Service

Workshop Manual
Fabia II 2007 ➤ , Fabia II 2009 ➤ ,
Fabia II 2011 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Rapid NH 2013 ➤ ,
Roomster 2006 ➤ , Yeti 2010 ➤ ,
Yeti 2011 ➤
1,2/63; 77 kW TSI engine
Engine ID
CBZ CBZ
A B
Edition 09.2012

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
01 - Self-diagnosis
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
 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
1,2/63; 77 kW TSI engine - Edition 09.2012

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Self diagnosis, safety measures, cleanliness regulations, directions . . . . . . . . . . . . . . . . . . 3
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Regulations concerning safety precautions when working on the fuel system . . . . . . . . . . 3
1.3 Release pressure in the high pressure area of the fuel system . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Rules of cleanliness to observe when working on the fuel supply system . . . . . . . . . . . . . . 5
1.5 Safety measures to apply when working on the fuel injection and ignition system . . . . . . 6
1.6 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Additional instructions when undertaking assembly work on the air-conditioning system . . 9

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

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Unit mounting - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Checking and adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1 V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.1 V-ribbed belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3 Removing and installing bracket for top auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.4 Removing and installing bracket for bottom auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Camshaft drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Removing and installing the top timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Removing and installing the bottom timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4 Removing and installing crankshaft-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Inspect piston, piston rings and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Contents i
 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
1,2/63; 77 kW TSI engine - Edition 09.2012

1 Cylinder head - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Test timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.4 Removing and installing timing chain and drive chain for oil pump . . . . . . . . . . . . . . . . . . 77
2 Cylinder head - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1 Removing and installing cylinder head cover and camshaft . . . . . . . . . . . . . . . . . . . . . . . . 84
2.2 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.3 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.4 Testinf the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1 Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2 inspect camshaft, axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.4 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.4 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.5 Testing oil pressure and oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.2 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.3 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.1 Coolant regulator - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.2 Removing and installing belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.4 Removing and installing coolant recirculation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.1 Parts of cooling system on the side next to the body - Summary of components . . . . . . . . 126
3.2 Parts of cooling system on the side next to the body - Summary of components . . . . . . . . 128
3.3 Removing and installing fan shroud for radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.4 Removing and installing fan shroud for radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.7 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

1 Fuel tank and fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.1 Fuel tank - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.2 Fuel tank - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.3 Fuel tank version I. - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.4 Fuel tank version Il. - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.5 Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.6 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.7 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.8 Removing and installing fuel tank version I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.9 Removing and installing fuel tank version Il. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.10 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

ii Contents
 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
1,2/63; 77 kW TSI engine - Edition 09.2012

1.11 Removing and installing fuel delivery unit version I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

1.12 Removing and installing fuel delivery unit version Il. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.13 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 165
1.14 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.15 Removing and installing fuel gauge sender -2- G169 - fuel tank version Il. . . . . . . . . . . . . 184
1.16 Removing and installing suction jet pump - fuel tank version Il. . . . . . . . . . . . . . . . . . . . . . . 186
2 Separating quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3 Electronic Engine Power Control (Electronic throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.2 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4 Activated charcoal container system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.1 Activated charcoal container system - Summary of components . . . . . . . . . . . . . . . . . . . . 195
4.2 Activated charcoal container system - Summary of components . . . . . . . . . . . . . . . . . . . . 196
4.3 Activated charcoal container system - Summary of components . . . . . . . . . . . . . . . . . . . . 197
4.4 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.5 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.1 Charge air system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.2 Charge air system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

1 Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.1 Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.2 Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2 Intake manifold and fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.2 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 220
2.3 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.4 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.1 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.2 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.3 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.4 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.1 High pressure pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.1 Removing and installing injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.2 Replace Teflon gasket ring and supporting washer at injection valve . . . . . . . . . . . . . . . . 235
6 Testing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
6.1 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
7.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Contents iii
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1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

1.1 Catalytic converter and component parts - Summary of components . . . . . . . . . . . . . . . . 245
1.2 Catalytic converter and component parts - Summary of components . . . . . . . . . . . . . . . . 246
1.3 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.4 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.5 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.6 Middle and rear silencer for vehicles manufactured up to 06.10 - Summary of components
........................................................................ 251
1.7 Middle and rear silencer for vehicles manufactured as of 06.10 - Summary of components
........................................................................ 252
1.8 Removing and installing catalytic converter with pre-exhaust pipe . . . . . . . . . . . . . . . . . . 253
1.9 Replacing middle or rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.10 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.11 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.1 Ignition system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

iv Contents
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00 – Technical data
1 Technical data
(SRL000530; Edition 09.2012)

1.1 Engine number

The engine number (“engine identification characters” and “serial
number”) is located on the engine closely above the connection
of the engine with the gearbox.

In addition, the “engine identification characters” and the “serial

number” are indicated on the vehicle data sticker -arrow- which is
located on the air guide pipe.
♦ The engine identification characters have 4 digits starting with
the letter “C”.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched in the cylinder block including the
serial number.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine control unit.

1.2 Engine characteristics

Edition: 07.2012
Version: 3.0

1. Technical data 1
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Engine identification characters CBZA CBZB

Manufactured Fabia II 03.10 ► ----
Roomster 03.10 ► ----
Octavia II ---- 02.10 ►
Yeti ---- 09.09 ►
Rapid NH 07.12 ► 07.12 ►
Exhaust limit values conforming to EU5 EU5
Displacement cm 3 1197 1197
Power output kW at rpm 63/4800 77/5000
Torque Nm at rpm 160/1500-3500 175/1550-4100
Bore ∅ mm 71,0 71,0
Stroke mm 75,6 75,6
Compression ratio 10:1 10:1
Cylinder / valves per cylinder 4/2 4/2
RON unleaded 95 1) unleaded 95 1)
Ignition system, fuel injection Simos 10 Simos 10
Type of fuel preparation Direct injection homogeneous Direct injection homogeneous
Knock control 1 sensor 1 sensor
Lambda control 2 Lambda probes 2 Lambda probes
Three-way catalytic converter yes yes
Exhaust gas recirculation no no
Intake manifold change-over no no
Camshaft adjustment no no
Secondary air system no no
Exhaust gas turbocharger yes yes
Balancing shaft no no
1) At least 91 RON in exceptional cases, although engine output
is reduced

2 Rep. gr.00 - Technical data

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01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations, directions

1.1 Self-diagnosis
This Rep.-Gr. is deleted.
For this use the “Vehicle self-diagnosis”, “Measuring method” and
“Fault finding” ⇒ Vehicle diagnostic tester.

1.2 Regulations concerning safety precau‐

tions when working on the fuel system

WARNING

♦ The safety measures for the pressure reduction in the high

pressure area of the fuel system must be observed
⇒ page 4 .
♦ The fuel system is under pressure! Wear safety goggles
and safety clothing, in order to avoid injuries and skin con‐
tact with fuel. Place a clean cleaning cloth around the
connection point before detaching wiring. Reduce pres‐
sure by carefully removing the wiring.

For vehicles Fabia II, Roomster, Rapid NH

♦ The fuel delivery unit is activated when the ignition is switched
on and by the door contact switch of the driver door. Before
opening the fuel system and for reasons of safety, if the battery
is not disconnected, the plug -2- must be disconnected from
the fuel pump control unit.
For the vehicles Octavia II, Yeti

1. Self diagnosis, safety measures, cleanliness regulations, directions 3

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♦ The fuel delivery unit is activated when the ignition is switched

on and by the door contact switch of the driver door. For rea‐
sons of safety, if the battery is not disconnected, the plug -3-
must be disconnected from the fuel pump control unit -1-
before opening the fuel system.
Continued for all vehicles

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel!
♦ Wear fuel-resistant gloves!

1.3 Release pressure in the high pressure

area of the fuel system

WARNING

♦ The injection system consists of a high pressure part

(max. pressure of 12 MPa = 120 bar) and a low pressure
part (pressure of approx. 0.6 MPa = 6 bar).
♦ Before opening the high pressure area, e.g. removing the
high pressure pump, the fuel distributor, the injection
valves, the fuel pipes or the fuel pressure sender -G247- ,
the fuel pressure in the high pressure area with a remain‐
ing pressure of approx. 0.6 MPa (6 bar) must be reduced.
The procedure for this is described below.

– Connect the ⇒ Vehicle diagnostic tester and carry out the tar‐
geted function “remove high fuel pressure”.
– Switch off ignition.

4 Rep. gr.01 - Self-diagnosis

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For vehicles Fabia II, Roomster, Rapid NH

– For safety reasons before opening the fuel system disconnect
the plug from the fuel pump control unit -2-.
For the vehicles Octavia II, Yeti

– For safety reasons before opening the fuel system disconnect

the plug from the fuel pump control unit -3-.
Continued for all vehicles

WARNING

The fuel lines are pressurized! Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.
Before opening the high pressure area, lay cleaning cloths
around the connection point.

– Now lay a clean cleaning cloth around the connection point

and carefully open it up, in order to reduce the remaining pres‐
sure of approx 0.6 MPa (6 bar). Collect the fuel which flows
out.

Note

♦ Interrogate the fault memory of the engine control unit at the

end of the following work and delete all the fault entries.
♦ If the fault memory was erased, the readiness code must be
generated ⇒ Vehicle diagnostic tester.

1.4 Rules of cleanliness to observe when

working on the fuel supply system
Carefully observe the following five rules for cleanliness when
working on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.

1. Self diagnosis, safety measures, cleanliness regulations, directions 5

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1.5 Safety measures to apply when working

on the fuel injection and ignition system

WARNING

♦ The safety measures for the pressure reduction in the high

pressure area of the fuel system must be observed
⇒ page 4 .
♦ The fuel system is under pressure! Wear safety goggles
and safety clothing, in order to avoid injuries and skin con‐
tact with fuel. Place a clean cleaning cloth around the
connection point before detaching wiring. Reduce pres‐
sure by carefully removing the wiring.

Observe the following points to prevent injury to persons and/or

damage to the injection and ignition system:
♦ Do not touch or remove ignition leads and ignition coils with
power output stages with the engine running or at start speed.
♦ 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.
♦ If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure,
open lid of fuse carrier in the engine compartment and unplug
fuse for Motronic current supply relay -J271- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
For vehicles Fabia II, Roomster, Rapid NH
♦ The fuel delivery unit is activated when the ignition is switched
on and by the door contact switch of the driver door. Before
opening the fuel system and for reasons of safety, if the battery
is not disconnected, the plug -2- must be disconnected from
the fuel pump control unit.
For the vehicles Octavia II, Yeti

6 Rep. gr.01 - Self-diagnosis

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♦ The fuel delivery unit is activated when the ignition is switched

on and by the door contact switch of the driver door. Before
opening the fuel system and for reasons of safety, if the battery
is not disconnected, the plug -3- must be disconnected from
the fuel pump control unit.
Continued for all vehicles

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, the active
charcoal container-unit, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger could be injured by the release of
the passenger airbag in the event of an accident.

1.6 General notes on the injection system

Repairing ignition ⇒ page 259 .
♦ The engine control unit is equipped with self-diagnosis. Before
repairs and also for fault finding, first of all interrogate the fault
memory. Also check the vacuum hoses and connections (un‐
metered air).
♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ electronic catalogue of original 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.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnostic tester.
♦ When opening the driver door the fuel pump is activated for 2
seconds in order to build up the pressure in the fuel system.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety measures ⇒ page 6 .

1.7 General notes on the ignition system

♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the 4AV control unit.

1. Self diagnosis, safety measures, cleanliness regulations, directions 7

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♦ The engine control unit is equipped with self-diagnosis; in‐

spect ⇒ 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 interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnostic tester.
Safety measures ⇒ page 6 .
Setting data, spark plugs:
♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Octavia II .
♦ ⇒ Maintenance ; Booklet Yeti .
♦ ⇒ Maintenance ; Booklet Rapid NH

1.8 General instructions for charge air sys‐

tem

WARNING

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.

Caution

In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient 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
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.

♦ The charge-air system must be tight.

8 Rep. gr.01 - Self-diagnosis

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♦ Always replace self-locking nuts.

♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.
♦ Only use approved clamps for securing the hose connections
⇒ Electronic Catalogue of Original Parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Before connecting the oil feed line, fill the exhaust turbocharg‐
er via the connection fitting with engine oil.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.

1.9 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system

WARNING

Do not open the refrigerant circuit of the air conditioning sys‐

tem.

Note

In order to avoid damage to the condenser as well as to the re‐

frigerant lines and hoses, ensure that the lines and hoses are not
over-tensioned, 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 from the bracket ⇒ page 34 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

1. Self diagnosis, safety measures, cleanliness regulations, directions 9

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10 – Removing and installing engine

1 Removing and installing engine

1.1 Removing engine

(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Engine mount -T10416-
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-

Note

♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.

Caution

When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 3 .

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Before disconnecting the battery, if necessary remove the

adapter for the anti-theft wheel bolts from the luggage com‐
partment.
– Remove battery ⇒ Electrical System; Rep. gr. 27 .

10 Rep. gr.10 - Removing and installing engine

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– Remove air filter ⇒ page 226 .

– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Remove the right and left wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Drain coolant ⇒ page 118 .
– Remove drive shaft to the right ⇒ Chassis; Rep. gr. 40 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box.
– Unscrew the nut from the left coupling rod -2- and press off the
coupling rod from the anti-roll bar.
– Unscrew the nuts for the left steering joint -3- and press the
steering joint out of the suspension arm.

– Unscrew the nut -2- from the front left track control arm on
installed front left vehicle level sensor -G78- .
– Turn steering to full left lock.
– Swivel the steering joint outwards and secure the drive shaft
-1- with a band -A- in the wheelhouse.

– Detach coolant hoses -2- and -5-.

– Remove fuel line (press in the securing ring to the top) -3- and
-4-. Collect the fuel which flows out with a cleaning cloth.

1. Removing and installing engine 11

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– Loosen retaining clip for coolant hose -3-.

– Slacken the clamp -1- and detach the coolant hose -2- from
the engine.

– Detach the coolant hoses at the heat exchanger -arrows-.

– Detach vacuum hose -1- from intake manifold.

– Slacken clamps -2- and detach coolant hoses -3 ... 5-.
For models with automatic gearbox
– Remove the selector lever control cable from the gearbox ⇒
Gearbox; Rep. gr. 34 .
For vehicles with manual gearbox
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.
34 .
– Remove hydraulic clutch control from gearbox ⇒ Gearbox;
Rep. gr. 30 .

WARNING

After removing the slave cylinder or after separating the hy‐

draulic line, do not depress the clutch pedal.

Continued for all vehicles

– Remove/unclamp all electrical lines from the gearbox, gener‐
ator and starter motor and uncover them.
– Remove/unclamp all other necessary electrical cables from
the engine.
– Disconnect the vacuum and bleeder hoses from the engine.

12 Rep. gr.10 - Removing and installing engine

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– Disconnect the plug of the engine wiring harness -1- from the
engine control unit ⇒ page 242 .
– Unplug connector -2-.
– Unclip cable clip -3- -arrows-.
– Remove engine wiring harness and attach to engine control
unit.

– Disconnect plugs -1 and 2- and release cable strap -5-.

– Remove catalytic converter with pre-exhaust pipe
⇒ page 253 .

– Unscrew the screws -1, 3- and remove the bottom coolant pipe
-2-.

– Unbolt the pendulum support -arrows-.

For vehicles with air conditioning
– Remove V-ribbed belt ⇒ page 35 .

1. Removing and installing engine 13

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– Disconnect plug connection -1- for magnetic coupling at AC

compressor.

WARNING

Risk of injury through refrigerant.

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

Caution

Risk of damaging refrigerant lines and hoses.

♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.

– Release screws -arrows- for AC compressor.

– Attach AC compressor to lock carrier.
Continued for all vehicles
– Removing fan shroud ⇒ page 131 .

In order to lower the engine with the gearbox, the engine holder
-T10416- with the adapters -/1-, -/2- and -/3- is required.

– Turn the adapter T10416/1 up to the stop in the cylinder block.

14 Rep. gr.10 - Removing and installing engine

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– Fit the engine mount -T10416- with the adapters -/2- and -/3-
to the cylinder block.
– Attach the engine mount -T10416- with the screw -1- by hand
at the cylinder block.
– Tighten all screws on the engine mount -T10416- to 20 Nm.
– Place the engine/gearbox jack - V.A.G 1383 A- on the engine
mount -T10416 - and slightly raise the engine with the gear‐
box.

Note

♦ Check whether all hose and line connections between engine,

gearbox and body are released, if necessary release them.
♦ Use the double ladder -VAS 5085- for removing the fixing
bolts.

– Unscrew nut -3- and disconnect earth lead -4- from engine
mount.
– Release screws -2- from engine mount -1-.

– Release screws -2- from gearbox mount -1-.

Note

♦ The engine/gearbox assembly should be lowered with the help

of a second mechanic.
♦ Carefully lower engine with gearbox in order to avoid damage.

– Pull engine/gearbox unit as far forward as possible and lower

carefully and slowly downwards.
– Remove the gearbox from the engine ⇒ gearbox; Rep. gr.
34 .

1.2 Removing engine

(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Engine mount -T10416-
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-

1. Removing and installing engine 15

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Note

♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, the active
charcoal container-unit, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 3 .

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Remove air filter ⇒ page 227 .

– Before disconnecting the battery, if necessary remove the
adapter for the anti-theft wheel bolts from the luggage com‐
partment.
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Remove the right and left wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Drain the coolant from the cooling system ⇒ page 118 .
– Remove drive shaft to the right ⇒ Chassis; Rep. gr. 40 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box.

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– Unscrew the nut from the left coupling rod -2- and press off the
coupling rod from the anti-roll bar.
– Unscrew the nuts for the left steering joint -3- and press the
steering joint out of the suspension arm.

– Unscrew the nut -2- from the left track control arm if the front
left vehicle level sensor -G78- is present.
– Turn steering to full left lock.
– Swivel the steering joint outwards and secure the drive shaft
-1- with strap -A- in the wheelhouse.

– Pull off top coolant hose -2- and bottom coolant hose from
expansion reservoir.
– Disconnect the fuel feed line -3- (press in the securing ring to
the top) and catch the fuel which flows out with a cleaning
cloth.
– Detach the connecting hose -4- to the activated charcoal filter
system.

– Remove the hose -1- from the activated charcoal filter and
from the activated charcoal filter solenoid valve 1 -N80- .
– Remove activated charcoal filter -2-.
– Slacken the clamp -4- and detach the coolant hose -3- from
the engine.

1. Removing and installing engine 17

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– Release the coolant hoses at the heat exchanger -arrows- and

pull them off.

– Detach vacuum hose -1- from intake manifold.

– Slacken clamps -2- and detach coolant hoses -3 ... 5-.
For models with automatic gearbox
– Remove the selector lever control cable from the gearbox ⇒
Gearbox; Rep. gr. 34 .
For vehicles with manual gearbox
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.
34 .
– Remove hydraulic clutch control from gearbox ⇒ Gearbox;
Rep. gr. 30 .

WARNING

After removing the slave cylinder or after separating the hy‐

draulic line, do not depress the clutch pedal.

– Disconnect all electrical lines from the gearbox, generator and

starter motor and uncover them.
– Remove/unclamp all other necessary electrical cables from
the engine.
– Disconnect the vacuum and bleeder hoses from the engine.
– Disconnect the plug from the thermal switch and the radiator
fan.
– Disconnect the plug of the engine wiring harness from the en‐
gine control unit (front plug) ⇒ page 243 .

– Release guide for engine wiring harness and pull out upwards
-arrow-.

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– Open all fuses for the engine wiring harness at frame side rail
-arrows-.
– Open other attachments of the engine wiring harness, remove
engine wiring harness and attach to engine.
– Attach the cables with a cable strap at the engine.

– Disconnect plugs -1 and 2-.

– Remove pre-exhaust pipe Pos. 9 ⇒ page 246 .

– Unscrew the screw -2- and remove the bottom coolant pipe
-1-.
Vehicles with auxiliary heating.
– Slacken clamps -3- and pull off the coolant hoses -4 and 5-.

– Unscrew the screws -1 and 2- of the brackets for the coolant

pipes for the auxiliary heating -3-.
Continued for all vehicles

1. Removing and installing engine 19

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– Disconnect plug -2- from oil level and oil temperature sender
-G266- .
– Remove the hold-down device for the cable guide of the oil
level and oil temperature sender -G266- from the assembly
carrier at the front and place down on the assembly carrier.

– Unbolt the pendulum support -arrows-.

For vehicles with air conditioning
– Remove V-ribbed belt ⇒ page 35 .

– Disconnect plug connection -1- for magnetic coupling at AC

compressor.

WARNING

Risk of injury through refrigerant.

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

Caution

Risk of damaging refrigerant lines and hoses.

♦ Do not over-tension or buckle refrigerant lines and hoses.

– Release screws -arrows- for AC compressor.

– Attach AC compressor to lock carrier.
Continued for all vehicles

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In order to lower the engine with the gearbox, the engine mount
-T10416- with the adapters -/1-, -/2- and -/3- is required.

– Turn the adapter T10416/1 up to the stop in the cylinder block.

– Fit the engine mount -T10416- with the adapters -/2- and -/3-
to the cylinder block.
– Attach the engine mount -T10416- with the screw -1- by hand
at the cylinder block.
– Tighten all screws on the engine mount -T10416- to 20 Nm.
– Place the engine/gearbox jack - V.A.G 1383 A- on the engine
mount -T10416 - and slightly raise the engine with the gear‐
box.

Note

♦ Check whether all hose and line connections between engine,

gearbox and body are released, if necessary release them.
♦ Use the double ladder -VAS 5085- for removing the fixing
bolts.

– Release the screws -2- of the assembly bracket at the engine.

1. Removing and installing engine 21

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– Release the screws -2- of the assembly bracket at the gear‐

box.

Note

♦ The engine/gearbox assembly should be lowered with the help

of a second mechanic.
♦ When lowering carefully guide the engine/gearbox assembly,
in order to avoid damage.

– Pull engine/gearbox unit as far forward as possible and lower

carefully and slowly downwards.
– Remove the gearbox from the engine ⇒ gearbox; Rep. gr.
34 .

1.3 Securing the engine to the assembly

stand
Special tools and workshop equipment required
♦ Lifting device -MP 9-201 (2024 A)-
♦ Engine mount -MP 1-202-
♦ Assembly stand -MP 9-101-
♦ Adapter -MP1-202/8-
♦ Adapter -MP1-202/9-
♦ Workshop crane , e.g. -VAS 6100-
Work procedure
• Separate engine from gearbox.
– Attach the lifting device -MP9-201 (2024 A)- at the workshop
crane (e.g. -VAS 6100- ) and at the engine, as shown in the
figure. (The figure shows the 1.4 ltr./90 kW TSI Engine; the
fixing system is identical).

WARNING

Use securing pins on the hooks and rig pins to prevent release.
Use securing pins on the hooks and rig pins -arrows-, in order
to avoid injuries and damages to the engine.

– Lift off engine with installed engine mount -T10416- with work‐
shop crane e.g. -VAS 6100- from engine/gearbox jack - V.A.G
1383 A- .
– Remove engine mount -T10416- .

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– Screw engine mount -MP 1-202- with adapters -MP1-202/8-

and -MP1-202/9- to engine -arrows- and secure to the assem‐
bly stand -MP 9-101- .

1.4 Installing the engine

Special tools and workshop equipment required
♦ Double ladder , e. g. -VAS 5085-
♦ Catch pan , e.g. -VAS 6208-
♦ Pliers for spring strap clamps
♦ Grease -G 000 100-
♦ Cable strap
Precondition
• Fit engine and gearbox using engine mount -T10416- to the
engine/gearbox jack -V.A.G 1383 A- .
Work procedure
Installation is carried out in the reverse order. Pay attention to the
following:

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, the active
charcoal container-unit, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

1. Removing and installing engine 23

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Note

♦ All cable straps should be fastened again in the same place

when installing.
♦ Secure all hose connections with hose clamps ⇒ Electronic
Catalogue of Original Parts .
♦ Replace the self-locking nuts and screws when undertaking
assembly work.
♦ Replace screws which have been tightened to a torquing angle
as well as gasket rings and seals.

Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 3 .
For vehicles with manual gearbox
– Clean the serration of the drive shaft and if the clutch disc has
been used clean the hub serration, remove corrosion and only
apply a very thin layer of grease -G 000 100- to the serration
of the drive shaft. Subsequently move the clutch disc up and
down on the drive shaft until the hub fits smoothly on the shaft.
Always remove excess grease.
– After installing the coupling, check the centering of the clutch
disc ⇒ Gearbox; Rep. gr. 30 .
– Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ Gearbox; Rep. gr. 30 .
For models with automatic gearbox
– Replace the needle bearing -arrow- in the crankshaft
⇒ page 61 .
– Attach the selector lever control cable at the gearbox ⇒ Gear‐
box; Rep. gr. 34 .
Continued for all vehicles
– Check whether the dowel sleeves for centering the engine/
gearbox are present in the cylinder block; insert if necessary.

