
⇒ “4.2 Removing and installing intake manifold”, page 278
⇒ “4.3 Removing and installing the throttle valve control unit GX3
”, page 281
⇒ “4.4 Cleaning throttle valve control unit GX3 ”, page 282
4.1 Assembly overview - intake manifold
Note

1 - Line holder
2 - Line holder
3 - Fuel line
❑ between the high-pres‐
sure pump and the cou‐
pling point in the engine
compartment
4 - Coolant line
page 180
5 - Line holder
6 - Screw
❑ 3 Nm
7 - Gasket
sembly
8 - Screw
❑ Observe tightening se‐
quence ⇒ page 278
❑ 10 Nm
9 - Intake manifold
stalling intake manifold”,
page 278
10 - Vacuum line of the brake
booster Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ for vehicles without
pressure sensor for
purging air from the ac‐
tivated carbon filter - GX44-
❑ between intake manifold, brake booster and vacuum pump for brake - V192-
❑ comprises:


281
❑ clean ⇒ “4.4 Cleaning throttle valve control unit GX3 ”, page 282
12 - Sealing ring
13 - Screw
❑ 7 Nm
14 - Sealing ring
15 - Sealing ring
17 - Air guide pipe between the charge air cooler and the suction pipe.
❑ Removing and installing ⇒ “2.4.2 Removing and installing the air guide pipe between the charge air cooler
and the suction pipe”, page 245
18 - Sealing ring
❑ comprises:
page 278
287
20 - Screw
❑ is to be used n the event of breaking off the retaining lugs for intake manifold sender - GX9- ⇒ Electronic
parts catalogue
❑ 3 Nm
21 - Sealing ring
22 - Vent line unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ for vehicles with pressure sensor for purging air from the activated carbon filter - GX44-
4. Intake manifold 277

Tightening order for intake manifold

Step Tightening torque
1. Insert in the centre, starting alternately, by hand as
far as the stop
2. In the centre, starting alternately, 10 Nm
Assembly overview - Plug for intake manifold sender - GX9-

1 - Intake manifold sender - GX9- ⇒ “5.3 Removing and installing
intake manifold pressure sender GX9 ”, page 287
2 - Screw, 3 Nm
3 - Replace O-rings after disassembly
4 - Air guide pipe between the charge air cooler and the suction
pipe ⇒ “2.4.2 Removing and installing the air guide pipe between
the charge air cooler and the suction pipe”, page 245
4.2 Removing and installing intake manifold

Removing with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
– Detach vacuum hose -arrow- from intake manifold -1-.

– Remove fuel supply line from the brackets -arrows- at the in‐
take manifold -1-.
Vehicles without pressure sensor for purging air from the activat‐
ed carbon filter - GX44-
– Remove clips -b- of the line -2- from the intake manifold.
– Pull off the plug at the activated charcoal filter solenoid valve
1 - N80- .
– Press release buttons -arrows- and remove hose -c- from
crankcase ventilation
Protected by copyright. Copying-3- at the
for private same time.
– Remove line
with respect -4-
to the from the
correctness guide on
of information the
in this intakeCopyright
document. manifold -d-. AUTO A. S.
by ŠKODA
Vehicles with pressure sensor for purging air from the activated
– Disconnect plug connections -2- and -3-.
– Remove clips -7- of the line -6- from the intake manifold.
– Open the hose clips -1-.
both sides.
– Detach the vent line -5- from the suction pipe -6- -arrows-.
– Remove the activated charcoal filter system solenoid valve 1
- N80- .


– Unscrew screws -a- from intake manifold -1-.
– Release coolant pipe -2- in the points -b-.
– Place coolant tube, hoses and electrical cables sideways.
245 .
281 .
– Unscrew connecting screw -arrow- between intake manifold

-1- and charge air coolers -2-.
– Open clamp -5- and remove coolant hose -3-.
– Screw off mounting screws -arrows- at the intake manifold

-1-.
Note
Secure the mounting screws against removal with suitable

means!

– Push out Intake manifold from the receptacles -a- and -b-.
– Remove intake manifold.
Installing
– Replace gaskets and O-rings.
– Before installing, moisten O-rings with engine oil.
– Secure all hose connection ends with spring-type clips that
of Original Parts .
– Refit the hoses and electrical wiring to the original locations.
– Firstly hook the intercooler -1- on the intake manifold on the

side of the throttle valve -b-.
– Subsequently, hang the charge air cooler on the guide -a- on
the side of the coolant pump.
– Connect plug from charge pressure sender - GX26- ⇒ page
242 .
– Install the throttle valve control unit - GX3- ⇒ “4.3 Removing
281 .
– Screw in fixing screw -arrow- between the charge air cooler

and the intake manifold.
Note

♦ Summary of components - intake manifold ⇒ “4.1 Assembly

overview - intake manifold”, page 276
♦ Summary of components - charge air system ⇒ “2.1 Summary
of components - charge air system”, page 237 .
4.3 Removing and installing the throttle

valve control unit - GX3-
Throttle flap control unit - GX3- comprises:
♦ Throttle valve control unit - J338- .
♦ Throttle valve drive for electronic power control - G186- .

♦ Throttle valve drive angle sender 1 - G187- .

♦ Throttle valve drive angle sender 2 - G188- .
Removing
245 .
– Pull out connector -a-.
– Unscrew screws -arrows- and remove throttle valve control unit -
GX3- -1-.
Installing
Installation is carried out in the reverse order. When installing, observe
the following:
– Replace all O-rings.
– Before installing, moisten O-rings with engine oil.
When installing, pay attention to the correct seating of the ring.
If a new throttle flap control unit - GX3- was installed, or the throttle flap
control unit - GX3- cleaned:
– Adjust Throttle valve control unit - GX3- ⇒ Vehicle diagnostic tester.
♦ 0001 - Adaptation of throttle valve control unit -J338
Note

♦ Screws for throttle valve control unit - GX3- ⇒ “4.1 Assembly

overview - intake manifold”, page 276 .
4.4 Cleaning throttle valve control unit -

GX3-
♦ Acetone Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Paint brush
Note
♦ If a new engine control unit - J623- is installed, the throttle

valve control unit must be adjusted.
♦ Soiling and carbonisation in the limit stop can lead to incorrect
adjustment values.
♦ When cleaning the throttle valve housing it must not be
scratched.
Work procedure
and installing the throttle valve control unit GX3 ”, page 281 .

– Open throttle valve by hand and lock in open position using

wood or a plastic wedge -arrow-.
CAUTION
Danger when working with easily inflammable liquids.
Wear safety goggles and safety clothing.
♦ Accident prevention regulations and the safety instructions

must be observed when handling easily inflammable fluids.
♦ Do not use compressed air when cleaning throttle valve.
♦ Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact.
– Thoroughly clean the throttle valve housing using commer‐

cially available Acetone and a paint brush, particularly in the
area -arrows- of the closed throttle valve.
– Wipe the throttle valve housing with a fluffy cloth.
– Allow Acetone to dry off completely.
– Install the throttle valve control unit - GX3- ⇒ “4.3 Removing
and installing the throttle valve control unit GX3 ”, page 281 .
– Delete learnt values and adapt engine control unit - J623- to
the throttle valve control unit - GX3- ⇒ Vehicle diagnostic
tester.

5 Senders and sensors

⇒ “5.1 Removing and installing fuel pressure sender G247 ”, page
284
⇒ “5.2 Check fuel pressure sender G247 ”, page 285
⇒ “5.3 Removing and installing intake manifold pressure sender
GX9 ”, page 287
⇒ “5.4 Removing and installing pressure sensor for exhaust gas
1 G450 ”, page 289
⇒ “5.5 Removing and installing valve for air mass meter GX35 ”,
page 289
5.1 Removing and installing fuel pressure

sender - G247-
♦ Socket insert SW 27 - T40218- or commercially available
socket insert
Removing
WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Fuel under very high pressure creates
with respect to a risk
the correctness of injury.

