1.5 Tsi Evo 110 KW Engine 06.2017

Service
Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
1,5/110 kW TSI EVO Engine
Engine ID
DAD
A
Edition 06.2017
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
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 ŠKODA AUTO a. s. D4B8077F814

Octavia III 2013 ➤ , Octavia III 2014 ➤
1,5/110 kW TSI EVO Engine - Edition 06.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 precautions when 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 Safety precautions when working on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Additional instructions when undertaking assembly work on the air-conditioning system . . 8
3.6 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.9 Assembly of radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Disconnecting engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.6 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 Engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Assembly overview - V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Removing
AUTO A. S.and installing
AUTO A. S.V-ribbed belt or. accept
. . . .any
. .liability
.................................
unless authorised by ŠKODA ŠKODA does not guarantee 40
1.3
with respect Removing
to the correctness and installing
of information V-ribbed
in this document. Copyrightbelt tensioning
by ŠKODA AUTO A. S.� device . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.6 Replacing crankshaft sealing ring on the belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.1 Summary of components - cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contents i
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.4 Removing and installing oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.5 Check piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.6 Check radial clearance of connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Summary of components - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.6 Checking the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.3 Assembly overview - Adjustment tool for control times . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.4 Position crankshaft at the top dead centre (TDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.5 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.6 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.7 Pre-assembly and assembly of the adjustment tool for control times . . . . . . . . . . . . . . . . 97
2.8 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.9 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.10 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2 Removing and installing bracket for radial shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.3 Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.4 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.5 Removing and installing cam adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.6 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.7 Removing and installing camshaft control valve 1 in the exhaust N318 . . . . . . . . . . . . . . 135
3.8 Removing and installing valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.1 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
17 - Lubrication . . . . . .unless
. . .authorised
. . . . .by.ŠKODA
. . . AUTO
. . . A.. S.
. .ŠKODA
. . . AUTO
. . . A.. S.. does
. . .not. guarantee
. . . . .or.accept
. . . any
. .liability
. . . . . . . 149
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.1 Assembly overview - pan/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.3 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 158
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Summary of components - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.1 Summary of components - crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
ii Contents
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

4.1 Summary of components - oil pressure switch/oil pressure control . . . . . . . . . . . . . . . . . . 164
4.2 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.4 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 165
4.5 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2 Coolant pump and map-controlled engine cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.1 Summary of components - coolant pump and coolant thermostat . . . . . . . . . . . . . . . . . . . . 177
2.2 Summary of components - charge air cooler pump V188 . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Summary of components - coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . 180
2.4 Removing and installing charge air cooler pump V188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.6 Removing and installing toothed belt pulley for coolant pump drive . . . . . . . . . . . . . . . . . . 184
2.7 Removing and installing coolant temperature transmitter G62 . . . . . . . . . . . . . . . . . . . . . . 187
2.8 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 188
2.9 Removing and installing coolant temperature sender at engine outlet G82 . . . . . . . . . . . . 189
2.10 Removing and installing element for engine temperature control GX33 . . . . . . . . . . . . . . 190
2.11 Testing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.1 Summary of components - coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.1 Summary of components - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.2 Summary of components - fan shroud with a radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.3 Summary of components - fan shroud with two radiator fans . . . . . . . . . . . . . . . . . . . . . . 208
4.4 Summary of components - radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.6 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.7 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.8 Removing and installing radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.9 Removing and installing radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.10 Removing and installing the radiator blind control motor V544 . . . . . . . . . . . . . . . . . . . . . . 217
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.2 Drain the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.3 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.1 Summary of components - fuel pump G6 and fuel gauge sender . . . . . . . . . . . . . . . . . . . . 235
2.2 Summary of components - fuel system pressurisation pump G6 , vehicles with auxiliary
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.4 Removing and installing the fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.5 inspecting fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.6 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3 Quick couplings . . by. .copyright.
Protected . . . . .Copying
. . . . .for. private
. . . .or. commercial
. . . . . . .purposes,
. . . . .in. part
. . or
. .in.whole,
. . . .is.not
. .permitted
............. 256
3.1 Separating push-on
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A..S.�
couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 256
4 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Contents iii
4.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

4.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 261
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
5.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
5.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
5.3 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1.3 Removing and installing the exhaust gas turbocharger connection fitting . . . . . . . . . . . . . . 279
1.4 Removing and installing element for load pressure control GX34 . . . . . . . . . . . . . . . . . . 280
2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.4 Removing and installing charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.5 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2.6 Leak testing the charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.1 Installation location overview - engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3.3 Removing and installing the throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . 313
3.4 Cleaning throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
4 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4.1 Summary of components - fuel distributor with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4.2 Removing and installing
Protected by copyright. Copying forthe fuel
private distributor
or commercial purposes,. .in. part
. . or
. .in.whole,
. . . is. .not. permitted
...................... 317
4.3 Removing and
unless authorised by installing
ŠKODA AUTOinjectors
A. S. ŠKODA AUTO. . . .A..S.. does
. . . not
. . guarantee
. . . . . .or.accept
. . . .any. .liability
.................... 318
4.4 Clean injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
5.1 Removing and installing intake manifold pressure sender GX9 . . . . . . . . . . . . . . . . . . . . 326
5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
5.3 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
5.4 Removing and installing pressure sensor for exhaust gas 1 G450 . . . . . . . . . . . . . . . . . . 331
5.5 Removing and installing valve for air mass meter GX35 . . . . . . . . . . . . . . . . . . . . . . . . . . 332
6 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
6.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
6.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
6.3 Removing and installing high pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
7 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
7.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
8.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
iv Contents
1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

1.1 Summary of components - Pre-exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . 343
1.2 Removing and installing pre-exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . 345
1.3 Summary of components - Middle and rear part of the exhaust system . . . . . . . . . . . . . . 348
1.4 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1.5 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
1.6 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 354
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.4 Removing and installing position transmitter for inlet camshaft G1002 . . . . . . . . . . . . . . . . 357
1.5 Removing and installing position transmitter for exhaust camshaft G1003 . . . . . . . . . . . . 358
1.6 Removing and installing the engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Contents v
vi Contents
00 – Technical data
1 Denomination
(SRL001097; Edition 06.2017)
⇒ “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 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
3 - Engine codes with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
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 the “Engine code” .
♦ 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. Denomination 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 of vehicle data sticker ⇒ Maintenance ; Booklet
Octavia III .
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 test‐
er.
♦ 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
XN2 - Cam on cylinder 2
XN3 - Cam on cylinder 3Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
XN4 - Cam on cylinder 4 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
XW1 - Sensing wheel for inlet camshaft

XW2 - Encoder wheel for exhaust camshaft
Engine codes DADA

Manufactured 08.2017 ►
Emission standards EU6
Displacement cm3 1495
Output kW at rpm 110/5000
Torque Nm at rpm 250/1500-3500
Bore ∅ mm 74.5
Stroke mm 85.7
Compression ratio 10.5
Number of cylinders/valves per cylinder 4/4
2 Rep. gr.00 - Technical data

Engine codes DADA

Fuel - RON min. 95 unleaded
Ignition system/fuel injection Motronic MG 1
Firing order 1-3-4-2
Exhaust gas recirculation no
Balancing shaft module no
Intake manifold change-over no
Camshaft control valve, inlet / exhaust yes / yes
Exhaust gas turbocharger yes
1. Denomination 3
2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 4
⇒ “2.2 Safety precautions when 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 Safety precautions when working on the injection system”,
page 5
⇒ “2.6 Safety precautions when working on ignition system”, page
5
2.1 Safety precautions when working on

fuel supply system
Fuel under very high pressure creates a risk of injury.
– Wear protective gloves.
– Wear safety goggles
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
Protectedfuse for fuel
by copyright. pump
Copying control
for private unit - J538-
or commercial purposes,⇒in Current
part or in whole, is not permitted
flow diagrams, Electrical
unless authorised by ŠKODA fault
AUTO A.finding
S. ŠKODAand Fitting
AUTO locations.
A. S. does not guarantee or accept any liability
Risk of damage to the electronic components when disconnecting
the battery.
Disconnect the battery only when the ⇒ Electrical System; Rep.
gr. 27 battery is disconnected.
2.2 Safety precautions when working on ve‐

hicles with start-stop system
Risk of injury as a result of automatic engine start in vehicles with
start/stop system.
In vehicles with the start/stop system activated (identifiable by an
indication 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 air‐
bag activation.
Testers and measuring instruments must always be secured on
the rear seat using a seat belt and operated by a 2nd person from
there.
2.4 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
Protected reservoir
by copyright. Copying is or
for private opened.
commercial purposes, in part or in whole, is not permitted
– Cover the cap of the coolant
with expansion tank with
respect to the correctness a clothinand
of information this document. Copyright by ŠKODA AUTO A. S.�
open carefully.
2.5 Safety precautions when working on the

injection system
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.
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
system as well as of the test equipment.
Switch off ignition before an engine wash.
2. Safety instructions 5
3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 6
⇒ “3.2 General notes on the injection system”, page 6
⇒ “3.3 General notes on the ignition system”, page 7
⇒ “3.4 General instructions for charge air system”, page 7
⇒ “3.5 Additional instructions when undertaking assembly work
on the air-conditioning system”, page 8
⇒ “3.6 Foreign bodies in the engine”, page 8
⇒ “3.7 Contact corrosion”, page 8
⇒ “3.8 Cable routing and securing”, page 8
⇒ “3.9 Assembly of radiators and condensers”, page 9
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. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ 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 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.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ 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 Safety precautions when working on the injection system”,
page 5 .

3.3 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 ignition system”, page
5.
Test data, spark-plugs ⇒ Maintenance ; Booklet Octavia III
3.4 General instructions for charge air sys‐

tem
When undertaking all installation work, particularly in the engine
compartment due to its cramped construction, please observe the
following:
♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,
cooling fluid and refrigerant, brake fluid, vacuum) and electri‐
cal lines
unless authorised by in such
ŠKODA a way
AUTO that the
A. S. ŠKODA AUTO original
A. S. doesline guide or
not guarantee isaccept
re- any liability
with established.
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ 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.
♦ Inspect the air filter housing, the air filter element and the in‐
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. Repair instructions 7
3.5 Additional instructions when undertak‐

ing assembly work on the air-condition‐
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.
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
3.6 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 suita‐
ble plugs during assembly works on the engine, for example from
the screw plug set for engine - VAS 6122- .
3.7 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 .
3.8 Cable routing and securing

Install lines of all kinds so that the original routing can be restored.
♦ Fuel feed lines
♦ Hydraulic lines
♦ Brake fluid lines
♦ Coolant lines
♦ 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. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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).
3.9 Assembly of radiators and condensers

The radiator, condenser and charge air cooler may have minor
indentations on the fins, even if assembled correctly. This is not
a case of damage. Radiators, condensers and charge air coolers
must not be replaced because of these indentations.
3. Repair instructions 9
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
⇒ “1.2 Disconnecting engine and gearbox”, page 20
⇒ “1.3 Securing the engine to the assembly stand”, page 21
⇒ “1.4 Installing engine”, page 22
1.1 Removing engine

Special tools and workshop equipment required
♦ Disassembly tool for door panel - MP8-602/1-
♦ Extension - 2024 A /1- of lifting device - MP9-201 (2024A)-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine mount - T10497-
♦ Catch pan , e.g. -VAS 6208-
♦ Hose strap pliers , e.g. -VAS 6362-
♦ Locking pin - T10060A-
♦ Double ladder , e.g. -VAS 5085-
♦ Radiator protection mat - VAS 531003-
♦ 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 ⇒ Wheels, tyres; Rep. gr. 44 .
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 . 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 ⇒ Body Work;
Rep. gr. 66 .
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 307 .
– Removing fan shroud
⇒ “4.6 Removing and installing fan shroud”, page 214 .
10 Rep. gr.10 - Removing and installing engine

– Cover radiator with radiator protection mat - VAS 531003- .
WARNING
♦ Before opening the injection system high-pressure system, the

fuel pressure must be reduced.
– Remove the battery with the battery tray ⇒ Electrical System;
Rep. gr. 27 .
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 41 .
CAUTION
– Disconnect plug connection -1- on the control valve for the air
conditioning
Protected system
by copyright. Copying compressor - N280-
for private or commercial . in part or in whole, is not permitted
purposes,
– 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 ho‐

ses.
– Remove AC compressor with connected refrigerant hoses and
strap up to the right side.
Continued for all vehicles
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page 172 .
– Unlock catch -arrow- and remove vacuum hose -1-.

– Expose vacuum hose on the air guide pipe -2-.
1. Removing and installing engine 11

– Remove the vacuum hose -1- from the brake vacuum pump -
V192- -A-.
– Remove vacuum hose from the engine mounting.
– 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 cata‐
lytic 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 6 .

– Disconnect the fuel feed line -1- and vent line -2- to the acti‐
vated charcoal filter
⇒ “3.1 Separating push-on couplings”, page 256 .
– Disconnect the plug connection -1-.

– Unscrew retaining clip -2- from hoses from the coolant tank.
– Unlock catches using a screwdriver -arrow- and lay coolant
expansion tank to the side.
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.
– Loosen hose clamp -1- and remove coolant hose -2-.
– 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 - MP8-602/1- .

– Disconnect plug -1- from the engine control unit - J623-

⇒ “8.1 Removing and installing engine control unit J623 ”, page
340 .
– Take electrical plug connections -2- and -3- out of the holder
and disconnect.
– Expose the electric cables.

– Press back 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 a manual gearbox

– Disconnect connectors -1- and -2-.
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.
34 .
– Remove slave cylinder ⇒ Gearbox; Rep. gr. 30 .
For vehicles with automatic gearbox
– Unlock and disconnect the plug on the automatic gearbox ⇒
Gearbox; Rep. gr. 34 .
– Remove selector lever linkage, pull off mechatronics plug and
remove all holders from the gearbox ⇒ Gearbox; Rep. gr. 34 .

– Disconnect electrical plug connection -1-byatŠKODA
unless authorised the oil
AUTOlevel
A. S. and
ŠKODA AUTO A. S. does not guarantee or accept any liability
oil temperature sender - G266-with. respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– 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.
– Release screws -arrows- and remove heat shield for right drive
shaft.
– Remove assembly carrier without steering gear ⇒ chassis,
axles, steering; Rep. gr. 40 .

– Unscrew nuts -arrows- on right and left steering joint.
– If present, unscrew nuts -4- and screw -1- from the front left
vehicle level sensor - G78- -3- and place to one side.
– Unhook swivel hub from track control arm on left and right.
– Unscrew the drive shaft left and right ⇒ Axles, steering; Rep.
gr. 40 and strap up.
Note
Ensure that the surface protection of the drive shaft is not dam‐
aged.

– Swivel suspension strut left towards the outside and support

with extension -2024 A /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
To remove the screws for the assembly mountings, use a com‐

mercially available double ladder , e. g. -VAS 5085- .
– 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

♦ Additional hook - MP9-200/10 (10-222A/2)-
♦ Workshop crane , e.g. -VAS 6100-
♦ Shackle - 10-222A/12-
• Engine/gearbox unit with
removed and attached to engine mount -
T10497- .
– Remove starter ⇒ Electrical System; Rep. gr. 27 .

– Install shackle - 10-222A/12- on gearbox.

– Hook additional hook - MP9-200/10 (10-222A/2)- with shackle
- 10-222A/12- onto 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 ⇒ Gearbox; Rep.

gr. 34
– Remove the gearbox from the engine.
1.3 Securing the engine to the assembly

stand
♦ Lifting device - MP9-201 (2024 A)-
♦ Engine and gearbox mount - VAS 6095-
♦ Workshop crane , e.g.
with respect to the-VAS 6100-
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
• Gearbox disconnected from engine

⇒ “1.2 Disconnecting engine and gearbox”, page 20 .
– Suspend lifting device - MP9-201 (2024 A)- -A- from the en‐
gine and workshop crane - VAS 6100- -B- as shown in the
illustration.
– 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 - 2024 A /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- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Locking pin - T10060A- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Double ladder , e.g. -VAS 5085-

♦ 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.
♦ After installing new parts (engine/partial engine, cylinder head,
camshaft housing or exhaust gas turbocharger), the oil pres‐
sure control must be limited to the high pressure level for
approx. 1000 km. This takes into account the higher friction
when running in new components and ensures optimum evac‐
uation of particles from running-in wear ⇒ page 25 .
♦ The function to increase oil pressure does not always have to
be available on the engine control unit. In this case, the oil
pressure is not increased.

– 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.
– Move the clutch plate to and fro on the input shaft until the hub
moves freely on the shaft. Always remove excess grease.
– Check the centring of the clutch disc ⇒ Gearbox; Rep. gr. 30 .
– Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ Gearbox; Rep. gr. 30 .


– Replace the needle bearing -arrow- in the crankshaft
⇒ “3.2 Replace needle bearing for crankshaft”, page 62 .
Installation is carried out in the reverse order. When installing,
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 .
– Installing intermediate plate
⇒ Fig. ““Installing intermediate plate”“ , page 51 .
– If there are no dowel sleeves in the cylinder block for centring

the engine and gearbox, insert dowel sleeves -A-.
– Screw gearbox securely onto engine at positions -1-, -2-, -3-,
-6-, -7-, -8- and -9-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– 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
⇒ “2.5 Adjusting the unit mounting”, page 33 .
– Remove engine mount T10497 from engine.

– Install the starter engine ⇒ Electrical System; Rep. gr. 27 .
– Install slave cylinder ⇒ Gearbox; Rep. gr. 30 .
– Install linkages with linkage support ⇒ Gearbox; Rep. gr. 34 .
– Install assembly carrier ⇒ Axles, steering; Rep. gr. 40 .
– Install selector lever linkage, attach mechatronics plug and all
holders to the gearbox ⇒ Gearbox; Rep. gr. 34 .
– Install pendulum support
⇒ “2.4 Removing and installing pendulum support”,
page 33 .
– Install exhaust pipe with catalytic converter
⇒ “1.2 Removing and installing pre-exhaust pipe with catalytic
converter”, page 345 .
– Install drive shafts ⇒ Axles, steering; Rep. gr. 40 .
– Installing nuts for steering joint/wheel bearing housing left and
right ⇒ Axles, steering; Rep. gr. 40 .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr.
87 .
– Install the V-ribbed belt
⇒ “1.2 Removing and installing V-ribbed belt”, page 40 .
Electrical connections and proper routing ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
– Connect plug of the engine wiring harness to engine control
unit
340 .
– Connect the remaining electric cables to the engine and gear‐
box.
– Connect coolant hoses.
– Install pendulum support
⇒ “2.4 Removing and installing pendulum support”,
page 33 .
– Remove the front left and right wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Install front wheels ⇒ Wheels, tyres; Rep. gr. 44 .

– Adjust the assembly bracket

⇒ “2.5 Adjusting the unit mounting”, page 33 .
– Install the battery with the battery tray ⇒ Electrical System;
Rep. gr. 27 .
– Install air filter housing
– Checking the oil level ⇒ Maintenance ; Booklet Octavia III .
– Top up and bleed cooling system
⇒ “1.3 Draining and filling coolant”, page 172 .
– Interrogate all event memories and delete all event entries
which are caused by removing and installing the engine ⇒ Ve‐
hicle diagnostic tester.
After deleting the event memory of the engine control unit the
readiness code must be re-generated.
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:
Note

uation of particles from running-in wear.
– Connect the diagnostic device ⇒ Vehicle diagnostic tester and

carry out the function 0001 - Activate engine inlet .
Comply with the information given in the type plate ⇒ page 1 .
– Check Protected
the information on the
by copyright. Copying for vehicle type plate
private or commercial withinthe
purposes, ac‐
part or in whole, is not permitted
companying engine
unless authorised identity
by ŠKODA AUTOcard.
A. S. The
ŠKODAinformation
AUTO A. S. doesgiven mustor accept any liability
not guarantee
be the same.
– Carry out function 0001 - Replace the engine ⇒ Vehicle

diagnostic tester.
Tightening 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 Tightening torque

Screws/nuts M6 9 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. gr. 34
♦ Drive shaft screening ⇒ Axles, steering; Rep. gr. 40 .
Screws for assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”, page 27 .

2 Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”, page 27
⇒ “2.2 Removing and installing engine mount”, page 29
⇒ “2.3 Removing and installing gearbox mount”, page 30
⇒ “2.4 Removing and installing pendulum support”, page 33
⇒ “2.5 Adjusting the unit mounting”, page 33
⇒ “2.6 Check assembly bracket setting”, page 35
2.1 Assembly overview - assembly mountings
1 - Screw
❑ Replace after removal
❑ Tightening sequence
⇒ Fig. ““Engine support
bracket - tightening tor‐
que and tightening or‐
der”“ , page 28
❑ 40 Nm + 90°
2 - Engine support bracket
❑ Tightening torque and
tightening order
⇒ Fig. ““Engine support
bracket - tightening tor‐
der”“ , page 28
❑ removal and installation
⇒ “1.5 Removing and in‐
stalling engine support”,
page 44
3 - Engine mounting
❑ with supporting arm
stalling engine mount”,
page 29
4 - Screw
❑ 40 Nm + 90°
5 - Screw
❑ 20 Nm + 90°
6 - Screw
❑ 8 Nm
7 - Mounting bracket
8 - Screw
❑ 60 Nm + 90°
9 - Pendulum support
❑ removal andProtected
installation ⇒ “2.4 Removing and installing pendulum support”, page 33
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
2. Assembly bracket 27
10 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Pendulum support - tightening torque and tightening order”“ , page 29
11 - Screw
12 - Screw
13 - Screw
❑ Tightening torque ⇒ Gearbox; Rep. gr. 34
14 - Screw
❑ Tightening torque ⇒ Gearbox; Rep. gr. 34
15 - Screw
❑ 50 Nm + 90°
16 - Gearbox mount
❑ with supporting arm
❑ removal and installation ⇒ “2.3 Removing and installing gearbox mount”, page 30
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:

Level Screws Tightening torque/torque angle
1. -1…3- 40 Nm
2. -1…3- Turn 90° further

Pendulum support - tightening torque and tightening order
Note

be replaced.

1. -2- - -3- 50 Nm
2. -1- 130 Nm
2.2 Removing and installing engine mount

♦ Supporting device - T30099-
♦ Adapter - T40091/3-
♦ Hook - MP9-200/10-
♦ Adapter - MP9-200/18-
♦ Support - 10-222A/31-
♦ Surface - T30119-
Removing
– Unscrew retaining clip -2- from hoses from the coolant tank.
– Unscrew vacuum pump for brake - V192- together with the
bracket from the engine bearing ⇒ braking system; Rep. gr.
47 ,
– Place vacuum pump for brakes - V192- to the side with con‐
nected cables.
– Remove plenum chamber cover ⇒ Body Work; Rep. gr. 50 .
– Remove caps of screwed connections for front suspension
strut domes.
– Install adapter - MP9-200/18 (10-222A/18)- with hook for
MP9-200 and T30099 - MP9-200/10 (10-222A/10)- and sup‐
port - 10-222A/31-3- .
– Fit supporting device - T30099- , as shown in the illustration.

– Slightly pre-tension engine/gearbox unit with the spindle, do
not raise.
– Unscrew screws -arrows- and remove engine mount -1-.

Installing
Note

be replaced.
– Check assembly mounting adjustment

⇒ “2.6 Check assembly bracket setting”, page 35 .
– Remove supporting device - T30099- .
Tightening torques
• Assembly bracket
2.3 Removing and installing gearbox mount

♦ Adapter - T40091/3-
♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)-
♦ Adapter - MP9-200/18 (10-222A/18)- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Support - 10-222A/31- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Removing
Rep. gr. 27 .
– Remove the engine control unit
340 .
– 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.
strut domes.
port - 10-222A/31-3- .

– Attach spindle snap hook to the engine suspension eye.
– Pre-tension engine/gearbox unit with the spindle, do not raise.

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

– Unscrew screws -2- and then screws -1-.
– 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 - T30099- until the bolts se‐
curing 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 - T30099- .
Tightening torques
♦ Assembly bracket
♦ Air filter housing
⇒ “2.1 Assembly overview - air filter housing”, page 306 .
♦ Air filter housing
♦ Engine control unit
340 .

2.4 Removing and installing pendulum sup‐

port
gr. 66 .
– Remove screws -1-, -2- and -3-.
– Remove pendulum support -4- from assembly carrier -5-.
Installing
Installation is carried out in the reverse order.
Tightening torques
♦ Screws for pendulum support
2.5 Adjusting the unit mounting

♦ authorised
unless Adapter - T40091/3-
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
strut domes.
port - 10-222A/31-3- .
– Attach snap hook to the engine suspension eyes.
– Slightly pre-tension engine/gearbox unit with the spindles, do
not raise.
– 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
– Firstly, loosely insert the screws.
– 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.