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– Ensure that the intermediate plate has been inserted on the

sealing flange and is pushed onto the dowel sleeves
-arrows-.
– Screw on gearbox to engine ⇒ Gearbox; Rep. gr. 34 .
– When installing the engine/gearbox assembly, ensure clear‐
ance to the assembly carrier, AC compressor as well as to the
radiator fans.
– Tighten the new screws by hand for attaching the engine/
gearbox assembly at the engine and gearbox mounts.
For the vehicles Fabia II, Roomster
– Adjust assembly bracket and tighten screws ⇒ page 27 .
– Install pendulum support ⇒ page 28 .
For the vehicles Octavia II, Yeti
– Adjust assembly bracket ⇒ page 29 and tighten screws
⇒ page 28 .
– Install pendulum support ⇒ page 28 .
Continued for all vehicles
– Install drive shafts ⇒ Chassis; Rep. gr. 40 .
For vehicles with air conditioning
– Install AC compressor ⇒ page 34 .
– Install the V-ribbed belt ⇒ page 35 .
Continued for all vehicles
– Install slave cylinder ⇒ Gearbox; Rep. gr. 30 .
– Attach shift mechanism and adjust if necessary ⇒ Gearbox;
Rep. gr. 34 .
– Install the engine wiring harness and connect to the engine
control unit ⇒ page 242 .
For the vehicles Fabia II, Roomster
– Install catalytic converter with exhaust pipe ⇒ page 253 .
For the vehicles Octavia II, Yeti
– Install exhaust system ⇒ page 246 .
Continued for all vehicles
– Install the battery and pay attention to the necessary work after
re-connecting the battery ⇒ Electrical System; Rep. gr. 27 .
– Checking the oil level:
♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Octavia II .
♦ ⇒ Maintenance ; Booklet Yeti .
♦ ⇒ Maintenance ; Booklet Rapid NH .
– Top up and bleed cooling system ⇒ page 118 .
– Interrogate all fault memories and delete all fault entries, which
are caused by removing and installing the engine ⇒ Vehicle
diagnostic tester.
After deleting the fault memory of the engine control unit the
readiness code must be re-generated.

1. Removing and installing engine 25

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– Perform a test drive.

– Then perform a vehicle system test and if necessary eliminate
the resulting faults.
Tightening torques
Component Nm
Screws and nuts M6 10
M7 13
M8 20
M10 45
M12 60
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. gr. 34
Screws for assembly bracket:
♦ Fabia II, Roomster, Rapid NH ⇒ page 27
♦ Octavia II, Yeti ⇒ page 28

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2 Assembly bracket

2.1 Assembly bracket

(Fabia II, Roomster, Rapid NH)

Note

♦ When installing, first of all insert all screws for bracket and
screw in by hand by at least two - three turns.
♦ Tighten screws for bracket in the sequence according to the
numerical marking in the figures.

2.1.1 Tightening torques

Assembly bracket - engine
2 - 20 Nm + torque a further 90° (1/4 turn) - replace

3 - 30 Nm + torque a further 90° (1/4 turn) - replace

4 - 16 Nm

Note

The assembly bracket can be fitted with a dynamic vibration

damper -1-. This damper is an inseparable component part of the
assembly bracket - it is not removed.

Assembly bracket - gearbox

Note

Tighten screws -1- in the following sequence: rear, front and then
upwards.

1 - 50 Nm + torque a further 90° (1/4 turn) - replace

2 - 40 Nm + torque a further 90° (1/4 turn) - replace

Pendulum support

Note

Before tightening the screws -1- press off gearbox in the elonga‐
ted holes of the pendulum support to the front in such a way that
there is maximum distance between the gearbox and the assem‐
bly carrier.

A - 30 Nm + torque a further 90° (1/4 turn) - replace

B - 40 Nm + torque a further 90° (1/4 turn) - replace

2. Assembly bracket 27
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2.2 Unit mounting - summary of compo‐

nents
(Octavia II, Yeti)

1 - Gearbox support bracket

2 - Screw
❑ Tightening torque ⇒
Gearbox; Rep. gr. 34
3 - Engine mounting
4 - 40 Nm + torque a further 90°
(1/4 turn)
❑ replace
5 - Bracket for activated char‐
coal filter
6 - 9 Nm
7 - 9 Nm
8 - 20 Nm + torque a further 90°
(1/4 turn)
❑ replace
9 - 20 Nm + torque a further 90°
(1/4 turn)
❑ replace
10 - Connecting part
11 - 40 Nm + torque a further
90° (1/4 turn)
❑ replace
12 - 60 Nm + torque a further
90° (1/4 turn)
❑ replace
13 - Pendulum support
❑ removing: First remove
screw -14-, then screws
-15-.
❑ installing: First tighten screws -15-, then screw -14-.
14 - 100 Nm + torque a further 90° (1/4 turn)
❑ replace
15 - Bolts
❑ replace
❑ Strength category 8.8: 40 Nm + torque a further 90° (1/4 turn)
❑ Strength category 10.9: 50 Nm + torque a further 90° (1/4 turn).

16 - 60 Nm + torque a further 90° (1/4 turn)

❑ replace
17 - 40 Nm + torque a further 90° (1/4 turn)
❑ replace
18 - Gearbox mount

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2.3 Checking and adjusting the assembly

bracket
(Octavia II, Yeti)

2.3.1 Checking the assembly bracket

(Octavia II, Yeti)
– Check dimensions on the right hanger for engine/gearbox unit:
• Between engine bracket and engine support there must be a
distance -a- = 10 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.

Note

The distance -a- can also be checked e.g. with suitable round
bars.

Only if there is an acoustic complaint (engine or gearbox knock

on the frame side rail when cornering) and the dimension -a- is
not 10 mm:
– Adjust the assembly bracket ⇒ page 29 .

2.3.2 Adjusting the unit mounting

(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Supporting device -T30099-
♦ Surface -T30099/1-
♦ Adapter -MP9-200/3 (10-222A/3)-
♦ Lifting eye -10-222A/12-
♦ Snap hook
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .

2. Assembly bracket 29
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– Install supporting device -T30099- and support engine in fitting

position. The figure shows the version with the 1.4 ltr./90 kW
TSI Engine; the hanger is identical.
– Uniformly pre-tension the engine/gearbox assembly at both
spindles, but do not raise.

– Release the screws -2- of the assembly bracket at the engine.

– Slightly loosen the screws -2- of the unit mounting at the gear‐
box (less than 1 revolution).
– Successively replace all the screws of the assembly bracket
(as long as it has not already been performed when installing
the engine) and insert these loosely.

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– Move the engine/gearbox assembly with an assembly lever

between the supporting arm of the engine mount -1- and the
engine support -2- until the following dimensions are set:
• Between engine bracket and engine support there must be a
distance -a- of 10 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm of the engine mount -1-; the dimension
-x- must be the same at the front and rear.

Note

The distance -a- = 10 mm can also be checked e.g. with suitable

round bars.

– Tighten the screws for the engine side assembly bracket

⇒ page 28 .

– Make sure that on the gearbox side the edges of the support‐
ing arm of the gearbox mount -2- and the gearbox support
-1- are parallel.
• The dimension -x- must be the same on both mount sides.
– Tighten the screws for the gearbox side assembly bracket
⇒ page 28 .
Further installation occurs in reverse order.

2. Assembly bracket 31
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13 – Crankshaft group
1 V-ribbed belt drive

1.1 V-ribbed belt - Summary of components

1.1.1 Summary of components - Vehicles without air conditioning

1 - V-ribbed belt
❑ Routing of the ribbed V-
belt ⇒ page 33
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ removing and installing
⇒ page 35
2 - Crankshaft-belt pulley
❑ removing and installing
⇒ page 51
❑ Clamping surfaces must
be free of oil and grease.
3 - Fixing screw
❑ for crankshaft - belt pul‐
ley
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
❑ Tightening torque;
slacken and tighten
⇒ page 51
4 - Diamond coated washer
❑ diamond coated washer
pressed onto the belt
pulley
❑ replace if damaged
5 - 20 Nm
❑ When loosening and
tightening, counterhold with the wrench for the water pump and power-assisted steering -MP 1-308
(V.A.G 1590)- to this end rework wrench for the water pump and power-assisted steering -MP 1-308
(V.A.G 1590)- ⇒ page 123
6 - Belt pulley for coolant pump
❑ removing and installing ⇒ page 123
7 - 9 Nm
8 - Vacuum hose
❑ to solenoid valve for coolant circuit -N492- at intake manifold

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9 - Coolant pump
❑ removing and installing ⇒ page 124
10 - 23 Nm
11 - AC generator
❑ removing and installing ⇒ Electrical System; Rep. gr. 27
❑ to facilitate the positioning of the AC generator drive the threaded bushings on the generator slightly
backwards
12 - 25 Nm
13 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with wrench to slacken the V-ribbed belt
❑ Secure the tensioning device with a 4 mm hexagon wrench or a locating pin -T10060 A-

Routing of the V-ribbed belt

1 - Belt pulley for coolant pump
2 - Tensioning pulley
3 - Belt pulley for generator
6 - Crankshaft-belt pulley

1. V-ribbed belt drive 33

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1.1.2 Summary of components - Vehicles with air conditioning

1 - V-ribbed belt
❑ Routing of the ribbed V-
belt ⇒ page 35
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ removing and installing
⇒ page 35
2 - Fixing screw
❑ for crankshaft - belt pul‐
ley
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
❑ Tightening torque;
slacken and tighten
⇒ page 51
3 - Crankshaft-belt pulley
❑ removing and installing
⇒ page 51
❑ Clamping surfaces must
be free of oil and grease.
4 - Diamond coated washer
❑ diamond coated washer
pressed onto the belt
pulley
❑ replace if damaged
5 - 20 Nm
❑ When loosening and
tightening, counterhold with the wrench for the water pump and power-assisted steering -MP 1-308
(V.A.G 1590)- to this end rework wrench for the water pump and power-assisted steering - MP 1-308
(V.A.G 1590)- ⇒ page 123
6 - Belt pulley for coolant pump
❑ removing and installing ⇒ page 123
7 - 9 Nm
8 - Vacuum hose
❑ to solenoid valve for coolant circuit -N492- at intake manifold
9 - Coolant pump
❑ removing and installing ⇒ page 124
10 - Guide pulley, 40 Nm
11 - 25 Nm
12 - Plastic cover
13 - Bracket for top auxiliary units
❑ with oil filter and engine oil cooler
❑ removing and installing ⇒ page 36

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14 - AC generator
❑ removing and installing ⇒ Electrical System; Rep. gr. 27
❑ to facilitate the positioning of the AC generator drive the threaded bushings on the generator slightly
backwards
15 - 40 Nm + torque a further 90° (1/4 turn)
❑ replace
16 - 25 Nm
17 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
18 - 25 Nm
19 - Fitting sleeve
20 - Bracket for bottom auxiliary units
❑ for tensioning device and AC compressor
❑ removing and installing ⇒ page 38
21 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with wrench to slacken the V-ribbed belt
❑ Secure the tensioning device with a 4 mm hexagon wrench or a locating pin -T10060 A-
❑ to remove, release screw Pos. 12

Routing of the V-ribbed belt

1 - Belt pulley for coolant pump
2 - Guide pulley
3 - Belt pulley for generator
4 - Tensioning pulley
5 - Belt pulley for AC compressor
6 - Crankshaft-belt pulley

1.2 Removing and installing V-ribbed belt

Special tools and workshop equipment required
♦ Locking pin -T10060 A-
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .

Caution

Risk of damage through reversing the rotation direction of an

already used V-ribbed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the V-ribbed belt.

1. V-ribbed belt drive 35

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For vehicles without air conditioning

– Loosen the V-ribbed belt by swivelling the tensioning device
with a ring spanner -in direction of arrow-.
– Interlock the tensioning element with the locking pin -T10060
A- .
For vehicles with air conditioning

– Loosen the V-ribbed belt by swivelling the tensioning device

with a ring spanner -in direction of arrow-.
– Interlock the tensioning element with the locking pin -T10060
A- .
Continued for all vehicles
– Remove the V-ribbed belt.
Install

Note

♦ Before fitting the V-ribbed belt make sure that all assemblies
(AC generator, AC compressor, coolant pump) are securely
mounted.
♦ Pay attention to the correct position and rotation direction of
the V-ribbed belt in the belt pulley when installing it.

– First of all place the ribbed V-belt onto the crankshaft - belt
pulley. Then shift the belt onto the tensioning roller.
Further installation occurs in a similar way in reverse order to re‐
moval.
– Start engine and check ribbed V-belt run.

1.3 Removing and installing bracket for top

auxiliary units
Removing
Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Hose binding claw
Removing
– Remove V-ribbed belt ⇒ page 35 .
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .
– Drain the coolant from the cooling system ⇒ page 118 .

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– Remove lambda probe -G39- -1-.

– Release screws -arrows- and remove heat shield -1-.

– Open the spring strap clamp -1- with the hose binding claw
and detach the coolant hose.

Note

When removing the oil feed line, make sure that the oil does not
penetrate into the generator! Therefore, cover the generator with
a clean cloth!

– Unscrew hollow screw -2- and fixing screw -3- and remove the
oil feed line.

– Unscrew fixing screws -1- and remove bracket.

Install

1. V-ribbed belt drive 37

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– Fit the bracket for auxiliary units to the cylinder block.

– Tighten fixing screws -1- to 25 Nm.
– Install oil feed line.
Tightening torques:
Component Nm
Fixing screw to exhaust turbocharger 8 Nm
Hollow screw (replace gasket rings) 20 Nm

– Connect the coolant hose -1- and attach it to the engine oil
cooler and remove the hose clamp -MP7-602 (3094)- .
– Top up and bleed cooling system ⇒ page 118 .
– Inspect coolant level in the coolant expansion reservoir, top
up with coolant if necessary.
– Install alternator ⇒ Electrical System; Rep. gr. 27 .
– Install the V-ribbed belt ⇒ page 35 .
Further installation occurs in a similar way in reverse order to re‐
moval.

1.4 Removing and installing bracket for bot‐

tom auxiliary units
(For vehicles with air conditioning)
Removing
– Remove V-ribbed belt ⇒ page 35 .
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .

WARNING

Risk of injury through refrigerant.

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

Caution

Risk of damaging refrigerant lines and hoses.

♦ Do not over-tension or buckle refrigerant lines and hoses.

– Remove AC compressor from the bracket ⇒ page 34 .

– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

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– Unscrew fixing screws -1- and remove holder with tensioning

element.
Install
– Fit the bracket for auxiliary units to the cylinder block.

– Tighten fixing screws -1- to 25 Nm.

Tightening torque of tensioning device: ⇒ page 34
The further assembly is carried out in reverse order to disassem‐
bly.

1. V-ribbed belt drive 39

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2 Camshaft drive

2.1 Camshaft drive - Summary of compo‐

nents

Note

♦ Before assembly oil all bearing and contact surfaces.

♦ If considerable quantities of metal swarf or abrasion is found
when carrying out engine repairs, this can be subject to dam‐
age to the crankshaft and conrod bearings. In order to avoid
consequential damage, after the repair perform the following
tasks:

– Carefully clean the oil galleries.

– Replace oil spray jets.
– Replace engine oil cooler.
– Replace oil filter.

1 - Cylinder head with cylinder

head cover
❑ Removing and installing
cylinder head
⇒ page 94
❑ Removing and installing
cylinder head cover
⇒ page 84
❑ The sealing surfaces
must not be reworked

Note

2 - Cylinder block
❑ Disassembling and as‐
sembling pistons and
conrods ⇒ page 63

40 Rep. gr.13 - Crankshaft group

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WARNING
The crankshaft must not
be removed. Merely re‐
leasing the crankshaft
bearing cover screws will
result in deformations of
the bearing seats of the
cylinder block. These de‐
formations reduce the
bearing clearance. Even
if the bearing shells were
not replaced, the
changed bearing clear‐
ance may cause dam‐
age to the bearing.
If the bearing cover
screws have been re‐
leased, replace the com‐
plete cylinder block to‐
gether with the crank‐
shaft.
It is not possible to meas‐
ure the crankshaft bear‐
ing clearance under
workshop conditions.

3 - Bracket for bottom auxiliary units

❑ for tensioning device and AC compressor
❑ Removing and installing ⇒ page 38 for vehicles with air conditioning
4 - 25 Nm
5 - Oil pan
❑ removing and installing ⇒ page 110
6 - 13 Nm
7 - Fixing screw
❑ for crankshaft - belt pulley
❑ replace
❑ The clamping surface of the fixing screw must be free of grease and oil.
❑ insert oiled (thread)
❑ Tightening torque; slacken and tighten ⇒ page 51
8 - Belt pulley
❑ Pay attention to tightening process ⇒ page 51
❑ Clamping surfaces must be free of oil and grease.
❑ Counterhold belt pulley with counterholder -T30004 (3415)- with bolt -T30004/2 (3415/2)- to prevent it
from turning
9 - Diamond coated washer
❑ diamond coated washer pressed onto the belt pulley
❑ replace if damaged
10 - Sealing ring
❑ replace
❑ removing and installing ⇒ page 50

2. Camshaft drive 41
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11 - 50 Nm
12 - Engine support bracket
13 - 20 Nm + torque a further 90° (1/4 turn)
❑ replace
14 - Sprocket
❑ for oil pump drive
❑ Clamping surfaces must be free of oil and grease.
❑ Counterhold sprocket with counterholder -T10172-
15 - Drive chain for oil pump
❑ mark running direction (installed position) before removing
16 - Bottom cover
17 - 5 Nm + 30° further
❑ replace
❑ Screw: M6x40
18 - 5 Nm + 30° further
❑ replace
❑ Screw: M6x20
19 - Bottom timing case
❑ removing and installing ⇒ page 45
20 - Bearing bolt, 18 Nm
21 - Sliding rail
❑ for timing chain
22 - Bearing bolt, 18 Nm
23 - 50 Nm + torque a further 90° (1/4 turn)
❑ replace
24 - Tensioning rail
❑ for timing chain
25 - Screw
❑ Pay attention to tightening process ⇒ page 43
26 - Top timing case
❑ removing and installing ⇒ page 43

Caution
Pay attention to tighten‐
ing process!

27 - Timing chain
❑ removing and installing ⇒ page 77

Note

28 - Sprocket
❑ Counterhold sprocket with counterholder -T10172-
29 - Chain tensioner, 60 Nm
❑ for timing chain
30 - Sealing ring

42 Rep. gr.13 - Crankshaft group

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2.2 Removing and installing the top timing

case
Special tools and workshop equipment required
♦ Hose binding claw
♦ Sealant ⇒ Electronic catalogue of original parts(ETKA)
♦ Screw M6x70 (2x) : adapt the screws by sawing off the heads
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
Removing
– Drain coolant ⇒ page 118 .
– Slacken clamps -1- and -2- and detach coolant hoses.
– Unlatch the clamp -3- and pull it towards the top with the cool‐
ant hoses.
– Place the coolant hoses to the rear.

– Unscrew fixing screws from top timing case -1-.

– Remove timing case.
Install
Installation is performed in the reverse order, pay attention to the
following points:

2. Camshaft drive 43
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– To better guide the timing case, screw two pin screws M6x70
-1- into the cylinder head cover.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove residual sealant from the sealing surfaces on the top

timing case and at the cylinder head with chemical sealant re‐
mover.
– Degrease the sealing surfaces.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).

Note

♦ The installation procedure must not last longer than 6 minutes

from the moment the sealant is applied until the moment the
fixing screws are tightened to 8 Nm.
♦ The sealant begins to harden after 6 minutes.
♦ Ensure that the tightening process of the fixing screws is car‐
ried out in two steps.

– Apply sealant on the sealing surface -1-.

– Apply a little more sealant in the area of the -arrows-.

– Position the timing case -1- onto the pin screws -2-.
Slide the timing case -1- up to the stop onto the cylinder head
cover.
Make sure that the timing case does not tilt.
– Release the stud bolts and screw in the fixing screws by hand.
Stage l of the tightening process.

44 Rep. gr.13 - Crankshaft group

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– Tighten the fixing screws to 5 Nm in the specified order -1- to

-5-.
Stage ll of the tightening process.

– Tighten the fixing screws to 8 Nm in the specified order -1- to

-7-.

– Push the clamp -3- from above fully into the bracket.
– Fit on the coolant hoses and attach the spring strap clamps
-1- and -2-.
– Top up coolant ⇒ page 118 .

2.3 Removing and installing the bottom tim‐

ing case
Special tools and workshop equipment required
♦ Assembly device -T10417/1-
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
♦ Sealant ⇒ Electronic catalogue of original parts(ETKA)
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .

2. Camshaft drive 45
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– Remove V-ribbed belt ⇒ page 35 .

– Remove dust cap -1-.
– Remove guide pulley -2-.
– Remove belt pulley for coolant pump, to do so counterhold the
belt pulley with the water pump wrench -V.A.G 1590- .
– Remove crankshaft-belt pulley ⇒ page 51 .
– Removing the oil pan ⇒ page 110 .

– Unscrew all the fixing screws from the timing case -1-.
– Carefully remove timing case.
Install
Installation is performed in the reverse order, pay attention to the
following points:

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove residual sealant from the sealing surfaces on the bot‐

tom timing case and at the cylinder block with chemical sealant
remover.
– Degrease the sealing surfaces.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).

Note

♦ The installation procedure must not last longer than 6 minutes

from the moment the sealant is applied until the moment the
fixing screws are tightened to 5 Nm + torqued a further 30°.
♦ The sealant begins to harden after 6 minutes.
♦ Insert new fixing screws.

– Apply sealant on the sealing surface -1-.

The sealant bead must be 2…3 mm thick and must run past
the area of the bolt holes all around the holes.

46 Rep. gr.13 - Crankshaft group

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– Fit the assembly device -T10417/1- on the crankshaft journal.

– Carefully slide the bottom timing case -1- together with the
gasket ring over the assembly device.
– Remove the assembly device from the crankshaft journal.

– Slide the bottom timing case onto the dowel pins -arrows- until
it rests against the cylinder block.
Make sure that the timing case does not tilt.

Caution

Pay attention to the tightening torque of the fixing screws!

When installing, use new screws.

– First of all tighten the new fixing screws of the timing case
evenly by hand.

– Tighten the fixing screws in the specified order -1- to -12-.

Tightening torque: 5 Nm + torque a further 30°.
Install crankshaft belt pulley ⇒ page 51 .
Tightening torques
Belt pulley for coolant pump: 20 Nm.
Guide pulley: 40 Nm.

2. Camshaft drive 47
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3 Sealing flanges and flywheel

3.1 Summary of components

1 - Fixing screw
❑ for crankshaft - belt pul‐
ley
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
❑ Tightening torque;
slacken and tighten
⇒ page 51
2 - Belt pulley
❑ removing and installing
⇒ page 51
❑ Clamping surfaces must
be free of oil and grease.
3 - Diamond coated washer
❑ diamond coated washer
pressed onto the belt
pulley
❑ replace if damaged
4 - Sealing ring
❑ replace
5 - Engine
6 - 60 Nm + torque a further 90°
(1/4 turn)
❑ replace
7 - Flywheel
❑ on vehicles with auto‐
matic gearbox - the two-
mass flywheel version
❑ removing and installing ⇒ page 49
8 - Intermediate plate
❑ must be positioned on dowel sleeves
❑ do not damage/bend during assembly work
9 - 10 Nm
❑ replace
10 - Sealing flange on the gearbox side
❑ Only replace sealing flange complete with gasket ring and rotor
❑ replace ⇒ page 55
11 - Engine speed sender -G28- , 5 Nm
❑ with captive screw
❑ removing and installing ⇒ page 260
12 - 5 Nm

48 Rep. gr.13 - Crankshaft group

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3.2 Removing and installing flywheel

Special tools and workshop equipment required
♦ Flywheel lock -MP1-223 (3067)-
or

♦ Engine mount -MP 1-202 (VW 540)-

♦ Bushing -T30010 (VW 540/1B)-
♦ Flywheel lock -MP 1-504-
Removing
• Gearbox is removed.
– Remove clutch on vehicles with manual gearbox ⇒ Gearbox;
Rep. gr. 30 .
Engine installed
– Insert the counterholder -MP1-223 (3067)- into the bore hole
on the cylinder block.
• Fitting position of the counterholder:
A - for tightening
B - for slackening

Engine removed
– Position the flywheel lock -MP 1-504- on the starter ring gear
of the flywheel disk and turn crankshaft until it rests against
the sleeve -T30010 - .

3. Sealing flanges and flywheel 49

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Vehicles with two-mass flywheel

– Rotate the secondary side -A- of the two-mass flywheel in such
a way that the screws -B- are positioned in the middle of the
holes -arrows-.

Caution

When unscrewing the screws -B-, ensure that no screw head

catches on the secondary side -A- of the two-mass flywheel,
otherwise the flywheel will be damaged.

Continued for all vehicles

– Release screws and remove flywheel.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

Use new screws for attaching.

Vehicles with two-mass flywheel

– Rotate the secondary side -A- of the two-mass flywheel in such

a way that the screws -B- are positioned in the middle of the
holes -arrows-.
Continued for all
1. Screw in all the screws by hand.
2. Tighten all the screws crosswise to 60 Nm.
3. Torque all the screws crosswise a further 90° (1/4 turn).

3.3 Replacing crankshaft seal on belt pulley

side
Special tools and workshop equipment required
♦ Gasket ring extractor -T30015 (3240)-
♦ Assembly device -T10417-
♦ Cap -T30003 (3161)-
Removing
– Remove V-ribbed belt ⇒ page 35 .
– Rotate the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 69 .
– Remove crankshaft-belt pulley ⇒ page 51 .

50 Rep. gr.13 - Crankshaft group

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– Push the adapter piece -3161- into the gasket ring extractor
-3240- .
– Unscrew the inner part of the gasket ring extractor -3240- up
to the beginning of the thread and lock with the knurled screw.

– Oil the thread head of the gasket ring extractor, position and
apply pressure when screwing it into the gasket ring as far as
possible.
– Slacken knurled screw and turn inner side in
-direction of arrow- against the crankshaft until the gasket ring
is pulled out.
Install

– Position the sleeve -T10417/1- on the crankshaft stub and

push the gasket ring over the sleeve.
– Remove the sleeve -T10417/1- from the crankshaft stub.