– Remove engine cover ⇒ page 41 .
pump .
– Place vacuum pump for brakes - V192- to the side with con‐
nected cables.
– Pull off connector -1- using assembly tool - T10118- .
– Remove screws from the coolant pipe -arrow-.
– Place a cloth below to absorb any fuel.
– Unscrew the fuel pressure sender - G247- -2- with the socket
insert SW 27 - T40218- .
Installing
– Before installing, coat the thread of the Fuel pressure encoder
- G247- and cone with engine oil.
♦ Fuel pressure sender - G247- ⇒ “2.1 Summary of components
- fuel distributor with injectors”, page 264 .
♦ Vacuum pump for brake - V192- ⇒ braking systems; Rep. gr.
pump .


page 207 .
5.2 Check fuel pressure sender - G247-

⇒ “5.2.1 Check fuel pressure sender G247 using Tester for pres‐
sure sensor VAS 6394 ”, page 285
⇒ “5.2.2 Check fuel pressure sender G247 using vehicle diag‐
nostic tester”, page 286
5.2.1 Check fuel pressure sender - G247- us‐

ing Tester for pressure sensor - VAS
6394-
♦ Adapter for measuring method/DSO (3-pin) - VAS 5570-
♦ Tester for pressure sensor - VAS 6394-
♦ Socket insert, elongated, SW 27 mm, commercially available
– Remove fuel pressure sender - G247- ⇒ “5.1 Removing and
installing fuel pressure sender G247 ”, page 284 .
– Moisten the sealing cone of the adapter -VAS 6394/3- with
clean engine oil and screw it into the fuel distributor with
22 Nm.
– Release the screw plug -2- and screw the fuel pressure sender
- G247- into the tester -VAS 6394/1- .
– Connect the pressure line -1- of the tester onto the adapter -
VAS 6394/3- .
5. Senders and sensors 285

– Electrically link the Adapter for measurement technology /

DSO (3-pole) - VAS 5570- the vehicle and the Fuel pressure
sender - G247- .
– Switch on the tester -VAS 6394/1- , for this step, briefly press
the button -A-.
Note
♦ If the button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If the tester -VAS 6394/1- is not displaying 0 bar, perform zero
point adjustment ⇒ Owner's Manual .
– Connect ⇒ Vehicle diagnostic tester.

– Start engine and run in idle.
In self-diagnosis, select 0001 - Read measured values
– Choose Fuel pressure from the directory.
– Compare the displayed tester fuel pressure tester -VAS
6394/1- with the actual value displayed at the vehicle diagno‐
sis tester .
– Read fuel pressure on vehicle diagnosis tester .
• The pressures may deviate maximum 0.5 MPa (5 bar) from
one another.
If the deviation is greater than 0.5 MPa (5 bar), replace the fuel
pressure sender - G247- .
– Repeat the test with the new fuel pressure sender - G247- and
compare both measured values.
If the measurements now match, install new fuel pressure sender
- G247- .
If the measured values still do not comply, test electrical line con‐
nection between fuel pressure sender - G247- and engine control
unit - J623- ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
♦ Fuel pressure sender - G247- ⇒ “2.1 Summary of components
- fuel distributor with injectors”, page 264 .
5.2.2 Check fuel pressure sender - G247- us‐

ing vehicle diagnostic tester
♦ Pressure gauge , e.g. -VAS 6550-
• Fill fuel tank 1/4 full.

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.
– Remove fuel feed line -1-.
– Collect the fuel which flows out with a cloth.
– Connect pressure gauge - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
♦ VAS 6550/1 between fuel line leading to engine and shut-off
tap -A-.
♦ VAS 6550/2 between fuel line leading to fuel tank and shut-off
tap -B-.
NOTICE
Risk of fuelwith
dripping
respect toout.
– Check the quick couplings for firm seating by pulling in the

opposite direction.
Make sure that the shut-off tap -C- is closed at the pressure gauge
- VAS 6550- -1-.
– Open shut-off taps -A- and -B- .
– Check Fuel pressure sender - G247- with ⇒ Vehicle diagnostic
tester.
– Select the following function:
♦ Systems capable of diagnostics
♦ 0001 - Engine electronics
♦ 0001 - Repair groups
♦ 24 - mixture preparation - injection
♦ G247 - Check the fuel pressure sensor
5.3 Removing and installing intake manifold

pressure sender - GX9-
The intake manifold pressure sender - GX9- comprises:

♦ Intake manifold temperature encoder - G72- .

♦ Intake manifold pressure sender - G71- .
Removing
– Release catches -a- and remove plug -1-.
If the mounting screws of the intake manifold are installed, un‐
screw them.
– Unlock intake manifold sender - GX9- -2- by pressing the lock‐

ing mechanism -b- down in -the direction of the arrow-.
– Turn intake manifold sender - GX9- -2- about 45 ° in

-direction of the arrow-.
– Remove intake manifold sender - GX9- -2- from the air guide
tube -3- in -the direction of the arrow-.
Installing
– Renew O-ring.
– Before positioning, moisten O-ring with oil.
Note

If the locking lugs brake, the sender can be secured with two
screws to 3 Nm ⇒ ETKA - Electronic Catalogue of Original Parts .
♦ Fastening screw for intake manifold sender - GX9- ⇒ “4.1 As‐

sembly overview - intake manifold”, page 276 .
5.4 Removing and installing pressure sen‐

sor for exhaust gas 1 - G450-
Removing
– Exhaust gas temperature sender 1 - G450- -1- using extension
SW 24 - T40284- .
Installing
O-ring is not available individually.
Replace Pressure sensor 1 for exhaust gas - G450- after removal.
♦ Exhaust gas pressure sensor 1 - G450- ⇒ “1.2 Summary of
components - camshaft housing”, page 81 .
5.5 Removing and installing valve for air

mass meter - GX35-
Note
The Module for air mass measurement - GX35- Is not used on all
vehicles.
Removing
– Unscrew
Protected byscrews
copyright. -arrows- and or
Copying for private remove the
commercial element
purposes, in partfor
or inair pres‐
whole, is not permitted
sure
unlesscontrol
authorised-byGX35-
ŠKODA AUTO-1-. A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Installing
– Check seal for damage.
Seal is not available individually, component Module for air mass
measurement - GX35-
♦ Module for air mass measurement - GX35- ⇒ “3.1 Assembly
overview - air filter housing”, page 273 .

6 Engine control unit

⇒ “6.1 Removing and installing engine control unit J623 ”, page
290
6.1 Removing and installing engine control

unit - J623-
⇒ “6.1.1 Removing and installing engine control unit J623 without
protective housing”, page 290
⇒ “6.1.2 Removing and installing engine control unit J623 with
protective housing”, page 290
6.1.1 Removing and installing engine control

unit - J623- without protective housing
Removing
Note
If the engine control unit is replaced, the ⇒ Vehicle diagnostic

tester must be connected and the function “Replace engine con‐
trol unit” must be carried out.
– Unlock catch in -direction of the arrow- and remove the engine

control unit -1-.
– Unlock plug connections for engine control unit - J623- and
pull off.
Installing
After installing a new engine control unit, the following work step
must be performed:
– Connect diagnostic unit ⇒ Vehicle diagnostic tester.
– Activate the engine control unit in operating mode “Software
version management” or “Targeted functions” and perform the
following:
♦ 0001 - Replace the engine control unit
6.1.2 Removing and installing engine control

unit - J623- with protective housing
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Special tools and workshop
with respect equipment
to the correctness required
♦ Hot air blowers - VAS 1978/14A- with push-on nozzle from the
wiring harness repair set - VAS 1978B-
♦ commercially available miniature grinder
Removing
Note
If the engine control unit is replaced, the ⇒ Vehicle diagnostic

tester must be connected and the function “Replace engine con‐
trol unit” must be carried out.

Remove the shear screws -arrows- as follows to remove the pro‐

tective housing -1-:
– Make a slot for a screwdriver in the head of shear screw -1-

with a miniature grinder -2-.
Note
♦ The threads of the shear screws are equipped with locking

agent. Warming the pull-off screw when grinding a slot for a
screwdriver makes it easier to undo it afterwards.
♦ If the shear screws still cannot be undone, warm the, up with
a hot air blower.
Undoing pull-off screws with a hot air blower

– Set the temperature adjustment potentiometer -2- to maximum
heating performance and set the air flow two stage switch
-3- to position 3.
CAUTION
Risk of burns from hot air blower.
♦ Only warm up the shear screws with a hot air blower.