Make sure that the edges of the supporting arm of the gearbox
sides and the gearbox support are parallel.
• Dimension -x- = -x-.
– Tighten gearbox mount screws.
Further installation occurs in reverse order.
Tightening torques
♦ Assembly bracket
♦ Charge-air system
⇒ “2.1 Summary of components - charge air system”,
page 283 .
♦ Battery tray ⇒ Electrical System; Rep. gr. 27 .
♦ Air filter
2.6 Check assembly bracket setting

The following dimensions must be reached:
• A distance of -a- = 10 mm must be present between engine
support
Protected -2- Copying
by copyright. and engine
for privatemount -1-. purposes, in part or in whole, is not permitted
or commercial
•withThe cast
respect to theedge on of
correctness the engine
information support
in this -2-
document. mustbybeŠKODA
Copyright parallel
AUTOwith
A. S.�
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 ⇒ “2.5 Adjusting the unit mounting”, page 33 .
3 Engine trim panel

⇒ “3.1 Removing and installing engine trim panel”, page 36
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 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
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-.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - V-ribbed belt drive”, page 37
⇒ “1.2 Removing and installing V-ribbed belt”, page 40
⇒ “1.3 Removing and installing V-ribbed belt tensioning device”,
page 42
⇒ “1.4 Removing and installing vibration damper”, page 43
⇒ “1.5 Removing and installing engine support”, page 44
⇒ “1.6 Replacing crankshaft sealing ring on the belt pulley side”,
page 47
1.1 Assembly overview - V-ribbed belt drive

⇒ “1.1.1 Summary of components - V-ribbed belt drive for vehicles
without air conditioning system”, page 37
⇒ “1.1.2 Summary of components - V-ribbed belt drive for vehicles
with air conditioning system”, page 39
1.1.1 Summary of components - V-ribbed belt drive for vehicles without air con‐
ditioning system
1. Cylinder block (pulley end) 37

1 - Screw
❑ to release and tighten
use counterholder -
T10475-
❑ 150 Nm + 180°
2 - Vibration damper
❑ with vibration damper
stalling vibration damp‐
er”, page 43
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 41
stalling V-ribbed belt”,
page 40
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it.
4 - Screw
❑ 20 Nm + 90°
5 - Tensioning device for V-rib‐
bed belt
❑ Swivel tensioning de‐
vice for V-ribbed belt with socket insert to slacken the V-ribbed belt
❑ lock with locking pin - T10060A-
❑ removal and installation ⇒ “1.3 Removing and installing V-ribbed belt tensioning device”, page 42
6 - Screw
❑ 23 Nm
7 - AC generator
❑ Removing and installing ⇒ Electrical System; Rep. gr. 27
❑ 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 39
❑ Depending on the
Protected by copyright. model
Copying of the
for private belt pulley
or commercial for AC
purposes, generator,
in part thepermitted
or in whole, is not correct length of the V-ribbed belt must
be assigned
unless ⇒ ŠKODA
authorised by ETKA - Electronic
AUTO Catalogue
A. S. ŠKODA AUTO A. S. doesof
notOriginal
guarantee orParts
accept any liability
38 Rep. gr.13 - Crankshaft group

Version of V-ribbed belt pulley with freewheel
1.1.2 Summary of components - V-ribbed belt drive for vehicles with air condi‐
tioning system
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 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ Routing of the ribbed V-
belt ⇒ page 42
⇒ “1.2.1 Removing and
installing V-ribbed belt
on vehicles without air
conditioning system”,
page 40
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it.
2 - Screw
❑ to release and tighten
use counterholder -
T10475-
❑ 150 Nm + 180°
3 - Vibration damper
❑ with vibration damper
stalling vibration damp‐
er”, page 43
4 - Tensioning device for V-rib‐
bed belt
❑ Swivel tensioning de‐
vice for V-ribbed belt
with socket insert to
slacken the V-ribbed belt

❑ lock with locking pin - T10060A-
❑ removal and installation ⇒ “1.3 Removing and installing V-ribbed belt tensioning device”, page 42
5 - Screw
❑ 20 Nm + 90°
6 - Screw
❑ 23 Nm
7 - AC generator
❑ Removing and installing ⇒ Electrical System; Rep. gr. 27
❑ 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 40
❑ 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
❑ for the AC compressor
9 - AC compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
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 without
air conditioning system”, page 40
⇒ “1.2.2 Removing and installing V-ribbed belt on vehicles with
air conditioning system”, page 41
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
– Swivel tensioning device in -direction of arrow- in order to
slacken the V-ribbed belt.
– Lock tensioning device 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- V-ribbed belt tensioning device.
3- Belt pulley-AC generator.
– Turn the tensioning element in the -direction of the arrow- and

pull out the locking pin - T10060A- .
– Release pressure on tensioning device.
– Check that the V-ribbed belt is positioned correctly.
– 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.
– Swivel tensioning device in -direction of arrow- to slacken the
V-ribbed belt.
– Lock tensioning device 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- V-ribbed belt tensioning device.
3- Belt pulley-AC generator.
4- Belt pulley-AC compressor
– Turn the tensioning element in the -direction of the arrow- and

pull out the locking pin - T10060A- .
– Release pressure on tensioning device.
– Check that the V-ribbed belt is positioned correctly.
– Start engine and check the that the V-ribbed belt is running
correctly.
1.3 Removing and installing V-ribbed belt

tensioning device
Removing
– Remove the V-ribbed belt from the tensioning device:
♦ Vehicles without air conditioning system
⇒ “1.2.1 Removing and installing V-ribbed belt on vehicles
without air conditioning system”, page 40 .
♦ Vehicles with air conditioning system
⇒ “1.1.2 Summary of components - V-ribbed belt drive for ve‐
hicles with air conditioning system”, page 39 .

– Unscrew screws -arrows- and pull off the tensioning device

-1- for V-ribbed belt.
Installing
Tightening torques
♦ Tensioning device screws - vehicles without air conditioning
system
hicles without air conditioning system”, page 37 .
♦ Tensioning device screws - vehicles with air conditioning
hicles with air conditioning system”, page 39 .
1.4 Removing and installing vibration damp‐

er
♦ Counterholder - T10475-
Removing
gr. 66 .
– Remove V-ribbed belt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “1.2 Removing and installing V-ribbed belt”, by
unless authorised page
ŠKODA 40AUTO
. A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Position piston of the cylinder 1 on TDC
⇒ “2.4 Position crankshaft at the top dead centre (TDC).”, page
90 .

– Loosen screw -arrow- for vibration damper; to do so, use

counterholder - 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:
Tightening torques
♦ Screw for vibration damper
⇒ “1.1 Assembly overview - V-ribbed belt drive”, page 37 .
1.5 Removing and installing engine support

♦ Adapter - T40091/3-
♦ Adapter - MP9-200/18-
♦ Support - 10-222A/31-
Removing
Rep. gr. 27 .
– Remove V-ribbed belt tensioning device
⇒ “1.3 Removing and installing V-ribbed belt tensioning de‐
vice”, page 42 .
– Remove top toothed belt guard
⇒ “2.5.1 Removing and installing top toothed belt guard”, page
92 .

– Unscrew bolt -1-.

– Loosen hose clamp -2- and remove coolant hose.
– Remove holder for cable harness -arrow- from the engine

support.
Note
Open closed lines and connections immediately with suitable

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

– 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.
– Remove pendulum support
⇒ “2.4 Removing and installing pendulum support”, page 33 .
strut domes.
port - 10-222A/31-3- .

– Attach snap hook to the engine suspension eyes.
– Slightly pre-tension engine/gearbox unit with the spindle, do
not raise.
– Remove engine mounts
⇒ “2.2 Removing and installing engine mount”, page 29 .
– Remove screws -arrows-.

– Unscrew screws -1-, -2- and -3-.

– Unscrew screws for gearbox mount
⇒ “2.3 Removing and installing gearbox mount”, page 30 .
– Press engine/gearbox unit slightly to the left and remove en‐
gine support.
Installing
Tightening torques
♦ Assembly bracket ⇒ “2 Assembly bracket”, page 27 .
♦ V-ribbed belt tensioning device
♦ Toothed belt guard
⇒ “2.1 Summary of components - toothed belt guard”,
page 87 .
♦ Coolant pipes
⇒ “3.1 Summary of components - coolant pipe”, page 198 .
♦ Charge-air system
page 283 .
♦ Air filter
♦ Removing and installing parts of the exhaust system
⇒ “1.1 Summary of components - Pre-exhaust pipe with cat‐
alytic converter”, page 343 .
♦ Battery tray ⇒ Electrical System; Rep. gr. 27 .
♦ Wiper arms ⇒ Electrical system; Rep. gr. 92 .
1.6 Replacing crankshaft sealing

correctness ring on inthe
with respect to the of information this document. Copyright by ŠKODA AUTO A. S.�
belt pulley side

♦ Assembly tool - T10485/1,2 and 3-
♦ Extractor tool - T20143-
– Remove toothed belt
⇒ “2.6 Removing and installing toothed belt”, page 93 .
– 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 Cylinder block on gearbox side

⇒ “2.1 Summary of components - cylinder block on gearbox side”,
page 50
⇒ “2.2 Removing and installing flywheel”, page 52
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 52
2.1 Summary of components - cylinder block on gearbox side
1 - Flywheel
stalling flywheel”,
page 52
❑ can be installed only in
one position
2 - Screw
❑ 60 Nm + 90°
3 - Fitting sleeve
❑ 2 pieces
4 - engine speed sender - G28-
stalling the engine
speed sender G28 ”,
page 359
5 - Screw
❑ Tightening torque
⇒ “1.1 Assembly over‐
view - ignition system”,
page 353
6 - Seal
7 - Intermediate plate
❑ do not damage/bend
during assembly work
❑ installing
⇒ Fig. ““Installing inter‐
mediate plate”“ ,
page 51
8 - Intermediate plate
❑ removal and installation ⇒ Fig. ““Installing intermediate plate”“ , page 51
9 - Screw
❑ 2 pieces
❑ for intermediate plate
❑ 25 Nm
10 - Fitting sleeve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ 2 pieces with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
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

❑ removal and installation ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 52
12 - Screw
⇒ Fig. ““Sealing flange on the gearbox side - tightening torque and tightening order”“ , page 51
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 52
Sealing flange on the gearbox side - tightening torque and tight‐

ening order
– Tighten screws gradually as follows:
Level Screws Tightening torque
1. -1…6- Tighten by hand as far as the stop
2. -1…6- tighten crosswise in steps up to
10 Nm
Installing 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 the intermediate plate onto the adapter sleeves
⇒ Fig. ““Installing intermediate plate”“ , page 51 ,
Screws 25 Nm
2. Cylinder block on gearbox side 51

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

♦ Counterholder - MP1-223 (3067)-
Removing
• Gearbox removed
– Remove clutch on vehicles with manual gearbox ⇒ Gearbox;
Rep. gr. 30 .
• Fitting position of the tool:
A - for tightening
B - for slackening
– Insert the counterholder - 3067- into the hole on the cylinder
block -B-.
– Loosen and remove all flywheel bolts.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.�

Note
Assembly of flywheel with rotor is only possible in one position.
– Insert the counterholder - 3067- into the hole on the cylinder

block -A-.
Tightening torque
♦ Screws for flywheel
⇒ “2.1 Summary of components - cylinder block on gearbox
side”, page 50 .
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.
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 .
Note
♦ For reasons of clarity, the work was performed with the engine
removed.
♦ Thewith
work sequences
respect areofidentical
to the correctness information inwith the engine
this document. installed
Copyright and
by ŠKODA AUTO A. S.�
gearbox removed.
– Remove flywheel or driver disc

⇒ “2.2 Removing and installing flywheel”, page 52 .
– 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
90 .
– Removing the oil pan
⇒ “1.3 Removing and installing oil pan”, page 153 .
– Remove the engine speed sender - G28- -arrow-

⇒ “1.6 Removing and installing the engine speed sender G28
”, page 359 .

– 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 or turn 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 55 .
♦ 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 55 .

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 sensor wheel 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 device - T10134- on clamping surface -A- of

the threaded spindle in a vice.
– Press assembly housing -C- downwards until it lies on hexa‐
gon nut -B-.
– Screw nut onto threaded spindle until inner part of the assem‐
bly 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 or turn it.

• 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.
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.
– Lay the sealing flange -1- with the front side on the assembly
device - T10134- in such a way that the positioning pin -D-
engages into the hole -3- of the sensor rotor -2-.
• Sealing flange must lie straight on the assembly device.

– 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 sealing flange, ensure that sender wheel remains

fixed in 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”
90 .
– 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- lies against the assembly
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 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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.

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.
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-.
D - Press sender wheel onto crankshaft flange using assembly

device - T10134- :
– Tighten nuts -B- on the assembly tool - T10134- with torque
wrench to 35 Nm.
• After tightening the nut to 35 mm 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 device - T10134- .
– Remove sealing lip support ring.
– Place calliper 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 59 .
If dimension »a« is achieved:
– Complete the remaining installation ⇒ page 60 .
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
Protected block.

– Tighten nuts -B- on the assembly device - T10134- to 40 Nm.

– Check the fitting position of the rotor on the crankshaft again
⇒ page 58 .
If the dimension »a« is too small again:
– Tighten nuts -B- on the assembly device - T10134- to 45 Nm.
– Check the fitting position of the rotor on the crankshaft again
⇒ page 58 .
Installing
– Tighten screws for sealing flange crosswise.
– Installing the oil pan
– Install intermediate plate / intermediate plate
side”, page 50 .
– Install the flywheel
⇒ “2.2 Removing and installing flywheel”, page 52 .
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 ⇒ Vehicle
diagnostic tester.
♦ 0001 - Engine electronics - Petrol engine 1.5 l
♦ 0001 - Repair groups
♦ 15 - Cylinder head, valve gear
♦ 15 - Correction Protected
values by copyright. Copying for private
of crankshaft or commercial purposes, in part or in whole, is not permitted
position
Note
The function is independent until the end.

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

erances.
♦ These tolerances 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.
Tightening torques
♦ Sealing flange on the gearbox side
side”, page 50 .
♦ Engine speed sender - G28-
side”, page 50 .
♦ Screw plug for bore in the cylinder block
⇒ Fig. ““Screw plug for TDC bore in the cylinder block behind
- tightening torque”“ , page 52 .

3 Crankshaft
⇒ “3.1 Measuring axial play of crankshaft”, page 62
⇒ “3.2 Replace needle bearing for crankshaft”, page 62
⇒ “3.3 Crankshaft dimensions”, page 63
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
Protected bearing
by copyright. seats
Copying of the
for private cylinderpurposes,
or commercial block.in part or in whole, is not permitted
♦ 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 needle bearing for crankshaft

Only for vehicles with automatic gearbox
♦ Centring mandrel -T30029 (3176)-
♦ Interior extractor - Kukko 21/2- or e.g. -VAS 251 605-
♦ 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.
– Drive in needle bearing with centring mandrel -T30029 (3176)-

flush with the crankshaft face.
3.3 Crankshaft dimensions Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
NOTICE with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
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.
Grinding dimension ∅ conrod journal
mm
Basic dimension 47.80 –0.022
–0.037
3. Crankshaft 63
4 Pistons and conrods

⇒ “4.1 Assembly overview - piston and conrod”, page 64
⇒ “4.2 Removing and installing the piston”, page 65
⇒ “4.3 Separating new connecting rod”, page 66
⇒ “4.4 Removing and installing oil injection nozzles”, page 67
⇒ “4.5 Check piston and cylinder bore”, page 68
⇒ “4.6 Check radial clearance of connecting rods”, page 69
4.1 Assembly overview - piston and conrod
1 - Screw
❑ Oil threads and contact
surface.
❑ 30 Nm + 90°
2 - Connecting rod bearing cap
❑ as a result of the con‐
rods separated in the
cracking
unless authorised process,
by ŠKODA AUTOtheA. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with conrod bearing
respect to the cap
correctness fits
of information in this document. Copyright by ŠKODA AUTO A. S.�
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 in‐
stallation position”“ ,
page 65
❑ 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 col‐
our -B-
❑ separate new conrod
⇒ “4.3 Separating new
connecting rod”, page 66
5 - Circlip
❑ 2 pieces
6 - Piston pin
❑ removal and installation ⇒ “4.2 Removing and installing the piston”, page 65

7 - Piston
❑ Mark the installation position and the assignment to cylinder
⇒ Fig. ““Fitting position of piston and assignment of piston to cylinder”“ , page 65
❑ removal and installation ⇒ “4.2 Removing and installing the piston”, page 65
❑ Check piston and cylinder bore ⇒ “4.5 Check piston and cylinder bore”, page 68
8 - Piston rings
❑ Compression rings
❑ Measure end gap ⇒ Fig. ““Measure piston ring end gap”“ , page 69
❑ Measure vertical gap ⇒ Fig. ““Measure piston ring vertical gap”“ , page 69
❑ 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 69
❑ Measure vertical gap ⇒ Fig. ““Measure piston ring vertical gap”“ , page 69
❑ 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 conrod and conrod bear‐
ing cap.
• Dimension -a- = 2.5 mm
4.2 Removing and installing the piston

4. Pistons and conrods 65

♦ Drift , e.g. -T10046-

♦ Commercially available piston ring tensioning strap
Removing
– Remove cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 75 .
– Mark installation position and assignment of the piston to the
cylinder
⇒ “4.1 Assembly overview - piston and conrod”, page 64 .
– Mark the installation position and assignment of the conrod to
the cylinder and to the conrod bearing cap
– 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 piston with commercially available piston ring tension‐
ing strap, check installation position
⇒ Fig. ““Fitting position of piston and assignment of piston to
cylinder”“ , page 65 .
– Install conrod bearing cap, check installation position
– Install cylinder head
Tightening torques
♦ Conrod bearing cap screws
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 alumi‐

nium 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 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
• 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
2- Oil spray nozzle (for cooling piston)
Tightening torques
Pressure relief valve 27 Nm
4.5 Check piston and cylinder bore

Inspecting piston
– Using anbyexternal
Protected micrometer,
copyright. Copying for private ormeasure pistonsin part
commercial purposes, approx.
or in whole, is not permitted
10 mmauthorised
unless from the lower
by ŠKODA edge
AUTO A. S.of skirt,AUTO
ŠKODA at 90° to the
A. S. does piston or
not guarantee pin
accept any liability
axis.
∅ piston in mm
Nominal value1) dimensions 74,4501) +0.009 -0.009
without coating
Nominal value2) dimensions af‐ 74,472 1) +0.017 -0.017
ter coating
• 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
Protected by copyright. Copying + 0.015
for private 1)
or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA+0.005
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Note
Cylinder bores must not be measured when cylinder block is

mounted on engine and gearbox support - VAS 6095- , as meas‐
urements 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.
– Mount the connecting rod bearing cover and tighten with 30
Nm without further turning angle.
Note
Do not twist the crankshaft.
– Remove conrod bearing cap.

– Measure the thickness of the plastigage.
• Axial clearance: 0.028 - 0.065 mm.
– Replace screws for conrod.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 71
⇒ “1.2 Summary of components - camshaft housing”, page 73
⇒ “1.3 Removing and installing cylinder head”, page 75
⇒ “1.4 Removing and installing camshaft housing”, page 79
⇒ “1.5 Checking compression”, page 83
⇒ “1.6 Checking the combustion chamber for tightness”,
page 85
1.1 Summary of components - cylinder head
1 - Cylinder head
⇒ “1.3
Protected Removing
by copyright. Copying and in‐ or commercial purposes, in part or in whole, is not permitted
for private
unlessstalling cylinder
authorised by ŠKODA AUTOhead”,A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
page 75
❑ check for distortion

⇒ Fig. ““Checking cylin‐
der head for distortion”“ ,
page 72
2 - Dowel pins
❑ 2 pieces
3 - Camshaft housing
❑ The camshafts cannot
be removed individually
❑ Summary of compo‐
nents
⇒ “1.2 Summary of com‐
ponents - camshaft
housing”, page 73
stalling camshaft hous‐
ing”, page 79
4 - Seal
❑ Different versions ⇒ ET‐
KA - Electronic Cata‐
logue of Original Parts
5 - Cylinder head bolt
❑ pay attention to order for
slackening ⇒ page 77
tightening order
⇒ Fig. ““Cylinder head - tightening torque and tightening order”“ , page 72
7 - Screw
❑ 20 Nm
1. Cylinder head 71
8 - Cylinder head gasket

❑ replace after removal ⇒ “1.3 Removing and installing cylinder head”, page 75
❑ Observe fitting position: Part number points to cylinder head.
9 - Screw for camshaft housing
⇒ Fig. ““Camshaft housing - tightening torque and tightening order”“ , page 75
Cylinder head - tightening torque and tightening order

Tighten screws gradually in the given sequence:
– Insert cylinder head bolts and tighten by hand.
1. -1…10- 40 Nm
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.
72 Rep. gr.15 - Cylinder head, valve gear

1.2 Summary of components - camshaft housing
1 - O-ring
❑ Check O-ring for dam‐
age
❑ O-ring is not available
separately; in the event
of damage, replace to‐
gether with exhaust cam
adjuster .
2 - Exhaust cam adjuster for
cylinder 3 - N595-
stalling cam adjuster”,
page 133
3 - O-ring
❑ Check O-ring for dam‐
age
❑ O-ring is not available
separately; in the event
of damage, replace to‐
gether with inlet cam ad‐
juster .
4 - Inlet cam adjuster for cylin‐
der 3 - N591-
page 133
5 - Screw
❑ 4 Nm
6 - Inlet cam adjuster for cylin‐
der 2 - N583-
page 133
7 - Screw
❑ 4 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
8 - Exhaust cam adjuster for cylinder 2 - N587-
❑ removal and installation ⇒ “3.5 Removing and installing cam adjuster”, page 133
9 - Screw
⇒ Fig. ““Camshaft housing - tightening torque and tightening order”“ , page 75
10 - Screw
❑ 8 Nm
11 - Screw
❑ 8 Nm
12 - Camshaft adjustment valve 1 in the outlet - N318-
⇒ “3.7 Removing and installing camshaft control valve 1 in the exhaust N318 ”, page 135
13 - O-ring
❑ Check O-ring for damage
1. Cylinder head 73
❑ 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-
⇒ “1.5 Removing and installing position transmitter for exhaust camshaft G1003 ”, page 358
❑ Summary of components ⇒ “1.1 Assembly overview - ignition system”, page 353
15 - O-ring
❑ 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
⇒ “3.3.2 Removing and installing the inlet camshaft on the belt pulley side”, page 122
17 - Sealing ring
❑ for exhaust camshaft on the belt pulley side
⇒ “3.3.3 Removing and installing the exhaust camshaft on the belt pulley side”, page 124
18 - Exhaust gas pressure sensor 1 - G450-
⇒ “5.4 Removing and installing pressure sensor for exhaust gas 1 G450 ”, page 331
❑ 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 - Seal
21 - O-ring
22 - Sealing ring
❑ for exhaust camshaft on the gearbox side
⇒ “3.3.4 Removing and installing the exhaust camshaft on the gearbox side”, page 125
23 - Pulley
❑ For coolant pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ removal and installation with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ “2.6 Removing and installing toothed belt pulley for coolant pump drive”, page 184
24 - Screw
❑ Tightening torque ⇒ Item 3 (page 178)
25 - Screw
❑ 8 Nm
26 - Screw
❑ 8 Nm
27 - Position sensor for intake camshaft - G1002-
⇒ “1.4 Removing and installing position transmitter for inlet camshaft G1002 ”, page 357

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
Camshaft housing - tightening torque and tightening order
Note
Replace screws which have been tightened to specified torquing

angle.

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

Removing
Note

uation of particles from running-in wear Diagnostic device
⇒ Vehicle diagnostic tester 0001 - Activate engine in-
let .

♦ 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 79 .
– Removing the intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 310 .
– Remove exhaust turbocharger
⇒ “1.2 Removing and installing exhaust gas turbocharger”,
page 275 .
1. Cylinder head 75
– Remove the roller towing lever and balancing elements

⇒ page 81 .
– Disconnect plugs -1-, -2- and -3-.
– Unscrew screw -1- at the engine support.

– Loosen and remove the screws for the cylinder head in the
sequence -1-10-
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.
Installing
NOTICE
Risk of damaging sealing surfaces.
– Carefully remove residual sealant from the cylinder head and

cylinder block.
– Make sure this does not cause any extended scoring or
scratching.
NOTICE
Risk of damaging the cylinder block.
♦ There must be no oil or coolant in the blind holes for the cyl‐
inder 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 cam‐
shaft 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 head or the cylinder head gasket is re‐
placed, the engine oil must be replaced.
– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.
1. Cylinder head 77
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.
– 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.
– 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
⇒ “2.4 Position crankshaft at the top dead centre (TDC).”,
page 90 .
– 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 or‐
der”“ , page 72 .
Note
Tightening up the cylinder head bolts after doing repair work is

not necessary.

note the following:
– Change engine oil ⇒ Maintenance ; Booklet Octavia III .
– Top up coolant
When a new cylinder head us installed, carry out function 0001
- Activate the engine inlet ⇒ Vehicle diagnostic tester,
Tightening torques
♦ Engine support bracket
⇒ Fig. ““Engine support bracket - tightening
Protected by copyright.torque and
Copying for tight‐
private or commercial purposes, in part or in whole, is not permitted
ening order”“ , page 28 . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 71 .

1.4 Removing and installing camshaft hous‐

ing
Note

let .

Removing
– Remove engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 36 .
– Remove the charge air pipe between the charge air cooler and
the exhaust turbocharger
⇒ “2.4.1 Removing and installing the charge air pipe between
the charge air cooler and the exhaust gas turbocharger”, page
288 .
– Push release button unless
-b- on hose for crankcase ventilation -1-
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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 cam‐
shaft - G1002- -1-.
1. Cylinder head 79
– 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-.
– Remove the heat shield on top of the catalyst ⇒ page 276 .
– Removing ignition coils
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 354 .
– Remove connection fitting on exhaust gas turbocharger
⇒ “1.3 Removing and installing the exhaust gas turbocharger
connection fitting”, page 279 .
– Remove the oil separator at the top
⇒ “3.2.2 Removing and installing oil separator”, page 163 .
– Remove coolant pump
⇒ “2.5 Removing and installing coolant pump”, page 181 .
– Remove the pulley for coolant pump drive
⇒ “2.6 Removing and installing toothed belt pulley for coolant
pump drive”, page 184 .
– Disconnect the fuel line from the high pressure pump
⇒ Item 5 (page 333) . Disconnect the plug coupling ⇒ from
the fuel system of the petrol engines; Rep. gr. 20 ; plug-in
couplings; disconnect plug-couplings , Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Remove high pressure pipe
⇒ “6.3 Removing and installing high pressure pipe”,
page 335 .
– Unscrew the fixing screw -b- for the coolant pipe.

– Remove the toothed belt from the camshafts
⇒ “2.10 Remove the toothed belt from the camshaft”,
page 114 .

– Remove bracket -1-.

– Screw in screws -arrows- , unclip the pipe from the intake
manifold
If the camshaft housing is to be replaced:
– If necessary, remove components that have remained on the
camshaft housing
⇒ “1.2 Summary of components - camshaft housing”,
page 73 .
– If necessary, remove outlet camshaft control
⇒ “3.4 Removing and installing camshaft control”, page 127 .
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

be replaced.
NOTICE
Risk of damaging the valve gear.
♦ When turning, the camshafts must not be moved axially.
1. Cylinder head 81
• Locating screw - T10340- screwed up to the stop into the cyl‐

inder block and tightened to 30 Nm.
• Crankshaft in direction of rotation of engine in contact with the
locating screw - T10340- = “TDC” position. ⇒ page 90
– 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 tooth‐
ed belt ⇒ page 91 ,

– Replace gasket ring -4-.