– Press the gasket ring with the assembly device -T10417- by

striking uniformly up to the stop in the timing case.
Install crankshaft belt pulley ⇒ page 51 .
Further installation occurs in a similar way in reverse order to re‐
moval.

3.4 Removing and installing crankshaft-belt

pulley
Special tools and workshop equipment required
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ Fixing screw -T10340-

3. Sealing flanges and flywheel 51

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Note

♦ In order to avoid that the tightening torque of the fixing screw

for the crankshaft-belt pulley is inaccurate due to slip, the fixing
screw -T10340- must be used in addition to the counterholder
-T30004- .
♦ The crankshaft is only locked in direction of rotation of engine
using the fixing screw -T10340- .

Caution

Risk of engine damage!

♦ The fixing screw -T10340- must not be used to slacken the
fixing screw for the crankshaft-belt pulley - only for tight‐
ening!
♦ The locating screw -T10340- must only be screwed in the
“TDC” position of the crankshaft.

Removing
– Remove V-ribbed belt ⇒ page 35 .
– Rotate the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 69 .
– Counterhold belt pulley with counterholder -T30004 (3415)-
with bolt -T30004/2 (3415/2)- and release fixing screw for belt
pulley.
– Remove the belt pulley together with the diamond coated
washer.
Install
Vehicles with auxiliary heating.

– Screw out the screws -1 and 2- of the brackets for the coolant
pipes for the auxiliary heating -3-.
Continued for all vehicles

52 Rep. gr.13 - Crankshaft group

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– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

Note

♦ Make sure that all clamping surfaces of the fixing screw are
free of oil and grease up to the crankshaft chain sprocket.
♦ Always use a new screw of the crankshaft belt pulley.

– Install the belt pulley together with the diamond coated washer
and tighten the new fixing screw by hand.

– Release screw plug -arrow- at cylinder block.

Note

♦ Using the fixing screw should prevent the crankshaft from

turning when tightening to the tightening torque.
♦ As a result the tightening torque may not be correct.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing 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 the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

Caution

Absolutely use the counterholder -T30004 (3415)- with bolt -

T30004/2 (3415/2)- when tightening the fixing screw of the belt
pulley in order to avoid damage to the fixing screw.

3. Sealing flanges and flywheel 53

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– Insert counterholder -3415- with the bolt -3415/1- into the

holes of the crankshaft belt pulley, support counterholder at
track control arm -A- and secure in this position with a cable
strap. Tighten cable strap.
– Tighten fixing screw of crankshaft-belt pulley in two stages:
Stage 1: Tightening torque: 150 Nm

– Mark at this stage the position of the fixing screw -3- to the
crankshaft belt pulley -1- -arrows-. The marking must not be
performed on the washer -2-, because the washer does not
turn along when tightening.
– Tighten fixing screw of crankshaft belt pulley to the 2nd step
as follows:
Stage 2: Torque screw a further 180° (1/2 turn).
Tightening may occur in successive stages.

– Release the fixing screw -T10340- from the cylinder block.

– Screw the screw plug again into the cylinder block. Tightening
torque: 30 Nm.

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– Install bracket for coolant pipe -2- and tighten screws -1-.
Tightening torque
Screw M6 = 10 Nm
Screw M8 = 20 Nm
– Install the V-ribbed belt ⇒ page 35 .
Further installation occurs in a similar way in reverse order to re‐
moval.

3.5 Replace sealing flange on the gearbox

side
Special tools and workshop equipment required
♦ Assembly tool -T10134-
♦ Feeler gauges
♦ Steel straightedge
♦ Screw M6x35 (3x)
♦ Screw M7x35 (2x)

3.5.1 Removing
Precondition
• Gearbox is removed.
– Remove flywheel and take off intermediate plate.
– Position engine on TDC for cylinder 1 ⇒ page 69 (do not
remove the screw cap for the camshafts).
– Removing the oil pan ⇒ page 110 .
– Remove engine speed sender -G28- -arrow-.
– Unscrew the fixing screws of the sealing flange.

Note

Sealing flange and rotor are pressed together with three M6 x 35

mm screws from the crankshaft.

– Screw three screws M6x35 into the threaded bores of the

sealing flange -arrows-.
– Screw the screws alternately (max 1/2 turn (180°) per screw)
in the sealing flange and press the sealing flange together with
the rotor from the crankshaft.

3. Sealing flanges and flywheel 55

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3.5.2 Install

Note

♦ The sealing flange with PTFE gasket ring is provided with

sealing lip supporting ring. This supporting ring is intended as
an assembly sleeve and must not be removed before instal‐
ling.
♦ Do not separate or turn the sealing flange and rotor after re‐
moving them from the spare part package.
♦ The rotor is given its fitting location by fixing the assembly tool
-T10134- to the positioning pin.
♦ The sealing flange and gasket ring form one unit and must be
replaced together with the rotor.
♦ The assembly tool -T10134- is given its fitting location to the
crankshaft by means of a guide bolt, which is guided into a
hole of the crankshaft.

Assembly tool -T10134-

A - Hexagon nut
B - Clamping surface
C - Assembly cup
D - Allan screw
E - Guide bolts (with red handle - for fuel engine)
F - Positioning pin
G - Guide bolts (with black handle - for diesel engine)
A - Mounting sealing flange with rotor on the assembly tool -
T10134-

– Screw the hexagon nut -A- right up to the clamping surface

-B- and grip the assembly tool -T10134- on the clamping sur‐
face -B- of the threaded spindle in a vice.

– Remove the securing clip -arrow- from the new sealing flange.

Note

Do not remove or turn the rotor from the sealing flange.

56 Rep. gr.13 - Crankshaft group

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– Lay the front side of the sealing flange on a clean and level
surface.
– Press down sealing lips supporting ring -A- in
-direction of the arrow-, until it rests on the level surface.

Note

The top edge of the rotor and the front edge of the sealing flange
must be flush.

• The locating hole -B- on the rotor -C- must be flush with the
marking -A- on the sealing flange.

– Lay the sealing flange with the front side on the assembly tool
-T10134- in such a way that the positioning pin -A- engages
into the hole -B- of the rotor.

Note

Make sure the sealing flange lies flat on the assembly tool.

– When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly tool in such
a way that the positioning pin cannot slide out of the rotor hole.
B - Mount the assembly tool -T10134- on the crankshaft flange
• The crankshaft flange must be free of grease and oil
• Crankshaft is at TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.

3. Sealing flanges and flywheel 57

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– Screw assembly tool -T10134- with Allan screws -A- up to the

stop onto the crankshaft flange.

– Screw in two M6x35 mm screws -A- by about 3 turns for seal‐

ing flange guide into the cylinder block.

– Move the assembly cup -C- by hand in the

-direction of the arrow- until the rotor -B- rests on the crank‐
shaft flange -A-. Subsequently insert the guide bolt with red
ball -F- fully into the threaded bore of the crankshaft. If the
guide bolt is correctly pushed in, then the handle has a dis‐
tance of approx. 10 mm from the assembly cup -C-. This gives
the rotor its final fitting location.
C - Pressing the rotor onto the crankshaft flange
– Screw in hexagon nut by hand onto the threaded spindle until
it rests against the assembly cup.

– Tighten the hexagon nut of the assembly tool using a torque

wrench with adapter.
Tightening torque: 35 Nm.

Note

After tightening the nut to 35 mm there must still be a narrow air

gap between the cylinder block and the sealing flange.

D - Inspecting the fitting position of the rotor on the crankshaft

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– Unscrew hexagon nut -E- up to the end of the threaded spin‐

dle.
– Unscrew two M6x35 mm screws -A- from the cylinder block.
– Release three knurled screws -B- from the sealing flange.
– Unscrew two Allan screws and remove assembly tool -
T10134- .
– Remove sealing lip supporting ring.

The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- = 0.5 mm between the crankshaft flange
-A- and the rotor -B-.

– Position the steel striaghtedge onto the crankshaft flange.

– Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
– Press down rotor ⇒ page 59 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing alternately cross‐
wise.
Tightening torque: 10 Nm.

– Install engine speed sender -arrow-.

Tightening torque: 5 Nm.
– Installing the oil pan ⇒ page 110 .
– Installing intermediate plate.
– Install flywheel with new screws.
E - Pressing down the rotor

3. Sealing flanges and flywheel 59

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– Screw assembly tool -T10134- with Allan screws up to the stop

onto the crankshaft flange.
– Screw in three knurled screws -A- into the flange.
– Subsequently insert the guide bolt with red ball -E- fully into
the threaded bore of the crankshaft. If the guide bolt is correctly
slipped on, then the handle has a distance of approx. 10 mm
from the assembly cup -B-.

– Tighten the hexagon nut of the assembly tool using a torque

wrench with adapter.
Tightening torque: 40 Nm.
– Inspect the fitting position of the rotor on the crankshaft again
⇒ page 58 .
If the dimension -a- is too small again:
– Tighten the hexagon nut of the assembly tool to 45 Nm.
– Inspect the fitting position of the rotor on the crankshaft again
⇒ page 58 .

60 Rep. gr.13 - Crankshaft group

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4 Crankshaft

Caution

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. These defor‐
mations will cause a reduction of the bearing clearance. If the
bearing shells are not replaced, the changed bearing clear‐
ance may cause damage to the bearing.
If the bearing cover screws have been released, replace the
complete cylinder block together with the crankshaft.
It is not possible to measure the crankshaft bearing clearance
with workshop tools.

4.1 Replace needle bearing for crankshaft

Only on vehicles equipped with automatic gearbox.
Special tools and workshop equipment required
♦ Centering mandrel -T30029 (3176)-
♦ Interior extractor -Kukko 21/2-
♦ Countersupport - Kukko 22/1-
Removing
– Pull out needle bearing with interior extractor -Kukko 21/2- and
countersupport -Kukko 22/1- .
Install

Note

The marked side of the needle bearing should be legible when in

its installed condition.

– Drive in the needle bearing using the centering pin -T30029- .

• Fitting position: The marked side of the needle bearing should
be legible when in its installed condition.

4. Crankshaft 61
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Depth of installation of the needle bearing

• Dimension -a-: 1.5 up to 1.8 mm

62 Rep. gr.13 - Crankshaft group

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5 Pistons and conrods

5.1 Summary of components

Note

Before assembly oil all bearing and contact surfaces.

1 - Circlip
2 - Piston pin
❑ if stiff, heat piston to 60°
C
❑ use drift -T10046- for re‐
moving and installing
3 - Piston
❑ check ⇒ page 65
❑ mark installation posi‐
tion and matching cylin‐
der
❑ arrow on the piston
crown faces towards the
belt pulley side
❑ use piston ring tension‐
ing strap for installing
❑ Piston ∅: 70,95 mm
(nominal dimension)
❑ Cylinder ∅: 71.00 mm
(nominal dimension)
4 - Piston rings
❑ Offset joint 120°
❑ Use piston ring pliers for
removing and installing
compression rings
❑ Marking “TOP” faces
piston crown
❑ Inspect gap clearance
⇒ page 64
❑ Inspect end clearance
⇒ page 64
5 - Oil scraper rings
❑ carefully remove and in‐
stall 3-part oil scraper rings by hand
❑ Inspect gap clearance ⇒ page 64
❑ End clearance cannot be measured
6 - 30 Nm + torque a further 90° (1/4 turn)
❑ replace
❑ Oil thread and contact surface
7 - Conrod bearing cap
❑ as a result of the conrods separated in the cracking process, the cover fits only in one position and only
to the relevant conrod
❑ Mark the assignment of the cylinder before removal -A-

5. Pistons and conrods 63

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❑ Fitting position: Marking -B- points to the belt pulley side (mark before removing if marking is missing)
8 - Bearing shell
❑ do not mix up used bearing shells
❑ insert bearing shells in the centre
9 - Pressure relief valve, 27 Nm
❑ Opening pressure: 0,2 MPa (2,0 bar)
10 - Oil injection nozzle
❑ for piston cooling
❑ Align the guide edge of the oil injection nozzle -arrow- to the area of the cylinder block being worked on.
11 - Conrod
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Marking -B- points to the belt pulley side (mark before removing if marking is missing)
❑ located axially by pistons
❑ separate new conrod ⇒ page 66

5.2 Inspect piston, piston rings and cylinder

bore
Inspecting piston ring gap clearance

Special tools and workshop equipment required

♦ Feeler gauges
– Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder.
Piston ring New Wear limit
dimensions in mm
1. Compression ring 0,20…0,40 1,0
2. Compression ring 0,40…0,60 1,0
Oil scraper ring 0,25…0,75 no wear indication
possible
Inspect piston ring end clearance

Special tools and workshop equipment required

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♦ Feeler gauges
– Clean ring groove before inspecting.
Piston ring New Wear limit
dimensions in mm
1. Compression ring 0,03…0,09 0,15
2. Compression ring 0,02…0,06 0,15
Oil scraper ring cannot be measured
Inspecting pistons

Special tools and workshop equipment required

♦ External micrometer 75...100 mm
– Measure about 7 mm from the lower edge and offset 90° to
piston pin axis.
• Deviations from specified dimension: max. 0,04 mm
Inspecting cylinder bore

Special tools and workshop equipment required

♦ Internal precision measuring instrument 50...100 mm
– Measure at 3 points crosswise in a transverse direction -A- and
lengthwise -B-.
• Deviations from specified dimension: max. 0,08 mm

5. Pistons and conrods 65

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Note

Do not measure the cylinder bore if the cylinder block is fixed to

the assembly stand -MP 1-202- with the engine mount -MP 9-101
- , as this may result in incorrect measurements.

5.3 Separating new conrod

It can happen that the predetermined breaking point on the new
conrod is not completely pierced. If the conrod bearing cap cannot
be removed by hand, then proceed as follows:
– Mark the assignment of the conrod to the cylinder.
– Slightly clamp the conrod in a vice provided with aluminium
protective jaws, as shown in the illustration.

Note

♦ Only tension the conrod slightly in order to avoid damage on

the conrod.
♦ The conrod is clamped below the broken 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.

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15 – Cylinder head, valve gear

1 Cylinder head - part 1

1.1 Summary of components

Testing compression pressure ⇒ page 100 .

Note

♦ When installing a replacement cylinder head, all the contact

surfaces between the hydraulic balancing elements, the cam
followers and the cam tracks must be oiled before installing
the cylinder head cover.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ If the cylinder head is replaced, also the entire coolant must
be replaced.
♦ Before assembly moisten all bearing and contact surfaces with
oil.
♦ Removing and installing intake manifold ⇒ page 223 .

1. Cylinder head - part 1 67

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1 - 20 Nm
2 - High pressure pump
❑ for fuel supply
❑ with fuel pressure regu‐
lating valve -N276-
❑ removing and installing
⇒ page 229
3 - 10 Nm
4 - Hall sender -G40-
❑ with O-ring
❑ replace the O-ring if it is
damaged
5 - 20 Nm
6 - Lifting eye
7 - 8 Nm + torque a further 90°
(1/4 turn)
❑ replace
❑ order of tightening
⇒ page 84
8 - Cylinder head cover
❑ removing and installing
⇒ page 84

Note

9 - 10 Nm
10 - Coolant temperature
sender -G62-
❑ before removing, re‐
duce pressure in cooling
system
11 - O-ring
❑ replace
12 - Cylinder head gasket
❑ replace
❑ metal gasket
❑ after replacing fill entire system with fresh coolant
13 - Cylinder head
❑ removing and installing:
♦ Fabia II, Roomster, Rapid NH ⇒ page 94
♦ Octavia II, Yeti ⇒ page 98
❑ check for distortion ⇒ page 69
❑ Sealing surfaces must be free of oil and grease
❑ after replacing fill entire system with fresh coolant
14 - Hydraulic balancing element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ oil contact surfaces

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15 - Oil pressure switch -F1- , 20 Nm

❑ check ⇒ page 114
❑ Cut open gasket ring if leaking and replace
16 - Roller rocker arm
❑ inspect roller bearings for smooth operation
❑ oil contact surfaces
❑ for installing, clip onto the balancing element with the locking clip
17 - Cylinder head bolt
❑ replace
❑ observe the mounting instructions and sequence for loosening and tightening ⇒ page 94
18 - Roller tappet
❑ Lightly moisten the contact surface with engine oil
19 - O-ring
❑ replace
❑ moisten with oil before inserting

Inspecting the cylinder head for distortion

Check with straightedge 500 mm , e. g. -VAS 6075- and feeler
gauge.
• Max. permissible distortion: 0.05 mm

1.2 Test timing

Special tools and workshop equipment required
♦ Fixing bolts -T10414-
♦ Fixing screw -T10340-
Test sequence
Vehicles with auxiliary heating.
– Unscrew the screws -1 and 2- of the brackets for the coolant
pipes for the auxiliary heating -3-.
Continued for all vehicles

1. Cylinder head - part 1 69

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– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

– Release screw plug -arrow- at cylinder block.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing 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 the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

– Separate the hoses -1- from the non-return valve.

– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.

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The grooves in the camshaft -arrows- must be in the position

shown.
– Insert the fixing bolt -T10414- up to the stop into the cylinder
head cover.

– Tighten fixing screw -1- by hand.

If the fixing bolt -T10414- cannot be inserted up to the stop into
the camshaft opening, the timing is not correct and must be set
⇒ page 71 .
The timing is O.K., if the fixing bolt -T10414- can be pushed up to
the stop into the cylinder head cover.
– Remove fixing bolt -T10414- and fixing screw -T10340- .
Further installation occurs in a similar way in reverse order to re‐
moval.

1.3 Setting the timing

Special tools and workshop equipment required
♦ Fixing bolts -T10414-
♦ Fixing screw -T10340-
♦ Counterholder -T10172 -
Work procedure
– Drain coolant ⇒ page 118 .
– Remove top timing case ⇒ page 43 .
– Separate the hoses -1- from the non-return valve.
– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.
Vehicles with auxiliary heating.

1. Cylinder head - part 1 71

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– Unscrew the screws -1 and 2- of the brackets for the coolant

pipes for the auxiliary heating -3-.
Continued for all vehicles

– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

– Release screw plug -arrow- at cylinder block.

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– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing 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 the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .
For vehicles manufactured up to 12.2009

Note

On these vehicles, the timing chain can slip off the crankshaft gear
when installing.

– Removing the oil pan ⇒ page 110 .

– Pull off the cover -1- from the oil pump.

Continued for all vehicles

– Release chain tensioner -arrow- for timing chain.

1. Cylinder head - part 1 73

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– Hold the camshaft sprocket with the counterholder -T10172-

and slacken the fixing screw -1- of the camshaft sprocket.
– Remove the camshaft sprocket together with the fixing screw.

– Place the chain sprocket -1- down on the integrated peg

-arrow- in the timing case.

Note

The integrated peg on the inner side of the timing case prevents
the chain sprocket from falling down.

– Position the camshaft sprocket -1- on the camshaft and tighten

the fixing screw -2- to 50 Nm.
– Hold the camshaft sprocket with the counterholder -T10172-
when tightening.
– Then turn back the crankshaft 90° (1/4 turn) in the opposite
direction of rotation of the engine.

Note

When subsequently adjusting the camshaft, damage to the valves

is prevented by turning the crankshaft in the opposite direction of
rotation of the engine.

– Turn the camshaft until the grooves -arrows- are in the position
shown.

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– Insert the fixing bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.
– Turn crankshaft up to the stop in direction of rotation of engine.

– Lift up the timing chain with the assembly device -T10118- .

For vehicles manufactured up to 12.2009

Note

On these vehicles, the timing chain can slip off the crankshaft gear
when installing.

– Check the correct position of the timing chain -1- on the crank‐
shaft gear from below.
Continued for all vehicles

– Place the timing chain -1- onto the chain sprocket -2-.

Note

♦ The timing chain must rest in the area of the sliding rail -3- and
be slightly tensioned.
♦ The timing chain must run through the middle of the sliding rail.

– Install fixing screw for camshaft sprocket and tighten by hand.

1. Cylinder head - part 1 75

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– Install chain tensioner and tighten to 60 Nm.

– Hold the camshaft sprocket with the counterholder -T10172-

and tighten the fixing screw -1- of the camshaft sprocket to 50
Nm.

Note

The fixing screw is only turned a further 90° (1/4 turn) after check‐
ing the timing at the end of the work procedure.

– Remove the fixing bolt -T10414 - from the camshaft.

– Release the fixing screw -T10340- from the cylinder block.
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the fixing screw -T10340- up to the stop in the cylinder
block.
– Turn crankshaft up to the stop in direction of rotation of engine.
The timing is O.K., if the fixing bolt -T10414- can be inserted in
the camshaft.
If the timing is not O.K., the setting of the timing must be repeated.
If timing is o.k.:

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Remove fixing bolt -T10414- and fixing screw -T10340- .
– Install top timing case ⇒ page 43 .

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– Install non-return valve. Tightening torque of the fixing screw

-2-: 8 Nm.
– Fit on hoses -1-.
For vehicles manufactured as of 12.2009
– Installing the oil pan ⇒ page 110 .
Continued for all vehicles

– Install screw plug. Tightening torque: 30 Nm

– Top up coolant ⇒ page 118 .
For vehicles manufactured as of 06.2011
– Erase the initialisation values and adapt the engine control unit
-J623- ⇒ Vehicle diagnostic tester.
Continued for all vehicles
Further installation occurs in a similar way in reverse order to re‐
moval.

1.4 Removing and installing timing chain

and drive chain for oil pump

Note

First of all, the timing chain must be removed in order to remove

the drive chain for oil pump.

Remove timing chain ⇒ page 77

Remove and install the drive chain for oil pump ⇒ page 81
Install timing chain ⇒ page 82
Special tools and workshop equipment required
♦ Fixing bolts -T10414-
♦ Fixing screw -T10340-
♦ Counterholder -T10172 -
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ Assembly device -T10417/1-

1.4.1 Remove timing chain

– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Drain coolant ⇒ page 118 .
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Remove V-ribbed belt ⇒ page 35 .
– Remove top timing case ⇒ page 43 .

1. Cylinder head - part 1 77

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Vehicles with auxiliary heating.

– Unscrew the screws -1 and 2- of the brackets for the coolant
pipes for the auxiliary heating -3-.
Continued for all vehicles

– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

– Release screw plug -arrow- at cylinder block.

– Removing the oil pan ⇒ page 110 .

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– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing 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 the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

– Separate the hoses -1- from the non-return valve.

– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.

– Insert the fixing bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.

– If present, remove dust cap -1-.

– Remove guide pulley -2-.
– Remove belt pulley for coolant pump, to do so counterhold the
belt pulley with the water pump wrench -V.A.G 1590- .
– Remove crankshaft-belt pulley ⇒ page 51 .

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– Slacken all the fixing screws of the timing case -1- carefully
remove the timing case.

– Release chain tensioner -arrow- for timing chain.

– Mark with a felt-tip pen the direction of rotation of the timing
chain.

– Hold the camshaft sprocket with the counterholder -T10172-

and slacken the fixing screw -1- of the camshaft sprocket.
– Remove the camshaft sprocket together with the fixing screw.
– Remove timing chain downwards.
Install timing chain ⇒ page 82

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1.4.2 Removing and installing the drive chain

for oil pump
Removing
– Pull off the cover -1- from the oil pump.
– Mark with a felt-tip pen the direction of rotation of the drive
chain for oil pump.

– Unscrew the fixing screws -arrows- of the oil pump.

– Remove the complete oil pump from the drive chain.

– Remove the drive chain for oil pump -1- from the rear ring gear
-2- of the crankshaft gear.
Install

– Place the drive chain for oil pump -1- on the rear ring gear
-2- of the crankshaft gear.

1. Cylinder head - part 1 81

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– Hook the oil pump with the chain sprocket into the drive chain
and tighten the new screws -arrows- to 14 Nm + torque a fur‐
ther 90° (1/4 turn.).

1.4.3 Installing timing chain

– Position the timing chain -1- from below at the front ring gear
-2- and guide it upwards between the sliding rail and the ten‐
sioning rail.
– Secure the timing chain, for example with a screwdriver -3-,
against falling down.

– Place the timing chain -1- onto the chain sprocket -2-.

Note

♦ The timing chain must rest in the area of the sliding rail -3- and
be slightly tensioned.
♦ The timing chain must run through the middle of the sliding rail
-3-.

– Install fixing screw for camshaft sprocket and tighten by hand.

– Tighten chain tensioner -arrow- to 60 Nm.

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– Hold the camshaft sprocket with the counterholder -T10172-

and tighten the fixing screw -1- of the camshaft sprocket to 50
Nm.

Note

The fixing screw is only turned a further 90° (1/4 turn) after check‐
ing the timing at the end of the work procedure.

– Remove the fixing bolt -T10414 - from the camshaft.

– Release the fixing screw -T10340- from the cylinder block.
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Test timing ⇒ page 69 .
If timing is o.k.:

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Install bottom timing case ⇒ page 45 .

– Fit the cover -1- on the oil pump.

– Installing the oil pan ⇒ page 110 .
– Install crankshaft belt pulley ⇒ page 51 .
– Install the V-ribbed belt ⇒ page 35 .
– Install top timing case ⇒ page 43 .
– Top up coolant ⇒ page 118 .
For vehicles manufactured as of 06.2011
– Erase the initialisation values and adapt the engine control unit
-J623- ⇒ Vehicle diagnostic tester.
Continued for all vehicles
Further installation occurs in a similar way in reverse order to re‐
moval.

1. Cylinder head - part 1 83

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2 Cylinder head - part 2

2.1 Removing and installing cylinder head

cover and camshaft

Note

The camshaft is located in the cylinder head cover.