♦ By warming the shear screws, the cover plate and parts in its
vicinity are heated up strongly too. Where necessary, protect
these parts by a piece of sheet covering.
– Heat the shear screw head -1- for approximately 20 to 30 sec‐

onds.
6. Engine control unit 291

Continued for slackened screws

– Unscrew shear screw -1- with a screwdriver -2-.
– Remove protective housing -1-.
NOTICE
Risk of engine control unit destruction.
If the engine control unit touches the plus pole of the battery, this
will destroy it.
– Unlock catch in -direction of the arrow- and remove the engine

control unit -1-.
– Unlock plug connections for engine control unit - J623- and
pull off.
– It is imperative for the protective housing to be put back in
place on the engine control unit - J623- .
– Clean the threaded holes for the shear bolts to remove
residues of locking agent. Cleaning can be done using a tap‐
per.
– Use new shear bolts.
After installing a new engine control unit, the following work step
must be performed:
– Activate the engine control unit in operating mode “Software
version management” or “Targeted functions” and perform the
following:
♦ 0001 - Replace the engine control unit

7 High pressure pump

⇒ “7.1 Summary of components - high pressure pump”, page
293
⇒ “7.2 Removing and installing the high pressure pump”, page
294
⇒ “7.3 Removing and installing high pressure pipe”, page 295
7.1 Summary of components - high pres‐

sure pump
Note


❑ do not disassemble
stalling the high pres‐
sure pump”, page
294
2 - Screw
sembly
❑ Pay attention to the pro‐
cedure for tightening ⇒
page 294
3 - O-ring
sembly
❑ before fitting moisten
with clean engine oil
4 - Roller tappet
❑ Moisten with engine oil
during installation
5 - Fuel line
❑ Feed line from the fuel Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
system pressurisation unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
pump - G6- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
6 - High pressure tube

stalling high pressure
pipe”, page 295
sembly
❑ Connections must not
be damaged
❑ Moisten thread of the union nuts with clean engine oil
❑ do not change bending form
❑ 16 Nm + 45°
7. High pressure pump 293

7 - Clamp
8 - Screw
❑ 8 Nm
To prevent the flange of the high pressure pump from becoming

deformed during installation, attach high pressure pump as fol‐
lows:
– Tighten screws in steps as follows:
Stage Screws M8 Tightening torque/torque angle
1. -2- by hand as far as the stop
2. -2- Tighten by 1 turn alternately until the
flange of the high pressure pump is at
the camshaft housing
3. -2- 20 Nm
4. -2- Turn 90° further
7.2 Removing and installing the high pres‐

sure pump
Removing
• Engine cold.
WARNING

NOTICE

– Place a cloth below to absorb leaking fuel.
– Remove high pressure pipe ⇒ “7.3 Removing and installing
high pressure pipe”, page 295 .
– Pull out connector -a-.
– Release the hose connection -b- by pressing the release but‐
ton -arrows- and remove the fuel supply line.
– Unscrew screws -2- and remove the high pressure pump -1-.

– Remove tappet -3- with rod magnet from the camshaft housing
-4-.
Installing
– Renew O-ring.
– Check that the roller tappet is not damaged. Renew if neces‐
sary.
– Moisten roller tappet -3- with clean engine oil.
– Slide the roller tappet -3- into the camshaft housing. Please
note the fitting position while doing this!
Installation roller tappet

• Lug -A- of the tappet -3- must be in groove -B- in the camshaft
housing -4-.
• When setting the position correctly, the contour must be -C-
visible!
• The roller tappet must rest on the cam of the camshaft.
– Turn crankshaft in direction of engine rotation until the roller
tappet is at the lowest point.
– Insert a new, oiled O-ring -2- into the slot of the high pressure
pump -3-.
– Tighten bolts hand-tight.
– Tighten the bolts to the specified torque.
– Screw in new screws hand-tight until they touch the flange of
the high-pressure pump.
• To prevent the flange of the high pressure pump from becom‐
ing deformed during installation, attach high pressure pump
as follows ⇒ page 294 :
– Check the fuel system for leaks.
Note

♦ High pressure pump ⇒ “7.1 Summary of components - high

pressure pump”, page 293 .
7.3 Removing and installing high pressure

pipe
Removing
WARNING
295
7. High pressure pump

NOTICE

– Place a cloth below to absorb any fuel.
– Unscrew union nuts -arrows-.
– Remove fastening screw on holder -1- and remove the high
pressure pipe.
Installing
The high pressure pipe must not be replaced.
• Outlets must not be damaged.
• Do not change bending change.
– Moisten thread of union nuts with clean engine oil.
– Hand-tighten union nuts -arrow- for high pressure pipe -2-,

ensure that the fit is tension-free.
– Tighten screw in holder -1- hand-tight.
– Tighten union nuts -arrow- to the specified tightening torque.
– Tighten fixing screw in holder -1- to the specified tightening
torque.
– Install air guide pipe ⇒ “2.4.1 Removing and installing the air
guide pipe between the charge air cooler and the exhaust gas
turbocharger”, page 242 .
– Install air filter housing ⇒ “3.2 Removing and installing air filter
Note

♦ Union nut and screw for high pressure pipe ⇒ “7.1 Summary
of components - high pressure pump”, page 293 .

8 Lambda probe
⇒ “8.1 Summary of components - lambda probe”, page 297
⇒ “8.2 Removing and installing Lambda probe”, page 297
8.1 Summary of components - lambda probe
Note
♦ New lambda probes are coated with assembly paste. This paste must not come into contact with the slots
of the lambda probe body.
♦ For a re-used lambda probe, only coat the thread with hot bolt paste. This paste must not come into contact
with the slots of the lambda probe body. Hot bolt paste ⇒ ETKA - Electronic Catalogue of Original Parts .
♦ The electrical cable wire connection of the lambda probe must be secured again at the same points during
installation. Contact between the electrical cable connection and the exhaust pipe must be prevented.
1 - Lambda probe 1 after cat‐

alytic converter - GX7-
❑ comprises:
♦ Lambda probe downstream
of catalytic converter -
G130-
♦ Lambda probe heater 1
downstream of catalytic
converter - Z29-
page 297
❑ 55 Nm
2 - Connector
❑ Lambda probe 1 up‐
stream of catalytic con‐
verter - GX10-
3 - Connector
❑ Lambda probe 1 down‐
stream of catalytic con‐
verter - GX7-
❑ comprises: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Z19-
page 297
❑ 55 Nm
8.2 Removing and installing Lambda probe

Installation overview of the Lambda sensor ⇒ page 297 .
8. Lambda probe 297

Lambda probe 1 in front of catalytic converter - GX10- comprises:

♦ Lambda probe - G39- .
♦ Lambda probe heater - Z19- .
Lambda probe 1 after catalytic converter - GX7- comprises:
♦ lambda probe downstream of catalytic converter - G130- .
♦ Lambda probe 1 heater after catalytic converter - Z29- .
♦ Set of tools - 3337-
Removing
– Disconnect electrical plug connections:
1- Lambda probe 1 in front of the catalytic converter - GX10-
2- Lambda probe 1 after catalytic converter - GX7-
– Unscrew respective lambda probe using a spanner from the

lambda probe ring spanner set - 3337- .
1- Lambda probe 1 after catalytic converter - GX7-
2- Lambda probe 1 in front of the catalytic converter - GX10-
Installing
observe the following: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Note
♦ New lambda probes are coated with assembly paste. This

paste must not come into contact with the slots of the lambda
probe body.
♦ For a re-used lambda probe, only coat the thread with hot bolt
paste. This paste must not come into contact with the slots of
the lambda probe body. Hot bolt paste ⇒ ETKA - Electronic
Catalogue of Original Parts .
♦ The electrical cable wire connection of the lambda probe must
be secured again at the same points during installation. Con‐
tact between the electrical cable connection and the exhaust
pipe must be prevented.
After replacing the lambda probe, erase the initialisation values

and adapt the engine control unit - J623- ⇒ Vehicle diagnostic
tester.
– Switch on the ignition and select:
♦ ⇒0001 - Adaptation of lambda probes

♦ Lambda probes ⇒ “8.1 Summary of components - lambda

probe”, page 297
8. Lambda probe 299

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Assembly overview - silencers”, page 300
⇒ “1.2 Removing and installing silencers”, page 309
⇒ “1.3 Separating exhaust pipes/silencers”, page 319
⇒ “1.4 Align exhaust system free of stress”, page 319
⇒ “1.5 Inspecting the exhaust system for leaks”, page 320
1.1 Assembly overview - silencers