– Fit gasket -4- onto dowel pins -2-.
– Carefully set the camshaft housing -3- onto the dowel pins
-2-.
Note
Make sure that the camshaft housing does not tilt.
– Tighten camshaft housing screws

page 73 .
– Install the toothed belt
page 114 .
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.
If the camshaft housing has been replaced:
– Carry out function Start the engine inlet with the ⇒ Ve‐
– Adjust position transmitter with the ⇒ Vehicle diagnostic tester.
♦ 0001 - Basic setting
♦ 0001 - Adapt camshaft position
Tightening torques
♦ Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 71 .
♦ Camshaft housing
page 73 .
♦ Coolant pipes
♦ by
Protected Exhaust gas turbocharger
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “1.1 Summary of components - exhaust gas turbocharger”,
page 270 .
♦ High pressure tube
⇒ “6.1 Summary of components - high pressure pump”, page
333 .
1.5 Checking compression

♦ Spark plug wrench - 3122 B-
♦ Compression tester - V.A.G 1763-
♦ Adapter - V.A.G 1381/1-
♦ Adapter - V.A.G 1381/5A-
1. Cylinder head 83
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.
– Pull out ignition coils at power output stage
page 354 .
– Remove the spark plugs with spark plug wrench - 3122 B- .

– 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 0.7 - 1.5 MPa
(7.0 - 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 ; Booklet Octavia III .
– Install ignition coils at power output stage
page 354 .
Because the electrical plug connections were disconnected and
the engine started, faults are stored in the event memory of the
engine control unit.
– Clear event memory and re-generate the readiness code
⇒ Vehicle diagnostic tester.
Tightening torques
♦ Screw for ignition coil with power output stage
⇒ “1.1 Assembly overview - ignition system”, page 353 .
♦ Spark plugs
1.6 Checking the combustion chamber for

tightness
♦ Spark plug wrench , e.g. -3122 B-
♦ Adapter - T40012- or -VAS 5161A/35-
– Remove ignition coils with power output stage
page 354 .
– Unscrew the spark plugs with the spark plug wrench - 3122
B- .
1. Cylinder head 85
– 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
vehicles without air conditioning system”, page 37 .
♦ Vehicles with air conditioning Pos. -2-
⇒ “1.1.2 Summary of components - V-ribbed belt drive for
vehicles with air conditioning system”, page 39 .
– Install adapter on the pressure hose of the compressed air
distribution.
Note
Perform a pressure unless
build-up in the
authorised “TDC”
by ŠKODA position
AUTO when
A. S. ŠKODA AUTO 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.
Tightening torques
♦ Spark plugs

2 Toothed belt drive

page 87
⇒ “2.2 Summary of components - toothed belt”, page 88
⇒ “2.3 Assembly overview - Adjustment tool for control times”,
page 90
⇒ “2.4 Position crankshaft at the top dead centre (TDC).”,
page 90
⇒ “2.5 Removing and installing toothed belt guard”, page 92
⇒ “2.6 Removing and installing toothed belt”, page 93
⇒ “2.7 Pre-assembly and assembly of the adjustment tool for
control times”, page 97
⇒ “2.8 Checking valve timing”, page 103
⇒ “2.9 Setting the timing”, page 106
⇒ “2.10 Remove the toothed belt from the camshaft”, page 114
2.1 Summary of components - toothed belt guard
1 - Top toothed belt guard

installing top toothed
belt guard”, page 92
❑ Note the vehicle type
plate ⇒ page 1
2 - Screw
❑ captive
❑ 8 Nm
3 -respect
with Bearings
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4 - Screw
❑ for coolant pipe
❑ 8 Nm
5 - Bottom toothed belt guard
installing bottom tooth‐
ed belt guard”,
page 92
6 - Screw
❑ 8 Nm
7 - Screw
tightening order
view - assembly mount‐
ings”, page 27
8 - Engine support bracket
2. Toothed belt drive 87

2.2 Summary of components - toothed belt
1 - Screw
❑ 7 Nm
2 - Screw cap
3 - O-ring
4 - Screw
❑ 50 Nm + 135°
5 - Toothed belt pulley, ex‐
haust camshaft
❑ With camshaft control
❑ Removing and installing
camshaft control
stalling camshaft con‐
trol”, page 127
6 - Guide bushing
7 - Toothed belt pulley, inlet
camshaft
❑ With camshaft control
❑ Removing and installing
camshaft control
stalling camshaft con‐
trol”, page 127
8 - Control valve
❑ Check the operating
valve
⇒ Fig. ““Check the con‐
trol valve”“ , page 89 .
❑ 140 Nm
9 - Tensioning pulley
❑ for removing and installing, remove engine support
10 - Screw
❑ Tightening torque and tightening order ⇒ “2.10 Remove the toothed belt from the camshaft”, page 114
11 - Guide pulley
❑ for removing and installing, remove engine support
12 - Screw
❑ 8 Nm
13 - Screw
❑ Component part of the guide pulley
❑ 40 Nm
14 - Crankshaft toothedunless
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
❑ removal and installation ⇒ “2.6 Removing and installing toothed belt”, page 93
❑ Set the timing ⇒ “2.9 Setting the timing”, page 106 .
16 - Holder for radial shaft seal
❑ removal and installation ⇒ “3.2 Removing and installing bracket for radial shaft seal”, page 118
17 - Sealing ring
18 - Camshaft control valve 1 - N205-
❑ removal and installation ⇒ “3.6 Removing and installing camshaft control valve 1 N205 ”, page 135
19 - Screw
❑ 8 Nm
20 - Screw
❑ 8 Nm
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
⇒ “3.3.1 Removing and installing oil seal for camshaft for holder Valve 1 for camshaft adjustment N205
”, page 120
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 Assembly overview - Adjustment tool for control times
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- 1.5 l TSI EVO en‐
gine, intake camshaft, blue
marking
G - Adapter for camshaft - VAS
611 007/7- 1.5 l TSI EVO en‐
gine, exhaust camshaft, red
marking
2.4 Position crankshaft at the top dead cen‐

tre (TDC).
Position piston of the cylinder 1 on »TDC« ⇒ page 90
Place piston of cylinder 1 for working on the toothed belt drive and
for the control timing adjustment on »TDC« ⇒ page 91
Position piston of the cylinder 1 on »TDC« .
gr. 66 .

– Undo locking screw behind for “TDC” bore -arrow- on the cyl‐
inder 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«
pump drive”,unless
page 184 .
– Position piston of the cylinder 1 on »TDC« ⇒ page 90 .
– 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 cam‐
shaft.

• 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 90 .
• 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-.
Tightening torques
side”, page 50 .
Locating screw - T10340- 30 Nm
2.5 Removing and installing toothed belt

guard
⇒ “2.5.1 Removing and installing top toothed belt guard”,
page 92
⇒ “2.5.2 Removing and installing bottom toothed belt guard”, page
92
2.5.1 Removing and installing top toothed belt

guard
Removing
– Remove camshaft control valve 1 - N205-
⇒ “3.6 Removing and installing camshaft control valve 1 N205
”, page 135 .
– Expose vacuum hose on the holder -3-.
– Unscrew bolts -2-.
– Remove top toothed belt guard -1-.
Installing
Installation is carried unless
out inauthorised
the reverse
by ŠKODAorder.
AUTO A.When
S. ŠKODAinstalling,
AUTO A. S. does not guarantee or accept any liability
observe the following: with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note the vehicle type plate ⇒ page 1
Tightening torques
♦ Top toothed belt guard
page 87 .
2.5.2 Removing and installing bottom toothed

belt guard
Removing
– Remove V-ribbed belt pulley from crankshaft
⇒ “1.4 Removing and installing vibration damper”, page 43 .


– Remove bottom toothed belt guard.
Installing
Tightening torques
♦ Bottom toothed belt guard
page 87 .

♦ Key - T10499A-
♦ Insertion tool - T10500-
♦ Torque wrench - V.A.G 1410- or -VAS 6583-
Removing
page 114 .
– Remove V-ribbed belt pulley from crankshaft
– Remove bottom toothed belt guard
⇒ “2.5.2 Removing and installing bottom toothed belt guard”,
page 92 .
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
Note

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

inder block and tightened to 30 Nm.
• Piston for cylinder 1 on “TDC” for working on the toothed belt
90 .
– Replace screw -4- and loosely insert a new screw

⇒ “3.4.2 Removing and installing camshaft control, outlet
side”, page 130 .
– Take the control valve -3- and loosely screw it in
⇒ “3.4.1 Removing and installing camshaft control, inlet side”,
page 127 .
• 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 crank‐
shaft toothed belt sprocket -2-.
– Install bottom toothed belt guard
⇒ “2.5.2 Removing and installing bottom toothed belt guard”,
page 92
– Installing the V-ribbed belt pulley
Place toothed belt

– Pull toothed belt upwards, then fit the tensioning pulley -2- and
camshaft sprockets -3- and -4- onto the guide roller -1-.
– Pull toothed belt upwards, 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 posi‐
tioned 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 tightening torque on the torque wrench - VAS
6583- the actual dimension specified on the tool insert -
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 ⇒ “2.9 Setting the timing”, page 106 .

Tightening torques
♦ V-ribbed belt drive
♦ Toothed belt guard
page 87 .
96 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Rep. gr.15 - Cylinder head, valve gear
♦ Toothed belt drive

⇒ “2.2 Summary of components - toothed belt”, page 88 .
♦ Camshaft housing
page 73 .
2.7 Pre-assembly and assembly of the ad‐

justment tool for control times
⇒ “2.7.1 Pre-assembly of the adjustment tool VAS 611 007 ”, page
97
⇒ “2.7.2 Electronically teach the adjustment tool VAS 611 007 and
carry out basic settings”, page 100
⇒ “2.7.3 Install Adjustment tool VAS 611 007 ”, page 102
2.7.1 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- 1.5 l TSI EVO en‐
gine, intake camshaft, blue col‐
our code marking
G - Adapter for camshaft - VAS
611 007/7- 1.5 l TSI EVO en‐
gine, 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 col‐
our 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 ring - VAS 611 007/2- -B-

by about 2 turns.
Note the colour coding -arrows- -a- and -arrow- -b-.

– Check shaft can move freely.

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

- VAS 611 007- and carry out basic set‐
tings
– Pre-assemble adjustment toolunless
- VAS 611 007- ⇒ page 98 .
– Connect electronic measurement to the adjustment tool - VAS
611 007- ⇒ Owner’s Manual ,
– Install software for adjustment tool - VAS 611 007- .⇒ Owner’s
Manual .
– Start the test sequence ⇒ owner’s manual .
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 function MODE 0 .
When this angle display appears, the control times can be

checked or set ⇒ “2.8 Checking valve timing”, page 103 .
– 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 ofbythe
unless authorised adjustment
ŠKODA tool - AUTO
AUTO A. S. ŠKODA VASA.611 007-
S. does not guarantee or accept any liability
do not disconnect the diagnostic
with respect device.

2.7.3 Install Adjustment tool - VAS 611 007-

– Pre-assemble adjustment tool - VAS 611 007- ⇒ page 98 .
– Electronically teach the adjustment tool - VAS 611 007- and
carry out basic settings ⇒ page 100 .
– Rotate both adapters for angle encoder - VAS 611 007/5- so
that the display is approx. »0 °«.
– Carry out preliminary work to check the control timings
⇒ “2.8 Checking valve timing”, page 103 .
– Check that the piston for cylinder 1 for working on the toothed
belt is at “TDC”
90 .
– 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.
– Turn the adapter for angle encoder - VAS 611 007/5- -E- by
hand until the lugs are against the grooves of the adapter for
camshaft - VAS 611 007/5- or the adapter 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.
– Tighten theto locking
with respect rings
the correctness - VAS 611
of information in this 007/2-
document. -B- hand-tight
Copyright by ŠKODA by
AUTO A. S.�
hand.
– Check if the brakes -a- at the adjustment tool - VAS 611 007-
are released at both sides.
2.8 Checking valve timing

♦ Adjustment tool - VAS 611 007-
• Timing belt is installed


gr. 66 .
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Remove air guide pipe
⇒ “2.4 Removing and installing charge air pipe”, page 288 .
shaft - G1002- -1-.
– Unscrew screw -arrow- and remove lock -1- of the intake cam‐
shaft on the transmission side.
– Install piston for cylinder 1 on “TDC” for working on the toothed
belt ⇒ page 90 .
– Install Adjustment tool - VAS 611 007-
⇒ “2.7.3 Install Adjustment tool VAS 611 007 ”, page 102 .
– 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 90 .
– unless
Display the angle forAUTO
control timesAUTO in the
A. S.display and compare
authorised by ŠKODA A. S. ŠKODA does not guarantee or accept any liability
them with tothe
with respect the setpoints.
Setpoint for angle in ° Inlet camshaft Exhaust camshaft

+0.5°±1.5° +1.5°±1.5°
If the control times are not OK, set the control times
⇒ “2.9 Setting the timing”, page 106 .
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.


must be replaced.
– Replace O-rings and seal after disassembly
Tightening torques
♦ Screw plug for “TDC” bore
♦ Locking screw for camshaft
page 73 ,
2.9 Setting the timing

NOTICE
– Test timing ⇒ “2.8 Checking valve timing”, page 103 .
Note
When adjusting the control times, leave the toothed belt ten‐
sioned. Only loosen the camshaft adjusters.
– Release the camshaft adjuster at the inlet side ⇒ page 128 .

– Release the camshaft adjuster at the outlet side
⇒ page 131 .
NOTICE
Risk of damaging the engine by means of adjusted control
times.
♦ So as not to adjust the timing
with respect the crankshaft
to the correctness must
of information in thisnot be turned
document. Copyright by ŠKODA AUTO A. S.�
on the TDC mounting.
Note
♦ To collect engine oil, place a cloth under the camshaft adjust‐

ers and over tensioning roller.
♦ Contact points of the toothed belt, camshaft sprocket, crank‐
shaft 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 runs out when the engine is
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 91 .
Note
♦ To set the control times, leave the control belt tensioned.

♦ Only disconnect camshaft adjuster.

Camshaft adjusters must still be able to rotate on the camshafts.
Set camshaft adjuster to »0 °« unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Check if the screws -a- for brakes on adjustment tool - VAS
611 007- are released on both sides.


– The two camshafts are set to »0.0 °«.
– For this purpose, turn the camshafts with the Adapter for angle
encoder - VAS 611 007/5- -e-.
– Stop camshafts using the Adapters 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 unless
brake symbol
authorised is »red«
by ŠKODA AUTO-A-.
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
• The symbol should not be »yellow« or »green«.

– Pre-torque intake camshaft adjuster with torque
⇒ page 129 .
– Pre-torque outlet camshaft adjuster with torque ⇒ page 133 .

– 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- as shown.
– Use plugs with outerunless
diameter
Protected ∅ 45 Copying
by copyright. - 50 mm.
for private or commercial purposes, in part or in whole, is not permitted
– Place a piece of paper in the stoppers to collect the engine oil.
– Place the plug in the camshaft adjusters as shown.
Note
On the camshaft adjuster on the outlet side -1- the plug must be
pressed in slightly before insertion.
Determine the inclination angle

– Install piston for cylinder 1 on »TDC« for working on the tooth‐
ed belt ⇒ page 91 .

– Read out and note the control times in the display. The figure
shows the values as an example.
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 angle of inclination results from the difference between
the desired value and the value read after two crankshafts are
rotated through.
♦ The pitch angle is used to set the control times.
Example:
Angle in ° Inlet camshaft Exhaust camshaft

Value read after double crankshaft rotation -1.2° -1.0°
in the direction of the engine
Setpoint for angle +0.5°±1.5° +1.5°±1.5°
Angle of inclination determined +1.7° +2.5°
Slope angle = setpoint value - read value
Sample calculation, intake camshaft: + 1,7° = + 0,5° - (-1,2°)
Example calculation, exhaust camshaft: + 2,5° = + 1,5° -
(-1,0°)
– Set the determined angle of inclination for camshafts

⇒ page 110 .
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.
– Release the camshaft adjuster at the outlet side
⇒ page 131 .
NOTICE

times.
♦ So as not to adjust the timing the crankshaft must not be turned

belt is at “TDC” ⇒ page 91 .

– 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 109 .
– For this purpose, turn the camshafts with the Adapter for angle
encoder - VAS 611 007/5- -e-.
If the two camshafts are set to the determined inclination angle:
Protected– byTighten screws

copyright. Copying -a- for
for private brakes purposes,
or commercial on adjustment tool is- VAS
in part or in whole, 611
not permitted
007-
unless authorised by on
ŠKODAbothAUTOsides usingAUTO
A. S. ŠKODA 10 Nm.A. S. does not guarantee or accept any liability

– 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 129 .
– Pre-torque outlet camshaft adjuster with torque ⇒ page 133 .
– 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- as shown.
– Use plugs with outer diameter ∅ 45
Protected - 50 mm.
– Place a piece of paper in the stoppers
with respect toto
thecollect the
correctness engine oil.
– Place the plug in the camshaft adjusters as shown.
Note
On the camshaft adjuster on the outlet side -1- the plug must be
pressed in slightly before insertion.

– Install piston for cylinder 1 on »TDC« for working on the tooth‐
ed belt ⇒ page 91 .
– Test timing ⇒ “2.8 Checking valve timing”, page 103 .
NOTICE
– Read control times and compare with setpoints.
Setpoint for angle in ° Inlet camshaft Exhaust camshaft

+0.5°±1.5° +1.5°±1.5°
If the control times are not OK, set the control times
⇒ “2.9 Setting the timing”, page 106 .
– Tighten inlet camshaft adjuster with final tightening torque
⇒ page 130 .

– Tighten outlet camshaft adjuster with final tightening torque

⇒ page 133 .
Tightening torques
♦ Camshaft control
♦ Screw plug for “TDC” bore
2.10 Remove the toothed belt from the cam‐

shaft
♦ Key - T10499A-
gr. 66 .
– Remove holder for radial shaft seal
⇒ “3.2 Removing and installing bracket for radial shaft seal”,
page 118 .
– Place engine on “TDC for cylinder 1” for work on the toothed
belt drive ⇒ page 91 .
– Release unless
the camshaft
authorised by adjuster atA.the outlet side
ŠKODA AUTO S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ page 131with. respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– 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.
♦ So as not to adjust the timing the crankshaft must not be turned

Installing

– Fit on the toothed belt ⇒ page 95 .
– Tension timing belt ⇒ page 96 .
Tightening torques
♦ Tensioning pulley
⇒ “2.2bySummary
Protected of components
copyright. Copying - toothed
for private or commercial belt”,
purposes, in part page 88is.not permitted
or in whole,

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 116
⇒ “3.2 Removing and installing bracket for radial shaft seal”, page
118
⇒ “3.3 Removing and installing gasket ring for camshaft”,
page 120
⇒ “3.4 Removing and installing camshaft control”, page 127
⇒ “3.5 Removing and installing cam adjuster”, page 133
⇒ “3.6 Removing and installing camshaft control valve 1 N205 ”,
page 135
⇒ “3.7 Removing and installing camshaft control valve 1 in the
exhaust N318 ”, page 135
⇒ “3.8 Removing and installing valve stem seal”, page 136
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 dimen‐
sions”, page 148
❑ inspecting valve guides
⇒ “4.1 inspecting valve
guides”, page 148
2 - Hydraulic balancing ele‐by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
ment unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ Do not interchange
❑ Oil contact surface
3 - Locking clip
❑ for hydraulic balancing
element
4 - Roller rocker finger
stalling camshaft hous‐
ing”, page 79
⇒ Fig. ““Mounting roller
towing lever”“ ,
page 117
❑ mark the fitting position
for re-installation
❑ inspect roller bearings
for smooth operation
❑ oil the contact surfaces
before installing
5 - Valve collets
❑ removal and installation ⇒ “3.8 Removing and installing valve stem seal”, page 136

6 - Valve spring plate

7 - Valve spring
❑ Fitting position ⇒ Fig. ““Fitting position of the valve spring”“ , page 117
❑ See also ⇒ Electronic parts catalogue
8 - Valve stem gasket
❑ Fitting position ⇒ Fig. ““Mounting valve stem seal”“ , page 117
❑ pay attention to different version
❑ See also ⇒ Electronic parts catalogue
9 - Cylinder head
❑ Summary of components ⇒ “1.1 Summary of components - cylinder head”, page 71
❑ removal and installation ⇒ “1.3 Removing and installing cylinder head”, page 75
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 117

3.2 Removing and installing bracket for ra‐

dial shaft seal
♦ Centring mandrel - T10576-
♦ Torx Bit T30 - T10584-
♦ Torque wrench , e.g. -V.A.G 1783-
Removing
– Remove camshaft control valve 1 - N205-
”, page 135 .
92 .
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.
Installing
Installation is carried out in Protected
the reverse order.
by copyright. When
Copying installing,
for private or commercial purposes, in part or in whole, is not permitted
observe the following: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Check the radial shaft seal for damage and if necessary re‐
place it
⇒ “3.3.1 Removing and installing oil seal for camshaft for hold‐
er Valve 1 for camshaft adjustment N205 ”, page 120 .
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 - N205- , 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 119

– 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
92 .
– Install camshaft control valve 1 - N205-
”, page 135 .
– Install the engine cover
Tightening torques
♦ Holder for radial shaft seal
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 N205 ”, page 120
⇒ “3.3.2 Removing and installing the inlet camshaft on the belt
pulley side”, page 122
⇒ “3.3.3 Removing and installing the exhaust camshaft on the belt
pulley side”, page 124
⇒ “3.3.4 Removing and installing the exhaust camshaft on the
gearbox side”, page 125
3.3.1 Removing and installing oil seal for cam‐

shaft for holder Valve 1 for camshaft
adjustment - N205-
♦ Extractor tool - T20143/2-
♦ Centring mandrel - T10576-
Removing
– Holder for sealing ring
page 118 .
– Insert the vice with protective jaws.
Note with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ 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 - N205- , 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 121

– 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
Installation is carried out in the reverse order. When
unlessinstalling,
observe the following: with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Insert holder for radial shaft seal

page 118 .
3.3.2 Removing and installing the inlet cam‐

shaft on the belt pulley side
♦ Assembly tool - T10478 B-
♦ Spindle - T10585-
Removing
– Remove inlet camshaft control
page 127 .
– 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 cam‐

shaft -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 123

– 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
page 127 .
3.3.3 Removing and installing the exhaust

camshaft on theunless
belt pulley side
♦ Assembly device - T10478 B- with screw -T10478/5-
Removing
– Remove engine support
⇒ “1.5 Removing and installing engine support”, page 44 .
– Remove outlet camshaft control
side”, page 130 .
– 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
side”, page 130 .
– install (set the timing)
page 114 .
– Install engine support
⇒ “1.5 Removing and installing engine support”, page 44 .
3.3.4 Removing and installing the exhaust

camshaft on the gearbox side
Removing
3. Valve gear 125

– 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
3.4 Removing and installing camshaft con‐

trol
page 127
⇒ “3.4.2 Removing and installing camshaft control, outlet side”,
page 130
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 127

Remove inlet camshaft control

CAUTION

– Lay the fuel hoses to the side.
92 .
belt ⇒ page 91 .
NOTICE

oil.
– Remove holder for radial shaft seal
page 118 .
– 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 131 .
page 114 .
– Unscrew control valve -2- and remove camshaft control.
– Remove oil from camshaft and camshaft housing.
Installing
• Fix camshafts to “TDC” position for work on the toothed belt
⇒ page 91 .
• Crankshaft is at “TDC” position.
must be replaced.
– Remove oil from camshaft adjuster with cloth.
– Check control valve -3- before installation

⇒ Fig. ““Check the control valve”“ , page 89 .
– 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
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.
Level Control valve for intake Tightening 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 129

Tighten inlet camshaft adjuster with final tightening torque.

– Tighten control valve -2- for camshaft adjuster in 2 stages with
final tightening torque.
Level Control valve for intake Tightening 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- .