Special tools and workshop equipment required

♦ Fixing bolts -T10414-
♦ Fixing screw -T10340-
♦ Counterholder -T10172 -
♦ Sealant - D 154 103 A1- (cylinder head cover/cylinder head)
♦ Sealant - D 189 500 A1- (cylinder head cover/cylinder head)
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
♦ Screw M6x70 (2x) : adapt the screws by sawing off the heads

2.1.1 Remove cylinder head cover

Note

♦ On vehicles as of production date 06.2011, the cylinder head

cover on the cylinder head is sealed with a coated metal gas‐
ket. The cylinder head cover was fitted with a firm gasket.
♦ Replace the gasket when carrying out repairs.
♦ The cylinder head covers which are sealed with sealant 189
500 A1 and D 154 103 A1 must be additionally sealed with
these sealants.

– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System; Rep. gr. 27 .
– Drain coolant ⇒ page 118 .
– Remove top timing case ⇒ page 43 .

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Vehicles with auxiliary heating.

– Unscrew the screws -1 and 2- of the brackets for the coolant
pipes for the auxiliary heating -3-.
Continued for all vehicles

– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

– Release screw plug -arrow- at cylinder block.

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– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing 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 the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

– Separate the hoses -1- from the non-return valve.

– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.

– Insert the fixing bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.
For vehicles manufactured up to 12.2009

Note

On these vehicles, the timing chain can slip off the crankshaft gear
when installing.

– Removing the oil pan ⇒ page 110 .

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– Pull off the cover -1- from the oil pump.

Continued for all vehicles

– Release chain tensioner -arrow- for timing chain.

– Hold the camshaft sprocket with the counterholder -T10172-

and slacken the fixing screw -1- of the camshaft sprocket.
– Remove the camshaft sprocket together with the fixing screw.

– Place the chain sprocket -1- down on the integrated peg

-arrow- in the timing case.

Note

The integrated peg on the inner side of the timing case prevents
the chain sprocket from falling down.

– Detach hose to air filter from cylinder head cover.

(Fabia II, Roomster, Rapid NH)

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– Release screws -1- and remove retaining clip.

– Disconnect plug -2- at charge pressure sender -G31- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338- and then from the exhaust gas turbocharger.
– Remove the cover for the ignition leads and release the fixing
screw -4-.
For the vehicles Octavia II, Yeti

– Release screws -1- and remove retaining clip.

– Disconnect plug -2- at charge pressure sender -G31- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
– Remove the cover for the ignition leads and release the fixing
screw -4-.
Continued for all vehicles

– Disconnect all the spark plug connectors -arrows- using the

extractor -T10112 A- from the spark plugs and lay the ignition
cables to the rear.

– Detach the non-return valve -1- from the cylinder head cover
towards the rear in -direction of arrow-.
– Remove the high pressure pump ⇒ page 230 .
– Unplug connectors from the fuel injection valves.

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– Release the screws -arrows- and disconnect the fuel distribu‐

tor from the injection valves.
– Remove exhaust turbocharger ⇒ page 203 .
– Disconnect the plug from the Hall sender -G40- .
– Pull out oil dipstick.
– Slacken the fixing screws of the cylinder head cover crosswise
from outside to inside and unscrew.
– Carefully remove the cylinder head cover.

Note

On vehicles with sealant, ensure no dirt and sealant residues get

into the cylinder head.

Remove and install camshaft ⇒ page 89 .

Install cylinder head cover ⇒ page 90 .

2.1.2 Removing and installing camshaft

Removing
– Remove fixing bolt -T10414- .
– Place the cylinder head cover on the work bench as shown.
– Release the fixing screws for the bearing frame in the specified
order -1- to -10-.
– Remove bearing frame.

– Lift the camshaft -1- out of the cylinder head cover -2-.
Install

Note

Before fitting, moisten the camshaft and the camshaft bearings

lightly with engine oil.

– Place the camshaft -1- in the cylinder head cover -2-.

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– Insert the fixing bolt -T10414 - into the nuts of the camshaft
and tighten the screw by hand.
– Position the bearing frame onto the bearing surfaces of the
camshaft.
The bearing frame is put into the correct position by means of the
centering pins -arrows-.

– Tighten securing bolts -1- through -10- in sequence given to 8

Nm.
Install cylinder head cover ⇒ page 90 .

2.1.3 Install cylinder head cover

Note

♦ On vehicles as of production date 06.2011, the cylinder head

cover on the cylinder head is sealed with a coated metal gas‐
ket. The cylinder head cover was fitted with a firm gasket.
♦ Replace the gasket when carrying out repairs.
♦ The cylinder head covers which are sealed with sealant 189
500 A1 and D 154 103 A1 must be additionally sealed with
these sealants.

Caution

Before installing the cylinder head cover, screw in the pin

screws (M 6 x 70) at the cylinder head.
The pin screws guide the cylinder head cover and prevent the
roller rocker arms sliding off from the balancing elements.

Precondition
• The pistons must not be positioned at top dead centre.
For vehicles with sealant

WARNING

Wear protective gloves when working with sealant and grease

remover!

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– Remove residual sealant from the sealing surfaces at the cyl‐

inder head cover and at the cylinder head with chemical
sealant remover.
– Degrease the sealing surfaces.
– Screw in two pin screws (M 6 x 70) -1- into the cylinder head
before fitting on the cylinder head cover.

Caution

The cylinder head cover is sealed with 2 different sealants!

Note

The sealant must not be applied too thickly, as otherwise excess

sealant may penetrate into the oil bores and possibly cause en‐
gine damage.

– Apply sealant -D 189 500 A1 - on the sealing surface -1-.

The sealant bead must be 2…3 mm thick and must run past
the area around the bolt holes on the inside.
– Apply a thin layer of sealant -D 154 103 A1 - evenly to the
gridded sealing surfaces -2-.
For vehicles with coated metal gasket

– Screw in two pin screws (M 6 x 70) -1- into the cylinder head
before fitting on the cylinder head cover.

Note

♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the new gasket with the utmost care. Any damage will
result in leaks.

– Fit new gasket for cylinder head cover onto cylinder head.
Continued for all vehicles
– Check if the roller rocker arms rest on the balancing elements.
– Carefully fit the cylinder head cover over the pin screws and
position the dowel pins onto the cylinder head.

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– Tighten the new fixing screws of the cylinder head cover in the
specified order -1- to -12-.
Tightening torque: 8 Nm + torque a further 90° (1/4 turn).

Caution

The sealant for the cylinder head cover must absolutely be re‐
moved in the area of the -arrows-.
In order to avoid leakage, the sealant for the cylinder head
cover and the sealant for the timing case must not mix.

– Remove excess sealant in the area of the -arrows-.

– Turn crankshaft up to the stop in direction of rotation of engine.

– Lift up the timing chain with the assembly device -T10118- .

For vehicles manufactured as of 12.2009

– Check the correct position of the timing chain -1- on the crank‐
shaft gear from below.
Continued for all vehicles

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– Place the timing chain -1- onto the chain sprocket -2-.

Note

♦ The timing chain must rest in the area of the sliding rail -3- and
be slightly tensioned.
♦ The timing chain must run through the middle of the sliding rail
-3-.

– Install fixing screw for camshaft sprocket and tighten by hand.

– Tighten chain tensioner to 60 Nm.

– Hold the camshaft sprocket with the counterholder -T10172-

and tighten the fixing screw -1- of the camshaft sprocket to 50
Nm.

Note

The fixing screw is only turned a further 90° (1/4 turn) after check‐
ing the timing at the end of the work procedure.

– Remove the fixing bolt -T10414 - from the camshaft.

– Release the fixing screw -T10340- from the cylinder block.
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the fixing screw -T10340- up to the stop in the cylinder
block.
– Turn crankshaft up to the stop in direction of rotation of engine.
The timing is O.K., if the fixing bolt -T10414- can be inserted in
the camshaft.
If the timing is not O.K.:
– Repeat the setting of the timing ⇒ page 71 .
If timing is o.k.:

2. Cylinder head - part 2 93

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– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Remove fixing bolt -T10414- and fixing screw -T10340- .
– Install top timing case ⇒ page 43 .
– Install exhaust turbocharger ⇒ page 203 .
For vehicles manufactured as of 12.2009
– Installing the oil pan ⇒ page 110 .
Continued for all vehicles
– Install crankshaft belt pulley ⇒ page 51 .
– Install high pressure pump ⇒ page 230 .
Further installation occurs in a similar way in reverse order to re‐
moval.

2.1.4 Removing and installing the cylinder

head
(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Support -T10358-
♦ Spindle -MP9-200/10-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
♦ For vehicles Fabia II, Roomster:
♦ Supporting device -MP9-200 (10-222A)-
♦ For vehicles Rapid NH:
♦ Supporting device -T30099-
♦ Support -MP9-200/3-
♦ Surface -T30099/1-
Removing
Requirements
• Engine temperature should not exceed 35 °C, because the
cylinder head could be twisted when slackening the screws.
• The pistons must not be in TDC.
Observe safety measures ⇒ page 3 .
Observe rules for cleanliness ⇒ page 5 .

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Drain coolant ⇒ page 118 .

– Remove coolant regulator housing from cylinder head.

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– Remove top timing case ⇒ page 43 .

– Remove bottom timing case ⇒ page 45 .
– Remove bracket for top auxiliary units ⇒ page 36 .
– Remove exhaust turbocharger ⇒ page 203 .
– Removing the intake manifold ⇒ page 223 .
For vehicles Rapid NH
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Position supporting device -T30099- with bracket -
MP9-200/3- .
– Unscrew the fixing screw for the gearbox and screw down the
bracket -T10358- .
– Support the engine via the spindle -MP9-200/10- in its installed
position and slightly pre-tension.
For vehicles Fabia II, Roomster
– Fit supporting device -MP9-200 (10-222A)- .

– Unscrew the fixing screw for the gearbox and screw down the
bracket -T10358- . (The figure shows the version with the 1.4
ltr./90 kW TSI Engine; the engine mount is identical).
– Support the engine via the spindle -MP9-200/10- in its installed
position and slightly pre-tension.
Continued for all vehicles

– Separate fuel lines -3- and -4-. To do so press the release

buttons.

WARNING

The fuel feed line is pressurized! Wear safety goggles and

safety gloves, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
hose connections. Then reduce the pressure by carefully re‐
moving the hose.

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– Unscrew nut -1- and disconnect earth lead -2- from engine
mount.
– Unscrew screws -arrows- and remove engine mount.
– Remove cylinder head cover ⇒ page 84 .
– Remove the tensioning rail and the sliding rail of the timing
chain.
– Remove the roller rocker arms together with the balancing el‐
ements and lay aside on a clean surface.
– Ensure that the roller rocker arms and the balancing elements
are not mixed up.

– Release the cylinder head bolts in the specified sequence and

remove.
– Carefully remove the cylinder head.
Install

Note

♦ As of 20.10.2010, the non-return valve which was installed in

the cylinder block at the top and was only accessible after re‐
moving the cylinder head, is no longer fitted.
♦ As of 21.10.2010, the non-return valve is installed in the cyl‐
inder block from the oil pan side.

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Tightening torque of non-return valve -arrow-: 7 Nm.

Precondition
• The pistons must not be in TDC.

Note

♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the new gasket with the utmost care. Any damage will
result in leaks.
♦ There must be no oil or coolant in the blind holes of the cylinder
head bolts in the cylinder block.

– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
– Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.
– Position piston of cylinder 1 to top dead centre and slightly turn
the crankshaft anticlockwise again.
– Position the new cylinder heads. The legend (part number)
must be legible.
– Insert the cylinder head. Pay attention to the centering pins in
the cylinder block.
– Insert new cylinder head bolts and tighten by hand.

– Tighten cylinder head bolts in the tightening order shown as

follows:
♦ Tighten all screws to 40 Nm.
♦ Then, torque all bolts further to 90° (1/4 turn) with a rigid
wrench.
♦ Finally, once again turn all bolts through a further 90° (1/4 turn).

– Insert the hydraulic balancing elements in the cylinder head

and position the relevant roller rocker arm on the valve stem
ends or balancing elements.
– Install cylinder head cover ⇒ page 84 .
– Set the timing ⇒ page 71 .
Further installation occurs in reverse order to removal.
– Top up and bleed cooling system ⇒ page 118 .

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2.2 Removing and installing the cylinder

head
(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Supporting device -T30099-
♦ Surface -T30099/1-
♦ Spindle -MP9-200/10-
♦ Support -T10358-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
Removing
Requirements
• Engine temperature should not exceed 35 °C, because the
cylinder head could be twisted when slackening the screws.
• The pistons must not be in TDC
Observe safety measures ⇒ page 3 .
Observe rules for cleanliness ⇒ page 5 .

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Drain the coolant from the cooling system ⇒ page 118 .

– Remove coolant regulator housing from cylinder head.
– Remove top timing case ⇒ page 43 .
– Remove bottom timing case ⇒ page 45 .
– Remove bracket for top auxiliary units ⇒ page 36 .
– Remove exhaust turbocharger ⇒ page 203 .
– Removing the intake manifold ⇒ page 223 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Fit supporting device -T30099- .
– Unscrew the fixing screw for the gearbox and screw down the
bracket -T10358- as shown. (The figure shows the version
with the 1.4 ltr./90 kW TSI Engine; the hanger is identical).
– Support the engine via the spindle in its installed position and
slightly pre-tension.

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– Disconnect the fuel feed line -1- and the cable to the activated
charcoal filter -2-. To do so press the release buttons.

WARNING

The fuel feed line is pressurized! Wear safety goggles and

safety gloves, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
hose connections. Reduce pressure by carefully removing the
hose.

– Release the fixing screws -2- and remove the activated char‐
coal filter upwards.

– Unscrew screws -arrows- and remove engine mount.

– Remove cylinder head cover ⇒ page 84 .
– Remove the tensioning rail and the sliding rail of the timing
chain.
– Remove the roller rocker arms together with the balancing el‐
ements and lay aside on a clean surface.
– Ensure that the roller rocker arms and the balancing elements
are not mixed up.

– Release the cylinder head bolts in the specified sequence and

remove.
– Carefully remove the cylinder head.
Install

Note

♦ As of 20.10.2010, the non-return valve which was installed in

the cylinder block at the top and was only accessible after re‐
moving the cylinder head, is no longer fitted.
♦ As of 21.10.2010, the non-return valve is installed in the cyl‐
inder block from the oil pan side.

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Tightening torque of non-return valve -arrow-: 7 Nm.

Precondition
• The pistons must not be in TDC

Note

♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the new gasket with the utmost care. Any damage will
result in leaks.
♦ There must be no oil or coolant in the blind holes of the cylinder
head bolts in the cylinder block.

– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
– Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.
– Position piston of cylinder 1 to top dead centre and slightly turn
the crankshaft anticlockwise again.
– Position the new cylinder heads. The legend (part number)
must be legible.
– Insert the cylinder head. Pay attention to the centering pins in
the cylinder block.
– Insert new cylinder head bolts and tighten by hand.

– Tighten cylinder head bolts in the tightening order shown as

follows:
♦ Tighten all screws to 40 Nm.
♦ Then, torque all bolts further to 90° (1/4 turn) with a rigid
wrench.
♦ Finally, once again turn all bolts through a further 90° (1/4 turn).

– Insert the hydraulic balancing elements in the cylinder head

and position the relevant roller rocker arm on the valve stem
ends or balancing elements.
– Install cylinder head cover ⇒ page 84 .
– Set the timing ⇒ page 71 .
Further installation occurs in a similar way in reverse order to re‐
moval.
– Top up and bleed cooling system ⇒ page 118 .

2.3 Testing the compression

Special tools and workshop equipment required

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♦ Spark plug wrench -3122 B-

♦ Compression tester -V.A.G 1763-
♦ Extractor -T10112 A-
Test condition
• Engine oil temperature must be at least 30°C.
Work procedure
– Pull out the spark plug connector -arrows- with the extractor -
T10112 A- .
– Unscrew the spark plugs with spark plug wrench -3122 B- .
– Open lid of fuse carrier in the engine compartment and unplug
the fuse for fuel pump control unit ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Check compression pressure using the compression tester -
V.A.G 1763- .

Note

Use of tester ⇒ Operating Instructions .

– Operate starter until the tester no longer indicates a pressure

rise.
Compression readings
New engine Wear limit Difference between
cylinders
1...1.5 MPa 0,7 MPa 0.3 MPa
(10...15 bar) (7 bar) (3 bar)
If the specified values are not reached, test the combustion cham‐
ber for tightness ⇒ page 101 .
The further assembly is carried out in reverse order to disassem‐
bly. Pay attention to the following:
– Delete the contents of the fault memory for the engine control
unit at the end of the work as error messages were stored due
to disconnecting the plugs ⇒ Vehicle diagnostic tester.

2.4 Testinf the combustion chamber for

tightness
Special tools and workshop equipment required
♦ Pressure hose -MP1-210 (VW 653/3)- (replace gasket ring
with a spark plug gasket ring)
♦ Extractor -T10112 A-
♦ Spark plug wrench -3122 B-
Test sequence
– Unscrew the spark plugs with spark plug wrench -3122 B- .
– Position piston of the relevant cylinder to top dead centre
(TDC).
– Screw the pressure hose MP 1-210 into the spark plug thread.
– Connect pressure hose to compressed air.

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– With the assistance of a second mechanic, lock the screw at

the crankshaft on “top dead centre position” in order to avoid
the displacement of the piston after pressure build-up.
– Build up a pressure of approx. 0.3 MPa (3 bar) in the com‐
bustion chamber.
– 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.

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3 Valve gear

3.1 Valve gear - Summary of components

1 - 50 Nm + torque a further 90°

(1/4 turn)
❑ replace
2 - Camshaft sprocket
❑ take note of the position
when installing the tim‐
ing chain
3 - 10 Nm
4 - Hall sender -G40-
❑ with O-ring
❑ replace the O-ring if it is
damaged
5 - Cylinder head cover
❑ removing and installing
⇒ page 84
6 - Non-return valve
7 - 10 Nm
8 - O-ring
❑ replace if damaged
❑ before fitting moisten
lightly with engine oil
9 - Camshaft
❑ removing and installing
⇒ page 84
❑ Inspecting axial play
⇒ page 104
❑ moisten with oil before
installing (also axial
bearing collar)
10 - Valve collet
11 - Valve spring retainer
12 - Valve stem seal
❑ replace
13 - Valve spring
❑ with the cylinder head removed, remove and install with blank holder -3362-
❑ with cylinder head installed ⇒ page 105
14 - Valve guide
❑ check ⇒ page 104
15 - Cylinder head
❑ removing and installing ⇒ page 94
16 - Valves
❑ do not rework, only grinding in is permissible
❑ Valve dimensions ⇒ page 104

3. Valve gear 103

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17 - 15 Nm
18 - Gasket
❑ replace
19 - Dowel pins
20 - 8 Nm
❑ observe the order of tightening up
❑ removing and installing ⇒ page 84
21 - Bearing frame
❑ for camshaft
❑ removing and installing ⇒ page 84

3.2 inspect camshaft, axial play

Special tools and workshop equipment required
♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge
Perform measurement with the cylinder head cover installed.
Checking the axial play of the camshaft
• Wear limit: 0,4 mm

Valve dimensions

Note

Valves must not be reworked. Only grinding in is permissible.

Dimension Inlet valve Exhaust valve

∅a mm 35,5 30,0
∅b mm 5,98 5,96
c mm 98,67 98,36
α ∠° 44° 50' 44° 50'

3.3 Inspect valve guides

Special tools and workshop equipment required
♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge

104 Rep. gr.15 - Cylinder head, valve gear

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Work procedure

Note

If the valve is replaced when carrying out repair work, use a new
valve for the measurement.

– Insert valve into guide. The end of valve stem must be flush
with guide. Because of the different stem diameters only use
inlet valve in inlet guide or outlet valve in outlet guide.
– Determine valve rock.
• Wear limit: 0,8 mm

Note

If the wear limit is exceeded, repeat measurement with new

valves.

If the valve rock is exceeded:

– Replace the cylinder head.

3.4 Replacing valve stem seals

Special tools and workshop equipment required
♦ Spark plug wrench -3122 B-
♦ Valve lever -MP 1-211 (VW 541/1A/5) -
♦ Pressure hose -MP 1-210 (VW 653/3)-
♦ Assembly device for valves -MP 1-213 (2036)-
♦ Valve supporting plate -MP 1-218-
♦ Valve stem seal insertion tool - MP 1-233 (3365)-
♦ Valve stem seal extractor -MP 1-230 (3364)-
Removing

Note

With cylinder head removed, use valve lever -MP 1-211- , as‐
sembly device for valves -MP 1-213- and valve supporting plate
-MP 1-218- .

With cylinder head installed:

– Remove cylinder head cover ⇒ page 84 .
– Remove roller rocker arm and place on a clean surface. Make
sure that you do not mix up the roller rocker arms.
– Unscrew the spark plugs with spark plug wrench -3122 B- .
– Put the piston of the relevant cylinder at “bottom dead centre”.

3. Valve gear 105

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– Screw the assembly device -MP 1-213 (2036)- onto the cylin‐
der head.
– Screw the pressure hose -MP 1-210 (VW 653/3)- in the spark
plug thread.
– Connect pressure hose to compressed air [min. 0.6 MPa (6
bar) overpressure] and remove the valve spring with valve
lever -MP 1-211 (VW 541/1A/5) - and pressure plate -VW
541/7- .
– Pull off valve stem seal with extractor for valve stem seal -MP
1-230 (3364)- .
Install
– Insert the supplied plastic bushings on the relevant valve stem.
This will prevent any damage to the new valve stem seals.

– Insert the new valve stem seal -1- into the insertion tool for
valve stem seal -MP 1-233 (3365)- .
– Oil the sealing lip of the valve stem seal and carefully slide
over the valve -2- onto the valve guide.
– Install camshaft housing ⇒ page 84 .
Further installation occurs in a similar way in reverse order to re‐
moval.

106 Rep. gr.15 - Cylinder head, valve gear

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17 – Lubrication
1 Lubrication system

Note

♦ The oil level must not be above the max. marking - risk of
damage to catalytic converter!
♦ If considerable quantities of metal swarf or abrasion is found
when carrying out engine repairs, this can be subject to dam‐
age to the crankshaft and conrod bearings. In order to avoid
consequential damage, after the repair perform the following
tasks:

– Carefully clean the oil galleries.

– Replace oil spray jets.
– Replace engine oil cooler.
– Replace oil filter.
Inspecting oil pressure ⇒ page 114 .
Check the engine oil, amount of oil and oil specification:
♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Octavia II .
♦ ⇒ Maintenance ; Booklet Yeti .
♦ ⇒ Maintenance ; Booklet Rapid NH .

1. Lubrication system 107

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1.1 Summary of components

1 - Screw cap
❑ Replace seal if dam‐
aged
2 - Oil feed line
❑ to exhaust gas turbo‐
charger
3 - Dipstick
❑ Oil level must not ex‐
ceed the max. marking!
4 - Bracket for top auxiliary
units
❑ with oil filter and engine
oil cooler
❑ removing and installing
⇒ page 36
5 - Gasket
❑ replace if damaged
6 - Guide bushing
7 - Oil filter, 20 Nm

Note

❑ with gasket rings

❑ with non-return valve
❑ slacken and tighten with
oil filter wrench -3417-
❑ Pay attention to change
intervals:
♦ ⇒ Maintenance ; Booklet
Fabia II
♦ ⇒ Maintenance ; Booklet
Roomster
♦ ⇒ Maintenance ; Booklet Octavia II
♦ ⇒ Maintenance ; Booklet Yeti
♦ ⇒ Maintenance ; Booklet Rapid NH .
8 - 25 Nm
9 - Gasket
❑ replace if damaged
10 - 8 Nm + torque a further 90° (1/4 turn)
❑ replace
11 - Engine oil cooler
❑ removing and installing ⇒ page 113
12 - 8 Nm
13 - Top timing case
❑ removing and installing ⇒ page 43

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Caution
Pay attention to tighten‐
ing process!

14 - 25 Nm
15 - Bottom timing case
❑ removing and installing ⇒ page 45
16 - 5 Nm + 30° further
❑ Screw: M6x20
17 - 5 Nm + 30° further
❑ Screw: M6x40
18 - Chain
❑ removing and installing ⇒ page 77
❑ for oil pump
❑ mark running direction (installed position) before removing
19 - Fixing screw
❑ for crankshaft - belt pulley
❑ replace
❑ The clamping surface of the fixing screw must be free of grease and oil.
❑ insert oiled (thread)
❑ Tightening torque; slacken and tighten ⇒ page 51
20 - Crankshaft-belt pulley
❑ removing and installing ⇒ page 51
❑ Clamping surfaces must be free of oil and grease.
21 - Diamond coated washer
❑ diamond coated washer pressed onto the belt pulley
❑ replace if damaged
22 - Sealing ring
❑ replace
❑ removing and installing ⇒ page 50
23 - Bottom cover
24 - 20 Nm + torque a further 90° (1/4 turn)
25 - Sprocket
❑ for oil pump drive
❑ Clamping surfaces must be free of oil and grease.
❑ Lock chain sprocket with counterholder -T10172-
26 - Oil pump
❑ removing and installing ⇒ page 112
❑ must be replaced completely
27 - 13 Nm
❑ Slacken and tighten the bolts at the gearbox side with socket insert -T10058-
28 - 10 Nm
29 - Oil level and oil temperature sender -G266 -
❑ replace if damaged
❑ check ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

1. Lubrication system 109

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30 - Sealing ring
❑ replace if damaged
31 - Oil drain plug, 30 Nm
❑ with captive seal
❑ replace
32 - Oil pan
❑ removing and installing ⇒ page 110
33 - 14 Nm + torque a further 90° (1/4 turn)
34 - Sealing ring
❑ replace
35 - Suction line
36 - 8 Nm
37 - 8 Nm
38 - Oil separator
❑ install with sealant ⇒ Electronic Catalogue of Original Parts (ETKA)
39 - Non-return valve

Note

1.2 Removing and installing oil pan

Special tools and workshop equipment required
♦ Socket insert -T10058-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
♦ Silicone sealant ⇒ Electronic catalogue of original parts (ET‐
KA)
♦ Catch pan , e.g. -VAS 6208-
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Drain engine oil:
♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Octavia II .
♦ ⇒ Maintenance ; Booklet Yeti .
♦ ⇒ Maintenance ; Booklet Rapid NH .
For vehicles Fabia II, Roomster, Rapid NH
– Remove catalytic converter with pre-exhaust pipe
⇒ page 253 .
For the vehicles Octavia II, Yeti
– Remove exhaust pipe Pos. 9 ⇒ page 246 .