⇒ “1.1.1 Summary of components- silencer, Superb II”, page
300
⇒ “1.1.2 Summary of components - damper, Karoq, vehicles with
front-wheel drive”, page 302
⇒ “1.1.3 Summary of components - silencer, Karoq, vehicles with
four-wheel drive”, page 304
⇒ “1.1.4 Summary of components - muffler, Kodiaq with front
drive”, page 306
⇒ “1.1.5 Summary of components - muffler, Kodiaq with four-
wheel drive”, page 308
1.1.1 Summary of components-Protected

silencer, Superb II
300 Rep. gr.26 - Exhaust system

1 - Clamping sleeve
❑ different versions ⇒ Fig.
““Difference between
clamping sleeves”“ ,
page 302
❑ before tightening, align
exhaust system free of
stress ⇒ “1.4 Align ex‐
haust system free of
stress”, page 319
❑ Tighten screwed con‐
nections uniformly
❑ Installation position of
front clamp ⇒ “2.1 Sum‐
mary of components -
exhaust gas cleaning”,
page 321
rear clamp ⇒ Fig. ““In‐
stallation position of rear
clamp”“ , page 302
❑ Tightening torque ⇒ Fig.
page 304
2 - Front silencer
❑ this is a single unit as
original equipment, re‐
place individually when
carrying out repairs ⇒
stalling silencers”,
page 309
❑ Installing the exhaust
system without tension
⇒ “1.4 Align exhaust
system free of stress”,
page 319
3 - Retaining strap
❑ Observe part number ⇒ ETKA - Electronic Catalogue of Original Parts
❑ Observe part number ⇒ ETKA
unless authorised - Electronic
by ŠKODA Catalogue
AUTO A. S. ŠKODA AUTO A.of Original
S. does Partsor accept any liability
not guarantee
5 - Screw
❑ 20 Nm
6 - Rear right silencer
❑ this is a single unit as original equipment, replace individually when carrying out repairs ⇒ “1.2 Removing
and installing silencers”, page 309
❑ Installing the exhaust system without tension ⇒ “1.4 Align exhaust system free of stress”, page 319
7 - Retaining strap
9 - Rear left silencer
1. Exhaust pipes/silencers 301

10 - Separation point
❑ the arrows indicate the coupling points of the exhaust system
Installation position of rear clamp

– Install clamping sleeve in the position shown.
• Screw connections point to the right.
• The bolted connection -arrow- must not protrude under the
bottom edge of the clamping sleeve.
Difference between clamping sleeves

♦ Clamping sleeve -A-: 95 mm long.
♦ Clamping sleeve -B-: 88 mm long.
Installation dimension for vehicles with marking on the exhaust

pipe
1 - Clamping sleeve
2 - Exhaust pipe
a - Installation dimension
A - Marking on the exhaust pipe
♦ Dimension -a- for clamping sleeves version -A- = 5 mm
♦ Dimension -a- for clamping sleeves version -B- = 8.5 mm
Specified torques
♦ Clamping sleeve version -A-: 23 Nm
♦ Clamping sleeve version
Protected -B-:Copying
by copyright. 30 Nm for private or commercial purposes, in part or in whole, is not permitted
1.1.2 Summary of components - damper, Karoq, vehicles with front-wheel drive

1 - Clamping sleeve
❑ different versions ⇒ Fig.
page 304
❑ before tightening, align
stress ⇒ “1.4 Align ex‐
haust system free of
stress”, page 319
nections uniformly
front clamp ⇒ “2.1 Sum‐
mary of components -
exhaust gas cleaning”,
page 321
rear clamp ⇒ Fig. ““In‐
stallation position of rear
clamp”“ , page 304
❑ Tightening torque ⇒ Fig.
page 304
2 - Front silencer
page 309
page 319
3 - Retaining strap
5 - Screw
❑ 20 Nm
7 - The middle silencer
9 - Retaining strap

10 - Rear silencer

• Bolted connections to the left.


pipe
1 - Clamping sleeve
2 - Exhaust pipe
Specified torques
♦ Clamping sleeve version -B-: 30 Nm
1.1.3 Summary of components - silencer, Karoq, vehicles with four-wheel drive

1 - Screw
❑ 20 Nm
❑ Observe part number ⇒
3 - Retaining strap
4 - Rear silencer
page 309
page 319
5 - Nut
sembly
❑ 3 Nm
6 - Exhaust flap control unit -
J883-
stalling the exhaust flap
control unit J883 ”, page
333
7 - Retaining strap
8 - Clamping sleeve
❑ different versions ⇒ unless
Fig. ““Difference
authorised by ŠKODA between
AUTO A. S. clamping
ŠKODA AUTO sleeves”“ , page
A. S. does not 306
❑ before tightening, align exhaust system free of stress ⇒ “1.4 Align exhaust system free of stress”,
page 319
❑ Tighten screwed connections uniformly
❑ Installation position of front clamp ⇒ “2.1 Summary of components - exhaust gas cleaning”, page
321
❑ Installation position of rear clamp ⇒ Fig. ““Installation position of rear clamp”“ , page 306
❑ Tightening torque ⇒ Fig. ““Difference between clamping sleeves”“ , page 306
9 - Front silencer




pipe
1 - Clamping sleeve
2 - Exhaust pipe
Specified torques
1.1.4 Summary of components - muffler, Kodiaq with front drive

1 - Clamping sleeve
❑ Fitting position ⇒
“2.1.1 Summary of com‐
ponents - Exhaust emis‐
sion control, Superb III,
Karoq, Kodiaq with front
wheel drive”, page
321
❑ align exhaust system
free of stress before
tightening ⇒ “1.4 Align
stress”, page 319
nections uniformly ⇒
“1.4 Align exhaust sys‐
tem free of stress”, page
319
2 - Front silencer
❑ as first equipment, this
is a single unit with rear
silencer; replace individ‐
ually when carrying out
repairs
installing silencers – Ko‐
diaq, vehicles with front-
wheel drive”, page
316
❑ Separate exhaust
pipes/silencers ⇒
“1.3 Separating exhaust
pipes/silencers”, page
319
❑ Installing
Protected the exhaust
system
unless authorised without
by ŠKODA AUTOtension
system free of stress”, page 319

3 - Retaining strap
❑ replace if damaged
5 - Screw
❑ 20 Nm
6 - Clamping sleeve
❑ Fitting position ⇒ Fig. ““Installation position of rear clamp”“ , page 308
❑ align exhaust system free of stress before tightening ⇒ “1.4 Align exhaust system free of stress”, page
319
❑ Tighten screwed connections uniformly ⇒ “1.4 Align exhaust system free of stress”, page 319
7 - Rear silencer
❑ as first equipment, this is a single unit with front silencer; replace individually when carrying out repairs
❑ Removing and installing ⇒ “1.2.4 Removing and installing silencers – Kodiaq, vehicles with front-wheel
drive”, page 316
❑ Separate exhaust pipes/silencers ⇒ “1.3 Separating exhaust pipes/silencers”, page 319
8 - Retaining strap

10 - Screw
❑ 20 Nm
11 - Retaining strap
13 - Screw
❑ 20 Nm
14 - Exhaust flap control unit - J883-
❑ Removing and installing ⇒ “2.3 Removing and installing the exhaust flap control unit J883 ”, page
333
15 - Nut
❑ 3 Nm
Installation position of rear clamp with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
– Re-install clamping sleeve in the position shown.

• The bolted connection -arrow- must not protrude beyond the
1.1.5 Summary of components - muffler, Kodiaq with four-wheel drive

1 - Clamping sleeve
❑ Fitting position ⇒
“2.1.2 Summary of com‐
cleaning, Kodiaq, with
four-wheel drive”, page
324
❑ align exhaust system
free of stress before
tightening ⇒ “1.4 Align
stress”, page 319
nections uniformly ⇒
“1.4 Align exhaust sys‐
tem free of stress”, page
319
2 - Rear silencer
installing silencers – Ko‐
diaq, with four-wheel
drive”, page 318
page 319
3 - Screw
❑ 20 Nm
5 - Retaining strap
6 - Nut
❑ 3 Nm
7 - Exhaust flap control unit - J883-
❑ Removing and installing ⇒ “2.3 Removing and installing the exhaust flap control unit J883 ”, page
333
1.2 Removing and installing silencers

⇒ “1.2.1 Removing and installing the silencers, Superb III”, page
310
⇒ “1.2.2 Removing and installing the silencer, Karoq, vehicles
with front-wheel drive”, page 311
⇒ “1.2.3 Removing and installing theProtected
fuel delivery unit,
by copyright. Karoq,
Copying ve‐or commercial purposes, in part or in whole, is not permitted
for private
hicles with four-wheel drive”, page 313
⇒ “1.2.4 Removing and installing silencers – Kodiaq, vehicles with
front-wheel drive”, page 316
⇒ “1.2.5 Removing and installing silencers – Kodiaq, with four-
wheel drive”, page 318

1.2.1 Removing and installing the silencers,

Superb III
Note
♦ for first version the unit, replace individually when carrying out
repairs.
♦ A separating point has been provided in the connecting pipe
to remove parts of the exhaust system separately.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.
CAUTION
Risk of accident from silencer weight.
♦ A second mechanic is required to remove the silencers.