Tightening torques
♦ Summary of components - toothed belt
3.4.2 Removing and installing camshaft con‐

trol, outlet side
♦ Mounting bracket - T10554-
♦ 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

CAUTION

– Lay the fuel hoses to the side.
92 .
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 91 .
3. Valve gear 131

– 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 128 .
page 114 .
– Unscrew securing bolt -1- and remove camshaft control -2-.
– Remove oil from camshaft
withand camshaft
respect housing.
Installing
• Fix camshafts to “TDC” position for work on the toothed belt
⇒ page 91 .
• Crankshaft is at “TDC” position.
must be replaced.
– Remove oil from camshaft adjuster with cloth.
– Before installing the camshaft adjuster, place the guide sleeve
⇒ Item 6 (page 88) .
– 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

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.
Level Fitting screw for exhaust Tightening 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.
Level 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

unless-authorised
V.A.G by 1332-
ŠKODAwithAUTOinsert
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
tool - V.A.G 1332/1- . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

note the following:
– Replace seal in cover for exhaust camshaft.
Tightening torques
♦ Summary of components - toothed belt
3.5 Removing and installing cam adjuster

Installation overview - cam adjuster
3 - Inlet cam adjuster for cylinder 2 - N583-
Removing
3. Valve gear 133

Cam adjuster for cylinder 3

288 .
– Push release button -b- on hose for crankcase ventilation -1-
– 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 O-ring for damage.
Replace the O-ring and the cam adjuster in the event of damage
⇒ “1.2 Summary of components - camshaft housing”, page 73 .
– 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-.
Tightening torques
♦ Summary of components - camshaft housing
page 73 .
♦ Summary of components - exhaust gas turbocharger
page 270 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted


trol valve 1 - N205-
Removing
NOTICE

oil.
– Unscrew screws -1- and remove camshaft control valve 1 in
the exhaust - N205- .
Note
♦ The screws-1- are to be guided through pipes in Valve 1 for

camshaft adjustment in the inlet - N205- .
♦ If the pipe is also unscrewed when the screw is unscrewed,
the screw with the pipe can nevertheless still be used.
Installing
– Replace sealing ring ⇒ Item 17 (page 89) .
Tightening torques
♦ Camshaft control valve 1 - N205-
⇒ “2.2 Summary of components - toothed belt”, page 88

trol valve 1 in the exhaust - N318-
Removing
– withRelease screws
respect to the -arrows-
correctness and
of information remove
in this camshaft
document. Copyright byadjustment
ŠKODA AUTO A. S.�
valve 1 - N205- -1-.
Installing
If the O-ring is damaged, replace together with camshaft control
valve 1 - N205- .
Tightening torques
♦ Camshaft control valve 1 - N205-
page 73
3. Valve gear 135

3.8 Removing and installing valve stem seal

⇒ “3.8.1 Removing and installing valve stem seal with cylinder
head installed”, page 136
⇒ “3.8.2 Removing and installing valve stem seal with cylinder
head removed”, page 141
3.8.1 Removing and installing valve stem seal

with cylinder head installed
♦ Spark plug wrench , e.g. -3122 B-
♦ 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
⇒ “1.4 Removing and installing camshaft housing”, page 79 .
– Unscrew the spark plugs with the spark plug wrench - 3122
B- .
– 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 cyl‐
inder 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 137

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 5161 A/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 5161 A/35- -I-
hand-tight into the respective spark plug thread.
– Connect the air adapter - VAS 5161 A/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
Protected by copyright. Copying punch
for privatespike -
VAS 5161/3A- -C- andunless
detach the by
authorised fixed
ŠKODA valve
AUTOcone pieces
A. S. ŠKODA AUTOwith
a plastic hammer. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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 push‐
ed on shell - VAS 5161A/40-1- -G- in the guide plate - VAS
5161A/40- -A-.
VAS 5161A/32-1-
with respect to -F-.
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note
Continue for both sides

– Press down mounting cartridge - VAS 5161A/32-1- -F- with
pressure fork - VAS 5161/2- -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 139

– 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 oil sealing lip of the valve stem seal -8-.
– Install valve stem seal
⇒ Fig. ““Mounting valve stem seal”“ , page 117 .
– Carefully slide valve stem seals -8- with suppressor for valve
stem seal - 3365- -A- on the valve -1-.
– Carefully push valve stem seals -8- with suppressor for valve
stem seal - 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 117 .
If the valve collets were removed from the assemble cartridge -

VAS 5161A/32-1- -F- they must be inserted into the insertion
device - 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 valveProtected
colletsbypoints
copyright.to the top.
Copying for private or commercial purposes, in part or in whole, is not permitted
– Remove disc. The spring pressure
with pushes the
respect to the disc back
correctness up‐ in this document. Copyright by ŠKODA AUTO A. S.�
of information
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-.
– 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 139 ,
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
relieved
– Repeat the procedure for each valve.

Installing
– Replace seal between coolant lines and exhaust gas turbo‐
charger ⇒ Item 18 (page 274) .
– Install coolant line on exhaust gas turbocharger
⇒ Item 15 (page 274) .
– Install spark plugs ⇒ Maintenance ; Booklet Octavia III .
– Install camshaft housing
Tightening torques unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Coolant line for exhaust gas turbocharger
⇒ “1.1.3 Assembly overview - Piping on the exhaust gas tur‐
bocharger”, page 274 .
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 - 3365-
Cylinder head tensioning device - VAS 6419-
3. Valve gear 141

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 81 .
– Remove cylinder head

Affix cylinder head cylinder head tensioning device - VAS 6419-

– Insert the cylinder head tensioning device - VAS 6419- into the
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.
– 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 the button

⇒ Item c (page 142) .
– 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-

3. Valve gear 143

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 5161 A/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
unlesshammer.


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
Protected - VAS
by copyright. 5161A/32-1-
Copying -F- purposes, in part or in whole, is not permitted
for private or commercial
– 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.
– 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.
3. Valve gear 145

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 117 .
– Carefully slide valve stem seals -8- with suppressor for valve
stem seal - 3365- -A- on the valve -1-.
– Carefully push valve stem seals -8- with suppressor for valve
stem seal - 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 117 .
If the valve collets were removed from the assemble cartridge -

VAS 5161A/32-1- -F- they must be inserted into the insertion
device - 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-
146
Rep. gr.15 - Cylinder head, valve gear
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 139 ,
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
relieved
– Repeat the procedure for each valve.

Installing
– Install cylinder head
3. Valve gear 147

4 Inlet and exhaust valves

⇒ “4.1 inspecting valve guides”, page 148
⇒ “4.2 Testing valves”, page 148
⇒ “4.3 Valve dimensions”, page 148
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 30

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - pan/oil pump”, page 149
⇒ “1.2 Engine oil”, page 153
⇒ “1.3 Removing and installing oil pan”, page 153
⇒ “1.4 Removing and installing oil pump”, page 156
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 158
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 67 .
1. Sump, oil pump 149

1 - Oil pan
stalling oil pan”,
page 153
2 - Screw
⇒ Fig. ““Oil sump - tight‐
ening torque and tight‐
ening order”“ ,
page 152
3 - Sealing ring
❑ for oil drain plug with re‐
placeable gasket ring
⇒ page 153
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 152
❑ for vehicles with re‐
placeable gasket ring
⇒ page 153unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ 30 Nm
5 - Baffle
– with oil suction pipe
6 - Seal
7 - Screw
⇒ Fig. ““Oil pump - tightening torque and tightening order”“ , page 152
8 - Sealing ring
❑ replace ⇒ “1.6 Replacing crankshaft sealing ring on the belt pulley side”, page 47
9 - Screw
⇒ Fig. ““Oil pump - tightening torque and tightening order”“ , page 152
10 - Oil pump
❑ removal and installation ⇒ “1.4 Removing and installing oil pump”, page 156
11 - Fitting sleeve
❑ 2 pieces
12 - Seal
13 - Dipstick
14 - Sealing ring
❑ 2 pieces
150 Rep. gr.17 - Lubrication

❑ Check for damage and replace if necessary
15 - Sealing ring
16 - Fit pin
17 - Oil filter
❑ pay attention to the notes ⇒ page 149
❑ Before installing, lightly coat sealing ring with clean engine oil
❑ removal and installation ⇒ “4.3 Removing and installing oil filter housing”, page 165
❑ 20 Nm
18 - Supports
❑ for the oil filter
❑ Tighten loosened screw connector ⇒ Fig. ““Secure the oil filter screw connector”“ , page 151
19 - Plugs
20 - Screw
❑ 9 Nm
21 - Oil level and oil temperature sender - G266-
⇒ “1.5 Removing and installing oil level and oil temperature sender G266 ”, page 158
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.
Tightening torques
Screw connector -2- 50 Nm

Oil sump - tightening torque and tightening order

1. -1 … 19- Tighten by hand as far as the stop
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further
4. -Arrows- ⇒ Gearbox; Rep. gr. 34
Oil pump - tightening torque and tightening order

Le Screws Tightening torque/torque angle
ve
l
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:
♦ ⇒ Maintenance ; Booklet Octavia III
Engine oil change “Engine oil: drain off”:
♦ ⇒ Maintenance ; Booklet Octavia III
1.3 Removing and installing oil pan

♦ Oil filter tool - 3417-
♦ Socket - T10058-
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and
unlessgloves
♦ Silicone sealant ⇒ Electronic Catalogue of Original Parts“ET‐
KA”
Removing
gr. 66 .
– Drain engine oil ⇒ Maintenance ; Booklet Octavia III .
– Remove the ribbed V-belt
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 ho‐

ses.
– 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 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 aunless

liquid seal -2- that is highly adhesive
when hardened. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Carefully lever the oil pan at the recess -arrow- from the cyl‐
inder 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 open parts 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 seal‐
ant.
– 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 screws
⇒ Fig. ““Oil sump - tightening torque and tightening order”“ ,
page 152 .

– 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 instal‐
ling oil sump. Only then fill with engine oil.
– Fill with engine oil and check the oil level ⇒ Maintenance ;
Booklet Octavia III .
Tightening torques
♦ Oil filter
⇒ “1.1 Assembly overview - pan/oil pump”, page 149 .
♦ Oil pan screws
⇒ “1.1 Assembly overview - pan/oil pump”, page 149
♦ Gearbox screws ⇒ Gearbox; Rep. gr. 34 .
1.4 Removing and installing oil pump
Removing
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove V-ribbed belt tensioning device
⇒ “1.3 Removing and installing V-ribbed belt tensioning de‐
vice”, page 42 .
– Remove the generator ⇒ Electrical System; Rep. gr. 27 .
– Remove toothed belt
– Remove sealing ring.
⇒ “1.6 Replacing crankshaft sealing ring on the belt pulley
side”, page 47
– 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 illustration.
– Slide the oil pump onto the locating pins and tighten the screws
⇒ Fig. ““Oil pump - tightening torque and tightening order”“ ,
page 152 ,
– Insert new sealing ring
⇒ “1.6 Replacing crankshaft sealing ring on the belt pulley
side”, page 47 .
Tightening torques
♦ Oil pump

1.5 Removing and installing oil level and oil

temperature sender - G266-
Removing
gr. 66 .
– 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.
Tightening torques
♦ Oil level and oil temperature sender - G266-

2 Engine oil cooler

⇒ “2.1 Summary of components - engine oil cooler”, page 159
⇒ “2.2 Removing and installing engine oil cooler”, page 159
2.1 Summary of components - engine oil cooler
1 - Engine oil cooler

❑ pay attention to the
notes
⇒ “1 Sump, oil pump”,
page 149
stalling engine oil cool‐
er”, page 159
2 - Screw
❑ 8 Nm + 90°
3 - Sealing rings
2.2 Removing and installing engine oil cool‐

er
Removing
– Drain coolant ⇒ “1.3 Draining unless
and filling
Protected coolant”,
by copyright. page
Copying 172or.commercial purposes, in part or in whole, is not permitted
for private
– Removing the intake manifold with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove electrical coolant pump
⇒ “2.4 Removing and installing charge air cooler pump V188
”, page 180 .
– Remove charge air cooler
⇒ “2.2 Removing and installing charge air cooler”,
page 285 .
2. Engine oil cooler 159

– Loosen coolant pipe

– Unscrew bolts -arrows- and remove engine oil cooler -1-.
Installing
– Insert new O-rings.
– Installing the intake manifold
– Top up coolant ⇒ page 176 .
Tightening torques
♦ Engine oil cooler
⇒ “2.1 Summary of components - engine oil cooler”,
page 159 .

3 Crankcase ventilation
⇒ “3.1 Summary of components - crankcase ventilation”,
page 161
⇒ “3.2 Removing and installing oil separator”, page 162
3.1 Summary of components - crankcase ventilation
1 - Oil separator below

stalling oil separator”,
page 162
tightening order
⇒ Fig. ““Oil separator
below - tightening tor‐
der”“ , page 162
❑ replace if damaged
2 - Screw
❑ 9 Nm
3 - Seal
4 - Sealing ring
❑ 2 pieces
5 - Vent line
❑ from fuel tank
6 - Screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ 9 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
7 - Seal
❑ for cap
8 - Screw cap
9 - Ventilation hose
❑ from exhaust turbo‐
charger
10 - Sealing ring
11 - Oil separator above
❑ removal and installation ⇒ “3.2 Removing and installing oil separator”, page 162
⇒ Fig. ““Oil separator above- tightening torque and tightening order”“ , page 162
12 - Seal
3. Crankcase ventilation 161

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 162
⇒ “3.2.2 Removing and installing oil separator”, page 163
3.2.1 Removing and installing oil separator

Removing
gr. 66 .
– Remove the pump for charge air cooling - V188- from the en‐
gine
⇒ “2.4 Removing and installing chargeProtected
air cooler pump
by copyright. V188
”, page 180 , unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Unclip the electric wiring harness from oil separator.
– Loosen the screws in the sequence -9- to -1- and remove.
– Remove oil separator.
Installing
– Replace gasket.
– Tighten screws in the sequence -1 … 9- ⇒ page 162 .
Tightening torques
♦ Oil separator
⇒ “3.1 Summary of components - crankcase ventilation”, page
161 .
♦ Electric coolant pump
⇒ “2.2 Summary of components - charge air cooler pump V188
”, page 179 .

3.2.2 Removing and installing oil separator

288 .
– Disconnect vent lines -2- and -3-. To do so, press the locks.
– Unclip and move clear the electric wiring loom -4-.

– Remove oil separator.
Installing
– Replace gasket.
– Tighten screws in the sequence -1 … 8-
⇒ Fig. ““Oil separator above- tightening torque and tightening
order”“ , page 162 .
Tightening torques
♦ Oil separator
⇒ “3.1 Summary of components - crankcase ventilation”, page
161 .
3. Crankcase ventilation 163

4 Oil filter, oil pressure switch

⇒ “4.1 Summary of components - oil pressure switch/oil pressure
control”, page 164
⇒ “4.2 Testing oil pressure and oil pressure switch”, page 165
⇒ “4.3 Removing and installing oil filter housing”, page 165
⇒ “4.4 Removing and installing valve for oil pressure control N428
”, page 165
⇒ “4.5 Removing and installing oil pressure sender G10 ”,
page 166
4.1 Summary of components - oil pressure switch/oil pressure control
1 - Screw
❑ 8 Nm
2 - Oil pressure control valve -
N428-
⇒ “4.4 Removing and
installing valve for oil
pressure control N428 ”,
page 165
3 - O-ring
❑ is a component part of
position -2-
❑ In case of leaks replace
valve for oil pressure
control - N428- .
4 - Sealing ring
5 - Oil pressure sender - G10-
❑ black insulation
❑ Switching pressure:
0.03 - 0.06 MPa
(0.3 - 0.6 bar)
❑ check in Targeted Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
fault finding ⇒ Vehi‐ with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
cle diagnostic tester
stalling oil pressure
sender G10 ”,
page 166
❑ 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‐
♦ 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- .
Installing
When the screw has been loosened
⇒ Fig. ““Secure the oil filter screw connector”“ , page 151
– Lightly lubricate gasket ring with clean engine oil.
– Tighten oil filter with oil filter wrench - 3417- .
Tightening torques
♦ Oil filter
4.4 Removing and installing valve for oil

pressure control - N428-
Removing
gr. 66 .
4. Oil filter, oil pressure switch 165


– 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 ⇒ Body Work; Rep. gr. 66 .
Tightening torques
♦ Oil pressure control valve - N428-
⇒ “4.1 Summary of components - oil pressure switch/oil pres‐
sure control”, page 164 .
4.5 Removing and installing oil pressure

sender - G10-
Removing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
the intake manifold arrows
the charge air cooler and the intake manifold”, page 290 .
– Unplug connector -arrow-.

– Disconnect connectors -1- and -3-.

– Remove and move clear the electric wiring loom -5-.
– 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-
Note
Before replacing, cut open the sealing ring.
– Checking the oil level ⇒ Maintenance ; Booklet Octavia III .

Tightening torques
♦ Oil pressure sender - G10-
4. Oil filter, oil pressure switch 167

19 – Cooling
1 Cooling system
⇒ “1.1 Connection diagram for coolant hoses”, page 168
⇒ “1.2 Check cooling system for leaks”, page 169
⇒ “1.3 Draining and filling coolant”, page 172
1.1 Connection diagram for 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 172
2 - Cylinder head and cylinder
block
nents
ponents - cylinder
head”, page 71
3 - Charge-air cooler in intake
manifold
nents
ponents - charge air
system”, page 283
stalling charge air cool‐
er”, page 285
❑ Leak testing the charge
air cooler
⇒ “2.6 Leak testing the
charge air cooler”,
page 294
4 - Exhaust gas turbocharger
nents
ponents - exhaust gas Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
turbocharger”, unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
page 270 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

stalling exhaust gas turbocharger”, page 275
5 - Engine oil cooler
❑ Summary of components ⇒ “2.1 Summary of components - engine oil cooler”, page 159
❑ removal and installation ⇒ “2.2 Removing and installing engine oil cooler”, page 159
168 Rep. gr.19 - Cooling

6 - Integrated exhaust manifold

7 - Heat exchanger for heating
8 - Coolant pump
❑ with Module for engine temperature control - GX33-
9 - Coolant radiator
❑ Summary of components ⇒ “4.1 Summary of components - radiator/radiator fan”, page 205
❑ removal and installation ⇒ “4.5 Removing and installing radiator”, page 211
10 - Charge air cooling circuit radiator
❑ Summary of components ⇒ “4.1 Summary of components - radiator/radiator fan”, page 205
11 - Charge air cooler pump - V188-
❑ Summary of components ⇒ “2.2 Summary of components - charge air cooler pump V188 ”, page 179
❑ removal and installation ⇒ “2.4 Removing and installing charge air cooler pump V188 ”, page 180
12 - Auxiliary heating
❑ Additional equipment
1.2 Check cooling system for leaks

⇒ “1.2.1 Checking with the cooling system testing device V.A.G
1274 ”, page 169
⇒ “1.2.2 Checking with the cooling system testing device V.A.G
1274 B ”, page 170
1.2.1 Checking with the cooling system test‐

ing device - V.A.G 1274-
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
Test condition
• Engine must be warm.
CAUTION
Wear safety goggles, safety gloves and safety clothing.

sure.
Hot steam may escape when the expansion reservoir is opened.
1. Cooling system 169

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

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

adapter - V.A.G 1274/8 - on the coolant expansion reservoir.
– Using the hand pump of the testing device, generate an over‐
pressure of approx. 0.15 MPa (1.5 bar).
• The pressure must not drop below 0.02 MPa (0.2 bar) after 10
minutes.
If the pressure falls below 0.02 MPa (0.2 bar):
– Search position of the
withleak and
respect to therepair fault.
Note
♦ A fall in 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.
Testing the pressure relief valve in the cap

– Screw the cooling system testing device - V.A.G 1274- with
adapter - V.A.G 1274/9 - onto the cap.
– Build up overpressure using hand pump on cooling system
testing device - V.A.G 1274- .
Blue filler cap:
♦ The pressure relief valve must open at 0.14-0.16 MPa (1.4-1.6
bar).
Black filler cap:
bar).
If the pressure relief valve opens too early or too late:
– Renew cap.
1.2.2 Checking with the cooling system test‐

ing device - V.A.G 1274 B-
♦ Cooling system testing device , e.g. -V.A.G 1274 B-

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‐
vice - V.A.G 1274 B- .
Test (self-test) of the cooling system testing device - V.A.G 1274

B-
– Use the cooling system testing device - V.A.G 1274 B- 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 1274 B- 30 seconds long.
Pressure is not established or the pressure drops:
The cooling system testing device - V.A.G 1274 B- 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 1274 B- is OK and can
be used for the test.
Check cooling system for leaks
• Engine must be warm.
CAUTION

sure.


– Fit the cooling system testing device - V.A.G 1274 B- with

adapter -V.A.G 1274/8- onto 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 1274 B- .
• 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 1274 B- is

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

– Screw the screw cap into the adapter for cooling system test‐
ing device - V.A.G 1274/9- .
– Build up overpressure using hand pump on cooling system
testing device - V.A.G 1274 B- .
Blue filler cap:
bar).
Black filler cap:
bar).
If the pressure relief valve opens too early or too late:
– Renew cap.
1.3 Draining and filling coolant with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ 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.
gr. 66 .
– 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 anti-freeze in the
specified mixing ratio ⇒ Maintenance ; Booklet Octavia III .
– Connect coolant hoses
⇒ Fig. ““Connect coolant hose with quick coupling”“ ,
page 206 .
– 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 adapt‐
er -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 pump in the cooling system draws the coolant out
of the coolant reservoir -VAS 6096- and fills the cooling sys‐
tem.
– Remove the cooling system charge unit - VAS 6096- from the
coolant expansion tank. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Fill up coolant to “Max” marking. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– 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 176 .
– Fit the cooling system testing device - V.A.G 1274 B- with
adapter -V.A.G 1274/8- onto the coolant expansion tank
⇒ “1.2.2 Checking with the cooling system testing device
V.A.G 1274 B ”, page 170 .
– Build up a pressure of 0.1 MPa (1 bar) using hand pump on
cooling system testing device - V.A.G 1274 B- .
– Then release the pressure on the cooling system tester -
V.A.G 1274 B- and remove the tester
⇒ “1.2.2 Checking with the cooling system testing device
V.A.G 1274 B ”, page 170 .
– 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” markings.
• When the engine is at operating temperature, the coolant level
may be at or above the “Max” marking.

2 Coolant pump and map-controlled

engine cooling
⇒ “2.1 Summary of components - coolant pump and coolant ther‐
mostat”, page 177
⇒ “2.2 Summary of components - charge air cooler pump V188 ”,
page 179
⇒ “2.3 Summary of components - coolant temperature transmit‐
ter”, page 180
⇒ “2.4 Removing and installing charge air cooler pump V188 ”,
page 180
⇒ “2.5 Removing and installing coolant pump”, page 181
pump drive”, page 184
⇒ “2.7 Removing and installing coolant temperature transmitter
G62 ”, page 187
⇒ “2.8 Removing and installing coolant temperature sender at
radiator outlet G83 ”, page 188
⇒ “2.9 Removing and installing coolant temperature sender at
engine outlet G82 ”, page 189
⇒ “2.10 Removing and installing element for engine temperature
control GX33 ”, page 190
⇒ “2.11 Testing the coolant pump”, page 193
2.1 Summary of components - coolant pump and coolant thermostat
2. Coolant pump and map-controlled engine cooling 177

1 - Toothed belt
❑ For coolant pump
2 - Pulley
❑ For coolant pump drive
stalling toothed belt pul‐
ley for coolant pump
drive”, page 184
3 - Screw
❑ 20 Nm + 90°
4 - Toothed belt guard
❑ For coolant pump tooth‐
ed belt
5 - Screw
❑ 8 Nm
6 - Coolant pump unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
stalling coolant pump”,
page 181
❑ replace toothed belt
when changing coolant
pump
7 - Screw
⇒ page 184
❑ 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-
⇒ “2.10 Removing and installing element for engine temperature control GX33 ”, page 190
11 - Screw
❑ Corrected tightening torque for the use of the insertion tool - T10572- and the torque wrench - V.A.G
1783-
❑ 5 Nm
12 - Seal
❑ replace

2.2 Summary of components - charge air cooler pump - V188-
1 - Charge air cooler pump -

V188-
❑ With holder
stalling charge air cooler
pump V188 ”,
page 180
2 - Coolant hose
3 - Screw
❑ 8 Nm
4 - Coolant hose

2.3 Summary of components - coolant temperature transmitter
1 - O-ring
2 - Coolant temperature send‐
er at radiator outlet - G83-
installing coolant tem‐
perature sender at radi‐
ator outlet G83 ”,
page 188
3 - O-ring
4 - Support ring
er - G62-
stalling coolant temper‐
ature transmitter G62 ”,
page 187
6 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Replace withafter
respectremoval
7 - Support ring
8 - Screw
❑ 8 Nm
9 - Coolant temperature sen‐
sor at engine output - G82-
perature sender at en‐
gine outlet G82 ”,
page 189
10 - Screw
❑ 8 Nm
11 - Retaining clip
❑ Check for secure seating
2.4 Removing and installing charge air cool‐

er pump - V188-
♦ Hose clamps up to 25 mm - MP7-602 (3094)-

Removing
CAUTION

sure.
– Open cap -arrow- for coolant expansion tank.
gr. 66 .

– Place catch pan underneath.
– At the charge air cooler pump - V188- disconnect coolant ho‐
ses 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 .
Tightening torques
♦ Charge air cooler pump - V188-
”, page 179
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
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
288 .
– 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 ho‐
ses 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.
♦ 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
unless authorised 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 195 ,
note the following:
– Top up coolant ⇒ page 174 .
Tightening torques
♦ Toothed belt guard of the coolant pump
⇒ “2.1 Summary of components - coolant pump
Protected by and
copyright. coolant
thermostat”, page 177 . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Screws for coolant pump
⇒ “2.1 Summary of components - coolant pump and coolant
thermostat”, page 177

pulley for coolant pump drive
♦ Assembly sleeve - T10505-
Screw - T10479/4-
Counterholder - T10172- with adapters -T10172/2-
Extractor - T10221A-
Removal tool - T10498-
Removal wedge - 3409-
Rig pin - T10504/1-
Removing

• 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 adapt‐

er -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 for puller - T10221A- -b- must be placed in the centre
of the head of the screw - T10479/4- -a-.
– 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 tooth‐
ed 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 cam‐
shaft, 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
Protected byon the Copying for private or commercial purposes, in part or in whole, is not permitted
copyright.
gearbox side”, page 125 . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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 cam‐
shaft 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
Tightening torques
♦ Toothed belt pulley
thermostat”, page 177 .
♦ Summary of components - camshaft housing
page 73 .
2.7 Removing and installing coolant temper‐

ature transmitter - G62-
♦ Removal tool - T10498- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Removing
• Engine cold.
gr. 66 .

– 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 send‐
er - G62- -1-.
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 - G62- immediately in‐

to cylinder head in order to avoid loss of coolant.
Tightening torques
♦ Coolant temperature sender - G62-
⇒ “2.3 Summary of components - coolant temperature trans‐
mitter”, page 180

ature 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.
gr. 66 .

– 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
Protected outlet
by copyright. - for private or commercial purposes, in part or in whole, is not permitted
Copying
G83- immediately into the neck to avoid loss
unless of coolant.
– Remove front noise insulation ⇒ Body Work; Rep. gr. 66 .

ature sender at engine outlet - G82-
♦ Removal tool - T10498-
Removing
• Engine cold.
gr. 66 .
– 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 send‐
er at the engine outlet - G82- -2-.
Installing
– Replace O-ring -3-.
Note unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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.
Tightening torques
♦ Coolant temperature sensor at engine output - G82-
⇒ “2.3 Summary of components - coolant temperature trans‐
mitter”, page 180 .
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 ⇒ Electrical System; Rep. gr. 27 .
288 .

– Release holder -a- for cable harness and place it laterally.