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Continued for all vehicles

– Disconnect plug at oil level and oil temperature sender -
G266- .
– Release screw -1- from bracket for coolant pipe.
– Unscrew both fixing screws -3- and remove the bottom cover
plate.
– Loosen bolts for oil pan crosswise and release.
– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove the remaining sealant on the cylinder block and on

the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
Install

Note

♦ Replace M6 oil pan bolts.

♦ Pay attention to the use by date on sealant.
♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant.

1. Lubrication system 111

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

3 mm).
– Apply silicone sealant to the clean sealing surface of the oil
pan, as shown in the illustration. The sealant bead must be:
♦ be 2...3 mm thick
♦ run past the area around the bolt holes on the inside
-arrows-

Note

The sealant bead must not be thicker otherwise excess sealant

may get into the oil pan and block the strainer in the oil suction
pipe.

– Fit oil pan immediately and lightly tighten all oil pan screws.
– Tighten the screws of the oil pan to 13 Nm.
– Tighten the fixing screws of the cover plate at the gearbox to
40 Nm.
Further installation occurs in a similar way in reverse order to re‐
moval.

Note

After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.

1.3 Removing and installing oil pump

Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
– Removing the oil pan ⇒ page 110 .
– Pull off the cover -1- from the oil pump.

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– Unscrew the fixing screws -arrows- of the oil pump.

– Remove the complete oil pump from the drive chain.
Install

– Hook the oil pump with the chain sprocket into the drive chain
and tighten the new screws -arrows- to 14 Nm + torque a fur‐
ther 90° (1/4 turn.).
Tightening torque of the suction line: 8 Nm.
– Installing the oil pan ⇒ page 110 .

1.4 Removing and installing engine oil cool‐

er
Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Hose binding claw
Removing
– Drain the coolant from the cooling system ⇒ page 118 .
For vehicles Fabia II, Roomster, Rapid NH
– Open the spring strap clamp with the hose binding claw and
detach the coolant hose -1-.
For the vehicles Octavia II, Yeti

1. Lubrication system 113

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– Open the spring strap clamp with the hose binding claw and
detach the coolant hose -1-.
Continued for all vehicles
– Release the four fixing screws from the engine oil cooler and
remove the engine oil cooler.
Install

Note

Replace gasket if damaged.

For vehicles Fabia II, Roomster, Rapid NH

– Position the engine oil cooler -2- at the bracket and tighten the
fixing screws crosswise to 8 Nm + torque a further 90° (1/4
turn).
– Place the coolant hose -1- onto the oil cooler fitting and attach
it with the spring strap clip.
For the vehicles Octavia II, Yeti

– Position the engine oil cooler -2- at the bracket and tighten the
fixing screws crosswise to 8 Nm + torque a further 90° (1/4
turn).
– Place the coolant hose -1- onto the oil cooler fitting and attach
it with the spring strap clip.
Continued for all vehicles
– Top up and bleed cooling system ⇒ page 118 .
– Inspect coolant level in the expansion reservoir, top up with
coolant if necessary.

Note

If the engine oil cooler was replaced, the coolant must be

changed.

1.5 Testing oil pressure and oil pressure

switch -F1-
Special tools and workshop equipment required
♦ Oil pressure tester , e.g. -V.A.G 1342 -
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Vehicle Diagnosis, Measurement and Information System -
VAS 505X-
Conditions
• Coolant temperature at least 80°C (radiator fan must have run
at least once).

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• Engine oil level o.k., test:

♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Octavia II .
♦ ⇒ Maintenance ; Booklet Yeti .
♦ ⇒ Maintenance ; Booklet Rapid NH .

Note

Functional test and repair of the visual and acoustic oil pressure
display ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations, ⇒ Vehicle diagnostic tester.

Test sequence
– Disconnect plug -1- and remove the oil pressure switch -2-.

– Screw oil pressure switch into the test equipment.

– Screw tester in the cylinder head instead of the oil pressure
switch.
– Connect brown cable of tester to earth (-).
– Connect voltage tester to battery positive terminal and to oil
pressure switch.
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch -F1- .
If the LED does not light up:
– Start engine and increase engine speed.
• The LED must light up at an oil overpressure of 0.03…0.07
MPa (0.3...0.7 bar), if not replace oil pressure switch.
– Increase engine speed further.
• At 2000 rpm and an oil temperature of 80°C the oil overpres‐
sure should be at least 0.2 MPa (2.0 bar).
At a higher engine speed the oil overpressure must not be greater
than 0.7 MPa (7 bar).
Tightening torque of the oil pressure switch: 20 Nm

1. Lubrication system 115

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19 – Cooling
1 Cooling system

WARNING

Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.

Note

♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ The hose connections are secured with spring-type clips. In
case of repair only assign the spring strap clamps via the ⇒
Electronic catalogue of original parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ 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).
♦ The arrows which are on the coolant pipes and the coolant
hose ends must stand opposite to each other.

1.1 Connection diagram for coolant hoses

(Fabia II, Roomster, Rapid NH)

Note

♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
♦ The radiator and the charge air cooler are removed and in‐
stalled together ⇒ page 133 .

116 Rep. gr.19 - Cooling

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1 - Expansion reservoir
2 - Coolant recirculation pump
-V50-
❑ removing and installing
⇒ page 125
3 - Charge air cooler
❑ in the intake manifold
⇒ page 208
4 - Coolant regulator housing
5 - Heat exchanger of heating
system
6 - Throttle valve
❑ in the coolant hose, not
visible from the outside
7 - Radiator
❑ removing and installing
⇒ page 133
8 - Charge air cooler
9 - Cylinder head/cylinder
block
❑ fill with fresh coolant af‐
ter replacing
10 - Non-return valve
❑ in the coolant hose, not
visible from the outside
11 - Engine oil cooler
12 - Coolant pump
❑ removing and installing
⇒ page 124

1.2 Connection diagram for coolant hoses

(Octavia II, Yeti)

Note

♦ This engine is fitted with a radiator combination of engine and

low temperature radiators for charge air system.
♦ Engine and low temperature radiators are arranged as one
component part.

1. Cooling system 117

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1 - Expansion reservoir
2 - Coolant recirculation pump
-V50-
❑ removing and installing
⇒ page 125
3 - Coolant pump
❑ removing and installing
⇒ page 124
4 - Charge air cooler
❑ in the intake manifold
⇒ page 209
5 - Heat exchanger of heating
system
6 - Coolant regulator housing
7 - Non-return valve
❑ in the coolant hose, not
visible from the outside
8 - Throttle valve
❑ in the coolant hose, not
visible from the outside
9 - Radiator
❑ removing and installing
⇒ page 133
10 - Exhaust gas turbocharger
❑ removing and installing
⇒ page 203
11 - Low temperature radiator
for charge air system
❑ Engine and low temper‐
ature radiators are ar‐
ranged as one compo‐
nent part
12 - Cylinder head and cylinder block
❑ fill with fresh coolant after replacing
13 - Engine oil cooler
14 - Non-return valve
❑ in the coolant hose, not visible from the outside
15 - Auxiliary heating
❑ only for vehicles with special equipment

1.3 Draining and filling up coolant

Special tools and workshop equipment required
♦ Catch pan , e.g. - VAS 6208-
♦ Pliers for spring strap clamps
♦ Refractometer
♦ Cooling system charge unit -VAS 6096-

118 Rep. gr.19 - Cooling

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Draining

Note

♦ Collect drained coolant in a clean container for reuse or proper

disposal.
♦ Observe the disposal instructions.

WARNING

Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.

– Open compensation bottle.

– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Place a catch pan - VAS 6208- under the radiator.

Note

♦ Depending on the components which must be removed

⇒ page 116 , the coolant from the cooling system, from the
charge air cooling system or from both cooling systems must
be drained.
♦ If the coolant must be replaced, it should be drained from both
cooling systems.

Drain the coolant from the cooling system

For vehicles Fabia II, Roomster, Rapid NH
– Open spring strap clamp -arrow- and pull off the bottom cool‐
ant hose at the engine radiator connection.
For the vehicles Octavia II, Yeti

1. Cooling system 119

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– Disconnect plug -1- from coolant temperature sender at radi‐

ator outlet -G83- .
– Open spring strap clamp -arrow- and pull off the coolant hose
from the bottom radiator connection.
Drain the coolant from the charge air cooling system
For vehicles Fabia II, Roomster, Rapid NH

– Open spring strap clamp -arrow- and pull off the bottom cool‐
ant hose at the connection of the additional radiator for the
charge air system.
For the vehicles Octavia II, Yeti

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– Separate the coolant hose (quick coupling) -arrow- on the bot‐

tom connection fitting of the additional radiator for coolant of
charge air system.
Continued for all vehicles

Note

Observe all the disposal instructions!

Top up and bleed cooling system.

Select the appropriate coolant additive from the ⇒ ETKA - Elec‐
tronic catalogue of original parts .
– In a clean reservoir mix water and coolant additive in the
specified mixing ratio:
♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Octavia II .
♦ ⇒ Maintenance ; Booklet Yeti .
♦ ⇒ Maintenance ; Booklet Rapid NH
– Reposition the removed coolant hose onto the relevant sup‐
port.
For the vehicles Octavia II, Yeti
– Connect coolant temperature sender -G83 - .
Continued for all vehicles
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
With cooling system charge unit -VAS 6096-
– Screw adapter for cooling system tester -V.A.G 1274/8- onto
expansion tank.
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
– Fill up coolant up to Max. marking on the expansion reservoir.
Without cooling system charge unit -VAS 6096-

Caution

In order to secure the refrigerating capacity of the charge air

cooling system, the following work steps must absolutely be
observed.

– Fill up the coolant slowly up to the top marking of the criss-

crossed field (max.) on the expansion reservoir.
Continued for all vehicles
– Fit cooling system tester -V.A.G 1274 B- onto expansion tank
and apply pressure of 0.15 MPa (1.5 bar) to cooling system
⇒ page 137 .

1. Cooling system 121

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Note

Applying pressure to the cooling system will eliminate any air

bubbles.

– Fill with coolant up to “MAX." marking on expansion tank if

necessary.
– Seal expansion reservoir.
– Switch off the air-conditioning system and the heating.
Vehicles without auxiliary heating.
– Start the engine and maintain the engine speed for about 3
minutes at approx. 2000 r.p.m.
– Run engine until radiator fan -V7- starts.
Vehicles with auxiliary heating.

Caution

The auxiliary heating must only be switched on, if the refriger‐

ant circuit is filled up -as described below-.

– Connect vehicle diagnosis, measurement and information

system -VAS 5051- .
– Start the engine and maintain the engine revolutions for about
3 minutes at about 2000 r.p.m.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”, “18 - Auxiliary heating system” and “03 - Ac‐
tuator diagnosis”.
– Press the right arrow on the display so often until the coolant
shut-off valve of heating system - N279- is shown.
– Perform self-diagnosis of the coolant shut-off valve of heating
system -N279- and maintain the engine speed at approx. 2000
rpm for about 1 minute.
Continued for all vehicles

WARNING

Hot steam may escape when the compensation bottle is

opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.

– Inspect coolant level, top up with coolant if necessary. When

engine is at operating temperature the coolant level must be
at the “MAX" marking, when engine is cold between the “MIN"
and the “MAX" markings.

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2 Parts of cooling system engine side

2.1 Coolant regulator - Summary of components

1 - Cylinder head
2 - O-ring
❑ replace
3 - Coolant pipe
4 - O-ring
❑ replace
5 - Retaining clip for coolant
pipe
6 - 11 Nm
7 - Coolant regulator housing
8 - Gasket
❑ replace
9 - Coolant temperature send‐
er -G62-
❑ before removing, re‐
duce pressure in cooling
system if necessary
10 - 10 Nm
11 - O-ring
❑ replace

2.2 Removing and installing belt pulley for

coolant pump
Special tools and workshop equipment required
♦ Wrench for the water pump and power-assisted steering -MP
1-308 (V.A.G 1590) -

2. Parts of cooling system engine side 123

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Change wrench for the water pump and power-assisted steering

-MP 1-308-
– Because of modified fixing screws for the belt pulley of the
coolant pump, these three curvatures must be filed open.
-a- at least 1 mm
Removing
– Remove V-ribbed belt ⇒ page 35 .

– Release screws -arrows- and remove holder from timing case.

Note

The bracket at the timing case only serves as transport security

of the engine before the first installation and must not be refitted.

– Release the screws for the belt pulley for coolant pump, to do
so counterhold with wrench for the water pump and power-
assisted steering -V.A.G 1590 - .
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ Tightening torque: 20 Nm

2.3 Removing and installing coolant pump

Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
Removing

Note

♦ The integrated gasket of the coolant pump must not be sepa‐

rated from the coolant pump.
♦ If damage and leak present, replace coolant pump with gasket
completely.

– Drain the coolant from the cooling system ⇒ page 118 .

– Remove belt pulley for control pump ⇒ page 123 .

124 Rep. gr.19 - Cooling

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– Disconnect the vacuum line -1- of the solenoid valve for cool‐
ant circuit -N492- from the coolant pump.
– Release screws -arrows- and remove coolant pump.
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ Tightening torque: 9 Nm
– Install belt pulley for coolant pump ⇒ page 123 .
– Top up and bleed cooling system ⇒ page 118 .

2.4 Removing and installing coolant recircu‐

lation pump -V50-
Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094) -
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Unplug connector -1-.
– Release screw -3- and remove coolant recirculation pump -
V50- from bracket.
– Place a catch pan -VAS 6208- under the engine.
– Pinch off coolant hoses -2- with hose clamps -MP7-601- and
detach the hoses from the coolant recirculation pump -V50- .
Install
♦ Tightening torque: 8 Nm.
Installation is performed in the reverse order, pay attention to the
following points:
– Inspect coolant level, if necessary top up cooling system and
bleed ⇒ page 118 .

2. Parts of cooling system engine side 125

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3 Radiator and radiator fan

3.1 Parts of cooling system on the side next

to the body - Summary of components
(Fabia II, Roomster, Rapid NH)

Note

♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
♦ The radiator and the charge air cooler are removed and in‐
stalled together ⇒ page 133 .

1 - Radiator
❑ removing and installing
⇒ page 133
❑ after replacing fill entire
system with fresh cool‐
ant
2 - Coolant hose
❑ to exhaust gas turbo‐
charger
3 - Coolant hose
❑ to radiator for charge-air
system
4 - Coolant hose
❑ to exhaust gas turbo‐
charger
5 - Coolant hose
❑ to charge-air cooler in
the intake manifold
6 - The fan ring
7 - Coolant hose
❑ to coolant pipe below
the intake manifold
8 - Coolant hose
❑ to engine oil cooler
9 - Expansion reservoir
❑ with coolant shortage
warning light sender -
G32-
❑ Check the cooling sys‐
tem for tightness
⇒ page 136
10 - Connector
11 - Screw cap
❑ Testing the pressure relief valve in the cap ⇒ page 136

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12 - 5 Nm
13 - Plastic inserts
❑ for fixing screws
14 - Support
15 - Coolant hose
❑ at coolant recirculation pump -V50-
16 - Radiator fan -V7-
17 - Fan shroud
❑ removing and installing ⇒ page 131
18 - 2 Nm
❑ mounted up to 05.10
19 - Heat shield
❑ mounted up to 05.10
20 - 8 Nm
21 - Bottom radiator bearing
22 - Charge air cooler
23 - Coolant hose
❑ at coolant regulator housing
24 - Thermo-switch for radiator fan -F18- , 35 Nm
❑ for fan
25 - O-ring
❑ replace if damaged
26 - Top radiator bearing
27 - 5 Nm
28 - Coolant hose
❑ to the expansion reservoir

3. Radiator and radiator fan 127

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3.2 Parts of cooling system on the side next

to the body - Summary of components

3.2.1 Radiator with a radiator fan - Summary of components

(Octavia II, Yeti)

Note

♦ This engine is fitted with a radiator combination of engine and low temperature radiators for charge air
system.
♦ Engine and low temperature radiators are arranged as one component part.

1 - Radiator with low tempera‐

ture radiator for charge air sys‐
tem
❑ removing and installing
⇒ page 135
❑ after replacing fill entire
system with fresh cool‐
ant
2 - Coolant hose
❑ to exhaust gas turbo‐
charger
3 - Coolant hose
❑ to low temperature radi‐
ator for charge air sys‐
tem
4 - Coolant hose
❑ to exhaust gas turbo‐
charger
5 - Coolant hose
❑ to charge-air cooler in
the intake manifold
6 - Radiator fan -V7-
7 - Coolant hose
❑ to coolant pipe below
the intake manifold
8 - Coolant hose
❑ to engine oil cooler
9 - Expansion reservoir
❑ with coolant shortage
warning light sender -
G32-
❑ Check the cooling sys‐
tem for tightness ⇒ page 136
10 - Connector
11 - Screw cap
❑ Testing the pressure relief valve in the cap ⇒ page 136

128 Rep. gr.19 - Cooling

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12 - 5 Nm
13 - Plastic inserts
❑ for fixing screws
14 - Support
15 - Coolant hose
❑ at coolant recirculation pump -V50-
16 - Fan shroud
❑ removing and installing ⇒ page 132
❑ different versions of the fan shrouds are mounted ⇒ Electronic Catalogue of Original Parts
17 - 5 Nm
18 - 5 Nm
19 - Coolant hose
❑ at coolant regulator housing
20 - Coolant hose
❑ to heat exchanger of heating system
21 - Inlet connections
❑ for top coolant hose
22 - Inlet connections
❑ for bottom coolant hose
23 - Retaining clip
❑ check tightness
24 - Coolant temperature sender at radiator outlet -G83-
25 - O-ring
❑ replace if damaged
26 - Bottom radiator bearing
27 - Top radiator bearing
28 - 5 Nm

3. Radiator and radiator fan 129

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3.2.2 Radiator with two radiator fans - Summary of components

(Octavia II, Yeti)

Note

♦ This engine is fitted with a radiator combination of engine and low temperature radiators for charge air
system.
♦ Engine and low temperature radiators are arranged as one component part.

1 - Radiator with low tempera‐

ture radiator for charge air sys‐
tem
❑ removing and installing
⇒ page 135
❑ after replacing fill entire
system with fresh cool‐
ant
2 - Coolant hose
❑ to charge-air cooler in
the intake manifold
3 - Coolant hose
❑ to exhaust gas turbo‐
charger
4 - Coolant hose
❑ to low temperature radi‐
ator for charge air sys‐
tem
5 - Coolant hose
❑ to exhaust gas turbo‐
charger
6 - Expansion reservoir
❑ with coolant shortage
warning light sender -
G32-
❑ Check the cooling sys‐
tem for tightness
⇒ page 136
7 - Connector
8 - Screw cap
❑ Testing the pressure re‐
lief valve in the cap
⇒ page 136
9 - 5 Nm
10 - Plastic inserts
❑ for fixing screws
11 - Support
12 - Coolant hose
❑ to engine oil cooler
13 - Coolant hose
❑ to coolant pipe below the intake manifold

130 Rep. gr.19 - Cooling

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14 - Coolant hose
❑ at coolant recirculation pump -V50-
15 - Fan shroud
❑ removing and installing ⇒ page 132
16 - Right radiator fan -V177-
17 - Connector
18 - Radiator fan -V7-
19 - 5 Nm
20 - Coolant hose
❑ at coolant regulator housing
21 - Retaining clip
❑ check tightness
22 - Coolant temperature sender at radiator outlet -G83-
23 - O-ring
❑ replace if damaged
24 - Inlet connections
❑ for bottom coolant hose
25 - O-ring
❑ replace if damaged
26 - Bottom radiator bearing
27 - Top radiator bearing
28 - 5 Nm
29 - 5 Nm
30 - Coolant hose
❑ to heat exchanger of heating system
31 - Inlet connections
❑ for top coolant hose

3.3 Removing and installing fan shroud for

radiator fan -V7-
(Fabia II, Roomster, Rapid NH)

Note

Different versions of the fan shrouds are mounted ⇒ Electronic

Catalogue of Original Parts .

Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .

3. Radiator and radiator fan 131

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– Disconnect plug connection -arrow-.

– Open the retaining clamps of the coolant hose -1- at the fan
shroud -2-.

– Release the support for the top right as well as left fan shroud
and lift the fan shroud out of the supports.
– Remove fan shroud downwards.
Install
Installation is carried out in the reverse order.

3.4 Removing and installing fan shroud for

radiator fan
(Octavia II, Yeti)

Note

The removal and installation of the fan shroud with two radiator
fans is similar to the removal and installation with one radiator fan.

Removing
– Remove air filter ⇒ page 227 .

132 Rep. gr.19 - Cooling

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– Unscrew the top fixing screws of the fan shroud -arrows-.

– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Disconnect the plug connection -1- and unscrew the bottom
fixing screws of the fan shroud -arrows-.
– Remove fan shroud downwards.
Install
Installation is performed in the reverse order, pay attention to the
following points:
Tightening torques:
Component Nm
Fan shroud at radiator 5

3.5 Removing and installing radiator

(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Pliers for spring strap clamps
Removing
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .
– Drain coolant ⇒ page 118 .
– Remove fan shroud with radiator fan -V7- ⇒ page 131 .
– Disconnect plug from thermo-switch for radiator fan -F18- .
– Detach top coolant hose from radiator connection fitting.
– Detach top coolant hose from connection fitting of charge air
cooler.
– Unscrew fixing screws for radiator bearing on right and left,
position 27 ⇒ page 126 .
– Push the radiator to the rear and remove the right and left ra‐
diator bearing position 26 ⇒ page 126 .
Vehicles without air conditioning system
– Push the radiator together with the charge air cooler upwards
out of the bottom rubber bearings and remove it laterally down.
Vehicles with air conditioning
– Remove V-ribbed belt ⇒ page 35 .

WARNING

Risk of injury through refrigerant.

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

3. Radiator and radiator fan 133

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Caution

Risk of damaging the condenser as well as the refrigerant lines

and hoses.
♦ Do not over-tension or buckle refrigerant lines and hoses.

– Remove the AC compressor from the bracket for auxiliary

units and secure it with connected refrigerant hoses to the
body.
– Mark the installation position of the screws -1- on the right and
left and only slacken them.
– Push the radiator together with the charge air cooler and the
condensor upwards out of the lower rubber bearings.
To do so, pull the plastic housing of the lock carrier down‐
wards. There is very little space on the right between the
refrigerant line and the body.
– Lay the radiator with the condensor to the rear.

– Release the screws -arrows- of the condensor -2- from the

radiator -1-.
– Draw the condensor forwards and attach to the lock carrier.
– Remove the radiator together with the charge air cooler later‐
ally down.
Continued for all vehicles

– Push the radiator -1- in -direction of arrow- out of the lateral

brackets on the charge-air cooler -2-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

134 Rep. gr.19 - Cooling

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– On vehicles with air conditioning system, push the plastic

housing of the lock carrier upwards into the initial position and
tighten the screws -1- on the right and left.
Tightening torque: 8 Nm
– Top up coolant ⇒ page 118 .

3.6 Removing and installing radiator

(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Catch pan , e.g. - VAS 6208-
♦ Pliers for spring strap clamps
Removing
– Drain coolant ⇒ page 118 .
– Removing fan shroud ⇒ page 132 .
– Remove top left coolant fitting fom radiator, to do so raise the
retaining clip -arrow-.
– Detach the connection fitting of the top right coolant hose for
the low temperature radiator.
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .
– Remove headlights ⇒ Electrical System; Rep. gr. 94 .
Vehicles with air conditioning

WARNING

Do not open the refrigerant circuit of the air conditioning sys‐

tem.
In order to avoid damage to the condenser as well as to the
refrigerant lines and hoses, ensure that the lines and hoses are
not over-tensioned, kinked or bent.

3. Radiator and radiator fan 135

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– Unscrew fixing screws at condenser -arrows-.

Continued for all vehicles

– Release screws for radiator bearing -1-.
– Swivel the radiator slightly backwards.
– Unhook radiator upwards and remove downwards.
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Top up and bleed cooling system ⇒ page 118 .
Tightening torques: ⇒ page 128

3.7 Checking the coolant system for leak‐

tightness

3.7.1 Checking with the cooling system test‐

ing device -V.A.G 1274-
Special tools and workshop equipment required
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/9-
Test condition
• Engine is at operating temperature.
Test sequence

WARNING

Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.

– Open compensation bottle.

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– 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. 0,1 MPa (1,0 bar).
If the pressure drops:
– Search position of the leak and repair fault.
Testing the pressure relief valve in the cap

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

adapter -V.A.G 1274/9 - on the cap.
– Operate the handpump.
• The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).
If the pressure relief valve does not open:
– Replace cap.