Joint damper removal unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove rear underfloor trim panel ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underfloor trim panel .
– Remove rear tunnel bridge -1- ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Underfloor trim panel; installing and remov‐
ing tunnel bridge .
– Place the engine and gearbox jack under the damper and
support the damper.
– Loosen clamping sleeve -1- between exhaust pipe with cat‐

alytic converter and front silencer and slide forwards.
– Loosen screws -8- and remove the bracket -7-.
– Detach retaining loop -4-.
– Remove silencer.
Remove separate rear silencer -5- or -9-
– Place the engine and gearbox jack under the removed silencer
and support the silencer.
If the mufflers are connected using clamping sleeves, loosen the
clamping sleeves and push them away, item -1- ⇒ “1.1.1 Sum‐
mary of components- silencer, Superb II”, page 300 .
If the silencers are not connected using clamping sleeves, dis‐
connect rear silencer at the respective coupling point ⇒ “1.3 Sep‐
arating exhaust pipes/silencers”, page 319 .
– Remove screw -8- with removed silencer and loosen holder
-7-.

Remove the separate front damper

– Remove rear underfloor trim panel ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underfloor trim panel .
– Remove rear tunnel bridge -1- ⇒ General body repairs, exte‐

rior; Rep. gr. 66 ; Underfloor trim panel; installing and remov‐
ing tunnel bridge .
– Place the engine and gearbox jack under the damper and
support the damper.
– Loosen clamping sleeve -1- between exhaust pipe with cat‐

alytic converter and front silencer and slide forwards.
If the mufflers are connected using clamping sleeves, loosen the
clamping sleeves and push them away, item -1- ⇒ “1.1.1 Sum‐
mary of components- silencer, Superb II”, page 300 .
If the silencers are not connected using clamping sleeves, dis‐
connect the front silencer at the respective coupling points ⇒
“1.3 Separating exhaust pipes/silencers”, page 319 .
– Loosen and remove the screw -8- and remove the mounting
bracket -7-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Detach retaining loop -4-. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
Installing
Installation is carried out in the reverse order. Pay attention to the
following:
– Align exhaust system free of stress ⇒ “1.4 Align exhaust sys‐
tem free of stress”, page 319 .
Note installation position of clamping sleeve ⇒ Fig. ““Installation
position of front clamp”“ , page 323 .
♦ Exhaust system ⇒ “1.1.1 Summary of components- silencer,
Superb II”, page 300 .
♦ Underfloor trim panel ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underfloor trim panel .
1.2.2 Removing and installing the silencer,

Karoq, vehicles with front-wheel drive
Note
repairs.


CAUTION

– Remove front damper -2- from the middle damper-3- in the
area of the -arrow- ⇒ “1.3 Separating exhaust pipes/silencers”,
page 319 .
– Remove tunnel bridge -4-.
– Slacken clamping sleeve -1-.
– Detach retaining loop -arrow-.

– Remove front silencer.

Remove the separate middle damper

– Separate the middle damper -2- from the front damper-1- and
the rear damper-4- In the area of the -arrow- ⇒ “1.3 Separating
exhaust pipes/silencers”, page 319 .
– Detach retaining loops -3-.
– Remove middle damper -2-.
Remove the separate exhaust gas rear damper

– Remove exhaust gas rear damper -4- from the middle
damper-2- in the area of the -arrow- ⇒ “1.3 Separating exhaust
pipes/silencers”, page 319 .
– Remove exhaust gas rear damper -4-.
Installing
♦ Silencer ⇒ “1.1.2 Summary of components - damper, Karoq,
vehicles with front-wheel drive”, page 302 .
♦ Clamping sleeve ⇒ “1.1.2 Summary of components - damper,
Karoq, vehicles with front-wheel drive”, page 302 .
♦ Tunnel bridge and underfloor trim panel ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underfloor trim panel .
1.2.3 Removing and installing the fuel delivery

unit, Karoq, vehicles with four-wheel
drive
♦ Tensioning strap - T10038-
Note
repairs.


CAUTION

– Remove front damper -3- from the exhaust gas rear
– Loosen the screws -arrows- of the clamping sleeve -1- and

slide the sleeve backwards.
– Secure the exhaust pipe -1- with tensioning strap -2- to the
propshaft.


– Remove front damper -3-.
Remove the separate exhaust gas rear damper

– Remove exhaust gas rear damper -4- from the rear
– Remove the electrical plug connections -6- at the exhaust flap
control unit - J883- .
– Remove exhaust gas rear damper -4-.
Joint damper removal
– Position engine and gearbox jack under the sound damper.
Unscrew


propshaft.
– Remove the electrical plug connections -6- at the exhaust flap

control unit - J883- .
Installing
♦ Silencer ⇒ “1.1.3 Summary of components -unless
silencer,
Protected Karoq,Copying for private or commercial purposes, in part or in whole, is not permitted
by copyright.
vehicles with four-wheel drive”, page 304 . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
♦ Clamping sleeve ⇒ “1.1.3 Summary of components - silencer,
Karoq, vehicles with four-wheel drive”, page 304 .
1.2.4 Removing and installing silencers – Ko‐

diaq, vehicles with front-wheel drive
CAUTION

Joint damper removal
– Remove rear tunnel bridge ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underfloor trim panel; Removing and installing
tunnel bridge .
– If present, remove rear left underfloor trim panel ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underfloor trim panel .
– Remove front central underfloor trim panel ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underfloor trim panel .

– Disconnect electrical plug connection -6- on the exhaust flap

control unit - J883- -7-.
– Support the front muffler with engine/gearbox jack e.g. -V.A.G
1383A- or -VAS 6931- .
– Remove screw -5- -9- and -10- for holders -4-. -8- and -11-.
Removing the rear silencer
– Disconnect electrical plug connection -6- on the exhaust flap
control unit - J883- -7-.
– If required, remove rear muffler -3- from the front muffler -2-
⇒ “1.3 Separating exhaust pipes/silencers”, page 319 .
– Support rear muffler with engine/gearbox jack e.g. -V.A.G
1383A- or -VAS 6931- .
– Remove screws -5- and -9- for mounting brackets -4- and
-8-.
– Remove rear silencer.
Remove front silencer
– Remove rear tunnel bridge ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underfloor trim panel; Removing and installing
tunnel bridge .
– Remove front central underfloor trim panel ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underfloor trim panel .
– If required, remove rear muffler -3- from the front muffler -2-
⇒ “1.3 Separating exhaust pipes/silencers”, page 319 .
– Support the front muffler with engine/gearbox jack e.g. -V.A.G
1383A- or -VAS 6931- .
– Push out screw -10- from the mounting bracket -11-.
– Remove front silencer.
Installing
following:
– Align the holes in the front bracket at the front with the mark‐
ings on the fuel tank tensioning strap.
– unless
Align the rear
authorised bracket
by ŠKODA AUTOholes parallel
A. S. ŠKODA AUTOto the
A. S. frame
does side orrail.
not guarantee accept any liability
Note installation position of clamp ⇒ page 319 .
♦ Exhaust system ⇒ “1.1 Assembly overview - silencers”,
page 300 .

1.2.5 Removing and installing silencers – Ko‐

diaq, with four-wheel drive
CAUTION

– Disconnect electrical plug connection on the exhaust flap con‐
trol unit - J883- ⇒ “2.3 Removing and installing the exhaust
flap control unit J883 ”, page 333 .
propshaft.
– Release retaining strap screws -1- of the crash sensor -2-.