– Remove fuel line -b- from the holders -1- at the intake 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 mani‐
fold -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 with
screw -4- with the Working tool - T10572- and Torx
bit T30 - T10573- .

– Unscrew screw -arrow- for Module for engine temperature

control - GX33- -3-.
– 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 196 .
Power Control element -1- for Module for engine temperature

control - GX33- only fits the coolant pump shaft -2- in one position.

Power Control -3- is guided through the knurled pin on the coolant
pump -4-.
Observe the mounting sequence.
– If necessary, insert the coolant pump shaft into the mounting
position ⇒ page 195 .
– 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- .
Tightening torques
♦ Module for engine temperature control - GX33-
thermostat”, page 177 .
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 temper‐
ature control GX33 ”, page 190 .

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 195 .
Bring cooling pump to installation position.

• The testing tool - T10577- Is connected to the coolant pump
-1- ⇒ page 194 ,
– 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 - byT10577-
unless authorised ŠKODA AUTO and Module
A. S. ŠKODA AUTOfor engine
A. S. does tempera‐
not guarantee or accept any liability
ture controlwith -respect
GX33- to the. correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Testing the coolant pump

• The testing tool - T10577/1- -B- is connected to the coolant
pump -1- ⇒ page 194 .
– Bring cooling pump to installation position ⇒ page 195 .
• 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 cool‐
ant pump is too difficult to turn.
The testing tool - T10577/1- can then be rotated without resist‐
ance.
– Replace cooling pump
– 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 resist‐
ance.
If the overload protection is not activated, the coolant pump must
be replaced because the end stops are not reached.
– Replace cooling pump

3 Coolant pipes
⇒ “3.1 Summary of components - coolant pipe”, page 198
⇒ “3.2 Removing and installing coolant pipes”, page 199
3.1 Summary of components - coolant pipe
1 - Coolant hose
❑ Connection diagram
⇒ “1.1 Connection dia‐
gram for coolant hoses”,
page 168
2 - Clamp
3 - Coolant pipe - front bottom
installing the front bot‐
tom coolant pipe”,
page 203
page 168
4 - Screw
❑ 8 Nm
5 - Front top coolant pipe
installing the front top
coolant pipe”,
page 202
page 168
6 - Screw
❑ 3.5 Nm
7 - Clamp
8 - Coolant hose
⇒ “1.1 Connection diagram for coolant hoses”, page 168
9 - Coolant tube bottom left
❑ removal and installation ⇒ “3.2.1 Removing and installing the lower left coolant pipe”, page 199
❑ Connection diagram ⇒ “1.1 Connection diagram for coolant hoses”, page 168
10 - Clamp
11 - Coolant hose
12 - Screw
❑ 8 Nm
13 - Coolant hose unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

14 - Clamp
15 - Screw
❑ 8 Nm
16 - Coolant tube top left
❑ removal and installation ⇒ “3.2.2 Removing and installing the upper left coolant pipe”, page 201
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
199
⇒ “3.2.2 Removing and installing the upper left coolant pipe”, page
201
⇒ “3.2.3 Removing and installing the front top coolant pipe”, page
202
⇒ “3.2.4 Removing and installing the front bottom coolant pipe”,
page 203
3.2.1 Removing and installing the lower left

coolant pipe
♦ Hose binding claw - VAS 6362-
Removing
gr. 66 .
– Remove air filter housing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “2.2 Removing and installing air filter housing”,
with respect page 307
to the correctness .
⇒ “2.4 Removing and installing charge air pipe”, page 288 .
CAUTION

sure.
3. Coolant pipes 199


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

-c-.
– Release screw -1- 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 connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Parts .
Tightening torques
♦ Summary of components - coolant pipe

3.2.2 Removing and installing the upper left

coolant pipe
Removing
gr. 66 .
CAUTION

sure.
– Release hose clamp -arrow- to the right and remove the cool‐
ant 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.
3.2.3 Removing and installing the front top

coolant pipe
Removing
288 .
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 - 3094- .
– Loosen hose clamps on right and left.
– Remove cooling pipe.
Installing
Tightening torques
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 285 .
– Pinch off coolant hoses at coolant pipe -1- with the hose
clamps up to 25 mm - 3094- .
– Loosen hose clamps -2- and remove coolant hoses.
– Remove coolant pipe -1-.
Installing
Tightening torques
♦ Summary of components - coolant pipe unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

4 Radiator and radiator fan

⇒ “4.1 Summary of components - radiator/radiator fan”,
page 205
⇒ “4.2 Summary of components - fan shroud with a radiator fan”,
page 207
⇒ “4.3 Summary of components - fan shroud with two radiator
fans”, page 208
⇒ “4.4 Summary of components - radiator blind”, page 209
⇒ “4.5 Removing and installing radiator”, page 211
⇒ “4.6 Removing and installing fan shroud”, page 214
⇒ “4.7 Removing and installing radiator fan V7 ”, page 215
⇒ “4.8 Removing and installing radiator fan 2 V177 ”, page 215
⇒ “4.9 Removing and installing radiator blind”, page 216
⇒ “4.10 Removing and installing the radiator blind control motor
V544 ”, page 217
4.1 Summary of components - radiator/radiator fan
1 - Coolant radiator
stalling radiator”,
page 211
2 - Coolant hose
❑ to remove, raise the
holding clamps
❑ Connect
⇒ Fig. ““Connect coolant
hose with quick cou‐
pling”“ , page 206
3 - Retaining clip
4 - O-ring
er at radiator outlet - G83-
perature sender at radi‐
ator outlet G83 ”,
page 188
6 - O-ring
❑ Moisten with coolant
7 - Coolant hose
❑ to remove, raise the
holding clamps
❑ Connect with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ Fig. ““Connect coolant

hose with quick cou‐
pling”“ , page 206
4. Radiator and radiator fan 205

8 - O-ring
9 - Coolant hose
❑ to remove, raise the holding clamps
❑ Connect ⇒ Fig. ““Connect coolant hose with quick coupling”“ , page 206
10 - Air deflector
11 - Air deflector
12 - 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.
13 - Charge air cooling circuit radiator
14 - Condenser
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
15 - Bottom radiator bearing
16 - O-ring
❑ No spare part; is part of Pos. -17-
17 - Coolant hose
❑ to remove, raise the holding clamps
❑ Connect ⇒ Fig. ““Connect coolant hose with quick coupling”“ , page 206
18 - 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 with a radiator fan
1 - Screw
❑ 5 Nm
2 - Fan shroud
stalling fan shroud”,
page 214
3 - Radiator fan - V7-
installing radiator fan V7
”, page 215

4.3 Summary of components - fan shroud with two radiator fans
1 - Screw
❑ 5 Nm
2 - Fan shroud
stalling fan shroud”,
page 214
3 - Screw
❑ 5 Nm
4 - Radiator fan - V7-
installing radiator fan V7
”, page 215
5 - Radiator fan 2 - V177-
installing radiator fan 2
V177 ”, page 215

4.4 Summary of components - radiator blind

⇒ “4.4.1 Summary of components - radiator blind”, page 209
⇒ “4.4.2 Summary of components - component parts of the radi‐
ator blind”, page 210
4.4.1 Summary of components - radiator blind
1 - Bumper bracket
2 - Seal
❑ rear
3 - Control motor for radiator
blind - V544-
installing the radiator
blind control motor V544
”, page 217
4 - Catch pegs
❑ for seal
5 - Ambient temperature sen‐
sor - G17-
⇒ Item 12 (page 209)
❑ attached to the front
seal
❑ ⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
6 - Radiator blind
stalling radiator blind”,
page 216
7 - Connector
❑ Radiator blind control
motor - V544-
❑ attached to bracket
❑ ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations
❑ for plug contact on front bumper bracket ⇒ Item 7 (page 209)
9 - Screw
❑ 8 Nm
10 - Catch pegs
❑ for seal
11 - Wiring
Protected loom
❑ Radiator
with respect toblind controlof motor
the correctness information- V544-
in this document. Copyright by ŠKODA AUTO A. S.�
❑ ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

12 - Seal
❑ front

Wiring loom placement on the frame of the radiator blind

– Wiring loom -2- for the control motor for radiator blind - V544-
is attached in the retaining tab in the frame of the radiator blind
-1- -arrows-.
4.4.2 Summary of components - component parts of the radiator blind
1 - Connecting bridge
2 - Screw
❑ 2 Nm
3 - Control motor for radiator
blind - V544- unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
installing the radiator
blind control motor V544
”, page 217
4 - Flaps
❑ Note arrangement
⇒ Fig. ““Arrangement of
the lamellas”“ ,
page 211
5 - Screw
❑ 2 Nm
6 - Surround
7 - Wiring loom
8 - Engine mount

Arrangement of the lamellas

1 - Left flaps
2 - Right flaps
Šipka - Control flap
4.5 Removing and installing radiator

WARNING
There is risk of injury from radiator fans starting up automati‐
cally.
– Before carrying out work in the fan shroud area, remove the
electrical plug connections of the fan.
Note
The coolant radiator and charge air cooling circuit radiator are
removed together.
Removing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .
– 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.
– Press the catches for the top radiator mounting -arrows- at the
same time, e.g. with screwdrivers, and unclip the mounting on
both sides.
– Partially tilt cooler into the engine compartment.
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 . by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
CAUTION

To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or bent.
– Unlock the left and right catches from the cooler -1- arrow
-A- and raise the condenser.
– Press the radiator downwards until the radiator bearing de‐
flects at the bottom, to do so, unhook the condenser -2- from
the radiator -1-.
– 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
Do not replace the cooler when there is light pressure on the fins
⇒ “3.9 Assembly of radiators and condensers”, page 9 .
– Replace O-rings.
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 ⇒ Body Work; Rep. gr. 63 .

– Install fan shroud
– Connect coolant hoses with quick coupling
⇒ Fig. ““Connect coolant hose with quickto the
with respect coupling”“ , information in this document. Copyright by ŠKODA AUTO A. S.�
correctness of
page 206 .
– Top up coolant
Tightening torques
♦ Screw for top radiator bearing
⇒ “4.1 Summary of components - radiator/radiator fan”,
page 205 .

4.6 Removing and installing fan shroud

Removing
WARNING
cally.
gr. 66 .
– Unscrew bolts -3-.
– Release catch - 2 -.
– Slide the cover -1- forwards and out of the brackets -arrows-.
– Remove cover -1-.
– Slacken the coolant hose with
-2- respect
and layto theaside.
– Remove air deflector -1-.

– Remove air deflector lower section -1-.

– Remove plug -1- for radiator fan, for this purpose slide screw
clamp backwards arrow -A- and press release button down.
– Press locking lugs for fan shroud left and right simultaneously
arrow -B- and remove fan shroud downwards from the radia‐
tor.
Note
When there is light pressure on the fins

⇒ “3.9 Assembly of radiators and condensers”, page 9 .
Installing
Tightening torques
♦ Air guide
4.7 Removing and installing radiator fan -

V7-
WARNING
cally.
Removing
– Unscrew screws -arrow- and remove radiator fan - V7- .
Installing
Tightening torques
♦ Fan screw
⇒ “4.2 Summary of components - fan shroud with a radiator
fan”, page 207 .
4.8 Removing and installing radiator fan 2 -

V177-
WARNING
cally.
– Before carrying out work
unlessin the fan
authorised shroud
by ŠKODA area,
AUTO A. S. disconnect
ŠKODA AUTO A. S. does not guarantee or accept any liability
the electrical plug connections
with respect of the
to the fan. of information in this document. Copyright by ŠKODA AUTO A. S.�
correctness

Removing
– Disconnect plug connection -arrow-.
– Remove screws -2- and radiator fan 2 - V177- .
Installing
Tightening torques
♦ Fan screw
⇒ “4.3 Summary of components - fan shroud with two radiator
fans”, page 208 .
4.9 Removing and installing radiator blind

♦ Disassembly tool for door panel - MP8-602/1-
♦ Removalunless
wedge - 3409-
Removing
gr. 66 .
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .
– If used, remove plug connections -2- and -3-.
– Detach bracket -arrows- on lock carrier -1-.

– Pull radiator blind -1- with seal -2- out to the front.
– Secure the radiator blind -1- so that it does not fall down.

– Loosen the seal -2- out of the retaining tabs -arrows-.

– Remove the seal -2- from the radiator blind -1-.
– Remove radiator blind -1- downwards.
Installing
Make sure that the guides of the radiator blind -2- correctly en‐
gage in the bumper carrier -1- -arrow-.
After replacing the radiator blind, perform basic setup ⇒ Vehicle
diagnostic tester.
– Erase the event memory ⇒ Vehicle diagnostic tester.
– Connect vehicle diagnosis tester and perform basic setup
♦ 0001 - Adaptation of the control motor for radia-
tor blind - V544
4.10 Removing and installing the radiator

blind control motor - V544-
– Remove radiatorby blind
unless authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ “4.9with
Removing
respect to theand installing
correctness radiator
of information blind”, page
in this document. 216
Copyright .
by ŠKODA AUTO A. S.�
– Loosen the seal -2- out of the retaining tabs -arrows- at top
and bottom.
– Unclip the seal -2- from the locking lugs -arrows- at top and
bottom.

– Loosen the seal -2- out of the retaining tabs -arrows- on right
and left.
– Put the flaps of the radiator blind to “open”, as shown in the

illustration.
– To do so, move the connecting bridge -1-.
– Raise the engine mount Pos. 8 ⇒ Item 8 (page 210) with the
flaps upwards out of the support -arrows- in the frame -1-.
– Push the radiator blind control motor - V544- with flaps -2- as
far as possible to the left arrow -B-.

– Pry the flaps -2- on the right side out of the frame -1-.
– Mark the fitting position of the connecting bridge -1-.

– Use the plug -5- as reference point.
– Pry the connecting bridge -1- out of the guide rollers -3- and
-4- of the flaps -2-.
– Remove the control flap -1- from the radiator blind control mo‐
tor - V544- -2-.
– To do this, release locking tabs -arrows-.
– If used, unscrew screw -3-.

– Swivel the radiator blind control motor - V544- upwards in
-direction of arrow-.
– Remove the radiator blind control engine - V544- from the pin
-4-.
If necessary, then detach and remove the flaps from the engine
mount ⇒ Item 8 (page 210) .
Installing

– Position and secure the flaps -1- to -8- as shown.

– Slide on and secure the control flap -6-.
During assembly, note the position of the plug connection
-arrow-, which points downwards.
Note the arrangement of the flaps - the flaps overlap.
The top flap partially overlaps the next flap attached below it.
Num‐ Left flaps Num‐ Right flaps

ber ber
1 Flap 1, left 5 Flap 1, right
2 Flap 2, left 6 Control flap
– Bring connecting bridge -1- to correct fitting position.

To do this, use the mark prepared earlier or use the plug -5- as
reference point.
Make sure that the connecting bridge is lying correctly on the
guide rollers when you lock it.
– Insert engine mount Pos. 8 ⇒ Item 8 (page 210) with the flaps
onto the support in the frame -1-.
Make sure that the radiator blind control motor - V544- correctly
engages with the flaps into the frames -arrows-.

– Reconnect connector -2-.

– Secure the wiring loom in the retaining tabs -arrows-.
– Place the seal -2- on the frame of the radiator blind -1-.
Note the fitting position at the recess points -3- and -4-.
– Secure seal -2- in the retaining tabs.
After replacing the radiator blind control motor - V544- , perform
basic setup ⇒ Vehicle diagnostic tester.
– Erase the event memory ⇒ Vehicle diagnostic tester.
– Connect vehicle diagnosis tester and perform basic setup
♦ 0001 - Adaptation of the control motor for radia-
tor blind - V544

20 – Fuel supply system

1 Fuel tank
⇒ “1.1 Assembly overview - fuel tank”, page 222
⇒ “1.2 Drain the fuel tank”, page 223
⇒ “1.3 Removing and installing the fuel tank”, page 228
1.1 Assembly overview - fuel tank
1 - Screw cap
❑ screw in until there is an
audible click
❑ attached to the fuel tank
lid unit with anti-loss
washer
2 - Earth connection
❑ for fuel filler neck
❑ for discharging the elec‐
trostatic charge
⇒ Fig. ““Earth connec‐
tion for fuel filler neck”“ ,
page 234
3 - Screw
❑ 8 Nm + 90°
4 - Lock ring
❑ 110 Nm
5 - Sealing ring
❑ install when dry Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
6 - Fuel pump - G6- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ with integrated fuel filter,

the fuel filter cannot be
replaced individually
❑ Checking fuel pump
electrics ⇒ Vehicle diag‐
nostic tester
nents
⇒ “2 Fuel pump”,
page 235
⇒ Fig. ““Fitting location of the fuel delivery unit”“ , page 223
❑ removal and installation ⇒ “2.3 Removing and installing fuel delivery unit”, page 237
❑ inspecting fuel pump ⇒ “2.5 inspecting fuel pump”, page 243
7 - Fuel tank
❑ removal and installation ⇒ “1.3 Removing and installing the fuel tank”, page 228
8 - Heat shield
❑ for fuel tank
9 - Shield locking mechanism
❑ for heat shield
222 Rep. gr.20 - Fuel supply system

❑ 4 pieces
10 - Tensioning strap
❑ mark installed position before removing
❑ check correct fitting
11 - Screw
❑ 20 Nm + 90°
❑ For fuel pump control unit -J538-
❑ for vehicles with auxiliary heating
❑ for dosing pump -V54-
❑ pay attention to correct fit of the dosing pump in the holder
14 - Fuel line
❑ to the engine
❑ pushed into the fuel tank
❑ do not kink
❑ disconnect and connect ⇒ “3 Quick couplings”, page 256
15 - Fuel line
❑ to the dosing pump -V54-
❑ do not kink
16 - Dosing pump -V54-
Fitting location of the fuel delivery unit

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

⇒ “1.2.1 Emptying fuel tank when fuel pump is intact”,
page 223
⇒ “1.2.2 Emptying fuel tank when the fuel pump is damaged when
more than 3/4 full”, page 226
⇒ “1.2.3 Emptying fuel tank when the fuel pump is damaged when
less than 3/4 full”, page 227
1.2.1 Emptying fuel tank when fuel pump is

intact
1. Fuel tank 223

♦ Fuel extraction device , e.g. -VAS 5190-

♦ Adapter for fuel extraction - VAS 5190/3-
♦ Removal wedge - 3409-
♦ Remote control - V.A.G 1348/3A-
♦ Auxiliary measuring set, , e. g. -V.A.G 1594 C-
♦ Adapter - VAS 5565-
Note
If the fuel extraction device - VAS 5190- is still fitted with an ex‐
traction hose with a fixed tip, replace it by the version with a screw-
type tip.
– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .
– Screw on fuel extraction adapter - VAS 5190/3- to extraction
house.
Safety precautions when working on the fuel supply system
page 4 .
Observe rules for cleanliness
– Switch off ignition and all electrical loads, and pull out ignition
key.
CAUTION
Risk of injury caused by fuel which is under high pressure.
Lay a clean cloth around the connection point and carefully slack‐
en the connection point in order to relieve the pressure in the fuel
system.
– Pull out the fuel feed line -1- and catch the fuel which flows out
with a cleaning cloth

– Connect the fuel extraction device - VAS 5190- with the adapt‐
er for the fuel extraction - VAS 5190/3- to the fuel feed line.
– Secure the earth cable of the fuel extraction device to a bare
metal part of the body.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip cover -1- for closing flange from holder catches

-arrows- using the disassembly wedge - 3409- .
– Push the sealing grommet -1- downwards out of the cover

-2-.
– Guide cover -2- along the electrical wiring loom -3- in the di‐
rection of the fuel pump.
– Unlock and pull off connector -1-.

– Unlock the connector -2- for dosing pump - V54- of the auxil‐
iary heating and remove.
1. Fuel tank 225


– Connect adapter - VAS 5565- to fuel delivery unit -1-.
– Connect remote control - V.A.G 1348/3A- to adapter -
VAS 5565- and to battery positive terminal in engine compart‐
ment.
– Connect connection -5- (yellow) from the adapter - VAS 5565-
with adapter cables -3- from the adapter set - V.A.G 1594 C-
to the minus pole terminal on the battery.
Note
This step is only intended to ensure that the fuel pump runs when
the engine is switched off.
– Open the fuel tank cap and clean around the fuel filler neck
-2-.
– Unscrew the cap -1- for the fuel filler neck.
– Operate the remote control - V.A.G 1348/3A- and the shut-off
tap on the fuel extraction device - VAS 5190- until the fuel tank
is emptied.
NOTICE
Risk of damage to fuel pump.
The fuel pump must not run »dry«.
1.2.2 Emptying fuel tank when the fuel pump

is damaged when more than 3/4 full
page 4 .
⇒ unless
“3.1 Rules
Protected of cleanliness”,
by copyright. page
Copying for private 6 . purposes, in part or in whole, is not permitted
or commercial
– Make a mark -arrow- on hose with insulating tape at distance
-a- = 1010 mm from end of extraction hose.

-2-.
– Push the extraction hose of the fuel extraction device as far

into the fuel tank bracket as necessary until the previously ap‐
plied marking -arrow- terminates with the filler neck -2-.
In the fuel tank there is a flap -1- on the lower end of the filler neck,
which must not be damaged by the extraction hose of the fuel
extraction device . Therefore, the hose must only be pushed in up
to the previously made marking -arrow-.
– Drain the fuel tank through the filler neck as much as possible.
When no more fuel is extracted, the fuel tank is emptied just
enough for the sender flange to be opened safely.
– Carefully pull out the extraction hose.
If the extraction hose becomes stuck to the check valve while be‐
ing pulled out, do not pull the extraction hose violently.
If this is the case, remove the fuel delivery unit and hold the check
valve open by hand. Make sure that your arm does not come in
contact with fuel.
1.2.3 Emptying fuel tank when the fuel pump

is damaged when less than 3/4 full
♦ Key - T10202-
page 4 .
– Remove fuel delivery unit lock ring unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ “2.3 Removing and installing fuel delivery unit”,
with respect to thepage 237of .information in this document. Copyright by ŠKODA AUTO A. S.�
correctness
1. Fuel tank 227

– Lift closing flange -2- of fuel delivery unit.

– Remove gasket -1- from the opening of the fuel tank and care‐
fully raise the flange of the fuel pump slightly higher.
– Insert suction hose of fuel extractor - VAS 5190- as far as
possible into fuel tank.
– Extract fuel using the fuel extraction device - VAS 5190- .
When only emptying the fuel tank:
– Reinstall the fuel delivery unit
⇒ “2.3 Removing and installing fuel delivery unit”, page 237 .
1.3 Removing and installing the fuel tank

♦ Engine and gearbox jack , e.g. -V.A.G 1383A-
• The fuel tank must be empty for weight reasons when remov‐
ing it. If necessary, extract fuel from the fuel tank
⇒ “1.2 Drain the fuel tank”, page 223 .
Removing
page 4 .
key.
– Removing rear seat bench ⇒ byBody
Protected Work;
copyright. Rep.
Copying gr. or72
for private .
– Unclip cover -1- for closing
with flange
respect to from holderof catches
the correctness information in this document. Copyright by ŠKODA AUTO A. S.�


-2-.
– Reach between bottom plate and fuel tank with a finger and
push up the catch -2- in direction of arrow -A-.
– Simultaneously pull the fuel pump control unit - J538- -1- at
the electric wiring loom -3- carefully out of the uptake arrow
-B- and lay aside.
– Unlock and disconnect electrical plug connection -2- from

closing flange.
For vehicles with auxiliary heating

– Disconnect plug connection -2- of dosing pump - V54- .
1. Fuel tank 229


-2-.
– Close the opening of the fuel filler neck with a clean plug, so
that no dirt can penetrate.
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Remove right rear wheel brake calliper and place to the side
⇒ Brake systems; Rep. gr. 46 .
Note
Do not open the brake line when removing the brake calliper.
– Disconnect the plug connection at the ABS speed sensor and

undo the line from the brackets at the rear axle ⇒ Brake sys‐
tems; Rep. gr. 45 .
– Unscrew screws -1- and -2- for fuel filler neck.
– Remove the vent lines -1- and -2- from the activated charcoal
filter, do so by disconnecting the push-fit couplings
⇒ “3 Quick couplings”, page 256 .
– Loosen ventilation lines from fasteners on the holder
-arrows-.
– Loosen ventilation line -1- from fastener on the holder

-arrow-.
– Remove underbody cover on lower left ⇒ Body work; Rep. gr.
66 .

– Remove screws -2- and remove tunnel bridge -1- in

– Loosen the clamping sleeve -arrow- and slide it forwards.
Note
A second person is required for the further work.
– Remove screws of the suspension of the centre and rear si‐

lencers
⇒ “1.4 Replacing middle or rear part of the exhaust system”,
page 349 .
– Move the centre and rear of the exhaust system in the direction
of the vehicle's longitudinal axis and then turn it outwards, as
shown in the figure.
– Place the centre and rear of the exhaust system on the rear
axle.
Make sure that the rear axle is not damaged.
To protect the rear axle, place a cloth underneath the middle and
rear silencer.
CAUTION
system.
1. Fuel tank 231

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

Note
For vehicles with auxiliary heating, the fuel line -1- for the dosing
pump - V54- must also be disconnected
CAUTION
Risk of accident due to the fuel tank weight.
The fuel tank must be empty for removal


– Remove holder for exhaust system retaining strap -arrow-.
– Unscrew securing bolt -3- and remove tensioning strap -7-.
– Support the fuel tank using the engine/gearbox jack - V.A.G

1383A- .

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

The filler neck must be “extracted” between body and rear axle.
– Lower the fuel tank a little and carefully unscrew it outwards
and downwards.
Remove fuel tank from the engine and gearbox jack - V.A.G
1383A- with a second mechanic.
Make sure you do not kink the vent and fuel lines.
Installing
Installation is carried out in the reverse order. Pay attention to the
following:
Note
For vehicles with auxiliary heating and additional heating the dos‐
ing pump - V54- must also be tested for firm seating on the holder.
Make sure that the filler neck of the fuel tank is correctly inserted
into the opening of the fuel
Protected tank lid
by copyright. unitfor-2-.
Copying private or commercial purposes, in part or in whole, is not permitted
Make sure that the with
sealing grommet of the fuel tank lid unit -2- is
seated correctly on the fuel filler neck.