3.7.2 Checking with the cooling system test‐

ing device -V.A.G 1274 B-
Special tools and workshop equipment required
♦ Cooling system testing device , e.g. -V.A.G 1274 B-
♦ Adapter , e.g. -V.A.G 1274/8-
♦ Adapter , e.g. -V.A.G 1274/9-
Test condition
• Engine is at operating temperature.
Test sequence

WARNING

Hot steam or hot coolant may escape when the compensation

bottle is opened.
♦ Wear safety goggles and safety clothing, in order to avoid
eye injuries and scalding.
♦ Cover the cap with a cloth and open carefully.

– Open the cap of the coolant expansion reservoir.

– Screw adapter -V.A.G 1274/8- into the coolant expansion bot‐
tle.
– Connect the connecting piece -V.A.G 1274 B/1- to the adapter
-V.A.G 1274/8- .

3. Radiator and radiator fan 137

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– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Using the hand pump of the testing device generate a pressure
of approx. 0.1 MPa (1.0 bar).

WARNING

Risk of scalding!
♦ 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 ab‐
solutely 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«.

If the pressure drops:

– Search position of the leak and repair fault.
Test the pressure valve in the cap
– Screw the screw cap into the adapter -V.A.G 1274/9- .
– Connect the connecting piece -V.A.G 1274 B/1- to the adapter
-V.A.G 1274/9- .

– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Generate a pressure for testing the pressure valve in the screw
cap.
• The pressure valve should open at a pressure of 0.14...0.16
MPa (1.4...1.6 bar).
If the valve does not open in the prescribed pressure range:
– Replace cap.

138 Rep. gr.19 - Cooling

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20 – Fuel supply system

1 Fuel tank and fuel delivery unit

Note

♦ Fuel hoses at the engine must only be secured with spring-

type clips ⇒ electronic catalogue of original parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Separate push-fit couplings for fuel lines ⇒ page 187 .

1.1 Fuel tank - Summary of components

(Fabia II)

1 - Fuel tank
❑ support with engine/
gearbox jack -
V.A.G 1383 A- when re‐
moving
❑ removing and installing
⇒ page 150
2 - 25 Nm
3 - Tensioning strap
4 - Vent line
❑ to solenoid valve 1 for
activated charcoal filter -
N80- in engine compart‐
ment
5 - Fuel feed line
❑ black
❑ to fuel rail at intake
manifold
6 - Fuel filter
❑ with integrated fuel
pressure regulator 0.4
MPa (4 bar)
❑ blue return-flow line in
the middle and black
feed line on the edge
❑ Fitting location: Pin at fil‐
ter housing must en‐
gage in the recess of the
guide for the fixing
clamp
❑ the direction of flow is
marked by arrow
7 - 5 Nm
❑ for collar clamp for fuel filter
8 - Sealing ring
❑ moisten with fuel before installing

1. Fuel tank and fuel delivery unit 139

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9 - Fuel gauge sender -G-

❑ removing and installing ⇒ page 165
10 - Fuel delivery unit
❑ removing and installing ⇒ page 158
❑ inspecting fuel pump ⇒ page 166
❑ Clean strainer if dirty
❑ Fitting position of flange of fuel delivery unit ⇒ page 141
11 - Return-flow line
❑ from the fuel filter into the fuel delivery unit
❑ blue
12 - Feed line
❑ from the fuel delivery unit into the fuel filter
❑ black
13 - Union nut
❑ use wrench for union nut -MP1-227 (3217)- for removing and installing
14 - 10 Nm
15 - Vent valve
❑ to remove, unclip valve at side and take out of filler neck.
❑ before installing, unscrew cap -16-
❑ check ⇒ page 141
16 - Screw cap
17 - Sealing ring
❑ replace if damaged
18 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing ⇒ Body Work; Rep. gr. 55
19 - Gravity valve
❑ to remove, unclip valve at top and lift out of filler neck
❑ inspect valve for blockage:
♦ Valve in a vertical position: open
♦ Valve tilted 45°: closed
20 - Vent line
❑ between activated charcoal filter -21- and vent line -4-
21 - Activated charcoal filter
❑ Summary of components of activated charcoal container system ⇒ page 195
❑ Checking the fuel tank venting ⇒ page 197
22 - 10 Nm
23 - Vent line
❑ clipped in place on fuel tank

140 Rep. gr.20 - Fuel supply system

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Fitting location of the fuel delivery unit

Note

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

The marking on the flange must be aligned with the marking on

the fuel tank.
The -arrow- shows the direction of travel.
Connect blue or blue marked return-flow line -1- to the connection
with the marking -R-.
Connect black feed line -2- to connection with marking -V-.

Inspect vent valve

Lever in off position: valve closed.
Lever pushed in direction of arrow: valve open.

Note

Before installing the vent valve, unscrew the cap from the filler
neck.

1.2 Fuel tank - Summary of components

(Roomster, Rapid NH)

1. Fuel tank and fuel delivery unit 141

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1 - Fuel tank
❑ support with engine/
gearbox jack -
V.A.G 1383 A- when re‐
moving
❑ removing and installing
⇒ page 150
2 - Sealing ring
❑ replace if damaged
3 - Fuel delivery unit
❑ Fitting position of flange
of fuel delivery unit
⇒ page 143
❑ removing and installing
⇒ page 158
❑ inspecting fuel pump
⇒ page 166
❑ Clean strainer if dirty
4 - Union nut
❑ slacken and tighten with
wrench for union nut -
MP1-227 (3217)-
5 - Return-flow line
❑ from the fuel delivery
unit to the fuel filter
❑ blue
6 - Feed line
❑ from fuel filter to fuel de‐
livery unit
❑ black
7 - Overflow hose
8 - Screw cap
9 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing ⇒ Body Work; Rep. gr. 55
10 - Earth connection
11 - O-ring
❑ replace
12 - Vent valve
❑ check ⇒ page 144
13 - Gravity valve
❑ to remove, unclip valve and lift up and out of the filler neck
❑ inspect valve for blockage:
❑ Valve open vertically
❑ Valve tilted 45°, closed
14 - Activated charcoal filter
❑ Summary of components of activated charcoal container system ⇒ page 195
❑ Checking the fuel tank venting ⇒ page 197

142 Rep. gr.20 - Fuel supply system

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15 - Vent line
16 - O-ring
❑ replace
17 - 10 Nm
18 - Circlip
19 - Heat shield
❑ for fuel tank
20 - 25 Nm
❑ replace
21 - Straps
❑ pay attention to different lengths
22 - Fuel feed line
❑ black
❑ from fuel filter to fuel distributor at intake manifold
23 - Fuel filter
❑ with integrated pressure limiting valve for fuel return-flow line
Opening pressure: 0,40 MPa (4,0 bar)
❑ do not interchange connections
❑ The direction of flow of fuel is marked by arrow
❑ Fitting position: Pin at filter housing must engage in the recess of the guide at the filter holder
24 - Screw clamp
❑ replaced with integrated bracket for fuel filter
25 - Vent line
❑ between activated charcoal filter Pos. 14 and vent line Pos. 25
26 - Vent line
❑ to solenoid valve 1 for activated charcoal filter in engine compartment

Fitting location of the fuel delivery unit

Note

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

The marking on the flange must be aligned with the marking on

the fuel tank.
The -arrow- shows the direction of travel.
Connect blue or blue marked return-flow line -1- to the connection
with the marking -R-.
Connect black feed line -2- to connection with marking -V-.

1. Fuel tank and fuel delivery unit 143

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Inspect vent valve

Lever in off position: valve closed.
Lever pushed in direction of arrow: valve open.

Note

Before installing the vent valve, unscrew the cap from the filler
neck.

1.3 Fuel tank version I. - Summary of com‐

ponents
(Octavia II, Yeti)

1 - Mounting part
2 - Screw cap
❑ replace if damaged
3 - Earth connection
❑ check for firm seating
4 - 11 Nm
5 - Guide
6 - 25 Nm
❑ replace
7 - Fuel tank
❑ removing and installing
⇒ page 153
8 - Circlip
9 - Bracket for the exhaust sys‐
tem
10 - Tensioning strap
❑ Check fitting position
11 - Heat shield
12 - Feed line
❑ to fuel rail
❑ check for firm seating
13 - Fuel filter
❑ removing and installing
⇒ page 148
14 - Vent line
❑ clipped in place on the
side of the fuel tank
❑ check for firm seating
15 - Sealing ring
❑ replace
❑ to be inserted dry into the opening of the fuel tank
❑ only moisten the inner seal of the flange with fuel for fitting purposes

144 Rep. gr.20 - Fuel supply system

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16 - Fuel delivery unit

❑ removing and installing ⇒ page 160
❑ inspecting fuel pump ⇒ page 166
❑ note the correct installed position of the fuel tank ⇒ page 145
❑ with sender for fuel gauge display -G-
❑ Removing and installing the sender for fuel gauge display -G- ⇒ page 165
❑ Clean strainer if dirty
17 - Lock ring, 110 Nm
❑ check for firm seating
❑ use wrench -T30101 (3087)- for removing and installing
18 - Feed line
❑ black
❑ clipped in place on the side of the fuel tank
❑ check for firm seating
19 - Return-flow line
❑ blue
❑ clipped in place on the side of the fuel tank
❑ check for firm seating
20 - Fuel pump control unit -J538 -
❑ after replacing, adapt the engine control unit -J623- to the fuel pump control unit -J538- ⇒ Vehicle diag‐
nostic tester
❑ check ⇒ Vehicle diagnostic tester
21 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing ⇒ Body Work; Rep. gr. 55

Fitting location of the fuel delivery unit

The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-.

Note

♦ The -arrow- shows the direction of travel.

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

1.4 Fuel tank version Il. - Summary of com‐

ponents
(Yeti)

1. Fuel tank and fuel delivery unit 145

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1 - Feed line
❑ black
❑ check for firm seating
2 - Return-flow line
❑ blue
❑ check for firm seating
3 - Sealing ring
❑ replace
❑ insert dry into the open‐
ing of the fuel tank
❑ only moisten the inner
seal of the flange with
fuel for fitting purposes
4 - Fuel delivery unit
❑ removing and installing
⇒ page 162
❑ inspecting fuel pump
⇒ page 166
❑ note the installed posi‐
tion of the fuel tank
⇒ page 147
❑ with sender for fuel
gauge display -G-
❑ Removing and installing
the sender for fuel
gauge display -G-
⇒ page 165
❑ Clean strainer if dirty
5 - Lock ring, 110 Nm
❑ check for firm seating
❑ use wrench -T30101
(3087)- for removing
and installing
6 - Fuel pump control unit -J538 -
❑ after replacing, adapt the engine control unit -J623- to the fuel pump control unit -J538- ⇒ Vehicle diag‐
nostic tester
7 - Screw cap
❑ replace if damaged
8 - Fixing screw
9 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing ⇒ Body Work; Rep. gr. 55
10 - Earth connection
❑ check for firm seating
11 - 11 Nm
12 - Tank ventilation
13 - Connector
❑ for fuel gauge sender -2- -G169-
14 - Fuel gauge sender 2 -G169-
❑ removing and installing ⇒ page 184

146 Rep. gr.20 - Fuel supply system

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15 - Suction spray pump

❑ clipped in place on fuel gauge sender 2 -G169-
❑ removing and installing ⇒ page 186
16 - Tank ventilation
17 - Vent line
18 - Fuel tank
❑ removing and installing ⇒ page 155
19 - Tensioning strap
❑ Check fitting position
20 - 25 Nm
❑ replace
21 - 23 Nm
22 - Heat shield
❑ riveted together with hanger of exhaust system
23 - 3 Nm
24 - Fuel filter
❑ Summary of components ⇒ page 148
25 - Vent line
❑ clipped in place on the side of the fuel tank
❑ check for firm seating

Fitting position of the flange of the fuel delivery unit and the fuel
gauge sender -2- -G169-
The marking on the flange must be aligned with marking on the
fuel tank -arrows-.

Note

The arrows on the fuel tank are hardly visible due to the floor
panel.

1. Fuel tank and fuel delivery unit 147

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1.5 Fuel filter - Summary of components

1 - Fuel filter
❑ with installed pressure
limiting valve for fuel re‐
turn-flow line
Opening pressure:
0.60…0.68 MPa (6.0…
6.8 bar)
❑ do not interchange con‐
nections
❑ Fitting position
⇒ page 148
2 - Fuel feed line
❑ black
❑ from fuel tank
❑ press in securing ring in
order to unlock
3 - Fuel return-flow line
❑ blue
❑ to fuel tank
❑ press in securing ring in
order to unlock
4 - Fuel feed line
❑ black
❑ to the engine
❑ press in securing ring in
order to unlock
5 - 3 Nm
6 - Support
❑ for fuel filter
❑ attached to the fuel tank

Fitting position of the fuel filter

The pin -2- at the filter housing must engage in the recess -1- of
the bracket.
The direction of flow is marked by arrows.

1.6 Extract fuel from the fuel tank

Special tools and workshop equipment required
♦ Hose adapter , e.g. -V.A.G 1318 -16 -
♦ Adapter , e.g. -V.A.G 1318 -17-
♦ Measuring tool set , e.g. -V.A.G 1594 C-

148 Rep. gr.20 - Fuel supply system

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♦ Battery
♦ Catch pan for fuel

Note

If there are functional problems of the fuel delivery unit suction off
fuel with fuel extraction device e.g. -VAS 5190- . -VAS 5190- .

Work procedure

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
For the vehicles Fabia II
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
For the vehicles Roomster
– Fold back the middle and rear seat and position vertically ⇒
Body Work; Rep. gr. 72 .
For vehicles Octavia II, Rapid NH
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
For the vehicles Yeti
– Remove rear seats with brackets ⇒ Body Work; Rep. gr. 72 .
– Remove floor covering under the rear seats.
For vehicles Fabia II, Roomster, Rapid NH
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
For the vehicles Octavia II, Yeti

1. Fuel tank and fuel delivery unit 149

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– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.
Vehicles with auxiliary heating.
– Unplug the 2-pin plug of the dosing pump -V54- .
Continued for all vehicles
– Unplug the 5-pin plug from the fuel delivery unit.

WARNING

The fuel feed line is pressurized! Wear safety goggles and

safety clothing, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
cable connections. Reduce pressure by carefully removing the
wiring.

– Pull off the fuel feed line and gather residual fuel in a cloth.

Note

Press in the securing ring in order to unlock the lines.

– Connect the adapter -V.A.G 1318/16- with the adapter -V.A.G

1318/17- and fit this “drain pipe” thus prepared onto the feed
support of the fuel delivery unit.
– Hold the “drain pipe” in a suitable fuel tank.
– Connect the battery and the contacts of the fuel pump with
adapter cables -A- from the adapter cable set -V.A.G 1594/C-
as follows:
Battery positive terminal (+) to contact -1- of the fuel pump
Battery negative terminal (-) to contact -5- of the fuel pump
The fuel pump runs and suctions off fuel.

WARNING

In order to prevent an overflow of fuel in case of a too small

fuel tank, the fuel pump must not run unattended.

1.7 Removing and installing the fuel tank

(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
Removing
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 148 .

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Note

♦ Observe safety measures when working on the fuel system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
For the vehicles Fabia II
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
For the vehicles Roomster
– Fold back the middle and rear seat and position vertically ⇒
Body Work; Rep. gr. 72 .
For vehicles Rapid NH
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
Continued for all vehicles
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
– Disconnect the plug from the fuel delivery unit.
– Clean around the fuel filler neck.
– Unscrew right rear wheel.
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Open fuel tank flap and unscrew cap from filler neck.

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– Unscrew fixing screws at tank filler neck -arrows-.

For the vehicles Fabia II
– Remove both ventilation lines ⇒ page 195 , Pos. 5 and 6 from
activated charcoal filter.
For vehicles Roomster, Rapid NH
– Remove both ventilation lines ⇒ page 196 , Pos. 6 and 7 from
activated charcoal filter.
Continued for all vehicles
– Removing rear axle ⇒ Chassis; Rep. gr. 42 .
For vehicles Roomster, Rapid NH
– Remove middle and rear silencer ⇒ page 255 .
Continued for all vehicles

WARNING

The fuel feed line is pressurized! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully releasing the connection
point.

Note

Always press in the securing ring in order to unlock the caps of

the fuel lines.

– Disconnect the feed line -1- and the vent line -2-.
– Support the fuel tank using the engine/gearbox jack -V.A.G
1383 A- .
For the vehicles Fabia II
– Unscrew tensioning strap for fuel tank.
– Unscrew the fixing screws from the fuel tank.
For vehicles Roomster, Rapid NH
– Unscrew tensioning straps and fixing screw of fuel tank
⇒ page 141 , Pos. 20.
– Remove heat shield for exhaust pipe from fuel tank.
Continued for all vehicles
– Carefully lower the engine/gearbox jack -V.A.G 1383 A- and
remove the fuel tank with the assistance of a second mechan‐
ic.
Install
– Check if the earth lead shows traces of oxidation on both con‐
nections, remove if necessary.

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

• The plug -1- on the metal plate ring -2- must be placed on
firmly.
• The contact tab -4- must be hung in the fuel tank -3- and se‐
cured with the spacer bush -5-.
Further installation occurs in reverse order. Pay attention to the
following:

For vehicles Rapid NH

Note

♦ Make sure that the heat shield for fuel tank -1- does not collide
with the tunnel-heat shield -2- when installing the fuel tank.
♦ Tunnel-heat shield -2- must moderately cover in direction of
travel -C- tunnel-heat shield of fuel tank.

Continued for all vehicles

♦ Lay the vent and fuel lines without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.

1.8 Removing and installing fuel tank ver‐

sion I.
(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
Removing
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 148 .

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .

1. Fuel tank and fuel delivery unit 153

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– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.

Note

For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must also be disconnected.

– Unplug the 5-pin plug -1- from the fuel pump.

– Clean around the fuel filler neck.
– Unscrew right rear wheel.
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .

– Unscrew screws -1- for filler neck on the body.

– Unclip the electrical cable from the bracket -2- at the top and
bottom of the filler neck.

– Disconnect vent line -1- (white) and fuel feed line -2- (black)
at the connection point.

Note

♦ For vehicles with auxiliary heating, the fuel line for the dosing
pump -V54- must also be disconnected.
♦ Press in the securing ring in order to unlock the lines.

– Remove middle and rear silencer ⇒ page 250 .

154 Rep. gr.20 - Fuel supply system

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– Release fixing screws -2- and -4- and remove the tensioning
strap.
– Support fuel tank using the engine/gearbox jack -V.A.G 1383
A- .
– Release fixing screws -1- and -3-.
– Slightly lower the fuel tank.

Note

The filler neck must be “extracted” between structure and rear

axle Lift down the fuel tank with a 2nd mechanic from engine/
gearbox jack -V.A.G 1383 A- .

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

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

• The plug -1- on the metal plate ring -2- must be placed on
firmly.
• The contact tab -4- must be hung in the fuel tank -3- and se‐
cured with the spacer bush -5-.
– Pull through the filler neck between the body and the rear axle
with the help of a second mechanic. Then position the fuel tank
onto the engine/gearbox jack -V.A.G 1383 A- .
Further installation occurs in reverse order. Pay attention to the
following:
♦ Lay the vent and fuel lines without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ Check earth connection of fuel tank/body at filler neck.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.

– Clip on cover -4- with fuel pump control unit -J538- -1-.
The arrow -2- on the cover points in direction of travel.

1.9 Removing and installing fuel tank ver‐

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

1. Fuel tank and fuel delivery unit 155

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Removing
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 148 .

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off all electrical components and withdraw key from ig‐
nition lock.
– Remove rear seat bench with brackets ⇒ Body Work; Rep.
gr. 72 .
– Remove floor covering under the rear seat bench.
– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.
Vehicles with auxiliary heating.
– Unplug the 2-pin plug of the dosing pump -V54- .
– Remove the rubber grommet from the cover of the fuel delivery
unit and pull out the wiring.
Continued for all vehicles

– Unplug the 5-pin plug -1- from the fuel tank.

– Remove the cover of the fuel gauge sender -2- -G169- (in the
figure on the right) and unplug the plug -right arrows-.
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew the cap from the fuel filler neck.
– Seal the filler neck with a clean foam piece in order to avoid
any foreign bodies from entering.
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .

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– Unscrew screws -1- for filler neck on the body.

– Unclip the electrical cable from the bracket -2- at the top and
bottom of the filler neck.

– Disconnect vent line -1- (white) and fuel feed line -2- (black)
at the connection point.

Note

Press in the securing ring in order to unlock the lines.

Vehicles with auxiliary heating.

– Separate the fuel line from the dosing pump -V54- .
Continued for all vehicles

– Remove rear tunnel bridge -arrows-.

– Unhook the rear silencer from two retaining straps.
– Slacken nuts of clamping sleeve.
– Remove screws for rear exhaust pipe hanger.

– Remove the rear silencer.

– First unscrew screws -2, 5- and -6-.
– Support the fuel tank using the engine/gearbox jack -V.A.G
1383 A- .
– Unscrew the screws for the tensioning straps -1, 3, 4- and
-7-.

1. Fuel tank and fuel delivery unit 157

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– Lower slightly the fuel tank using the engine/gearbox jack -

V.A.G 1383 A- .
– Then remove the fuel tank from the engine/gearbox jack -
V.A.G 1383 A- and pull through the filler neck between the
body and the rear axle with the help of a second mechanic.
Install
– Check both earth connections for corrosion, if necessary re‐
move corrosion.

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

• The plug -1- on the metal plate ring -2- must be placed on
firmly.
• The contact tab -4- must be hung in the fuel tank -3- and se‐
cured with the spacer bush -5-.
– Pull through the filler neck between the body and the rear axle
with the help of a second mechanic. Then position the fuel tank
onto the engine/gearbox jack -V.A.G 1383 A- .
Further installation occurs in reverse order. Pay attention to the
following:
♦ Lay the vent and fuel lines without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ Check the earth connection of the fuel tank at the body on the
filler neck.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.

– Clip on cover -4- with fuel pump control unit -J538- -1-.
The arrow -2- on the cover points in direction of travel.

1.10 Removing and installing fuel delivery

unit
(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Wrench for union nut -MP1-227 (3217)-
Removing
• The fuel tank must not be more than 3/4 full.

158 Rep. gr.20 - Fuel supply system

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Note

♦ If necessary, extract fuel from the fuel tank ⇒ page 148 .

♦ Observe the safety instructions before starting fitting work
⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
For the vehicles Fabia II
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
For the vehicles Roomster
– Fold back the middle and rear seat and position vertically ⇒
Body Work; Rep. gr. 72 .
For vehicles Rapid NH
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
Continued for all vehicles
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
– Disconnect the 5-pin plug, the feed line and the return-flow line
from the flange of the fuel delivery unit.

Note

Press in the securing ring in order to unlock the line.

WARNING

The fuel feed line is pressurized! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully releasing the connection
point.

– Unscrew union nut with wrench for union nut -MP1-227

(3217)- .

Note

♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.

– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
Installation of the fuel delivery unit occurs in reverse order to re‐
moval. Pay attention to the following:

1. Fuel tank and fuel delivery unit 159

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Note

♦ When inserting the fuel delivery unit, ensure that the fuel
gauge sender is not bent.
♦ Insert dry gasket ring of the fuel delivery unit into the opening
of the fuel tank.
♦ Only moisten gasket ring with fuel before assembly of the fuel
delivery unit.
♦ Pay attention to installed position of flange of fuel delivery unit:
The marking on the flange must be aligned with the marking
on the fuel tank -arrows-.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel hoses fit tightly.
♦ After installing the fuel delivery unit, check whether the feed,
return-flow and vent lines are clipped in place on the fuel tank.

1.11 Removing and installing fuel delivery

unit version I.
(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Key -T30101 (3087)-
Removing
• The fuel tank must not be more than 3/4 full.

Note

♦ If necessary, extract fuel from the fuel tank ⇒ page 148 .

♦ Observe the safety instructions before starting fitting work
⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
For the vehicles Octavia II
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
For the vehicles Yeti
– Remove rear seat bench with brackets ⇒ Body Work; Rep.
gr. 72 .
– Remove floor covering under the rear seat bench.

160 Rep. gr.20 - Fuel supply system

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Continued for all vehicles

– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.

Note

For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must also be disconnected.

– Unplug the 5-pin plug, the black feed line -1- and the blue re‐
turn-flow line -2-.

Note

♦ Press in the securing ring in order to unlock the lines.

♦ On vehicles with auxiliary heating the suction line for the dos‐
ing pump -V54- must be pulled out additionally (open lower
clamp).

– Open lock ring with the wrench -T30101- .

Note

♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.

– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
Installation is carried out in reverse order. Pay attention to the
following:
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.
– Insert the fuel delivery unit into the fuel tank in such a way that
the float arm of the sender for the fuel gauge display -G- is not
bent.
– Press the closing flange downwards, install the lock ring and
connect the fuel lines.

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Note

♦ Pay attention to installed position of flange of fuel delivery unit:

The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-. The -arrow- shows the direction of travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange the black feed line with the blue return-flow
line (arrows on the flange of the fuel delivery unit).
♦ Make sure the line connections and the 5-pin plug fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
and return-flow lines are also clipped on the fuel tank.

– Clip on cover -4- with fuel pump control unit -J538- -1-.
The arrow -2- on the cover points in direction of travel.

1.12 Removing and installing fuel delivery

unit version Il.
(Yeti)
Special tools and workshop equipment required
♦ Key -T30101 (3087)-
♦ Protective gloves
Removing
• The fuel tank must not be more than 1/3 full.