– Remove silencer -3-.
Installing
following:
– Align the brackets for the retaining straps so that the straps
are parallel.
– Align the holes of the rear brackets parallel to the frame side
rail.
Note installation position of clamp ⇒ “2.1.2 Summary of compo‐
nents - exhaust gas cleaning, Kodiaq, with four-wheel drive”, page
324 .

♦ Exhaust system ⇒ “1.1 Assembly overview - silencers”,

page 300 .
1.3 Separating exhaust pipes/silencers

♦ Body saw - V.A.G 1523A- or chain pipe cutter - VAS 6254-
Note

♦ The separating point is marked around the perimeter of the
exhaust pipe.
CAUTION
Risk of injury from ejected swarf.
Wear safety goggles and safety clothing.
– Cut through exhaust pipe at separation point -arrow- at right

angle with body saw - V.A.G 1523A- or chain pipe cutter - VAS
6254- .
– Position clamping sleeve in the centre between outer mark‐
ings -arrows-.
– Install rear clamping sleeve in the position shown.

♦ Clamping sleeve ⇒ “1.1 Assembly overview - silencers”, page
300 .
1.4 Align exhaust system free of stress

• The exhaust system is aligned when cold.

– Detach clamp sleeve screw connections -arrow-.
– Push the exhaust system so far forward in the direction of

travel until the retaining strap is pre-tensioned -a- = 5mm.
– Tighten bolted connections of clamping sleeve evenly ⇒ Fig.
““Installation position of front clamp”“ , page 323 .
♦ Summary of components ⇒ “1.1 Assembly overview - si‐
lencers”, page 300 .
1.5 Inspecting the exhaust system for leaks

– Start engine and run in idle.
– Close off exhaust pipes for the duration of the leak test, e.g.
with cloths or plugs.
– Check all connection points for tightness by listening: exhaust
gas turbocharger to cylinder head, turbocharger to pre-ex‐
haust pipe, etc.
– Eliminate any leak found.

2 Cleansing exhaust emissions

⇒ “2.1 Summary of components - exhaust gas cleaning”, page
321
⇒ “2.2 Removing and installing catalytic converter”, page 328
⇒ “2.3 Removing and installing the exhaust flap control unit J883
”, page 333
2.1 Summary of components - exhaust gas

cleaning
⇒ “2.1.1 Summary of components - Exhaust emission control,
Superb III, Karoq, Kodiaq with front wheel drive”, page 321
⇒ “2.1.2 Summary of components - exhaust gas cleaning, Kodi‐
aq, with four-wheel drive”, page 324
⇒ “2.1.3 Summary of components - Bearing for Kodiaq front ex‐
haust pipe”, page 328
2.1.1 Summary of components - Exhaust emission control, Superb III, Karoq,

Kodiaq with front wheel drive
1 - Screw
““Installing catalytic con‐
verter - tightening
torque and tightening
❑ 20 Nm
3 - Screw
verter - tightening
❑ 20 Nm
❑ comprises:
Z19-
probe”, page 297
page 297
❑ 55 Nm
2. Cleansing exhaust emissions 321

❑ comprises:
♦ Lambda probe downstream of catalytic converter - G130-
❑ Summary of components ⇒ “8.1 Summary of components - lambda probe”, page 297
❑ 55 Nm
6 - Nut
❑ Tightening torque and tightening order ⇒ Fig. ““Installing catalytic converter - tightening torque and tight‐
ening order”“ , page 324
❑ 20 Nm
7 - Pre-exhaust pipe with catalytic converter
❑ do not twist decoupling element more than 10° - risk of damage
❑ Do not load decoupler with tensile stress
❑ Do not damage wire mesh on decoupling element
❑ Protect catalytic converter against shocks and blows
❑ Removing and installing ⇒ “2.2 Removing and installing catalytic converter”, page 328
❑ Remove the protection for the decoupling element on the spare part as late as possible
❑ If the particulate filter is installed, the following must be carried out after replacement 01 - Adjust
learning values for particle filter
8 - Clamping sleeve
❑ different versions ⇒ Fig. ““Difference between clamping sleeves”“ , page 323
page 319
❑ Fitting position ⇒ Fig. ““Installation position of front clamp”“ , page 323
9 - Screw clamp
❑ Fitting position ⇒ Fig. ““Fitting position”“ , page 324
10 - Gasket
❑ Removing and installing ⇒ page 234
❑ Summary of components ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 227
❑ Removing and installing ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 231
12 - Screw
❑ 20 Nm
❑ in some Kodiaq vehicles, the front exhaust pipe Pos. -7- is additionally secured in the bracket ⇒
“2.1.3 Summary of components - Bearing for Kodiaq front exhaust pipe”, page 328
❑ The fuse can also be retrofitted to Kodiaq vehicles ⇒ “2.2.3 Removing and installing the front exhaust
pipe”, page 332
14 - Screw
❑ 20 Nm

Installation position of front clamp

• Angle -α- = approximately 20°.
• Bolted connection to the right.
• Nuts upwards.


pipe
1 - Clamping sleeve
2 - Exhaust pipe
Specified torques

Fitting position
Note

♦ Mark the part opposite the part to be replaced.
♦ Put the clamp back into position!
– Installation of the exhaust gas turbocharger and catalytic con‐

verter, as shown.
Installing catalytic converter - tightening torque and tightening or‐

der
1. – Position catalytic converter
on exhaust gas turbocharger,
loosely tighten clamp -arrow-
2. – Loosely screw in screws -3-, • It must still be pos‐
-5- and nuts -1-, -2- and -4- by sible to move the
hand catalytic converter
and the bracket
.
3. – Tighten screw clamp -arrow-. 15 Nm
4. – Tighten screws and nuts in 20 Nm
the order -1- to -5-
2.1.2 Summary of components - exhaust gas cleaning, Kodiaq, with four-wheel

drive

1 - Screw
verter - tightening
3 - Screw
verter - tightening
❑ comprises:
♦ Lambdaunless
probe heater
authorised -
Z19- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

page 297
ponents - lambda
probe”, page 297
❑ comprises:
♦ Lambda probe downstream
of catalytic converter -
G130-
❑ Tightening torque ⇒ “8.1 Summary of components - lambda probe”, page 297
6 - Nut
7 - Pre-exhaust pipe with catalytic converter
❑ do not twist decoupling element more than 10° - risk of damage
❑ Do not load decoupler with tensile stress
❑ Do not damage wire mesh on decoupling element
❑ Protect catalytic converter against shocks and blows
❑ Removing and installing ⇒ “2.2 Removing and installing catalytic converter”, page 328
❑ Remove the protection for the decoupling element -T10403- on the spare part as late as possible
❑ If the particulate filter is installed, the following must be carried out after replacement 01 - Adjust
learning values for particle filter
8 - Clamping sleeve
❑ different versions ⇒ Fig. ““Difference between clamping sleeves”“ , page 327

page 319
❑ Fitting position ⇒ Fig. ““Installation position of front clamp”“ , page 326
9 - Screw clamp
❑ Fitting position ⇒ Fig. ““Fitting position”“ , page 327
10 - Gasket
❑ Summary of components ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 227
❑ Removing and installing ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 231
❑ Tightening torque and tightening order ⇒ “1.1 Summary of components - exhaust gas turbocharger”,
page 227
12 - Screw
❑ 20 Nm
❑ in some Kodiaq vehicles, the front exhaust pipe Pos. -7- is additionally secured in the bracket ⇒
“2.1.3 Summary of components - Bearing for Kodiaq front exhaust pipe”, page 328
❑ The fuse can also be retrofitted to Kodiaq vehicles ⇒ “2.2.3 Removing and installing the front exhaust
pipe”, page 332
14 - Screw
15 - Mounting bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Installation position of front clamp

– Re-install clamping sleeve in the position shown.
• Angle -α- = approximately 20°.
• Bolted connection to the right.
• Nuts upwards.



pipe
1 - Clamping sleeve
2 - Exhaust pipe
♦ Dimension -a- for clamping sleeves
unless version
authorised by ŠKODA-A- = A.
AUTO 5 S.
mmŠKODA AUTO A. S. does not guarantee or accept any liability
Specified torques
Fitting position
Note

♦ Mark the part opposite the part to be replaced.
♦ Put the clamp back into position!
– Installation of the exhaust gas turbocharger and catalytic con‐

verter, as shown.