– Check both earth connections for corrosion, if necessary re‐
move corrosion.
– Check the fitting position of the earth lead.
1. Fuel tank 233

Earth connection for fuel filler neck

– Connect earth connection as shown in the illustration.
Ensure proper seating of plug connection.
♦ Plug -2- of the earth connection on the threaded ring -3- of the
fuel filler neck.
– Hook the contact peg -1- of the earth connection into the
mounting hole on the fuel tank -4- and push in the distance
sleeve -5-.
– Guide the filler neck between rear axle and structure with the
assistance of a 2nd mechanic. Finally position the fuel tank
onto the engine/gearbox jack - V.A.G 1383A- .
♦ Vent and fuel lines must be laid without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.
CAUTION
Risk of electrostatic charge.
♦ After installation, check electrical connection using an ohm‐

meter.
♦ Check the connection of the metal ring on the fuel filler neck
with a bare metal part of the body.
• Specified value approx. 0 ohm.
WARNING
Risk of fuel container explosion on fuel pump start-up!
After installing a new or completely emptied fuel tank, you must

replenish a minimum of 5 litres of fuel right away.
– Refill at least 5 litres of fuel.
♦ Fuel tank ⇒ “1.1 Assembly overview - fuel tank”, page 222 .

2 Fuel pump
⇒ “2.1 Summary of components - fuel pump G6 and fuel gauge
sender”, page 235
⇒ “2.2 Summary of components - fuel system pressurisation
pump G6 , vehicles with auxiliary heating”, page 236
⇒ “2.3 Removing and installing fuel delivery unit”, page 237
⇒ “2.4 Removing and installing the fuel gauge sender G ”,
page 241
⇒ “2.5 inspecting fuel pump”, page 243
⇒ “2.6 Removing and installing fuel pump control unit J538 ”, page
255
2.1 Summary of components - fuel pump - G6- and fuel gauge sender
1 - Fuel pump - G6-

❑ The fuel filter cannot be
replaced separately ⇒
Electronic Catalogue of
Original Parts “ETKA”
nostic tester
❑ inspectingunless
fuel pump by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
authorised
⇒ “2.5 inspecting fuel
pump”, page 243
stalling fuel delivery
unit”, page 237
2 - Sealing ring
❑ install when dry
3 - Lock ring
❑ 110 Nm
4 - Fuel pump control unit -
J538-
stalling fuel pump con‐
trol unit J538 ”,
page 255
❑ check ⇒ Vehicle diag‐
nostic tester
5 - Connector
❑ Fuel pump control unit -
J538-
❑ Ensure safe locking by
pulling
6 - Connector
❑ Fuel system pressurisation pump - G6- and fuel gauge sender - G-
❑ Ensure safe locking by pulling
7 - Fuel line
❑ to the engine
2. Fuel pump 235

❑ do not kink
8 - Fuel gauge sender - G-
❑ removal and installation ⇒ “2.4 Removing and installing the fuel gauge sender G ”, page 241
❑ Check with the fuel pump control unit - J538- ⇒ Vehicle diagnostic tester
2.2 Summary of components - fuel system pressurisation pump - G6- , vehicles

with auxiliary heating
1 - Fuel pump - G6-

nostic tester
❑ inspecting fuel pump
⇒ “2.5 inspecting fuel
pump”, page 243
unit”, page 237
❑ Fill the vehicle with at
least 5 litres of fuel after
installing
2 - Clamp
❑ Secure hose connec‐
tions with hose clamps
that comply with the ser‐
ies design:
3 - Clamp
❑ Secure hose connec‐
tions with hose clamps
that comply with the ser‐
ies design:
4 - Fuel line
❑ to the dosing pump -
V54- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

unit”, page 237
5 - Sealing grommet
❑ check for damage
❑ removal and installation ⇒ “2.3 Removing and installing fuel delivery unit”, page 237
6 - Fuel line
❑ to the engine
❑ do not kink
❑ Unlocking and connecting the quick couplings ⇒ “3 Quick couplings”, page 256

2.3 Removing and installing fuel delivery

unit
♦ Socket - T10202-
Removing
• The fuel tank must not be more than 3/4 full.
If necessary, extract fuel from the fuel tank
Observe the safety instructions before starting fitting work
page 4 .
key.

-2-.
2. Fuel pump 237

-B- and lay aside.
– Unlock and disconnect electrical plug connection -2- from

closing flange.
For vehicles with auxiliary heating

– Disconnect plug connection -2- of dosing pump - V54- .
– Remove the rubber grommet from the cover of the fuel delivery
unit and pull out the wiring.
– Open the bottom clamp and pull the suction line -2- for the
dosing pump - V54- out of the flange.
CAUTION
system.

– Disconnect fuel line -1- from the flange


– Open lock ring with the wrench - T10202- .
– Pull sealing flange -2- carefully out of the fuel tank opening.
– Remove sealing ring -1- from fuel tank opening.
CAUTION
Risk of accident due to fuel flowing out of the fuel pump which
is still full.
– Place a cloth below to absorb any fuel.

– Remove fuel pump from the fuel tank so that the electric cables
and fuel hoses are not damaged and the float arm of the send‐
er for fuel gauge display - G- is not bent.
Note
You must empty the old delivery unit before disposing of it if you
wish to replace the fuel delivery unit.
Installing
– Insert the new dry gasket ring for the flange into the opening
of the fuel tank and moisten only from the inside with fuel for
installing the closing flange.
– Insert the fuel pump into the fuel tank in such a way that the
float arm of the sender for the fuel gauge display - G- is not
bent.
NOTICE unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Risk of leaks if the sealing ring is damaged.
The gasket ring must not get damaged or squashed when insert‐
ing the sealing flange.
2. Fuel pump 239

• Clutch -2- on closing flange must point to opening -arrow- on

the lock ring and be located between tabs -3- and -4- on the
fuel tank.
– Press down the closing flange against the spring force and
bring it into the installation position.
– Insert lock ring and tighten using the wrench - T10202- .
Fitting location of the fuel delivery unit

• The marking -2- on the closing flange of the fuel pump -1- must
be located opposite to the arrow -3- on the fuel tank.
• The -arrow- shows the direction of travel.
– Connect fuel line ⇒ “3 Quick couplings”, page 256 .


– If the fuel delivery unit was replaced, disconnect the cover
-7- from the removal connection -6- at the marked separation
point and insert the standpipe -3- into the space -4- until the
reinforcement rests against the removal connection -6-.
– Push sleeve -2- on and secure with clamps -1-.
– Switch on the auxiliary heating and run it for at least 10 minutes
at full load to ensure the complete discharge of the fuel line.
following:
WARNING
Risk of fuel container explosion on fuel pump start-up!
After installing the fuel pump into the completely emptied fuel
tank, you must replenish a minimum of 5 litres of fuel right away.
Tightening torques
♦ Fuel pump lock ring
⇒ “2.1 Summary of components - fuel pump G6 and fuel gauge
sender”, page 235 .
2.4 Removing and installing the fuel gauge

sender - G-
Observe the safety instructions before starting fitting work
page 4 .
Fuel gauge sender - G- type
with1respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Removing
– Remove fuel delivery unit
– Disconnect electrical plug connection -1- on the closing flange,
thereby unlocking the plug lock.
– Unhook the electric cable from the holder -arrow- and expose
it.
2. Fuel pump 241

– Unlock the catches -3- and -4- and simultaneously pull out the
sender for fuel gauge display -G- -2- upwards.
Installing
following:
– Insert the fuel gauge sender -G- into the guides on the fuel
delivery unit and press down until it engages.
– Connect all electric cables to fuel pump.
– Install fuel delivery unit
Fuel gauge sender - G- type 2
Removing
– Remove fuel delivery unit
– Unlock the securing tabs -arrows- using a screwdriver and pull

the fuel gauge sender - G- up and out.
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Installing
– Connect the wiring and check correct installation of the plug.
– Insert the fuel gauge sender - G- into the guides on the fuel
delivery unit and press down until it engages.
– Install fuel delivery unit

2.5 inspecting fuel pump

⇒ “2.5.1 Checking fuel pressure”, page 243
⇒ “2.5.2 Checking the holding pressure”, page 246
⇒ “2.5.3 Check fuel flow rate”, page 250
2.5.1 Checking fuel pressure

♦ Pressure gauge , e.g. -VAS 6550-
page 4 .
• Voltage supply is O.K.
CAUTION
system.
– Remove fuel feed line -1-
– 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 fuel dripping out.
– Check the quick couplings for firm seating by pulling in the

opposite direction.
2. Fuel pump 243

Make sure that the shut-off tap -C- is closed at the pressure gauge
- VAS 6550- -1-.
– Open shut-off taps -A- and -B- .
– Switch on the ignition.
– Activate the fuel pump for fuel pressure generation ⇒ Vehicle
diagnostic tester.
– Read fuel pressure on pressure gauge - VAS 6550- .
• Set value: 0.4-0.7 MPa (4-7 bar).
If the specified value is reached:
– Test holding pressure
⇒ “2.5.2 Checking the holding pressure”, page 246 .
If the set value is exceeded:
– Replace fuel pump; the pressure limiting valve in the fuel pump
is faulty
If the set value is not reached:
– Proceed as follows to check fuel pressure at fuel pump:


-2-.

-B- and lay aside.
CAUTION
system.
– Remove fuel line -1- from closing flange

– Connect pressure gauge - VAS 6550- with adapter - VAS

6550/3-4- to the fuel pump -1-.
♦ VAS 6550/3-3 between the fuel feed lineProtected
-2- and shut-offCopying
by copyright. tap for private or commercial purposes, in part or in whole, is not permitted
-B-. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ VAS 6550/3-4 between fuel pump and shut-off tap -A-.
opposite direction.
NOTICE
2. Fuel pump 245


• Shut-off tap -C- is closed.
• Lever points in the direction of flow.
– Check the fuel pressure again ⇒ page 244
– Check fuel lines for possible restrictions or blockages.
– Check fuel lines for leaks and possible damage.
– Remove fuel pump and check it is clean
– Check that all hoses are connected -arrows-.

– Check fuel lines of pump for leaks and possible damage.
If no fault is found:
– Replace fuel pump
2.5.2 Checking the holding pressure

page 4 .
• Fuel pressure OK
⇒ “2.5.1 Checking fuel pressure”, page 243 .
CAUTION
system.



tap -A-.
tap -B-.
opposite direction.
NOTICE

opposite direction.
2. Fuel pump 247


– Check leaktightness and while doing so observe pressure
drop at pressure gauge - VAS 6550- .
– Switch on the ignition.
Activate the fuel pump for fuel pressure generation ⇒ Vehicle di‐
agnostic tester.
Note
If it becomes necessary to implement the actuator diagnosis sev‐

eral times in sequence, it may be necessary to start the engine
briefly before repeating the actuator diagnosis.
– Read off fuel pressure on pressure gauge.

• Set value: ≥ 0.4 MPa (4 bar).
– End the self-diagnosis and switch off the ignition.
– Protected
Observe the drop
by copyright. in pressure
Copying using the
for private or commercial pressure
purposes, gauge
in part or in whole,-VAS
is not permitted
6550-
unless .
• The pressure must not drop below 0.3 MPa (3 bar) after 10
minutes.
If pressure drops:
– Check all fuel lines for leaks and damage.
• Shut-off taps -A- and -B- are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure ⇒ page 248 .
– After pressure has built up, close cut-off tap -A- of pressure
gauge -VAS 6550- immediately. The lever is then at right angle
to direction of flow.
– Repeat holding pressure check.
If the pressure does not drop:
The leakage is on the engine side.
If pressure drops:
The leakage on the fuel tank side ⇒ page 248 .
Testing holding pressure on engine side
– Repeat holding pressure check. This time, close shut-off tap
-B- to check whether the leak actually is on the engine side.
If the pressure drops again:
– Check fuel line and fuel distributor with injectors for leaks.
Checking holding pressure on fuel tank side



-2-.
-B- and lay aside.
CAUTION
system.

2. Fuel pump 249


♦ VAS 6550/3-3 between the fuel feed line -2- and shut-off tap
-B-.
opposite direction.
NOTICE

opposite direction.

– Actuate fuel pump ⇒ page 248 .
– After pressure has built up, close cut-off tap -B- of pressure
gauge immediately.
If the pressure does not drop:
– Check the fuel lines in the direction of the engine for leaks.
If pressure drops:

– Check fuel lines of pump for leaks and possible damage.
2.5.3 Check fuel flow rate

Special tools and workshop equipment
unless authorisedrequired
♦ Pressure valve - VAS 6550/4-
♦ Remote control - V.A.G 1348/3A-
♦ Adapter for measuring method/DSO (5-pin) - VAS 5565-
♦ Multimeter , e.g. -V.A.G 1715-


♦ Measuring vessel
page 4 .
• Fuel pressure OK
⇒ “2.5.1 Checking fuel pressure”, page 243 .
• Battery voltage at least 11.5 V, connect a battery charger if
necessary.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
Note
The fuel delivery rate must first be checked in the engine com‐
partment using the targeted function »Check fuel flow rate, quick
test«. If the minimum fuel delivery rate is not reached, a further
test must be carried out at the flange of the fuel pump.
Checking the fuel delivery rate in the engine compartment, quick

test
– Connect ⇒ Vehicle diagnostic tester and start self-diagnosis
with »ODIS«.
– Switch on the ignition and select:
♦ ⇒
0001 - Engine control unit function
♦ ⇒
0001 - Check fuel flow rate, quick test
– Follow the instructions of the vehicle diagnosis tester .

– Open the fuel tank lid unit.
– Clean around the fuel filler neck -2-.
– Repeat the quick test ⇒ page 251 .
– Check the ventilation of the fuelunless
tank authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ “5.3 Checking the fuel tank venting”, page 265 .

– Check fuel delivery quantity at the fuel delivery unit
Checking fuel delivery rate at the fuel pump
2. Fuel pump 251



-2-.
-B- and lay aside.
– Remove plug -1- for fuel delivery unit.

– Disconnect plug connection -2- from auxiliary heating dosing
pump - V54- .


– Connect adapter - VAS 5565- -E- for the fuel pump -A-.
– Connect remote control - V.A.G 1348/3A- -D- to the adapter -
VAS 5565- and to battery positive terminal in the engine
compartment.
– Connected connection -5- (yellow) from adapter - VAS 5565-
using the auxiliary cable -C- from the auxiliary measuring set
- V.A.G 1594 C- to the negative terminal of the battery -B-.
The fuel delivery of the fuel pump is dependent on the battery
voltage. For this reason, additionally connect the multimeter -
V.A.G 1715- to the outgoing circuits -1- and -5- of the adapter for
measuring method/DSO (5-pin) - VAS 5565- .
Note
This step is only intended to ensure that the fuel pump runs when
the engine is switched off.
CAUTION
system.


♦ Pressure valve - VAS 6550/4- to shut-off tap -B-.
NOTICE

opposite direction.
– Hold hose on delivery valve - VAS 6550/4- in measuring ves‐
sel.
2. Fuel pump 253


Note
♦ Counterpressure must be built up against which the fuel pump

must work when the fuel delivery flow in the fuel line is being
measured.
♦ The counterpressure is set by turning the setting wheel
-arrow- of the pressure valve - VAS 6550/4- .
– Operate remote control - V.A.G 1348/3A- . While doing this,

slowly close the shut-off control valve -arrow- until the pres‐
sure gauge displays 0.4 MPa (4 bar) overpressure.
Note
From this point on do not move the position of the control valve.
– Drain measuring vessel.

– Operate remote control for 60 seconds, whilst measuring volt‐
age at fuel pump.
– Compare the fuel rate with the specified value.
Minimum fuel flow rate in cm3/60 s.
Note
Voltage at the fuel pump when engine is not running and pump is
approximately 2 volts less than battery voltage.
Read out examples:

During the test a voltage of 10.5 V was measured. Thus a mini‐
mum fuel flow rate of 1200 cm3/60 s is obtained.
– Check fuel lines for leaks and possible damage.


– Check fuel lines for leaks and damage.
2.6 Removing and installing fuel pump con‐

trol unit -J538-
key.
– Loosen catch pegs -arrows- of cover -1- with the disassembly
wedge - 3409- and remove the cover.
– Simultaneously
Protected by copyright. Copyingpull the fuel
for private pumppurposes,
or commercial controlin unit
part or-inJ538-
whole, is-1- at
not permitted
the electric
unless authorised wiring
by ŠKODA AUTO loom -3- carefully
A. S. ŠKODA AUTO A. S.out
does of
not the uptake
guarantee or accept any liability
-arrow B-.
– Take out fuel pump control unit - J538- inwards between fuel
tank and bottom plate.
– Disconnect plug
Installing
– Push fuel pump control unit - J538- into the uptake and push
in until there is an audible click.
2. Fuel pump 255

3 Quick couplings
⇒ “3.1 Separating push-on couplings”, page 256
3.1 Separating push-on couplings

♦ Lever - T10468-
The quick couplings of fuel, vacuum and ventilation lines are col‐
our marked. Either the colour point at the quick coupling or the
release button has the corresponding colour.
Observe safety measures
page 4 .
Push-on coupling Colour coding on the quick cou‐
pling
Fuel feed black
line
Fuel return-flow blue
line
Vent line White, beige
Vacuum line
Protected by copyright. Copying for privategreen
CAUTION
system.
Wear protective spectacles and protective gloves.
Version 1
Note
When the push-fit coupling is fitted with a plastic circlip, leave it

inserted when removing and installing the quick release.
Quick coupling with release buttons -arrows- on right and left.

The separation point -1- in the engine compartment must be held

in place.
– Insert the lever - T10468- between the heat shield and the stop
-arrow- of the fuel line -2- and hold.
Continued for all separation points.
– Press the quick coupling -1- in direction of arrow -A-.

– Press the release buttons and remove the quick coupling -1-
from the fuel line -2- in direction of the arrow -B-.
Pay attention to the assignment of the colours when installing
⇒ page 256 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 2
Push-on coupling with pull-release mechanism -arrow-
3. Quick couplings 257

– Press the quick coupling -1- in direction of arrow -A-.

– Pull pull-release mechanism -2- in direction of arrow -B-.
– Remove the quick coupling -1- from the fuel line -3- in direction
of the arrow -B-.
⇒ page 256 .
posite direction!
Version 3
Quick coupling with front button -arrow-.
– Press the release button -arrow- and detach the quick cou‐
pling.
⇒ page 256 .
posite direction!
Version 4
– Press the quick coupling in direction of arrow -A-.
– Press release buttons -arrow- and detach quick coupling.
⇒ page 256 .
posite direction!
Version 5
⇒ page 256
Protected .
– Check thetoquick
with respect coupling
the correctness for firm
of information seating
in this byCopyright
document. pulling in theAUTO
by ŠKODA op‐ A. S.�
posite direction!

Version 6
– Press push-on coupling -1- in -direction of arrow- and hold
pressed.
⇒ page 256 .
opposite direction!
Version 7
Quick coupling -1- with release buttons -arrows- right and left.
– Press quick coupling -1- in direction of arrow -A- and hold
pressed.
– Press the release buttons -2- in direction of arrow -B- and re‐
move the quick coupling -1-.
⇒ page 256 .
opposite direction!
3. Quick couplings 259

4 Accelerator control
⇒ “4.1 Assembly overview - accelerator module”, page 260
⇒ “4.2 Removing and installing accelerator pedal module GX2 ”,
page 261
4.1 Assembly overview - accelerator module
1 - Screw
❑ 6 Nm
2 - Connector
❑ Ensure safe locking by
pulling
3 - Accelerator pedal module -
GX2-
❑ with accelerator pedal
position sender - G79-
❑ with accelerator pedal
position sender 2 -
G185-
❑ for vehicles with auto‐
matic gearbox DSG with
kick-down switch
❑ After replacing in vehi‐
cles with automatic
gearbox DSG, adjust
the engine control unit
⇒ Vehicle diagnostic
tester
installing the accelera‐
tor module GX2 (Octa‐
via III)”, page 261

4.2 Removing and installing accelerator

pedal module - GX2-
⇒ “4.2.1 Removing and installing the accelerator module GX2
(Octavia III)”, page 261
⇒ “4.2.2 Disconnect connector for accelerator pedal module and
fit on”, page 262
4.2.1 Removing and installing the accelerator

module - GX2- (Octavia III)
Removing
– Tilt the cover for underbody -1- towards the front in
– Disconnect electrical plug connections -2- on the accelerator
pedal module, thereby pressing the release upwards.
– Remove accelerator module -3- from the uptake.

Installing
Tightening torques
♦ Screw for accelerator pedal module
⇒ “4.1 Assembly overview - accelerator module”, page 260 .
4. Accelerator control 261

4.2.2 Disconnect connector for accelerator

pedal module and fit on
Note
The plugs for the accelerator pedal module which are inserted,
must be disconnected and fit on in a different manner.
Disconnect connector 1K0 973 706

– Slightly press the piston slide valve -A- (grey) in direction of
arrow -1- and push it up to the stop in direction of arrow -2-.
– Hold the piston slide valve in this position and disconnect the
socket housing -B- towards the top in direction of arrow -3-.
The piston slide valve -A- remains in the bottom position.
Fit on connector 1K0 973 706

– Push the socket housing -B- down in -direction of arrow- until
the housing can be heard to lock in place.
The piston slide valve -A- moves automatically upwards.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.
Disconnect connector 8K0 973 706

– Pull piston slide valve -A- (red) upwards in direction of arrow
-1- up to the stop.
– Press the piston slide valve in direction of arrow -2- and dis‐
connect the socket housing -B- in direction of arrow -3-.
The piston slide valve -A- remains in the top position.
Fit on connector 8K0 973 706

– Push the socket housing -B- down in direction of arrow -1- up
to the stop.
– Lightly press the piston slide valve in direction of arrow -2- and
slide in the direction of arrow -3-.
The
unless piston by
authorised slide
ŠKODA valve
AUTO-A-A. S.can
ŠKODAonlyAUTO beA. pushed downwards
S. does not guarantee if any liability
or accept
the socket housing was pushed downwards »up to the stop«.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.

5 Activated charcoal filter system

⇒ “5.1 Assembly overview - activated charcoal filter system”, page
263
⇒ “5.2 Removing and installing activated charcoal filter”,
page 264
⇒ “5.3 Checking the fuel tank venting”, page 265
5.1 Assembly overview - activated charcoal filter system
1 - Vent line
❑ to activated charcoal fil‐
ter solenoid valve 1 -
N80-
❑ pushed into the fuel tank
⇒ Fig. ““Connection dia‐
gram at activated char‐
coal filter”“ , page 264
❑ disconnect and connect
⇒ “3 Quick couplings”,
page 256
2 - Screw
❑ 20 Nm
3 - Activated charcoal filter
❑ Installation location in
wheelhouse under the
wheelhouse liner
❑ removal and installation Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “5.2 Removing and in‐ with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
stalling activated char‐
coal filter”, page 264
❑ Checking breather
⇒ “5.3 Checking the fuel
tank venting”,
page 265
4 - Vent line
❑ to fuel tank
5. Activated charcoal filter system 263

Connection diagram at activated charcoal filter

1- Vent connection -A-
2- Connection to the fuel tank -T-
3- Connection to the Solenoid valve 1 for activated charcoal
filter - N80- -M-
4- Protective cap
5.2 Removing and installing activated char‐

coal filter
Observe safety instructions
page 4 .
page 4 .
– Remove rear wheel on the right ⇒ Wheels, tyres; Rep. gr. 44 .
gr. 66 .
– Disconnect the vent lines -1- and -2- on the activated charcoal
filter ⇒ “3 Quick couplings”, page 256 .
– Loosen ventilation lines from fasteners on the holder
-arrows-.


– Pull out catch -3- using a screwdriver and pull the activated
charcoal filter -2- down out of the lock -arrow-.
Installing
Tightening torques
♦ Screw for activated charcoal filter system
⇒ “5.1 Assembly overview - activated charcoal filter system”,
page 263 .
5.3 Checking the fuel tank venting

♦ Hand vacuum pump , e.g. -V.A.S 6213-
♦ Pressure gauge - VAS 6550 -
♦ Adapter - VAS 6550/3-1 -
♦ Screw plug set for engine , e.g. -VAS 6122-
page 4 .
• Ignition must be switched off.
Check activated charcoal filter solenoid valve 1 - N80-
– Detach vent line -2-

– Connect the hand vacuum pump - V.A.G. 1390 (VAS 6213)-

with adapter set - VAS 6550/3–1- and a standard commercially
available hose to the line to the Solenoid valve 1 for activated
charcoal filter - N80- .
– Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
in position -B- for “pressure”.
– Operate the hand vacuum pump - VAS 6213- several times.
A pressure of approx. 0.1 bar must build up.
If no pressure builds up:
– Check the line to the Solenoid valve 1 for activated charcoal
filter - N80- for damages and leaks.
The solenoid valve 1 for activated charcoal filter - N80- is not OK.
If pressure builds up:
The solenoid valve 1 for activated charcoal filter - N80- is OK.
Checking the vent connection of the activated charcoal filter and
the vent line
– Detach vent unless
line -2-
⇒ “3.1 Separating push-on
with respect couplings”,
to the correctness page in256
of information .
this document. Copyright by ŠKODA AUTO A. S.�
– Connect the hand vacuum pump - VAS 6213- with the adapter
set - VAS 6550/3-2- to the line leading to the activated charcoal
filter.
– Remove the rear right wheelhouse liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and
installing rear wheelhouse liner .

– Pull vent line -3- of the fuel tank off from connector -T- of the
activated charcoal filter and close connector -T- using suitable
means in the workshop.
No pressure should build up.
Vent connection is OK.
Vent connection -A- on the activated charcoal filter or line be‐

tween the engine compartment and activated charcoal filter is
blocked.
– Check the line between the engine compartment and activated
charcoal filter for blockage.
If no blockage in line:
Vent connection -A- on the activated charcoal filter is blocked.
– Remove ventilation cap -4- and check ventilation bore for con‐
tamination.
– Repeat check ⇒ page 266 .
If pressure builds up again:
– Replace
with respectactivated charcoal
to the correctness filter.
Check activated charcoal filter and vent line for leak-tightness.