Note

♦ Empty the fuel tank if necessary ⇒ page 148 .

♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Remove rear seat bench with brackets ⇒ Body Work; Rep.
gr. 72 .
– Remove floor covering under the rear seat bench.

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– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.
Vehicles with auxiliary heating.
– Unplug the 2-pin plug of the dosing pump -V54- .
Continued for all vehicles

– Disconnect the plug as well as the black fuel feed line -1- and
the blue fuel return-flow line -2- from the flange.

Note

Press in the securing ring in order to unlock the lines.

Vehicles with auxiliary heating.

– Pull out the suction line for the dosing pump -V54- (slacken
lower clamp).
Continued for all vehicles

– Open lock ring with the wrench -T30101- .

– Slightly raise the closing flange and check if the spring -2- is
still fastened on the flange -1-.
If the spring -2- is loose on the guide pipe -3-, hold it with your
fingers while removing the closing flange.
– Pull out closing flange and gasket ring of the fuel delivery unit
from the opening of the fuel tank and place to the side with the
connected lines.
– Remove the suction jet pump from the fuel gauge sender 2 -
G169- ⇒ page 184 .

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– Separate through the opening of the fuel tank the fuel line
-1- to the suction jet pump, to do so press the release button.
– Separate the fuel delivery line -2- from the fuel delivery unit.

Note

♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.

– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
Installation is carried out in reverse order. Pay attention to the
following:
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.
– Insert the fuel delivery unit into the fuel tank with the closing
flange placed to the side. Thus, do not bend the float arm of
the fuel gauge sender unit -G- .
– Install the fuel delivery unit and the fuel line.

• The spring -2- must be fastened to the retaining lugs -1- of the
closing flange.
– First of all guide the guide pipe -3- into the guide bore -4-.
– Then lower the closing flange in such a way that the guide pipe
-6- locks into the guide bore -5-.

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Note

Pay attention that the electrical cables -1- and the fuel feed line
-3- are routed according to the illustration and the float arm -2- is
not blocked.

– Press the closing flange down and bring it into the installation
position.
Further information:

♦ Fitting position of the fuel delivery unit: The peg -2- at the clos‐
ing flange must be located between the pegs -1- and -3-. The
-thick arrow- points in the direction of travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
line and the return-flow line are still clipped in place on the fuel
tank.

1.13 Removing and installing the sender for

fuel gauge display -G-
Removing
– Remove fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .
– Unlock the catches -arrows- using a screwdriver and pull out
the sender for fuel gauge display -G- towards the top.

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– Unlatch and disconnect the plugs of the electrical cables -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the wiring and check correct installation of the plug.
– Insert the sender for fuel gauge display -G- in the guides at the
fuel delivery unit and press downwards until it latches into po‐
sition.
– Install fuel delivery unit ⇒ page 158 .

1.14 Testing fuel pump

Special tools and workshop equipment required
♦ Key -T30101 (3087)-
♦ Pressure gauge , e.g. -V.A.G 1318- or pressure gauge , e.g. -
VAS 6550-
♦ Adapter , e.g. -V.A.G 1318/11-
♦ Hose adapter , e.g. -V.A.G 1318/16-
♦ Adapter set , e.g. - V.A.G 1318/17A-
♦ Double connection piece , e.g. - V.A.G 1318/23-
♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g.
-V.A.G 1348/3-3 -
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Multimeter , e.g. -V.A.G 1715-
♦ Adapter for measuring method/DSO (5-pin) , e.g. -VAS 5565-
♦ Measuring glass

Note

♦ The adapter set -V.A.G 1318/17A- replaces the adapter set -

V.A.G 1318/17- .
♦ The figures shown in the description were not changed for this
reason.

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Inspect proper operation and power supply ⇒ page 167

Check fuel pressure with pressure gauge -V.A.G 1318-
⇒ page 169
Check fuel pressure with pressure gauge -VAS 6550-
⇒ page 170
Check holding pressure with pressure gauge -V.A.G 1318 -
⇒ page 173
Check holding pressure with pressure gauge -VAS 6550-
⇒ page 174
Check fuel flow rate with pressure gauge -V.A.G 1318 -
⇒ page 176
Check fuel flow rate with pressure gauge -VAS 6550-
⇒ page 179
Check power consumption ⇒ page 183

1.14.1 Inspecting proper operation and power

supply
Test conditions
• Battery voltage at least 11.5 V.
• Fuel pump fuse O.K. ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
• Fuel pump control unit -J538- O.K.
Test sequence

Note

The function of the fuel pump is tested with the actuator diagnosis.

– Connect vehicle diagnosis, measurement and information

system -VAS 505X- .
– Switch on ignition.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”,“01 - Engine electronics” and “03 - Actuator di‐
agnosis”.
– On the display press the right arrow button up to the actuator
diagnosis of the fuel pump electronics.
• The fuel pump must now run slowly to the maximum speed.

Note

The fuel pump runs very quietly.

– Switch off ignition.

The fuel pump does not run:
For the vehicles Fabia II
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
For the vehicles Roomster
– Fold back the middle and rear seat and position vertically ⇒
Body Work; Rep. gr. 72 .

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For vehicles Octavia II, Rapid NH

– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
For the vehicles Yeti
– Remove rear seats with brackets ⇒ Body Work; Rep. gr. 72 .
– Remove floor covering under the rear seats.
For vehicles Fabia II, Roomster, Rapid NH
– Disconnect plug from fuel pump control unit -J538- -2-.
For the vehicles Octavia II, Yeti

– Disconnect plug -3- from fuel pump control unit -J538- .

Continued for all vehicles

– Testing the voltage supply with the voltage tester -V.A.G

1527B- between contact -1- and -6-.
• The LED must light up.
The LED does not light up:
– Determine and remove open circuit in the wiring according to
the current flow diagram ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
The LED lights up (power supply O.°K.):
– Remove fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .
– Check whether the electric wiring between the flange and fuel
pump is connected.
If there is no open circuit in the wiring:
– Fuel pump defective, replace the fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .

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1.14.2 Check fuel pressure with pressure

gauge -V.A.G 1318-
• The function of the fuel pump was checked ⇒ page 167 .

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

For vehicles Fabia II, Roomster, Rapid NH

– Remove the fuel feed line -3- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
For the vehicles Octavia II, Yeti

– Remove the fuel feed line -1- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
Continued for all vehicles

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– Install the pressure gauge -V.A.G 1318 - with the adapter set
-V.A.G 1318/17A- instead of the fuel feed line.
– Open shut-off cock of the pressure gauge. Level in position
-A-.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0,4 ... 0,7 MPa (4 ... 7,0 bar)
If fuel line is o.k.:
– Test holding pressure ⇒ page 173 .
If the specified pressure is exceeded:
– Check the return line between the fuel filter and fuel pump for
kinks and blockages.
If no fault is found:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.
If the measurement is less than the specification:

– Check the fuel pressure before the fuel filter. For this step
connect the pressure gauge -V.A.G 1318- with the adapter set
-V.A.G 1318/17A- between the fuel filter and the fuel feed line.
– Open shut-off cock of the pressure gauge. Lever points in di‐
rection of flow.
– Start engine and run in idle.

Caution

The shut-off cock must only be closed slowly. At a fuel pressure

of 0.8 MPa (8 bar), the shut-off cock must be immediately
opened, in order to avoid a damage of the pressure gauge.

– Slowly close the shutoff cock of the pressure measuring de‐

vice. The pressure must rise to at least 0,6 MPa (6,0 bar). If
the 0,6 MPa (6,0 bar) is reached, immediately open the shut-
off cock again!
If the pressure has risen:
– Fuel pump O.K., pressure limiting valve in the fuel filter defec‐
tive, replace the fuel filter.
If the pressure does not rise:
– Fuel pump defective, replace the fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .

1.14.3 Check fuel pressure with pressure

gauge -VAS 6550-
• The function of the fuel pump was checked ⇒ page 167 .

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Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

For vehicles Fabia II, Roomster, Rapid NH

– Remove the fuel feed line -3- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
For the vehicles Octavia II, Yeti

– Remove the fuel feed line -1- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
Continued for all vehicles

– Connect the pressure gauge -VAS 6550- with adapters -VAS

6550/1- and -VAS 6550/2- to the fuel feed line.
– Make sure that the discharge cock is closed and the shut-off
taps are opened.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0,4 ... 0,7 MPa (4 ... 7,0 bar)
If fuel line is o.k.:
– Test holding pressure ⇒ page 173 .
If the specified pressure is exceeded:
– Check the return line between the fuel filter and fuel pump for
kinks and blockages.
If no fault is found:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.
If the measurement is less than the specification:
– Check the fuel pressure before the fuel filter, to do so proceed
as follows:

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– Disconnect fuel feed line -arrow- at fuel filter.

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

VAS 6550/1- and -VAS 6550/2- between the fuel filter and the
fuel feed line.
– Make sure that the discharge cock is closed and the shut-off
taps are opened.
– Start engine and run in idle.

– Slowly close the shutoff cock -A-.

• The pressure must rise to at least 0.7 MPa (7.0 bar).
– If the 0.7 MPa (7.0 bar) is reached, immediately open the shut-
off cock again!
If the pressure has risen:
– Fuel pump O.K., pressure limiting valve in the fuel filter defec‐
tive, replace the fuel filter.
If the pressure does not rise:
– Fuel pump defective, replace fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .

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1.14.4 Checking holding pressure with pres‐

sure gauge -V.A.G 1318-
• Fuel pressure O.K. and pressure gauge -V.A.G 1318- con‐
nected in the engine compartment ⇒ page 169 .

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0,4 ... 0,7 MPa (4 ... 7,0 bar)
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0,3 MPa (3,0 bar) after 10
minutes.
If the pressure again drops:
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.

– Immediately close the shutoff cock of the pressure measuring

device. The lever then points in the position -B-.
If the pressure again drops:
– Check the low pressure pipe to the high pressure pump for
tightness.
If no fault is found:
– Replace high pressure pump ⇒ page 230 .
Now the pressure does no longer drop:
– Check the fuel line to the fuel filter for tightness.
If the fuel line is not found to be faulty:

– Check the non-return valve in the fuel delivery unit. For this
step connect the pressure measuring device -V.A.G 1318-
with the adapter -V.A.G 1318/17A- between the fuel filter and
the fuel feed line.
– Open shut-off cock of the pressure gauge. Lever points in di‐
rection of flow.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0,4 ... 0,7 MPa (4 ... 7,0 bar)

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– Immediately close the shut-off cock of the pressure measuring

device after the pressure has built up.
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0,3 MPa (3,0 bar) after 10
minutes.
If the pressure still drops:
– Non-return valve in the fuel pump faulty, replace fuel delivery
unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .
If the pressure does not drop:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.

1.14.5 Checking holding pressure with pres‐

sure gauge -VAS 6550-
• Fuel pressure O.K. and pressure gauge -VAS 6550- connec‐
ted in the engine compartment ⇒ page 170 .

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0,4 ... 0,7 MPa (4 ... 7,0 bar)
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0,3 MPa (3,0 bar) after 10
minutes.
If the pressure again drops:
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.

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– Immediately close the shut-off cock -B- of the pressure gauge

after the pressure has built up. The lever points at right angles
in the direction of flow.
Now the pressure does no longer drop:

Note

Search for leakage on the engine side. Repeat the holding pres‐
sure test. This time, close the shut-off cock -A- in order to deter‐
mine if a leak is indeed present on the engine side.

– Check the low-pressure line to the high pressure pump for

tightness.
If no fault is found:
– Replace high pressure pump ⇒ page 230 .
If the pressure again drops:
Search for leakage on the fuel tank side, to do so proceed in the
following manner:
– Check the fuel line to the fuel filter for tightness.
If the fuel line is not found to be faulty:
– Check the pressure holding valve in the fuel delivery unit. To
do so proceed in the following manner:

– Disconnect fuel feed line -arrow- at fuel filter.

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

VAS 6550/1- and -VAS 6550/2- between the fuel filter and the
fuel feed line.
– Make sure that the discharge cock is closed and the shut-off
taps are opened.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0,58 ... 0,70 MPa (5,8 ... 7,0 bar)

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– After the pressure has built up, close the shut-off cock -A-.
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0,3 MPa (3,0 bar) after 10
minutes.
If the pressure still drops:
– Non-return valve in the fuel pump faulty, replace fuel delivery
unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .
If the pressure does not drop:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.

1.14.6 Checking fuel flow rate with pressure

gauge -V.A.G 1318-

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
For the vehicles Fabia II
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
For the vehicles Roomster
– Fold back the middle and rear seat and position vertically ⇒
Body Work; Rep. gr. 72 .
For vehicles Octavia II, Rapid NH
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
For the vehicles Yeti
– Remove rear seats with brackets ⇒ Body Work; Rep. gr. 72 .
– Remove floor covering under the rear seats.
For vehicles Fabia II, Roomster, Rapid NH
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
For the vehicles Octavia II, Yeti

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– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.
Continued for all vehicles

– First of all check the plug -1- for correct fit. To do so, pull on
the plug without pressing the catch. If the plug was not cor‐
rectly plugged in, it may have caused a fault.
– Now unplug the plug -1-.
– Check the contacts at the plug and at the fuel delivery unit for
damage.

– Connect test instrument adapter/DSO (5-pin) -VAS 5565- to

connector and fuel delivery unit.
– Connect the remote control -V.A.G 1348/3A- to the adapter -
VAS 5565- and to the battery positive (+).

Note

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

For vehicles Fabia II, Roomster, Rapid NH

– Remove the fuel feed line -3- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
For the vehicles Octavia II, Yeti

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– Remove the fuel feed line -1- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
Continued for all vehicles

– Connect the pressure gauge -V.A.G 1318- with the double

connection piece -V.A.G 1318/23- and the adapter set -V.A.G
1318/17A- to the fuel feed line.
– Fit the hose adapter -V.A.G 1318/16- onto the adapter -V.A.G
1318/11- of the pressure measuring device and hold it in a
measuring glass.
– Close the shut-off cock of the pressure measuring device. The
lever then points in the position -B-.

WARNING

Danger of liquid spraying out when opening the shut-off valve.

Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact with fuel. Hold the container in front of
the free connection to the pressure gauge.

– Open shut-off cock of the pressure gauge. The lever then

points in the direction of flow -A-.
– Activate remote control -V.A.G 1348/3A- . While doing so,
slowly close the shut-off cock until the pressure gauge dis‐
plays 0.4 MPa (4 bar) overpressure. Now do not make any
further changes to the position of the shut-off cock.
– Empty measuring glass.

– The fuel flow rate 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- .
– Activate remote control for 30 seconds while measuring the
battery voltage.

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– Compare the fuel rate with the specified value.

*) minimum flow rate 1 cm3/30 s
**) Voltage at fuel delivery unit when engine not running and de‐
livery unit operating (approx. 2 volts less than battery voltage)
Read out examples:
During the test a voltage of 12.5 V was measured on the battery.
As the voltage on the fuel pump is approximately 2V less than the
battery voltage, a minimum flow rate of 580 cm 3/30 s is obtained.
If the minimum flow rate is not reached:
– Check the fuel lines for possible restrictions (kinks) or block‐
ing.
If no fault is found:

– Disconnect the feed hose -1- from the fuel filter inlet.
– Connect pressure gauge -V.A.G 1318- with the adapter set -
V.A.G 1318/17A- to the hose.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
– Replace fuel filter.
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and inspect the filter strainer for
soiling.
If you have still not found any fault up to this stage:
– Replace fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .
If the required fuel delivery volume has been achieved, but a fault
is still suspected in the fuel supply system (e.g. intermittent break‐
down of the fuel supply):
– Check power consumption of the fuel pump ⇒ page 183 .

1.14.7 Checking fuel flow rate with pressure

gauge -VAS 6550-
– Switch off the ignition and all electrical components and take
out the ignition key.
For the vehicles Fabia II
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
For the vehicles Roomster
– Fold back the middle and rear seat and position vertically ⇒
Body Work; Rep. gr. 72 .
For vehicles Octavia II, Rapid NH
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
For the vehicles Yeti
– Remove rear seats with brackets ⇒ Body Work; Rep. gr. 72 .
– Remove floor covering under the rear seats.

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For vehicles Fabia II, Roomster, Rapid NH

– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
For the vehicles Octavia II, Yeti

– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.
Continued for all vehicles

– First of all check the plug -1- for correct fit. To do so, pull on
the plug without pressing the catch. If the plug was not cor‐
rectly plugged in, it may have caused a fault.
– Now unplug the plug -1-.
– Check the contacts at the plug and at the fuel delivery unit for
damage.

– Connect test instrument adapter/DSO (5-pin) -VAS 5565- to

connector and fuel delivery unit.
– Connect the remote control -V.A.G 1348/3A- to the adapter -
VAS 5565- and to the battery positive (+).

Note

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

For vehicles Fabia II, Roomster, Rapid NH

180 Rep. gr.20 - Fuel supply system

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– Remove the fuel feed line -3- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
For the vehicles Octavia II, Yeti

– Remove the fuel feed line -1- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
Continued for all vehicles

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

VAS 6550/2- to the fuel feed line. Hold the adapter -VAS
6550/1- in a measuring glass.
– Make sure that the discharge cock is closed and the shut-off
taps are opened.

WARNING

Danger of liquid spraying out when opening the shut-off valve.

Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact with fuel. Hold the container in front of
the free connection to the pressure gauge.

– Activate remote control -V.A.G 1348/3A - . While doing this,

slowly close the shut-off cock -arrow- until the pressure gauge
displays 0,4 MPa (4 bar) overpressure. Now do not make any
further changes to the position of the shut-off cock.
– Empty measuring glass.

– The fuel flow rate 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- .
– Activate remote control for 30 seconds while measuring the
battery voltage.

1. Fuel tank and fuel delivery unit 181

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– Compare the fuel rate with the specified value.

*) minimum flow rate 1 cm3/30 s
**) Voltage at the fuel pump when engine is not running and pump
is operating.
Read out examples:
During the test a voltage of 10.5 V was measured. Thus a mini‐
mum flow rate of 580 cm3/30 s is obtained.
If the minimum flow rate is not reached:
– Check the fuel lines for possible restrictions (kinks) or block‐
ing.
If no fault is found:
– Take cap off fuel filler neck and repeat the test.
If the fuel flow rate is now reached:
– Check the ventilation of the fuel tank.
If the minimum flow rate is again not reached:
– Check the fuel filter, to do so proceed as follows:

– Disconnect fuel feed line -arrow- at fuel filter.

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

VAS 6550/1- to the fuel feed line. Hold the adapter -VAS
6550/2- in a measuring glass.
– Make sure that the discharge cock is closed and the shut-off
taps are opened.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
– Replace fuel filter.
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and inspect filter strainer for soiling.
If you have still not found any fault up to this stage:
– Replace fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .
If the required fuel flow rate has been achieved, but a fault is still
suspected in the fuel supply system (e.g. intermittent breakdown
of the fuel supply):
– Check power consumption of the fuel pump ⇒ page 183 .

182 Rep. gr.20 - Fuel supply system

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1.14.8 Checking power consumption

For the vehicles Fabia II
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
For the vehicles Roomster
– Fold back the middle and rear seat and position vertically ⇒
Body Work; Rep. gr. 72 .
For vehicles Octavia II, Rapid NH
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
For the vehicles Octavia II, Yeti
– Remove rear seat bench with brackets ⇒ Body Work; Rep.
gr. 72 .
– Remove floor covering under the rear seat bench.
For vehicles Fabia II, Roomster, Rapid NH
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
For the vehicles Octavia II, Yeti

– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.
Continued for all vehicles

– Connect the current probe -A- of the vehicle diagnosis, meas‐

urement and information system -VAS 505X- on the line -B- to
contact 1 of the 5-pin plug.
If the current probe cannot be connected on the line -B- to contact
“1” of the 5-pin plug because of the length of the insulation:

1. Fuel tank and fuel delivery unit 183

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– Connect test instrument adapter/DSO (5-pin) -VAS 5565- to

connector and fuel delivery unit.
– Connect the current probe -A- to the red cable - with the let‐
tering “current probe” - of the adapter for measuring method/
DSO (5-pin) -VAS 5565- .
Continued for all
– Start engine and run in idle.
– Measure voltage consumption of the fuel pump.
Specified value: max. 9 A

Note

If the fault in the fuel supply system is intermittent then tests can
be undertaken during a test drive but then two people are required
for this.

If the specfied current uptake is exceeded:

– Fuel pump defective, replace the fuel delivery unit:
♦ Fabia II, Roomster, Rapid NH ⇒ page 158 .
♦ Octavia II, Yeti (version l.) ⇒ page 160 .
♦ Yeti (version II.) ⇒ page 162 .

1.15 Removing and installing fuel gauge

sender -2- -G169- - fuel tank version Il.
(Yeti)
Special tools and workshop equipment required
♦ Key -T30101 (3087)-
• The fuel tank must not be more than 1/2 full.

Note

♦ If necessary, extract fuel from the fuel tank ⇒ page 148 .

♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .
♦ Make sure that the float arm of the fuel gauge sender -2- -
G169- is not bent.

Removing
– Switch off all electrical components and withdraw key from ig‐
nition lock.
– Remove rear seat bench with brackets ⇒ Body Work; Rep.
gr. 72 .
– Remove floor covering under the rear seat bench.
– Remove the left cover in direction of travel from the fuel gauge
sender -2- -G169- .
– Disconnect the plug connection.

184 Rep. gr.20 - Fuel supply system

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– Open lock ring with the wrench -T30101- .

– Slightly pull fuel gauge sender -2- -G169 - out of the opening
of the fuel tank, unlock securing tabs -arrows- and disconnect
suction jet pump.
– Remove gasket ring.
Install

Caution

When installing do not bend the float arm of the fuel gauge
sender -2- -G169 - .

– Insert the fuel gauge sender 2 -G169 - into the fuel tank.
– Position the suction jet pump in the fuel tank onto the sender.
The catches must click audibly.
– Insert new dry gasket ring for the flange into the opening of the
fuel tank and only now moisten the inside (position of the
flange) with fuel.
– Pay attention to the fitting location of the fuel gauge sender -2-
-G169- ⇒ page 147 .
– Check correct positioning of gasket ring.
– Tighten lock ring with wrench for union nut -T30101- .
Tightening torque: 110 Nm
– Mount the plug connection.
– Install cover.
– Insert the floor covering under the rear seat bench.
– Install rear seat bench with brackets ⇒ Body Work; Rep. gr.
72 .

1. Fuel tank and fuel delivery unit 185

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1.16 Removing and installing suction jet

pump - fuel tank version Il.
(Yeti)

Note

♦ The fuel tank consists of a left and right chamber. In order to

pump the fuel out of the left chamber -3- of the fuel tank into
the right chamber to the housing of the delivery unit -2-, a suc‐
tion jet pump -1- is required.
♦ The version of the fuel tank requires that the fuel is pumped
from the area of the fuel gauge sender -2- -G169- with a suc‐
tion jet pump to the fuel delivery unit.
♦ A check is only to be carried out, if the engine stops because
of fuel shortage, although the fuel gauge still indicates a fuel
tank which is 1/4 full.

Work procedure
– Remove fuel delivery unit ⇒ page 162 .
– Remove fuel gauge sender -2- -G169- ⇒ page 184 .
– Now the suction jet pump can be pulled out from the side of
the fuel gauge sender -2- -G169- (on left in direction of travel).
– Check, if the fuel lines on the suction jet pump are placed on
firmly and not damaged.
– Check the suction jet pump additionally for possible contami‐
nation.

186 Rep. gr.20 - Fuel supply system

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2 Separating quick couplings

Special tools and workshop equipment required
♦ Lever -T10468-

Note

♦ The quick couplings of fuel, vacuum and ventilation lines are

colour marked. Either the colour point at the quick coupling or
the release button has the corresponding colour.
♦ Observe safety measures ⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 5 .

Quick coupling Colour coding at the quick cou‐

pling
Fuel feed black
line
Fuel return-flow blue
line
Vent line White, beige
Vacuum line green

WARNING

The fuel feed line is pressurized! Wear safety goggles and

safety clothing, in order to avoid injuries and skin contact with
fuel. Place cleaning cloths around the connection point before
detaching hose connections. Reduce pressure by carefully re‐
moving the hose.

Version 1
Push-on coupling with release buttons -arrows- on right and left
Open

2. Separating quick couplings 187

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

– Insert the lever -T10468- between the heat shield and the stop
-arrow- of the fuel feed line -2- and hold it.
Continued for all separation points

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

– Press the release buttons and detach the quick coupling -1- in
-direction of arrow B- from the fuel flow line -2-.
Pay attention to the colour assignment when installing
⇒ page 187 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 2

Push-on coupling with pull-release mechanism -arrow-

Open

188 Rep. gr.20 - Fuel supply system

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

– Pull on the pull release -2- in -direction of arrow B-.
– Detach the quick coupling -1- in -direction of arrow B- from the
fuel flow line -3-.
Pay attention to the colour assignment when installing
⇒ page 187 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 3

Quick coupling with front release button -arrow-.

Open
– Press the release button -arrow- and detach the quick cou‐
pling.
Pay attention to the colour assignment when installing
⇒ page 187 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 4

Push-on coupling with release buttons -arrows- on right and left

Open
– Press quick coupling in -direction of arrow A-.
– Press release buttons -arrows- and detach quick coupling.
Pay attention to the colour assignment when installing
⇒ page 187 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 5

Push-on coupling with release buttons -arrows- on right and left

Open
– Press release buttons -arrows- and detach quick coupling.
Pay attention to the colour assignment when installing
⇒ page 187 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 6

2. Separating quick couplings 189

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Push-on coupling with release buttons -arrows- on right and left

Open
– Press push-on coupling -1- in -direction of arrow- and hold
pressed.
– Press release buttons -arrows- and detach quick coupling.
Pay attention to the colour assignment when installing
⇒ page 187 .
– Check the quick couplings for firm seating by pulling in the
opposite direction!