Installing catalytic converter - tightening torque and tightening or‐

der
1. – Position catalytic converter
on exhaust gas turbocharger,
loosely tighten clamp -arrow-
2. – Loosely screw in screws -3-, • It must still be pos‐
-5- and nuts -1-, -2- and -4- by sible to move the
hand catalytic converter
and the bracket
3. – Tighten screw clamp -arrow-. 15 Nm

4. – Tighten screws and nuts in 20 Nm
the order -1- to -5-.
2.1.3 Summary of components - Bearing for Kodiaq front exhaust pipe
1 - Pre-exhaust pipe with cat‐

alytic converter
haust gas cleaning”,
page 321
2 - Screw
cleaning”, page 321
⇒ by
Protected “2.2.3 Removing
copyright. and or commercial purposes, in part or in whole, is not permitted
Copying for private
with installing
respect to the the frontofex‐
correctness information in this document. Copyright by ŠKODA AUTO A. S.
haust pipe”, page
332
4 - Lock washer
❑ only for some vehicles
⇒ ETKA - Electronic
Catalogue of Original
Parts
❑ Lock washers can also
be retrofitted
❑ Removing and installing ⇒ “2.2.3 Removing and installing the front exhaust pipe”, page 332
5 - Rivet
❑ Breakaway rivet
❑ only for some vehicles ⇒ ETKA - Electronic Catalogue of Original Parts
2.2 Removing and installing catalytic con‐

verter
⇒ “2.2.1 Removing and installing pre-exhaust pipe with catalytic
converter”, page 329
⇒ “2.2.2 Installing and removing particle filter”, page 332
⇒ “2.2.3 Removing and installing the front exhaust pipe”, page
332

2.2.1 Removing and installing pre-exhaust

pipe with catalytic converter
♦ For vehicles with all-wheel drive Engine support - T10533-
♦ Hot bolt paste ⇒ ETKA - Electronic Catalogue of Original Parts
Note
The catalytic converter is removed with the pre-exhaust pipe.
Removing
– Take plug connections -1- and -2- out of the holder, discon‐
nect, detach and expose electric cables out of the attach‐
ments.
– Assignment of installation for screw clamp -2- between ex‐

haust gas turbocharger and catalytic converter ⇒ Fig. ““Fitting
position”“ , page 324 .
– Unscrew screw -2- and remove screw clamp.
– Unscrew screw -1- and nuts -arrows-.
noise insulation .
– Remove tunnel bridge -1-.

– Unscrew screws -1- and remove heat shield for right drive
shaft, if present.

– Remove the plastic cover for floor tunnel ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underfloor trim panel; installation
overview - underfloor trim panels .
– Loosen the clamping sleeve -arrow- and slide it backwards.

– Remove both lambda probes ⇒ “8.2 Removing and installing
Lambda probe”, page 297 .
– Disconnect electrical plug connection -1- at the oil level and

oil temperature sender - G266- .
– Remove pendulum support ⇒ “2.4 Removing and installing
pendulum support”, page 32 .

– Unscrew propshaft -1- from the angle gear ⇒ Rep. gr. 39 ;

Components for angle gears; Removing and installing angle
gear .
– Position engine support bracket - T10533- -A- as shown in the

illustration.
– Screw original screw of the pendulum support into the front
threaded hole to secure the pendulum support.
– Screw an M8x40 screw with washer into the left threaded hole
to secure the cover for noise insulation.
– Tighten bolts hand-tight.
– Push the engine with the engine support bracket - T10533-
forwards as far as possible.
– Press propshaft -1- to the side in -direction of arrow-.

– Remove catalytic converter backwards.
– Push screwdriver -2- into the recess -arrow- of the exhaust gas
turbocharger and lever out the sealing ring -1-.
Installing
do not twist decoupling element in the exhaust pipe more than
10° - risk of damage
Do not damage the wire mesh of the decoupling element.
– Replace the gasket and the self-locking nuts.
– Coat bolts and catalytic converter screws with hot bolt paste
⇒ ETKA - Electronic Catalogue of Original Parts .
For vehicles with particle filter
– After replacement, connect the diagnostic device ⇒ Vehicle
diagnostic tester.

♦ 01 - Adapt learnt values of particle filter

Note

♦ Exhaust pipe with catalytic converter ⇒ “2.1 Summary of com‐

ponents - exhaust gas cleaning”, page 321 .
♦ Front clamping sleeve ⇒ “2.1 Summary of components - ex‐
haust gas cleaning”, page 321 .
♦ Tunnel bridge ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underfloor trim panel; installing and removing tunnel bridge.
♦ Heat shield for right drive shaft ⇒ Chassis, axles, steering;
Rep. gr. 40 ; Drive shaft; installing and removing heat shield
for drive shaft .
2.2.2 Installing and removing particle filter

Removal and installation of the particulate filter is identical to re‐
moval and installation of the exhaust pre-pipe with catalytic con‐
verter ⇒ “2.2.1 Removing and installing pre-exhaust pipe with
catalytic converter”, page 329 .
Has the particulate filter been replaced:
♦ 01 - Adapt learnt values of particle filter
2.2.3 Removing and installing the front ex‐

haust pipe
♦ Rivet pliers , e.g. -VAS 6759-
Note
♦ Depending on equipment fitted, retaining washers for the

bracket can be installed for the front exhaust pipe. The lock
washers prevent the exhaust front pipe falling out of the brack‐
et when the vehicle is »started up«.
♦ Lock washers can also be retrofitted.
♦ Components for installation ⇒ ETKA - Electronic Catalogue
of Original Parts .
Removing
– Drill breakaway rivet -5- and remove lock washers -4- from the
front exhaust pipe bracket -3- ⇒ “2.1.3 Summary of compo‐
nents - Bearing for Kodiaq front exhaust pipe”, page 328 .
– Remove mounting bracket -3- from the front exhaust pipe.

Installing
– Check whether the breakaway rivets can be inserted into the
front exhaust pipe receptacle. Or drill openings with a diameter
of 7 mm.
– Insert bracket -1- in the front exhaust pipe receptacle.
– Insert lock washers -3- parallel to the bearing -2- as shown.
– Rivet lock washers -3-.
Summary of components ⇒ “2.1.3 Summary of components -
Bearing for Kodiaq front exhaust pipe”, page 328 .
2.3 Removing and installing the exhaust

flap control unit - J883-
Removing
– Disconnect electrical plug connection on the exhaust flap con‐
trol unit - J883- .
– Unscrew nuts -arrows- and remove exhaust flap control unit -
J883- -1-.
Note
The location of the exhaust flap control unit - J883- -1- may vary
depending on the vehicle type.
Installing
• The springs of the exhaust flap control unit - J883- -1- must
engage in the grooves -arrows- of the exhaust flap.
– Tighten the news nuts to the specified tightening torque.
– Connect electrical plug connection on the exhaust flap control
unit - J883- .
Note

♦ Exhaust flap control unit - J883-unless
⇒ “1.1.3 Summary
authorised by ŠKODA AUTOof compo‐
nents - silencer, Karoq, vehicles with
withrespect
four-wheel drive”,
page 304 .

28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 334
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 336
⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page
338
⇒ “1.4 Removing and installing position transmitter for inlet
camshaft G1002 ”, page 338
⇒ “1.5 Removing and installing position transmitter for exhaust
camshaft G1003 ”, page 339
⇒ “1.6 Removing and installing the engine speed transmitter G28
”, page 340
1.1 Assembly overview - ignition system
1 - Spark plug
❑ use spark plug wrench
e.g. - 3122B- for remov‐
ing and installing
❑ When installing new
spark plugs, grease the
spark plug connectors
-2- with lubricating paste
G 052 565 A1.
❑ Change interval, type
and electrode spacing:
♦ ⇒ Maintenance ; Booklet
Superb III
♦ ⇒ Maintenance ; Booklet Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Karoq unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ ⇒ Maintenance ; Booklet
Kodiaq
❑ 22 Nm
2 - Spark plug connector
❑ When installing new
spark plugs, grease the
spark plug connectors
with lubricating paste G
052 565 A1.
Note
Ignition coil with power stage and

spark plug connector are individual‐
ly available for the repair case ⇒
Electronic parts catalogue (ETKA) .
3 - Ignition coil with power output stage
334 Rep. gr.28 - Ignition system

Note
Ignition coil with power stage and

spark plug connector are individual‐
ly available for the repair case ⇒
Electronic parts catalogue (ETKA) .