– Release and pull off vent line -2-

– Connect the hand vacuum pump - VAS 6213- with the adapter
set - VAS 6550/3-2- to the line leading to the activated charcoal
filter.
gr. 66 .
– Pull vent line -3- of the fuel tank off from connector -T- of the
activated charcoal filter and close connector -T- using suitable
means in the workshop.
– Remove the protective cap from vent connection -A- on the
activated charcoal filter -2- and close the connection using a
suitable plug -1- from the screw plug set for engine - VAS
6122- .
Activated charcoal filter and vent line are leak-tight.
Activated charcoal filter or vent line is not leak-tight.

– Check activated charcoal filter as follows:

1 - Vent connection -A- is closed.
2 - Connector -T- is closed.
– Connect hand vacuum pump - VAS 6213- with a commercially

available hose -3- to connector -M- of the activated charcoal
filter -1-.
Activated charcoal filter is not leak-tight. Determine leaks by lis‐
tening, touching or using a leak search spray.
– Renew activated charcoal filter
⇒ “5.2 Removing and installing activated charcoal filter”, page
264 .
If pressure builds by up:
unless authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Activated charcoal filter is leak-tight.
– Check vent line for leak-tightness.
Installing
Make sure the line connections fit tightly.

21 – Turbocharging/supercharging
1 Exhaust gas turbocharger
page 270
⇒ “1.2 Removing and installing exhaust gas turbocharger”,
page 275
⇒ “1.4 Removing and installing element for load pressure control
GX34 ”, page 280
connection fitting”, page 279
1.1 Summary of components - exhaust gas

turbocharger
⇒ “1.1.1 Summary of components - exhaust gas turbocharger,
variant 1”, page 270
variant 2”, page 272
⇒ “1.1.3 Assembly overview - Piping on the exhaust gas turbo‐
charger”, page 274
1.1.1 Summary of components - exhaust gas turbocharger, variant 1
270 Rep. gr.21 - Turbocharging/supercharging


stalling exhaust gas tur‐
bocharger”, page 275
2 - Sealing ring
⇒ page 279
3 - Screw clamp
tightening order
ponents - Pre-exhaust
pipe with catalytic con‐
verter”, page 343
4 - Nut
❑ 14 Nm
5 - Release handle
6 - Locking clip
7 - Module for charge pressure
regulation - GX34-
❑ consists of:
♦ Charge pressure regulator -
V465-
♦ Position transmitter for
charge pressure regulator -
G581-
⇒ “1.4.1 Removing and installing element for charge pressure control, variant 1 GX34 ”, page 280
8 - Screw
❑ 8 Nm + 90°
9 - O-ring
10 - Screw
❑ 9 Nm
11 - Supports
⇒ “1.3 Removing and installing the exhaust gas turbocharger connection fitting”, page 279
12 - Screw
❑ Pin screw
❑ screwed on in the cylinder head
❑ 16 Nm
13 - Seal
14 - O-ring
1. Exhaust gas turbocharger 271

15 - Heat shield
❑ removal and installation ⇒ page 276
16 - Screw
❑ 25 Nm
17 - Screw
❑ 8 Nm
1.1.2 Summary of components - exhaust gas turbocharger, variant 2

2 - Screw
❑ 8 Nm + 90°
3 - Sealing ring
⇒ page 279
4 - Screw clamp
tightening order
ponents - Pre-exhaust
pipe with catalytic con‐
verter”, page 343
5 - Nut
❑ 14 Nm
6 - Locking clip
7 - Release handle
regulation - GX34-
❑ consists of:
♦ Charge pressure regulator - unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
V465- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Position transmitter for charge pressure regulator - G581-

⇒ “1.4.2 Removing and installing element for charge pressure control, variant 2 GX34 ”, page 281
9 - O-ring
10 - Screw
❑ 9 Nm

11 - Supports
⇒ “1.3 Removing and installing the exhaust gas turbocharger connection fitting”, page 279
12 - Seal
13 - O-ring
14 - Screw
❑ Pin screw
❑ screwed on in the cylinder head
❑ 16 Nm
15 - Heat shield
16 - Screw
❑ 25 Nm
17 - Screw
❑ 8 Nm

1.1.3 Assembly overview - Piping on the exhaust gas turbocharger

2 - O-ring
❑ If damaged, replace
hose for crankcase ven‐
tilation
3 - Hose
❑ for crankcase ventila‐
tion
4 - Screw
❑ 5 Nm
5 - Screw
❑ 9 Nm
6 - Oil feed line
7 - O-ring
8 - Screw
❑ 20 Nm
9 - O-ring
10 - Oil return-flow line
11 - Screw
❑ 9 Nm
12 - Screw
❑ 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 - Seal unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
19 - Screw
❑ 8 Nm

1.2 Removing and installing exhaust gas

turbocharger
♦ Screw plug set for engine , e.g. -VAS 6122-
Removing
Note

let .

♦ Close any open connections in the airway and in the outlet
path with plugs from closing plug set for engine - VAS 6122- .

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.
288 .
– Remove module for charge pressure regulation - GX34-
⇒ “1.4 Removing and installing element for load pressure
control GX34 ”, page 280 .


– 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.
– Also unscrew the screws -d- and -e- and remove baffle -5-.
– Place drip tray underneath, e.g., B. -VAS 6208- for collecting
liquids.
– Unscrew screws -arrows- and remove heat shield for right

cardan shaft, if present.
– Unscrew fastening bolts for coolant pipes -b- and -c-.

– Pinch off coolant hoses on coolant pipe with hose clamps up
to 25 with
mmrespect
- 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
converter”, page 345 .
– 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
– 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.

Installing

– 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
catalytic converter item -9-
– Install the screw clamp between the exhaust gas turbocharger
and the catalytic converter in the previously indicated instal‐
lation position
⇒ Fig. ““Installing catalytic converter - tightening torque and
tightening order”“ , page 348 .
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 . Secure all hose connections with hose clamps which com‐
ply with the series design ⇒ ETKA - Electronic Catalogue of
Original Parts .
– Check coolant level
To ensure the oil supply to the exhaust gas turbocharger, leave
the engine running for about 1 minute after installing the exhaust
gas turbocharger; do not rev up immediately.
– Electrical connections and proper routing ⇒ Current flow dia‐
If a new exhaust gas turbocharger with built-in pressure regulator
has been installed:
– Carry out function Start the engine inlet with the ⇒ Ve‐
– Adapting the engine control unit - J623- to the charge pressure
regulator - V465- ⇒ Vehicle diagnostic tester.
♦
unless 0001 -by ŠKODA
authorised AUTO A. S. of
Adaptation ŠKODA AUTO A. S.
charge does not guarantee
pressure or accept any-liability
regulator
V465
Tightening torques
♦ Exhaust gas turbocharger
page 270 .
♦ Exhaust pipe with catalytic converter
♦ Drive shaft screening ⇒ Axles, steering; Rep. gr. 40 .
1.3 Removing and installing the exhaust

gas turbocharger connection fitting
Removing
– Remove air filter housing:
⇒ “2.2 Removing and installing air filter housing”, page 307

– 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 groove must be engaged in the bore of the exhaust gas
turbocharger -a-.
– Tighten the screws -arrows- of the connection fitting-1-.

Tightening torques
♦ Connection fitting of the exhaust gas turbocharger
page 270 .
1.4 Removing and installing element for

load pressure control - GX34-
⇒ “1.4.1 Removing and installing element for charge pressure
control, variant 1 GX34 ”, page 280
⇒ “1.4.2 Removing and installing element for charge pressure
control, variant 2 GX34 ”, page 281
1.4.1 Removing and installing element for

charge pressure control, variant 1 -
GX34-
The Module for charge pressure regulation - GX34- consists of:
♦ Charge pressure regulator - V465-


Removing
gr. 66 .
– Unscrew screws -arrows- and remove heat shield for right
cardan shaft, if present.
– 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-.
Installing
– Replace locating screw s and locking clips.
♦ 0001 - Adaptation of charge pressure regulator -
V465
Tightening torques
♦ Module for charge pressure regulation - GX34- , Version 1
variant 1”, page 270 ,
♦ Right drive shaft screening ⇒ Axles, steering; Rep. gr. 40 .
1.4.2 Removing and installing element for

charge pressure control, variant 2 -
GX34-
The Module for charge pressure regulation - GX34- consists of:
♦ Charge pressure regulator - V465-
Removing
connection fitting”,
with respect page 279

– Disconnect the plug -4- on the position sender for charge

pressure regulator - G581- .
– Disconnect locking clips -3- and remove actuating lever -2-.
– Unscrew screws -arrows- and remove the element for charge
pressure control - GX34- .
Installing
Replace locating screw s and locking clips.
♦ 0001 - Adaptation of charge pressure regulator -
V465
Tightening torques
♦ Module for charge pressure regulation - GX34- , Version 2
variant 2”, page 272 ,

2 Charge-air system
⇒ “2.1 Summary of components - charge air system”, page 283
⇒ “2.2 Removing and installing charge air cooler”, page 285
⇒ “2.3 Removing and installing charge pressure sender GX26 ”,
page 286
⇒ “2.4 Removing and installing charge air pipe”, page 288
⇒ “2.5 Checking the charge-air system for leaktightness”,
page 292
⇒ “2.6 Leak testing the charge air cooler”, page 294
2.1 Summary of components - charge air system

Before a test or repair, check all charge air pipes, charge air hoses
and vacuum lines for tight connection and leak tightness.
1 - Charge air pipe between

the charge air cooler and the
exhaust gas turbocharger.
installing the charge air
pipe between the
charge air cooler and
the exhaust gas turbo‐
charger”, page 288
3 - Sealing ring
❑ Replace after removal unless
❑ moisten with engine oil with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4 - Intake manifold
nents
view - intake manifold”,
page 309
stalling intake manifold”,
page 310
5 - Screw
❑ 7 Nm
6 - Charge air cooler
❑ Mounting position
charge pressure sender
- GX26-
⇒ Fig. ““Mounting over‐
view - charge pressure
sender -GX26- ”“ ,
page 285
❑ removal and installation ⇒ “2.2 Removing and installing charge air cooler”, page 285
2. Charge-air system 283

7 - Sealing ring
❑ moisten with engine oil
8 - 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-
❑ removal and installation ⇒ “3.3 Removing and installing the throttle valve control unit GX3 ”, page 313
❑ clean ⇒ “3.4 Cleaning throttle valve control unit GX3 ”, page 314
9 - Sealing ring
10 - Sealing ring
11 - Screw
❑ 7 Nm
12 - Charge air pipe
unless between
authorised by ŠKODAtheAUTO
charge air cooler
A. S. ŠKODA AUTO A. and thenotintake
S. does manifold
guarantee arrows.
or accept any liability
⇒ “2.4.2 Removing and installing the charge air pipe between the charge air cooler and the intake mani‐
fold”, page 290
13 - Intake manifold pressure sender - GX9-
❑ comprises:
♦ Intake air temperature sender 2 - G299-
♦ Intake manifold pressure sender - G71-
⇒ “5.1 Removing and installing intake manifold pressure sender GX9 ”, page 326
❑ Summary of components
⇒ Fig. ““Assembly overview - Plug for intake manifold sender -GX9- ”“ , page 310
14 - Screw
❑ is to be used n the event of breaking off the retaining lugs for intake manifold sender - GX9- ⇒ Electronic
parts catalogue
❑ Tightening torque ⇒ Fig. ““Mounting overview - charge pressure sender -GX26- ”“ , page 285
15 - Sealing ring
17 - Charge pressure sender - GX26-
❑ Summary of components ⇒ Fig. ““Mounting overview - charge pressure sender -GX26- ”“ , page 285
❑ removal and installation ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 286
18 - Screw
❑ 3 Nm

Mounting overview - charge pressure sender - GX26-

⇒ “2.3 Removing and installing charge pressure sender GX26 ”,
page 286
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
gr. 66 .
– Remove electrical coolant pump
”, page 180 .
– 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-
– Release clampsProtected
for coolant hoses
by copyright. -arrows-
Copying for privateat charge air
or commercial cool‐in part or in whole, is not permitted
purposes,
er. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– 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 gasket rings.
– Install electric coolant pump
”, page 180 ,
– Top up coolant unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ “1.3 Draining and filling coolant”, page 172with.respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Tightening torques
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-
⇒ “3.3 Removing and installing the throttle valve control unit
GX3 ”, page 313 .
– Remove plug -a- also pull out-arrow- slightly.
– Unscrew mounting screws -b-.

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

sure sender - GX26- .
♦ Before positioning, moisten O-ring lightly with oil.
Tightening torque
♦ Charge pressure sender - GX26-
page 283 .

2.4 Removing and installing charge air pipe

⇒ “2.4.1 Removing and installing the charge air pipe between the
charge air cooler and the exhaust gas turbocharger”, page 288
charge air cooler and the intake manifold”, page 290
2.4.1 Removing and installing the charge air

pipe between the charge air cooler and
the exhaust gas turbocharger
Removing
– Unclip the vacuum line -1- from the receptacle -arrow- on the
charge air pipe -2-.
– Remove vacuum line -1- from the intake manifold, and press
the lock in -arrow-.
– Lay vacuum line to the side.
– Turn lock ring -1- for charge air 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 charge air pipe-2-.

– Detach the charge air pipe from the charge air cooler.
– Detach the charge air pipe from the exhaust turbocharger.
Installing
– Replace gasket 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 charge air pipe up to the stop on the exhaust gas
turbocharger.
– Press the charge air pipe up to the stop on the charge air
cooler.
– Insert the mounting bracket into the grooves for the charge air
pipe.
• The lugs on the mounting bracket -a- must be inserted in the
recesses behind -b- for the charge air pipe-2-.
– Press down charge air 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 charge air

pipe between the charge air cooler and
the intake manifold
Removing
47 ,
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
– Unscrew mounting screws -c- between holders -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-.
– Lift out mounting bracket -b- in the area -arrow- and pull out of
the recesses on the charge air pipe -2-.

– Pull off the charge air 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
charge air pipe.
– Tighten locating screws.
Tightening torques
♦ Charge air pipe
⇒ “3.1 Assembly overview - intake manifold”, page 309 .
♦ Vacuum pump for brake - V192- ⇒ brakingProtected
system; Rep. gr.
47 , unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
2.5 Checking the charge-air system for

leaktightness
♦ 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- .

– Detach vent line -3-. To do so, press the locks.

– Close open connections of vent line using suitable plugs from
– 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-.
– 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-

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 hose of the connection »A« Y distributor to connec‐
tion »II« of the turbocharger tester - V.A.G 1397A- .
– Put turbocharger tester - V.A.G 1397A- 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- .

– Detach vent line -3-. To do so, press the locks.

– Close open connections of vent line using suitable plugs from

– 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
A small amount of air escapes via the valves into the engine and
the exhaust gas system. For this reason no pressure test is pos‐
sible.
Read off the turbocharger tester - V.A.G 1397A-

– 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
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.
– Replace O-rings.

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Installation location overview - engine compartment”, page
299
1.1 Installation location overview - engine compartment
1 - Lambda probe 1 in front of

the catalytic converter - GX10-
❑ comprises:
♦ Lambda probe - G39-
♦ Lambda probe heater -
Z19-
nents
ponents - lambda
probe”, page 337
stalling Lambda probe”,
page 337
2 - Connector
❑ for Lambda probe 1 be‐
fore catalyst - GX10-
and Lambda probe 1
after catalyst - GX7-
❑ Overview of the fitting
positions
⇒ Fig. ““Contact assign‐
ment at bulkhead ple‐
num chamber”“ ,
page 301
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-
❑ Summary of components ⇒ “1.1Copying
Protected by copyright. Assembly overview
for private or commercial - purposes,
ignitioninsystem”, page
part or in whole, is not353
permitted
❑ removal and installation ⇒to“1.2
with respect Removing
the correctness and installing
of information ignition
in this document. coils
Copyright with AUTO
by ŠKODA output stage”, page 354
A. S.�
❑ When installing new spark plugs, grease the ignition coils with power output stage with lubricating paste
G 052 565 A1.
❑ Summary of components ⇒ “1.2 Summary of components - camshaft housing”, page 73
1. Injection system 299

6 - Module for air mass measurement - GX35-

❑ not fitted to all engines
❑ comprises:
♦ Air mass meter - G70-
♦ Temperature sensor in the air mass meter - G1005-
❑ Summary of components ⇒ “2.1 Assembly overview - air filter housing”, page 306
❑ removal and installation ⇒ “5.5 Removing and installing valve for air mass meter GX35 ”, page 332
7 - Coolant temperature sender at radiator outlet - G83-
❑ Summary of components ⇒ “2.3 Summary of components - coolant temperature transmitter”, page 180
⇒ “2.8 Removing and installing coolant temperature sender at radiator outlet G83 ”, page 188
8 - activated charcoal filter solenoid valve 1 - N80-
❑ comprises:
♦ Charge pressure sender - G31-
♦ Intake air temperature sender - G42-
❑Protected
Summary of components
by copyright. ⇒ commercial
Copying for private or Fig. ““Mounting overview
purposes, in part - ischarge
or in whole, pressure sender -GX26- ”“ , page 285
not permitted
❑ with
removal
respect to and installation
the correctness ⇒ “2.3
of information Removing
in this and installing
document. Copyright by ŠKODA AUTO charge
A. S.� pressure sender GX26 ”, page 286

❑ 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-
❑ Summary of components ⇒ “3.1 Assembly overview - intake manifold”, page 309
❑ comprises:
12 - Vacuum pump for brake - V192-
❑ Assembly overview ⇒ braking system; Rep. gr. 47
13 - Camshaft control valve 1 - N205-
❑ Summary of components ⇒ “2.2 Summary of components - toothed belt”, page 88
14 - Engine control unit - J623-
❑ removal and installation ⇒ “8.1 Removing and installing engine control unit J623 ”, page 340
300 Rep. gr.24 - Mixture preparation - injection

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-
Installation location overview: engine from top
1 - Camshaft control valve 1 -

N205-
nents
ponents - toothed belt”,
page 88
stalling camshaft control
valve 1 N205 ”,
page 135
2 - Camshaft adjustment valve
1 in the outlet - N318-
nents
ponents - camshaft
housing”, page 73
installing camshaft con‐
trol valve 1 in the ex‐
haust N318 ”, page 135
3 - Position sensor for exhaust
camshaft - G1003- unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
nents
ponents - camshaft
housing”, page 73
installing position trans‐
mitter for exhaust cam‐
shaft G1003 ”,
page 358
4 - Ignition coil 1 with power output stage - N70-
❑ removal and installation ⇒ “1.2 Removing and installing ignition coils with output stage”, page 354


8 - Exhaust gas pressure sensor 1 - G450-
⇒ “5.4 Removing and installing pressure sensor for exhaust gas 1 G450 ”, page 331
10 - High pressure pump
❑ with fuel dosage valve - N290-
❑ Summary of components ⇒ “6.1 Summary of components - high pressure pump”, page 333
❑ removal and installation ⇒ “6.2 Removing and installing the high pressure pump”, page 334
❑ Summary of components ⇒ “1.2
Protected Summary
by copyright. offorcomponents
Copying - camshaft
private or commercial purposes, in housing”,
part or in whole,page 73
is not permitted
❑ removal and installation ⇒with“3.5 Removing
respect andofinstalling
to the correctness information in cam adjuster”,
this document. page
Copyright 133 AUTO A. S.�
by ŠKODA

❑ Summary of components ⇒ Fig. ““Mounting overview - charge pressure sender -GX26- ”“ , page 285
❑ removal and installation ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 286
❑ comprises:
♦ Throttle valve control unit - J338-
♦ Throttle valve drive for electronic power control - G186-
❑ Summary of components ⇒ “3.1 Assembly overview - intake manifold”, page 309
❑ comprises:

Installation overview: engine from front
1 - Knock sensor 1 - G61-

nents
view - ignition system”,
page 353
installing knock sensor
1 G61 ”, page 357
2 - Oil pressure sender - G10-
nents
ponents - oil pressure
switch/oil pressure con‐
trol”, page 164
stalling oil pressure
sender G10 ”, page 166
3 - Fuel pressure sender -
G247-
nents unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ponents - fuel distributor
with injectors”,
page 316
stalling fuel pressure
sender G247 ”,
page 327
4 - Camshaft control valve 1 -
N205-
❑ Summary of components ⇒ “2.2 Summary of components - toothed belt”, page 88
5 - Injection valves
♦ Injection valve for cylinder 1 - N30-
❑ Summary of components ⇒ “4.1 Summary of components - fuel distributor with injectors”, page 316
❑ removal and installation ⇒ “4.3 Removing and installing injectors”, page 318

7 - Module for engine temperature control - GX33-

❑ comprises:
♦ Position sensor for engine temperature control - G1004-
♦ Actuator for engine temperature control - N493-
⇒ “2.1 Summary of components - coolant pump and coolant thermostat”, page 177
⇒ “2.10 Removing and installing element for engine temperature control GX33 ”, page 190
❑ removal and installation ⇒ “1.6 Removing and installing the engine speed sender G28 ”, page 359
9 - Charge air cooler pump - V188-
❑ Summary of components ⇒ “2.2 Summary of components - charge air cooler pump V188 ”, page 179
❑ removal and installation ⇒ “2.4 Removing and installing charge air cooler pump V188 ”, page 180
Installation overview: engine from rear

regulation - GX34-
❑ comprises:
♦ Charge pressure regulator -
V465-
♦ Position transmitter for
charge pressure regulator -
G581-
nents
ponents - exhaust gas
turbocharger”,
page 270
installing element for
load pressure control
GX34 ”, page 280
❑ comprises:
Z19-
nents
ponents - lambda Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
probe”, page 337 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ page 337
3 - Lambda probe 1 after cata‐
lytic converter - GX7-
❑ comprises:
♦ Lambda probe downstream of catalytic converter - G130-

♦ Lambda probe heater 1 downstream of catalytic converter - Z29-

❑ Summary of components ⇒ “7.1 Summary of components - lambda probe”, page 337
❑ removal and installation ⇒ “7.2 Removing and installing Lambda probe”, page 337
4 - Oil pressure control valve - N428-
⇒ “4.1 Summary of components - oil pressure switch/oil pressure control”, page 164
⇒ “4.4 Removing and installing valve for oil pressure control N428 ”, page 165
5 - Oil level and oil temperature sender - G266-
❑ Summary of components ⇒ “1.1 Assembly overview - pan/oil pump”, page 149
⇒ “1.5 Removing and installing oil level and oil temperature sender G266 ”, page 158
6 - Coolant temperature sensor at engine output - G82-
⇒ “2.9 Removing and installing coolant temperature sender at engine outlet G82 ”, page 189
7 - Coolant temperature sender - G62-
⇒ “2.7 Removing and installing coolant temperature transmitter G62 ”, page 187

2 Air filter
⇒ “2.1 Assembly overview - air filter housing”, page 306
⇒ “2.2 Removing and installing air filter housing”, page 307
2.1 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 meas‐
urement - GX35-
❑ 1.5 ± 0.2 Nm
5 - Module for air mass meas‐
urement - GX35-
❑ Not for all vehicles
❑ comprises:
Air mass meter - G70-
Temperature sensor in
the air mass meter -
G1005-
6 - Seal
urement - GX35-
❑ Check for damage and
replace if necessary
❑ No spare part, compo‐
nent Module for air
mass measurement -
GX35-
7 - Air filter top part
urement - GX35-
8 - Air filter top part
❑ For vehicles without Module for air mass measurement - GX35-
9 - Screw
❑ captive
10 - Air filter element with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Change intervals:
⇒ Maintenance ; Booklet Octavia III
11 - Louvre grille
❑ clean to remove dirt and salt residues
12 - Air filter bottom part
❑ remove mechanical foreign particles

13 - Water drain hose

❑ clean
14 - Air deflector
❑ two-piece
15 - Cover
❑ for air guide
16 - Screw
❑ 2 Nm
17 - Screw
❑ captive
❑ 2 Nm
18 - Air deflector
❑ on the lock support
2.2 Removing and installing air filter hous‐

ing
Removing
– Remove plug -d- if; Module for air mass measurement - GX35-
is available.
– Remove air filter housing -2- In points -a- and -b- upwards from
the rubber guides.
2. Air filter 307

– 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 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” .
Tightening torques
♦ Hose clamp

3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 309
⇒ “3.2 Removing and installing intake manifold”, page 310
⇒ “3.3 Removing and installing the throttle valve control unit GX3
”, page 313
⇒ “3.4 Cleaning throttle valve control unit GX3 ”, page 314
3.1 Assembly overview - intake manifold
1 - Screw
❑ 3 Nm
2 - Coolant line
3 - Seal
4 - Screw
❑ Observe tightening se‐
quence ⇒ page 310
❑ 10 Nm
5 - Intake manifold
stalling intake manifold”,
page 310
6 - Screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ 3 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
7 - Vacuum line of the brake

booster
8 - Sealing ring
9 - Throttle valve control unit -
GX3-
❑ comprises:
♦ Throttle valve control unit -
J338-
♦ Throttle valve drive for elec‐
tronic power control -
G186-
♦ Throttle valve drive angle
sensor 1 for electric power control - G187-
❑ clean ⇒ “3.4 Cleaning throttle valve control unit GX3 ”, page 314
10 - Sealing ring
11 - Screw
❑ 7 Nm
3. Intake manifold 309

12 - Screw
❑ 7 Nm
13 - Charge air pipe between the charge air cooler and the intake manifold arrows.
⇒ “2.4.2 Removing and installing the charge air pipe between the charge air cooler and the intake mani‐
fold”, page 290
14 - Sealing ring
16 - Sealing ring
❑ comprises:
18 - Screw
❑ is to be used n the event of breaking off the retaining lugs for intake manifold sender - GX9- ⇒ Electronic
parts catalogue
❑ 3 Nm
order of tightening
Level Screws Tightening torque
1. -Position 5- Insert in the centre, starting alternately,
by hand as far as the stop
2. -Position 5- In the centre, starting alternately, 10 Nm
Assembly overview - Plug for intake manifold sender - GX9-
1 - Intake manifold sender - GX9- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ “5.1 Removing and installing intake manifold pressure sender
GX9 ”, page 326
2 - Screw, 3 Nm
3 - Replace O-rings after disassembly
4 - Charge air pipe between the charge air cooler and the intake
manifold arrows
charge air cooler and the intake manifold”, page 290
3.2 Removing and installing intake manifold

Removing
♦ Torx insert T30 - T10574-


288 .
– Detach vacuum hose -arrow- from intake manifold -1-.
– Remove fuel supply line from the brackets -arrows- at the in‐
take manifold -1-.
– 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- remove hose -c- from crank‐
case ventilation -3-.
– Remove line -4- from the guide on the intake manifold -d-.