4 - Screw
❑ 8 Nm
5 - Screw
❑ 8 Nm
6 - Position sensor for exhaust camshaft - G1003-
❑ Removing and installing ⇒ “1.5 Removing and installing position transmitter for exhaust camshaft G1003
”, page 339
7 - O-ring
❑ O-ring is not available separately; in the event of damage, replace together with position transmitter for
exhaust camshaft - G1003- .
8 - O-ring
❑ O-ring is not available separately; in the event of damage, replace together with inlet camshaft 1 -
G1002- .
page 338
10 - Screw
❑ 8 Nm
11 - Sealing flange on the gearbox side
12 - Rotor
❑ Engine speed sender - G28-
13 - Plug
14 - Screw
❑ 5 Nm
15 - Engine speed transmitter - G28-
❑ Removing and installing ⇒ “1.6 Removing and installing the engine speed transmitter G28 ”, page
340 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
16 - Screw with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
❑ The tightening torque influences the knock sensor function
❑ 20 Nm
17 - Knock sensor 1 - G61-
❑ Removing and installing ⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page 338
1. Ignition system 335

1.2 Removing and installing ignition coils

with output stage
♦ Extractor -T10530-
Note
♦ The ignition coils are easier to remove when the engine is

warm. Using grease makes removal easier.
♦ Ignition coil with power stage and spark plug connector are
individually available for the repair case ⇒ Electronic parts
catalogue (ETKA) .
Removing
Ignition Coil Cyl. 3
– Unscrew screw
Protected -a- and
by copyright. remove
Copying theor hose
for private from
commercial the exhaust
purposes, in part or in gas
whole, is not permitted
turbocharger -2-.by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
Ignition Coil Cyl. 4
Continued for all ignition coils

– Press extractor -T10530- into the bore of the ignition coil -1-
as far as the stop.
– Tighten nuts -2- in -direction of arrow-.

– Remove ignition coil with extractor -T10530- in

-direction of arrow- out of the camshaft housing.
Installing
Note
♦ The spark plug must be removed from the ignition coil by hand.
♦ When installing new spark plugs, grease the spark plug con‐
nectors with lubricating paste G 052 565 A1.
– Coat the sealing grommet of the plug -arrow- with lubricating

paste G 052 565 A1.
– Insert the plug connector -1- onto the ignition coil by hand as
far as it can go. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
The ventilation duct -2- must be oriented towards the middle of
the connector sleeve -3-.

– Place all ignition coils loosely into the spark plug shafts.
– Align ignition coils to the connectors and simultaneously at‐
tach all connections to the ignition coils.
– Press ignition coils onto the spark plugs evenly by hand (do
not use an impact tool).

1.3 Removing and installing knock sensor 1

- G61-
Removing
noise insulation .
– Remove the AC compressor from the mounting bracket and
tie it up to the body ⇒ Heating, Air Conditioning; Rep. gr. 87 ;
AC compressor; removing and installing the AC compressor .
– Release screw -2- and remove knock sensor 1 - G61- .
Installing
– Knock sensor 1 - G61- -1- in compliance with figure.

Úhel α - 30° ± 5° Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note
The torque specification influences the function of knock sensor

1 - G61- .
– Screw in the screw -2- for knock sensor 1 - G61- .

♦ Knock sensor 1 - G61- ⇒ “1.1 Assembly overview - ignition
1.4 Removing and installing position trans‐

mitter for inlet camshaft - G1002-
NOTICE
Factory-installed sensors for the ignition system are not suitable
for tests and repairs. A crossover of ignition system igniters can
cause engine malfunctions and lead to handling malfunctions.
♦ Factory-fitted encoders are exclusively replaced by respective

sensors according to the ⇒ Electronic Parts Catalogue (ET‐
KA) .
♦ Do not use factory installed encoders for tests and repairs.
♦ Do not change the encoders either underneath or under dif‐
ferent vehicles.


Note
If engine oil touches the sealing ring for the coolant pump, it may
be damaged chemically.

– Remove position sensor for intake camshaft - G1002- -1- from
the camshaft housing.
Installing
Note
O-ring is not available separately; in the event of damage, replace

together with inlet camshaft 1 - G1002- .

♦ Position sensor for intake camshaft - G1002- ⇒ “1.1 Assembly
overview - ignition system”, page 334 .
1.5 Removing and installing position trans‐

mitter for exhaust camshaft - G1003-
NOTICE

sensorsProtected
according to the
by copyright. ⇒ Electronic
Copying Parts Catalogue
for private or commercial (ET‐
KA) . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ferent vehicles.
Removing


– Unscrew screw -arrow- and remove position sensor for ex‐
haust camshaft - G1003- -1-.
Installing
Note
O-ring is not available separately; in the event of damage, replace

together with position transmitter for exhaust camshaft - G1003- .

♦ Position sensor for exhaust camshaft - G1003- ⇒ “1.1 Assem‐
1.6 Removing and installing the engine

speed transmitter - G28-
Special tools and workshop equipmentProtected
required by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Socket insert 4 mm - T10370- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
NOTICE

sensors according to the ⇒ Electronic Parts Catalogue (ET‐
KA) .
ferent vehicles.
Removing
noise insulation .
– Remove the pump for charge air cooling - V188- from the en‐
gine ⇒ “2.4 Removing and installing electric coolant pump”,
page 190 ,
– Remove the oil separator at the bottom ⇒ “3.2.1 Removing
and installing oil separator”, page 173 .

– Separate the plug connection -4- for the engine speed sensor
- G28- -1-.
– Remove sealing plug -3- , thread these out from the engine
speed sensor - G28- -1- .

– Remove engine speed sender - G28- -1-.
Installing
Note
Carefully insert engine speed sender - G28- into the bore, so that
it does not fall between engine and gearbox.
– Tighten screw for engine speed sensor - G28- .

– Insert the sealing plug.
Make sure that the sealing plug is properly seated in the cylinder
block. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Tightening torques - summaries of
withcomponents
♦ Engine speed sender - G28- ⇒ “1.1 Assembly overview - ig‐

nition system”, page 334 .

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Service

Service Department. Technical Information

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Copyright © 2020 ŠKODA AUTO a. s. D4B8078C002

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.1 Summary of components - oil pressure switch/oil pressure control . . . . . . . . . . . . . . . . . . 176

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

2.4 Clean injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

1.1 Engine number, engine data

Vehicle data carrier on the camshaft housing

Engine codes DADA DPCA

2 Rep. gr.00 - Technical data

Engine codes DADA DPCA

2.1 Safety precautions when working on fu‐

2.2 Safety measures for working on vehi‐

2.3 Safety precautions during road tests in

4 Rep. gr.00 - Technical data

Increased risk of injury from unsecured testers and measuring

2.4 Safety precautions when working on

2.5 General safety instructions

2.6 Safety precautions when working on ig‐

6 Rep. gr.00 - Technical data

3.1 Rules of cleanliness

3.2 Foreign bodies in the engine

3.3 Contact corrosion

♦ Fuel feed lines

3.5 Assembly of radiators and condensers

3.6 General repair instructions

3.6.1 Additional instructions when undertak‐

Do not open the refrigerant circuit of the air conditioning system.

8 Rep. gr.00 - Technical data

3.6.2 General instructions for charge air sys‐

3.6.3 General notes on the ignition system

♦ ⇒ Maintenance ; Booklet Kodiaq

3.6.4 General notes on the injection system

3.6.5 General Instructions

Tighten all connections hand-tight, and then tighten with the

3.7 Checking the vacuum system

10 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

The engine is removed downwards together with the gearbox.

12 Rep. gr.10 - Removing and installing engine

– Cover radiator with radiator protection mat - VAS 531 003- .

Do not open the refrigerant circuit of the air conditioning system.

♦ Do not over-tension, buckle and bend refrigerant lines and

Continued for all vehicles

1. Removing and installing engine 13

– Mark the position of the clamp.

♦ Before loosening the coupling point between catalytic con‐

– Unscrew screw -2- and remove screw clamp.

do not twist decoupling element in the exhaust pipe more than

– Unscrew screws -arrows- and remove holder.

♦ To relieve the fuel pressure, place a clean cloth around the

Observe safety measures and rules for cleanliness ⇒ “3.1 Rules

14 Rep. gr.10 - Removing and installing engine

For vehicles without auxiliary heating

Vehicles fitted with auxiliary heating