– Unscrew screws -a- from intake manifold -1-.

– Release coolant pipe -2- in the points -b-.
– Place coolant tube, hoses and electrical cables sideways.
GX3 ”, page 313 .
– 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 287 .
– Install the throttle valve control unit - GX3-
GX3 ”, page 313 .
– Screw in fixing screw -arrow- between the charge air cooler

and the intake manifold.
Tightening torques
♦ Summary of components - intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 309
♦ Summary of components - charge air system
page 283 .
3.3 Removing and installing the throttle

valve control unit - GX3-
Throttle flap control unit - GX3- comprises:
♦ Throttle valve control unit - J338- .
♦ Throttle valve drive for unless
electronic power control
AUTO A.- S.G186-
ŠKODA .AUTO A. S. does not guarantee or accept any liability
authorised by ŠKODA
♦ Throttle valve drive angle sender 1 - G187- .
♦ Throttle valve drive angle sender 2 - G188- .

Removing
– Pull out connector -a-.
– Unscrew screws -arrows- and remove throttle valve control
unit - GX3- -1-.
Installing
– 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
Tightening torques
♦ Screws for throttle valve control unit - GX3-
3.4 Cleaning throttle valve control unit -

GX3-
♦ Acetone
♦ 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
GX3 ”, page 313 .

– 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-
GX3 ”, unless
pageauthorised
313
Protected . by ŠKODA
– Delete learnt values and adapt engine control unit - J623- to
the throttle valve control unit - GX3- ⇒ Vehicle diagnostic test‐

er.

4 Injection valves
⇒ “4.1 Summary of components - fuel distributor with injectors”,
page 316
⇒ “4.2 Removing and installing the fuel distributor”, page 317
⇒ “4.3 Removing and installing injectors”, page 318
⇒ “4.4 Clean injectors”, page 324
4.1 Summary of components - fuel distributor with injectors
1 - Fuel distributor
stalling the fuel distribu‐
tor”, page 317
2 - Screw
❑ 8 Nm + 90°
3 - Fuel pressure sender -
G247-
❑ check
⇒ “5.3 Check fuel pres‐
sure sender G247 ”,
page 328
❑ removal and installation Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “5.2 Removing and in‐ unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
stalling fuel pressure with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
sender G247 ”,
page 327
❑ 22 Nm + 10°
4 - Injector
stalling injectors”,
page 318
5 - O-ring
❑ 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 ⇒ “4.3 Removing and installing injectors”, page 318

11 - High pressure tube

❑ removal and installation ⇒ “6.3 Removing and installing high pressure pipe”, page 335
❑ 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
4.2 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, all seals on the injection valve must be replaced
because of 350 bar fuel pressure.
WARNING

– Place a clean cloth below to absorb leaking fuel.
page 335 .
4. Injection valves 317

– 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 318 .
– Position fuel distributor on the injectors.
– Press fuel distributor first to the right, then
Protected to the Copying
by copyright. left onto the or commercial purposes, in part or in whole, is not permitted
for private
injectors up to the stop. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– 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
page 335 .
Tightening torques
♦ Screws for fuel distributor
⇒ “4.1 Summary of components - fuel distributor with injec‐
tors”, page 316 .
4.3 Removing and installing injectors

♦ Removal tool - T10133/16A- from the Tool kit for engines FSI
- T10133 C-
♦ 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

⇒ “4.2 Removing and installing the fuel distributor”,
page 317 .

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 screw -D- slightly by hand.
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 loosening,

remove the extractor and begin to loosen the injector again using
the pressure element - T10581/3- ⇒ page 320 .
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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– 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 322 .
– 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 in width in two steps, as
described below.
– 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
⇒ “4.2 Removing and installing the fuel distributor”,
page 317 .
If injection valves have been cleaned or replaced:
– Connect ⇒ Vehicle diagnostic tester.
– Function 0001 - Reset the injection valve learning
values .
4.4 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 instructions and Owner’s Manual of the ultra‐
sound device.
– Place Mounting plate for injection units - VAS 6418/1- on the

cleaning unit.

Clean
– Remove injectors
⇒ “4.3 Removing and installing injectors”, page 318 .
– Remove the combustion chamber sealing ring ⇒ page 322 .
– 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
⇒ “4.3
Protected Removing
by copyright. Copyingand installing
for private injectors”,
or commercial page
purposes, in part or 318 . is not permitted
in whole,

5 Senders and sensors

⇒ “5.1 Removing and installing intake manifold pressure sender
GX9 ”, page 326
⇒ “5.2 Removing and installing fuel pressure sender G247 ”, page
327
⇒ “5.3 Check fuel pressure sender G247 ”, page 328
⇒ “5.4 Removing and installing pressure sensor for exhaust gas
1 G450 ”, page 331
⇒ “5.5 Removing and installing valve for air mass meter GX35 ”,
page 332
5.1 Removing and installing intake manifold

pressure sender - GX9-
The intake manifold pressure sender - GX9- comprises:
♦ Intake air temperature sender 2 - G299- .
♦ 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-

5.2 Removing and installing fuel pressure

sender - G247-
♦ Socket insert SW 27 - T40218- or commercially available
socket insert
WARNING

– Remove engine cover ⇒ page 36 .
47 ,
nected cables.
5. Senders and sensors 327

– Pull off connector -1- using assembly tool - T10118- .

– Unscrew screws from the coolant pipe -1-.
– Unscrew the fuel pressure sender - G247- -2- with the socket
insert SW 27 - T40218- .
Installing
Note
The thread of the fuel pressure sender must not be moistened

with oil.
Tightening torques
♦ Fuel pressure sender - G247-
tors”, page 316 .
♦ Vacuum pump for brake - V192- ⇒ braking system; Rep. gr.
47 ,
5.3 Check fuel pressure sender - G247-

⇒ “5.3.1 Check fuel pressure sender G247 using Tester for pres‐
sure sensor VAS 6394 ”, page 328
⇒ “5.3.2 Check fuel pressure sender G247 using vehicle diag‐
nostic tester”, page 330
5.3.1 Check fuel pressure sender - G247- us‐

ing Tester for pressure sensor - VAS
6394-
♦ Adapter for measuringProtected
method/DSO
by copyright. (3-pin)
Copying for- private
VASor5570-
♦ Tester for pressure sensor - VAS 6394-
♦ Socket insert, elongated, SW 27 mm, commercially available

– Remove fuel pressure sender - G247-
⇒ “5.2 Removing and installing fuel pressure sender G247 ”,
page 327 .
– 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- .
– 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.
Tightening torques
♦ Fuel pressure sender - G247-
tors”, page 316 .
5.3.2 Check fuel pressure sender - G247- us‐

ing vehicle diagnostic tester
• Fill fuel tank 1/4 full.
CAUTION
Lay a clean cloth around
with respectthe connection
to the point and
correctness of information carefully
in this document. slack‐
Copyright by ŠKODA AUTO A. S.�
system.


– Collect the fuel which flows out with a cloth.

tap -A-.
tap -B-.
NOTICE

opposite direction.
Make sure that the shut-off tap -C- is closed at the pressure gauge
- VAS 6550- -1-.
– Check Fuel pressure sender - G247- with ⇒ Vehicle diagnostic
tester.
– Select the following function:
♦ Systems
capable
unless ofŠKODA
authorised by diagnostics
♦ 0001 - Engine electronics
♦ 0001 - Repair groups
♦ 24 - mixture preparation - injection
♦ G247 - Check the fuel pressure sensor
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.
Tightening torques
♦ Exhaust gas pressure sensor 1 - G450-
page 73 .
5.5 Removing and installing valve for air

mass meter - GX35-
– Unscrew screws -arrows- and remove the element for air pres‐
sure control - GX35- -1-.
Installing
– Check seals for damage.
Seal is not available individually, component Module for air mass
measurement - GX35-
Tightening torques
♦ Module for air mass measurement - GX35-
332
Rep. gr.24 - Mixture preparation - injection
6 High pressure pump

⇒ “6.1 Summary of components - high pressure pump”,
page 333
⇒ “6.2 Removing and installing the high pressure pump”,
page 334
⇒ “6.3 Removing and installing high pressure pipe”, page 335
6.1 Summary of components - high pressure pump
1 - High pressure pump

❑ do not disassemble
stalling the high pres‐
sure pump”, page 334
2 - Screw
❑ Pay attention to the pro‐
cedure for tightening
⇒ page 333
3 - O-ring
❑ before fitting moisten
with clean engine oil
4 - Roller tappet
❑ Moisten with engine oil
during installation
5 - Fuel line
❑ Feed line from the fuel
system pressurisation
pump - G6-
6 - High pressure tube
stalling high pressure
pipe”, page 335
❑ Connections must not
be damaged
❑ Moisten thread of the
union nuts with clean
engine oil
❑ do not change bending formProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ 16 Nm + 45° with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
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:
6. High pressure pump 333

Level Screws M8 Tightening torque/torque angle

1. -3- Tighten by hand as far as the stop
2. -3- Tighten by 1 turn alternately until the
flange of the high pressure pump is at
the camshaft housing
3. -3- 20 Nm
4. -3- Turn 90° further
6.2 Removing and installing the high pres‐

sure pump
Removing
• Engine cold.
WARNING

NOTICE

– Place a cloth below to absorb leaking fuel.
page 335 .
– Pull out connector -a-.
– Unlock the hose connection -b- by pressing buttons -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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Check that the rollerwith
tappet
respectis notcorrectness
to the damaged. Renew
of information if document.
in this neces‐ Copyright by ŠKODA AUTO A. S.�
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 333 :
– Check the fuel system for leaks.
Tightening torques
♦ High pressure pump
333 .
6.3 Removing and installing high pressure

pipe
Removing
the charge air cooler and the exhaust unless
gas turbocharger”,
authorised by ŠKODApage AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
288 . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
WARNING

NOTICE

6. High pressure pump 335

– Unscrew union nuts -arrows-.

– Remove fastening screw on holder -1- and remove the high
pressure pipe.
Installing
• After disassembly, replace the high pressure pipe.
• 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
288 .
– Install air filter housing
⇒ “2.2 Removing and installing air filter
Protected housing”,
by copyright. page
Copying for private307 .
Tightening torques with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Union nut and screw for high pressure pipe

333 .

7 Lambda probes
⇒ “7.1 Summary of components - lambda probe”, page 337
⇒ “7.2 Removing and installing Lambda probe”, page 337
7.1 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.

❑ comprises:
♦ Lambda probe downstream
of catalytic converter -
G130-
♦ Lambda probe heater 1
downstream of catalytic
converter - Z29-
page 337
❑ 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:
Z19-
page 337
❑ 55 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
7.2 Removing and installing Lambda probe

Installation overview of the Lambda sensor ⇒ page 337 .
7. Lambda probes 337

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
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
Tightening torques
♦ Lambda probes
⇒ “7.1 Summary of components - lambda probe”, page 337
7. Lambda probes 339

8 Engine control unit

⇒ “8.1 Removing and installing engine control unit J623 ”,
page 340
8.1 Removing and installing engine control

unit - J623-
⇒ “8.1.1 Removing and installing engine control unit J623 without
protective housing”, page 340
⇒ “8.1.2 Removing and installing engine control unit J623 with
protective housing”, page 340
8.1.1 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
8.1.2 Removing and installing engine control

unit - J623- with protective housing
Removing
Special tools and
unless workshop equipment
authorised by ŠKODA required
♦ Hot air blowers - VAS 1978/14A- with push-on nozzle from the
wiring harness repair set - VAS 1978 B-
♦ 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.
8. Engine control unit 341

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.
Installing
– It is imperative for the protective housing to be put back in
place on the engine
Protectedcontrol unit
by copyright. - J623-
Copying . or commercial purposes, in part or in whole, is not permitted
for private
– Clean the threaded holestofor
with respect the shear
the correctness bolts toinremove
of information resi‐
this document. Copyright by ŠKODA AUTO A. S.�
dues of locking agent. Cleaning can be done using a tapper.
– Use new shear bolts.
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

26 – Exhaust system
1 Removing and installing parts of the
exhaust system
⇒ “1.1 Summary of components - Pre-exhaust pipe with catalytic
converter”, page 343
converter”, page 345
⇒ “1.3 Summary of components - Middle and rear part of the ex‐
haust system”, page 348
⇒ “1.4 Replacing middle or rear part of the exhaust system”, page
349
⇒ “1.5 Align exhaust system free of stress”, page 351
⇒ “1.6 Inspecting the exhaust system for leaks”, page 352
1.1 Summary of components - Pre-exhaust pipe with catalytic converter
1 - Screw
tightening order
⇒ Fig. ““Installing cata‐
lytic converter - tighten‐
ing torque and tighten‐
ing order”“ , page 348 .
❑ 20 Nm
3 - Screw
tightening order
⇒ Fig. ““Installing cata‐
lytic converter - tighten‐
ing torque and tighten‐
ing order”“ , page 348 .
4 - Lambda probe 1 in front of with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ comprises:
Z19-
nents
ponents - lambda
probe”, page 337
page 337
❑ 55 Nm
❑ comprises:
1. Removing and installing parts of the exhaust system 343

♦ Lambda probe downstream of catalytic converter - G130-

♦ Lambda probe heater 1 downstream of catalytic converter - Z29-
❑ Summary of components ⇒ “7.1 Summary of components - lambda probe”, page 337
❑ removal and installation ⇒ “7.2 Removing and installing Lambda probe”, page 337
❑ 55 Nm
6 - Nut
⇒ Fig. ““Installing catalytic converter - tightening torque and tightening order”“ , page 348 .
❑ 20 Nm
7 - 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
⇒ “1.2 Removing and installing pre-exhaust pipe with catalytic converter”, page 345
❑ Remove the protection for the decoupling element on the spare part as late as possible
❑ Installing the exhaust system without tension ⇒ “1.5 Align exhaust system free of stress”, page 351
8 - Clamping sleeve
❑ different versions ⇒ “1.5 Align exhaust system free of stress”, page 351
❑ before tightening, align exhaust system free of stress
⇒ “1.5 Align exhaust system free of stress”, page 351
❑ Tighten screwed connections uniformly
❑ Fitting position ⇒ Fig. ““Installation position of front clamp”“ , page 345
❑ Tightening torque ⇒ “1.5 Align exhaust system free of stress”, page 351
9 - Screw clamp
❑ Fitting position ⇒ Fig. ““Fitting position”“ , page 345
⇒ Fig. ““Installing catalytic converter - tightening torque and tightening order”“ , page 348
10 - Seal
❑ Summary of components ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 270
❑ removal and installation ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 275
12 - Screw
❑ 20 Nm
13 - Mounting bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ replace if damaged with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
14 - Screw
❑ 20 Nm
344 Rep. gr.26 - Exhaust system

Installation position of front clamp

– Install clamping sleeve in the position shown.
• Angle -α- = approximately 20°.
• Bolted connection to the right.
• Nuts upwards.
Fitting position
Note
♦ Before loosening the coupling point between catalytic con‐

verter and turbocharger, mark the position of the clamp!
♦ 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.
1.2 Removing and installing pre-exhaust

pipe with catalytic converter
Note
The catalytic converter is removed with the pre-exhaust pipe.

♦ Hot bolt paste ⇒ ETKA - Electronic Catalogue of Original Parts
• Fit all cable straps on againunless
inwiththe same
respect to theplace when
correctness installing.
– Take plug connections -1- and -2- out of the holder, disconnect
and expose electric cables.
– Remove the heat shield on top of the catalyst ⇒ page 276 .
– Assignment of installation for screw clamp -2- between ex‐
haust gas turbocharger and catalytic converter
⇒ Fig. ““Fitting position”“ , page 345 .

– Unscrew screw -2- and remove screw clamp.

– Unscrew screw -1- and nuts -arrows-.
– Release screws -arrows- of the holder.
– Remove tunnel bridge -1-.
– Unscrew screws -1- and remove heat shield for right drive
shaft, if present.


– Remove plastic cover for floor tunnel ⇒ Body Work; Rep. gr.
66 .
– Loosen the clamping sleeve -arrow- and slide it backwards.

– Remove catalytic converter backwards.
– Push screwdriver -2- into the recess -arrow- of the exhaust gas
turbocharger and lever out the sealing ring -1-.
Installing
observe the following: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
do not twist decoupling element
with respect in the
to the exhaust
correctness pipe more
of information in thisthan
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 .
– Align exhaust system free of stress
⇒ “1.5 Align exhaust system free of stress”, page 351 .

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 -1-5-.
Tightening torques
♦ Front clamping sleeve
♦ Tunnel bridge ⇒ Body work; Rep. gr. 66 .
♦ Right drive shaft screening ⇒ Axles, steering; Rep. gr. 40 .
1.3 Summary of components - Middle and rear part of the exhaust system
1 - Middle and rear part of the

exhaust system
❑ this is a single unit as
original equipment, re‐
place individually when
carrying out repairs
⇒ “1.4 Replacing middle
or rear part of the ex‐
haust system”,
page 349
❑ Installing the exhaust
system without tension
⇒ “1.5 Align exhaust
system free of stress”,
page 351
2 - Screw
❑ 20 Nm
❑ Observe part with number ⇒correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
respect to the
ETKA - Electronic Cata‐
4 - Retaining strap
❑ Observe part number ⇒

1.4 Replacing middle or rear part of the ex‐

haust system
♦ Body saw e.g. -V.A.G 1523/A-
♦ Protective goggles
Note
♦ To replace the middle or rear silencer individually, a separation

point is provided in the connecting pipe.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.
CAUTION
Risk of injury.
Wear safety goggles and safety clothing.
For vehicles with middle and rear part of the exhaust system as
a single unit for installation
– Use -arrow-body saw e.g. to separate exhaust pipe at right
angles at the separation point -V.A.G 1523/A- .
For vehicles with separable middle and rear part of the exhaust
system
– Loosen the clamping sleeve and slide it backwards.
Replace middle part of exhaust system

– Unscrew nuts -1- and -3- and remove the rear tunnel bridge
-2-.

– Loosen the clamping sleeve -arrow- and slide it forwards.
CAUTION
Risk of accident from silencer weight.
♦ A second mechanic is required to remove the silencers.
– Unscrew retaining strap screw -5- and remove middle part of

the exhaust system.
Replace rear part of the exhaust system

– Unscrew screws -2-, -3-, -4- and remove the middle and rear
part of the exhaust system.
Installing
– Position rear clamping sleeve when installing, between the

side markings -arrows-.

– Install rear clamping sleeve in the position shown.

• The threaded connections point to the fuel tank.
• Nuts downwards.
– Tighten bolted connections of clamping sleeve evenly.
– Align exhaust system free of stress
Tightening torques
♦ Middle and rear silencer
⇒ “1.3 Summary of components - Middle and rear part of the
exhaust system”, page 348 .
♦ Front clamping sleeve
♦ Rear clamping sleeve
♦ Remove the tunnel bridge and underbody cover ⇒ Body Work;
Rep. gr. 66 .
1.5 Align exhaust system free of stress

• The exhaust system is aligned when cold.
Note
Two variants of clamping sleeves can be fitted to the exhaust

system.
Difference between clamping sleeves:

♦ Clamping sleeve -A-: 95 mm long.
♦ Clamping sleeve -B-: 88 mm long.

– Slacken the nuts -3- and -4- at the clamping sleeve -1- and
align the intermediate pipe -2- (-arrow- points in direction of
travel).
– Set the clamping sleeve at a distance -a- from the marking
-A- on the pre-exhaust pipe:
♦ Dimension -a- for clamping sleeves version -A- = 5 mm
♦ Dimension -a- for clamping sleeves version -B- = 8.5 mm
– Push the exhaust system so far forward in the direction of

travel until the retaining strap is pre-tensioned -a- = 5mm.
– Re-install clamping sleeve in the position shown.

• Bolted connection to the right.
• Nuts upwards.
– Tighten bolted connections of clamping sleeve evenly.
Tightening torques
♦ Clamping sleeve version -A-: 23 Nm
♦ Clamping sleeve version -B-: 30 Nm
1.6 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.

28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 353
page 354
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 357
⇒ “1.4 Removing and installing position transmitter for inlet cam‐
shaft G1002 ”, page 357
⇒ “1.5 Removing and installing position transmitter for exhaust
camshaft G1003 ”, page 358
⇒ “1.6 Removing and installing the engine speed sender G28 ”,
page 359
1.1 Assembly overview - ignition system
1 - Spark plug
❑ use spark plug wrench
e.g. - 3122 B- 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 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
and electrode spacing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ Maintenance ; Book‐ with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
let Octavia III

❑ Observe part number ⇒
❑ 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 out‐

put stage
Note
Ignition coil with power stage and

spark plug connector are individual‐
ly available for the repair case ⇒
Electronic parts catalogue (ETKA) .
1. Ignition system 353


4 - Screw
❑ 8 Nm
5 - Screw
❑ 8 Nm
6 - Position sensor for exhaust camshaft - G1003-
⇒ “1.5 Removing and installing position transmitter for exhaust camshaft G1003 ”, page 358
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 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Check O-ring for damage unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ O-ring is not available separately; in the event of damage, replace together with inlet camshaft 1 -
G1002- .
10 - Screw
❑ 8 Nm
11 - Sealing flange on the gearbox side
12 - Rotor
❑ Engine speed sender - G28-
13 - Plug
14 - Screw
❑ 5 Nm
❑ removal and installation ⇒ “1.6 Removing and installing the engine speed sender G28 ”, page 359
16 - Screw
❑ The tightening torque influences the knock sensor function
❑ 20 Nm
17 - Knock sensor 1 - G61-
❑ removal and installation ⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page 357
1.2 Removing and installing ignition coils

with output stage
♦ Extractor -T10530-
354 Rep. gr.28 - Ignition system

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
288 .
– Unscrew screw -a- and remove the hose from the exhaust gas
turbocharger -2-.
Ignition Coil Cyl. 4
288 .
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
♦ Spark plugs are to 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.
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).
Tightening torques

1.3 Removing and installing knock sensor 1

- G61-
Removing
gr. 66 .
– Remove AC compressor from holder and strap up ⇒ Heating,
Air Conditioning; Rep. gr. 87 .
– Release screw -2- and remove knock sensor 1 - G61- .
Installing
– Knock sensor 1 - G61- -1- in compliance with figure.

Úhel α - 30° ± 5°
Note
The torque specification influences the function of knock sensor

1 - G61- .
– Screw in the screw -2- for knock sensor 1 - G61- .

Tightening torques
♦ Knock sensor 1 - G61-
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. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

shaft - G1002- -1-.
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- .
Tightening torques
♦ Position sensor for intake camshaft - G1002-
1.5 Removing and installing position trans‐

mitter for exhaust camshaft - G1003-
NOTICE
for tests and repairs. A crossover of ignition system igniters can
cause engine malfunctions and lead to handling malfunctions.

KA) .
ferent vehicles.
Removing
⇒ “3.1 Removing and installing engine trim panel”, page
Protected 36 . Copying for private or commercial purposes, in part or in whole, is not permitted
by copyright.


– 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- .
Tightening torques
♦ Position sensor for exhaust camshaft - G1003-
1.6 Removing and installing the engine

speed sender - G28-
♦ Socket insert 4 mm - T10370-
NOTICE
for tests and repairs. A crossover ofAUTO
ignition system igniters can
unless authorised by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
cause engine malfunctions and
with respect to the lead to
correctness handlingin this
of information malfunctions.

KA) .
ferent vehicles.
Removing
gr. 66 .
– Remove the pump for charge air cooling - V188- from the en‐
gine
”, page 180 ,
– Remove the oil separator at the bottom
⇒ “3.2.1 Removing and installing oil separator”, page 162 .

– 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.
Tightening torques
♦ Charge air cooler pump - V188-
”, page 179
♦ Engine speed sender - G28-

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2017 ŠKODA AUTO a. s. D4B8077F814

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

4.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

1.1 Engine number, engine data

Information about the construction of the crankshaft.

Vehicle data carrier on the camshaft housing

XW1 - Sensing wheel for inlet camshaft

Engine codes DADA

2 Rep. gr.00 - Technical data

Engine codes DADA

2.1 Safety precautions when working on

2.2 Safety precautions when working on ve‐

2.3 Safety precautions during road tests in

4 Rep. gr.00 - Technical data

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

2.4 Safety precautions when working on

2.5 Safety precautions when working on the

2.6 Safety precautions when working on ig‐

3.1 Rules of cleanliness

3.2 General notes on the injection system

6 Rep. gr.00 - Technical data

3.3 General notes on the ignition system

3.4 General instructions for charge air sys‐

♦ Ensure that there is adequate free access to all moving or hot

3.5 Additional instructions when undertak‐

Do not open the refrigerant circuit of the air conditioning system.

3.6 Foreign bodies in the engine

3.7 Contact corrosion

3.8 Cable routing and securing

8 Rep. gr.00 - Technical data

Secure all hose connections with hose clamps, assignment ⇒

3.9 Assembly of radiators and condensers

10 – Removing and installing engine

1.1 Removing engine

The engine is removed downwards together with the gearbox.

10 Rep. gr.10 - Removing and installing engine

– Cover radiator with radiator protection mat - VAS 531003- .

♦ Before opening the injection system high-pressure system, the

Do not open the refrigerant circuit of the air conditioning system.

♦ Do not over-tension, buckle and bend refrigerant lines and ho‐

– Unlock catch -arrow- and remove vacuum hose -1-.

1. Removing and installing engine 11

– 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

12 Rep. gr.10 - Removing and installing engine

– Disconnect the plug connection -1-.

Vehicles fitted with auxiliary heating