190 Rep. gr.20 - Fuel supply system

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3 Electronic Engine Power Control

(Electronic throttle)

3.1 Accelerator pedal module - Summary of

components
(Fabia II, Roomster, Rapid NH)

1 - Bearing bracket
❑ removing and installing
⇒ Chassis; Rep. gr. 46
2 - Connector
❑ black
❑ 6-pin
3 - Accelerator pedal module
❑ with accelerator pedal
position sender -G79-
and accelerator pedal
position sender 2 -
G185-
❑ to remove the sender re‐
move the bottom part of
the dash panel on the
driver's side
❑ if the accelerator pedal
module is replaced, an
adaptation of the engine
control unit has to be
performed on vehicles
with automatic gearbox
⇒ Vehicle diagnostic
tester
4 - 10 Nm

3.2 Accelerator pedal module - Summary of

components
(Octavia II, Yeti)

3. Electronic Engine Power Control (Electronic throttle) 191

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1 - Connector
❑ black, 6 pin
2 - Accelerator pedal position
sender -G79- with accelerator
pedal position sender 2 -G185-
❑ not adjustable
❑ the sender transmits the
driver's instructions to
the engine control unit
❑ -A- are openings for the
release tool
❑ removing and installing
⇒ page 192
❑ when replacing, the en‐
gine control unit must be
adapted ⇒ Vehicle diag‐
nostic tester on vehicles
with automatic gearbox
3 - 10 Nm
4 - Cap

3.3 Removing and installing accelerator

pedal module
(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Release tool -T10238- (for left-hand drive vehicle)
♦ Release tool -T10240- (for right-hand drive vehicle)
Removing
– Remove steering column cover -arrows-.
– Lever out the cap ⇒ page 191 , Pos. 4, with a screwdriver.
– Release fixing screw ⇒ page 191 , Pos. 3.

192 Rep. gr.20 - Fuel supply system

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– Push the release tool -T10238- (on right-hand drive vehicles

release tool -T10240 - ) as shown up to the stop into the pro‐
vided openings and remove the accelerator pedal module.
– Disconnect connector at accelerator pedal module
⇒ page 193 .
Install

– Fit the plug -2- onto the accelerator pedal module -5-
⇒ page 193 .
The plug must lock audibly.
– Push accelerator pedal module onto the fixing bolts -6-.
– Insert the centering pin -7- into the hole in the underbody.
– Fasten accelerator pedal module with screw -3- (10 Nm) and
fit on cap -4-.
– Re-install steering column cover.
– If the accelerator pedal module was replaced, an adaptation
of the engine control unit has to be performed on vehicles with
automatic gearbox ⇒ Vehicle diagnostic tester.

3.3.1 Disconnect connector for accelerator

pedal module and fit on
(Octavia II, Yeti)

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.

3. Electronic Engine Power Control (Electronic throttle) 193

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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 the 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- upwards 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- downwards up to the stop in
-direction of arrow 1-.
– Slightly press the piston slide valve in -direction of arrow 2-
and push it downwards in -direction of arrow 3-.
The piston slide valve -A- can only be pushed downwards if
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.

194 Rep. gr.20 - Fuel supply system

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4 Activated charcoal container system

Note

♦ The hose connections are secured with spring strap clips or

clamp-type clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ Use pliers for spring strap clips to fit the spring strap clips.
♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

4.1 Activated charcoal container system -

Summary of components
(Fabia II)

1 - Bleeder hose
2 - Activated charcoal filter sys‐
tem solenoid valve 1 -N80-
with connection line
❑ attached with bracket to
the intake manifold
❑ Valve is actuated
(pulsed) by engine con‐
trol unit -J623- when en‐
gine is warm
❑ check ⇒ Vehicle diag‐
nostic tester
❑ Valve closed when igni‐
tion is switched off
3 - To the non-return valve
4 - Intake manifold
5 - Vent line
6 - Vent line with gravity valve
7 - To the fuel filler flap unit
8 - Activated charcoal filter
❑ Fitting location: in rear
right wheelhouse
❑ attached to the vehicle
body
❑ filled by solenoid valve -
N80- and by gravity
valve
❑ Checking the fuel tank
venting ⇒ page 197
❑ removing:
– Removing the rear right
wheel.

– Remove plastic wheelhouse liner ⇒ Body Work; Rep. gr. 66 .

4. Activated charcoal container system 195

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– Disconnect lines -5- and -6-.

– Remove the activated charcoal filter from the body and push down.
❑ Installing:
– Installation is carried out in the reverse order.

9 - 10 Nm

4.2 Activated charcoal container system -

Summary of components
(Roomster, Rapid NH)

1 - Bleeder hose
2 - Activated charcoal filter sys‐
tem solenoid valve 1 -N80-
with connection line
❑ attached with bracket to
the intake manifold
❑ Valve is actuated
(pulsed) by engine con‐
trol unit -J623- when en‐
gine is warm
❑ check ⇒ Vehicle diag‐
nostic tester
❑ Valve closed when igni‐
tion is switched off
3 - To the non-return valve
4 - Intake manifold
5 - Activated charcoal filter
❑ Fitting location: in rear
right wheelhouse
❑ attached to the vehicle
body
❑ filled by solenoid valve -
N80- and by gravity
valve
❑ Checking the fuel tank
venting ⇒ page 197
❑ removing:
– Removing the rear right
wheel.

– Remove plastic wheel‐

house liner ⇒ Body
Work; Rep. gr. 66 .

– Disconnect lines -6- and -7-.

– Remove the activated charcoal filter from the body and push down.
❑ Installing:
– Installation is carried out in the reverse order.

196 Rep. gr.20 - Fuel supply system

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6 - Vent line
7 - Vent line with gravity valve
8 - To the fuel filler flap unit

4.3 Activated charcoal container system -

Summary of components
(Octavia II, Yeti)

1 - Activated charcoal filter

❑ Fitting position: in right
of engine compartment
❑ if the catch peg is un‐
locked, the activated
charcoal filter can be re‐
moved from the holder
❑ Checking the fuel tank
venting ⇒ page 198
2 - Pressure holding valve with
connection hose
3 - 8 Nm
4 - Vent line
❑ check for firm seating
❑ from fuel tank
5 - 8 Nm
6 - Support
❑ for activated charcoal fil‐
ter
7 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
❑ Valve closed when igni‐
tion is switched off
❑ valve is actuated
(pulsed) by engine con‐
trol unit when engine is
warm
8 - Connecting hose
❑ To intake manifold
❑ check for firm seating
9 - Air admission fitting

4.4 Checking the fuel tank venting

(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Hand vacuum pump, e.g. -V.A.G. 1390- or Hand vacuum
pump -VAS 6213-
Test condition
• The ignition must be switched off.

4. Activated charcoal container system 197

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For the vehicles Fabia II

– Remove the ventilation line -1- from the activated charcoal fil‐
ter to the activated charcoal filter system solenoid valve 1 -
N80- -2-.
– Connect hand vacuum pump -VAS 6213- to vent line -1- as
shown.
– Operate the hand vacuum pump several times. No vacuum
should build up.
If a vacuum builds up.
– Check the ventilation opening -3- on the activated charcoal
filter -4- for dirt and clean as required.
If no vacuum builds up:
– Shut off ventilation opening -3- on the activated charcoal filter
and once again operate the hand vacuum pump several times.
A vacuum should build up.
For vehicles Roomster, Rapid NH
– Remove the ventilation line -1- from the activated charcoal fil‐
ter to the activated charcoal filter system solenoid valve 1 -
N80- -2-.

– Connect hand vacuum pump -VAS 6213- to vent line -1- as

shown.
– Operate the hand vacuum pump several times. No vacuum
should build up.
If a vacuum builds up.
– Check the ventilation opening below the cover -4- on the ac‐
tivated charcoal filter -3- for dirt, clean as required.
If no vacuum builds up:
– Remove the cover -4-, shut off the ventilation opening on the
activated charcoal filter and once again operate the hand vac‐
uum pump several times. A vacuum should build up.
Continued for all vehicles
If no vacuum builds up:
– Replace activated charcoal filter.

4.5 Checking the fuel tank venting

(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Hand vacuum pump , e.g. -VAS 6213-
♦ Adapter set , e.g. - V.A.G 1318/17A-
♦ Adapter , e.g. -V.A.G 1318/20-1-

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Note

♦ The adapter set -V.A.G 1318/17A- replaces the adapter set -

V.A.G 1318/17- .
♦ The figures shown in the description were not changed for this
reason.

Test condition
• The ignition must be switched off.
Test sequence
– Detach vent line -2-. To do so press in the securing ring.

– Slide the control ring -1- on the hand vacuum pump -VAS
6213- in -the direction of arrow A- up to the stop.
– Operate the hand vacuum pump -VAS 6213 - several times.

– Then connect the hand vacuum pump - VAS 6213- -1- on the
vent line -2- as shown in the figure.
– Operate the hand vacuum pump -VAS 6213- several times.
• No vacuum should build up.
If a vacuum builds up.
– Check the air admission fitting on the activated charcoal filter
for dirt and clean as required.
If no vacuum builds up:

4. Activated charcoal container system 199

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– Shut off air admission fitting -arrow- and once again operate
the vacuum pump several times.
• A vacuum should build up.
If no vacuum builds up:
– Replace activated charcoal filter.

200 Rep. gr.20 - Fuel supply system

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21 – Turbocharging/supercharging
1 Exhaust gas turbocharger

Note

Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 8 .

1.1 Exhaust turbocharger - Summary of

components
Part I. ⇒ page 202
Part II. ⇒ page 203

1. Exhaust gas turbocharger 201

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1.1.1 Part I

1 - Solenoid valve 1 for activa‐

ted charcoal filter -N80-
❑ To intake manifold
2 - Non-return valve
❑ Fitting location: cylinder
head cover
3 - Connecting hose
4 - 8 Nm
5 - Inlet connection
6 - Exhaust turbocharger with
exhaust manifold
❑ with charge pressure
regulator -V465 -

Note

❑ removing and installing

⇒ page 203
7 - O-ring
❑ replace
8 - Connector

202 Rep. gr.21 - Turbocharging/supercharging

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1.1.2 Part Il

1 - Gasket
❑ replace
2 - Support
3 - 20 Nm
4 - Exhaust turbocharger with
exhaust manifold
❑ with charge pressure
regulator -V465 -

Note

❑ removing and installing

⇒ page 203
5 - O-ring
❑ replace
6 - Oil return pipe
7 - 8 Nm
8 - 10 Nm
9 - Heat shield
10 - 8 Nm
11 - Coolant pipes
12 - 8 Nm
13 - 1. stage 18 Nm, 2nd stage
12 Nm, 3rd stage 12 Nm
❑ replace
❑ observe the order of
tightening up
⇒ page 203
❑ Tightening torque of pin
screw in cylinder head:
18 Nm (insert oiled)
14 - Sealing ring
❑ replace
15 - Hollow screw
❑ Tightening torque: 20 Nm
16 - Oil feed pipe
17 - O-ring
❑ replace
18 - 8 Nm

1.2 Removing and installing exhaust gas

turbocharger
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-

1. Exhaust gas turbocharger 203

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♦ Hot screw paste -G 052 112 A3-

Caution

In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient 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
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.

Note

♦ Observe rules for cleanliness ⇒ page 3 .

♦ Observe general instructions for charge-air system
⇒ page 8 .

Removing
– Drain coolant ⇒ page 118 .
– Detach hoses -1- and plugs -2- from exhaust gas turbocharg‐
er.
For vehicles Fabia II, Roomster, Rapid NH

– Release screws -1- and remove retaining clip.

– Disconnect plug -2- at charge pressure sender -G31- with in‐
take air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338- and then from the exhaust gas turbocharger.
– Remove the cover for the ignition leads and release the fixing
screw -4-.
For the vehicles Octavia II, Yeti
– Release screws -1- and remove retaining clip.

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– Disconnect plug -2- at charge pressure sender -G31- with in‐

take air temperature sender 2 -G299 - .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
– Remove the cover for the ignition leads and release the fixing
screw -4-.
Continued for all vehicles

– Disconnect all the spark plug connectors -arrows- using the

extractor -T10112 A- from the spark plugs and lay the ignition
cables to the rear.
– Detach coolant hoses from coolant pipes -1-.

Note

Make sure that the oil does not penetrate into the generator!
Therefore, cover the generator with a clean cloth!

– Unscrew the hollow screw -4- of the oil pipe.

– Release fixing screws -2- and -3- and remove oil and coolant
pipes.
– Remove lambda probe -G39- -5-.
– Disconnect plug from generator.
– Release fixing screws -arrows- and remove the heat shield
from the exhaust turbocharger.
For vehicles Fabia II, Roomster, Rapid NH

– Remove bracket -1-.

– Remove catalytic converter with pre-exhaust pipe
⇒ page 253 .
For the vehicles Octavia II, Yeti

1. Exhaust gas turbocharger 205

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– Remove bracket -1-.

– Unscrew fixing nuts -arrows- at exhaust gas turbocharger.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Separate plug connections -1-.

– Unscrew fixing nuts -2-.

– Release the fixing screws of the bracket -3- and remove the
catalytic converter downwards.
Continued for all vehicles

– Release the fixing screw -1- of the oil return pipe -2- and pull
the oil return pipe out of the exhaust gas turbocharger.
– Release the fixing screws of the heat shield -3- and remove
the panel from the exhaust manifold.

– Unscrew all the fixing nuts -arrows- of the exhaust manifold.

– Remove exhaust manifold with exhaust turbocharger from cyl‐
inder head.
– Remove the gasket from the stud bolts.
Install
– Position exhaust turbocharger with exhaust manifold and gas‐
ket at cylinder head.

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– Tighten the fixing nuts consecutively in three stages in the

specified order -1- to -8-.
Stage Tightening torque
1. 18 Nm
2. 12 Nm
3. 12 Nm

Caution

The fixing nuts are tightened to the prescribed tightening se‐

quence and in three stages.
If the tightening sequence is not kept, this could lead to an in‐
correct position of the gaskets of the exhaust gas turbocharger
and/or result in a drop of the tightening torque of some nuts.

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

note the following:

Note

♦ After installing the turbocharger, run engine at idling speed for

about 1 minute to ensure that oil is supplied to the turbocharg‐
er.
♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
♦ Fill the exhaust turbocharger with engine oil at the connection
fitting for the oil feed line.
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.
♦ Secure all hose connections with corresponding hose clips.

Tightening torques:
Exhaust gas turbocharger - Summary of components part I.
⇒ page 202 .
Exhaust gas turbocharger - Summary of components part lI
⇒ page 203 .
Catalytic converter and component parts - Summary of compo‐
nents:
♦ Fabia II, Roomster, Rapid NH ⇒ page 245 .
♦ Octavia II, Yeti ⇒ page 246 .
– Top up coolant ⇒ page 118 .

1. Exhaust gas turbocharger 207

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2 Charge air system with exhaust gas

turbocharger
Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 8 .

2.1 Charge air system - Summary of com‐

ponents
(Fabia II, Roomster, Rapid NH)

Note

♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
♦ The radiator and the charge air cooler are removed and in‐
stalled together ⇒ page 133 .

1 - Radiator
❑ removing and installing
⇒ page 135
2 - Intake manifold
❑ removing and installing
⇒ page 223
3 - Seal
❑ pay attention to correct
seating when installing
the charge air cooler
4 - Gasket
❑ replace if damaged
5 - Charge-air cooler in intake
manifold
❑ removing and installing
⇒ page 211
6 - Coolant hose
❑ to exhaust gas turbo‐
charger
7 - 7 Nm
❑ when installing first
tighten evenly by hand,
then tighten crosswise
from the inside to the
outside to the recom‐
mended tightening tor‐
que
8 - Coolant hose
❑ to the expansion reser‐
voir
9 - Hose clamp
❑ attached to the timing
case
10 - Coolant hose
❑ to exhaust gas turbocharger

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11 - Coolant recirculation pump -V50-

❑ removing and installing ⇒ page 125
12 - 8 Nm
13 - Support
14 - Connector
15 - 10 Nm
16 - Coolant hose
❑ to engine oil cooler
17 - Coolant pipe
❑ attached to the oil pan
18 - 8 Nm
19 - Bottom coolant hose
20 - Charge air cooler
❑ removing and installing ⇒ page 133

2.2 Charge air system - Summary of com‐

ponents
(Octavia II, Yeti)

Note

♦ This engine is fitted with a radiator combination of engine and

low temperature radiators for charge air system.
♦ Engine and low temperature radiators are arranged as one
component part.

2. Charge air system with exhaust gas turbocharger 209

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1 - Radiator with low tempera‐

ture radiator for charge air sys‐
tem
❑ removing and installing
⇒ page 133
2 - Intake manifold
❑ removing and installing
⇒ page 223
3 - Seal
❑ pay attention to correct
seating when installing
the charge air cooler
4 - Gasket
❑ replace if damaged
5 - Charge air cooler
❑ removing and installing
⇒ page 211
6 - Coolant hose
❑ to exhaust gas turbo‐
charger
7 - 7 Nm
❑ when installing first
tighten evenly by hand,
then tighten crosswise
from the inside to the
outside to the recom‐
mended tightening tor‐
que
8 - Coolant hose
❑ to the expansion reser‐
voir
9 - Hose clamp
❑ attached to the timing case
10 - Coolant hose
❑ to exhaust gas turbocharger
11 - Coolant recirculation pump -V50-
❑ removing and installing ⇒ page 125
12 - 8 Nm
13 - Support
14 - Connector
15 - 10 Nm
16 - Coolant hose
❑ to engine oil cooler
17 - Coolant pipe
❑ attached to the oil pan

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18 - 8 Nm
19 - Bottom coolant hose
20 - Inlet connections
21 - O-ring
❑ replace if damaged

2.3 Removing and installing charge air cool‐

er
Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094) -
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-

Note

Observe the general notes for assembly work on the charge air
system ⇒ page 8 .

Removing
– Disconnect plug -1- and hose -3- from activated charcoal filter
system solenoid valve 1 -N80- .
– Remove the lines with the non-return valve -5- and the acti‐
vated charcoal filter system solenoid valve 1 -N80- from the
intake manifold.
– Disconnect coolant hoses -3- with hose clamps -3094 - and
detach from charge-air cooler.
– Release the fixing screws of the ignition transformer -N152-
and carefully place the ignition transformer onto the cylinder
head cover.
– Release fixing screws at charge air cooler -4-.
– Carefully pull the charge air cooler -4- out of the intake mani‐
fold.

Note

Pour the residual coolant out of the charge air cooler into a col‐
lecting tank.

Install
Installation is performed in the reverse order, pay attention to the
following points:

2. Charge air system with exhaust gas turbocharger 211

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– Slide the seal -1- in -direction of arrow- onto the edge of the
charge air cooler -2-.
– Check the correct seating of the new gasket at the intake
manifold.
– Slide the charge air cooler into the intake manifold.
– Press down the charge-air cooler up to the stop into the intake
manifold.

Note

Do not tilt the charge-air cooler when installing.

– First tighten the fixing screws uniformly crosswise until the

screw heads are positioned.
– Tighten the fixing screws crosswise to the tightening torque: 7
Nm.

212 Rep. gr.21 - Turbocharging/supercharging

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24 – Mixture preparation - injection

1 Fitting location of the injection system

1.1 Fitting location of the injection system

(Fabia II, Roomster, Rapid NH)

1 - Oil pressure switch -F1-

❑ in the left cylinder head
❑ check ⇒ page 114
2 - Solenoid valve for coolant
circuit -N492-
3 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
4 - Intake manifold pressure
sender -G71- and intake air
temperature sender -G42-
5 - Control valve for fuel pres‐
sure -N276-
6 - Knock sensor 1 -G61-
❑ at rear cylinder block
❑ 20 Nm
7 - Hall sender -G40-
8 - Ignition transformer -N152-
♦ D ignition transformer = ig‐
nition cable cyl. 1
♦ B ignition transformer = ig‐
nition cable cyl. 2
♦ C ignition transformer = ig‐
nition cable cyl. 3
♦ A ignition transformer = ig‐
nition cable cyl. 4
9 - Injection valves
❑ Injection valve for cylin‐
der 1 -N30-
❑ Injection valve for cylin‐
der 2 -N31-
❑ Injection valve for cylinder 3 -N32-
❑ Injection valve for cylinder 4 -N33-
❑ with Teflon gasket ring and supporting washer
❑ after removing the injection valve, the Teflon gasket ring and the supporting washer must be replaced
⇒ page 235
❑ Remove and install injection valve ⇒ page 233
10 - Charge pressure sender -G31- with intake air temperature sender 2 -G299-
11 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 220
❑ clean ⇒ page 222

1. Fitting location of the injection system 213

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❑ in case of replacement, erase initialisation values and adapt the engine control unit -J623- ⇒ Vehicle
diagnostic tester.
12 - Engine control unit -J623-
❑ removing and installing ⇒ page 242
13 - Fuel pressure sender -G247-
❑ check ⇒ page 239
14 - Engine speed sender -G28-
❑ removing and installing ⇒ page 260
15 - Coolant temperature sender -G62-
16 - Thermo-switch for radiator fan -F18- , 35 Nm
❑ for fan
17 - Charge pressure regulator -V465 -

Note

18 - Lambda probe downstream of catalytic converter -G130- and heater of lambda probe 1 downstream of
catalytic converter -Z29-
19 - Spark plugs, 25 Nm
20 - lambda probe -G39- and heating for lambda probe -Z19-
21 - High pressure pump with fuel pressure regulating valve -N276-
❑ removing and installing ⇒ page 230

1.2 Fitting location of the injection system

(Octavia II, Yeti)

214 Rep. gr.24 - Mixture preparation - injection

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1 - Oil pressure switch -F1-

❑ in the left cylinder head
❑ check ⇒ page 114
2 - Solenoid valve for coolant
circuit -N492-
3 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
4 - Intake manifold pressure
sender -G71- and intake air
temperature sender -G42-
5 - Engine control unit -J623-
❑ removing and installing
⇒ page 243
6 - Control valve for fuel pres‐
sure -N276-
7 - Knock sensor 1 -G61-
❑ at rear cylinder block
❑ 20 Nm
8 - Hall sender -G40-
9 - Ignition transformer -N152-
♦ D ignition transformer = ig‐
nition cable cyl. 1
♦ B ignition transformer = ig‐
nition cable cyl. 2
♦ C ignition transformer = ig‐
nition cable cyl. 3
♦ A ignition transformer = ig‐
nition cable cyl. 4
10 - Injection valves
❑ Injection valve for cylin‐
der 1 -N30-
❑ Injection valve for cylinder 2 -N31-
❑ Injection valve for cylinder 3 -N32-
❑ Injection valve for cylinder 4 -N33-
❑ with Teflon gasket ring and supporting washer
❑ after removing the injection valve, the Teflon gasket ring and the supporting washer must be replaced
⇒ page 235
❑ Remove and install injection valve ⇒ page 233
11 - Charge pressure sender -G31- with intake air temperature sender 2 -G299-
12 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 220
❑ clean ⇒ page 222
❑ in case of replacement, erase initialisation values and adapt the engine control unit -J623- ⇒ Vehicle
diagnostic tester.
13 - Fuel pressure sender -G247-
❑ check ⇒ page 239
14 - Engine speed sender -G28-
❑ removing and installing ⇒ page 260

1. Fitting location of the injection system 215

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15 - Coolant temperature sender -G62-

16 - Coolant temperature sender at radiator outlet -G83-
17 - Charge pressure regulator -V465 -

Note

18 - Lambda probe downstream of catalytic converter -G130- and heater of lambda probe 1 downstream of
catalytic converter -Z29-
19 - Spark plugs, 25 Nm
20 - lambda probe -G39- and heating for lambda probe -Z19-
21 - High pressure pump with fuel pressure regulating valve -N276-
❑ removing and installing ⇒ page 230

216 Rep. gr.24 - Mixture preparation - injection

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2 Intake manifold and fuel distributor

2.1 Intake manifold - Summary of compo‐

nents
Part I. ⇒ page 218
Part II. ⇒ page 219

2. Intake manifold and fuel distributor 217

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2.1.1 Part I

1 - Connecting hose
❑ at camshaft housing
2 - Connector
❑ for intake manifold pres‐
sure sender -G71-
3 - Connector
❑ for solenoid valve for
coolant pump control
4 - 10 Nm
5 - Non-return valve
❑ for crankcase ventila‐
tion
6 - Connecting hose
❑ to exhaust gas turbo‐
charger
7 - O-ring
❑ replace
8 - Intake manifold
❑ removing and installing
⇒ page 223
❑ with intake manifold
pressure sender -G71-
♦ The intake manifold pres‐
sure sender -G71- is at‐
tached to the intake mani‐
fold only using a plastic clip.
♦ If the plastic clip is dam‐
aged, attach the sender to
the intake manifold with
screws ⇒ Electronic Cata‐
logue of Original Parts .
Tightening torque: 3 Nm.
9 - Connecting hose
❑ to the coolant pump
10 - Solenoid valve for coolant circuit -N492-
11 - Inlet connections
12 - Clamp
13 - Fuel hose
❑ to high pressure pump
14 - Solenoid valve 1 for activated charcoal filter -N80-
15 - Connecting hose
❑ to the activated charcoal filter system
16 - Connecting hose
17 - Connector
❑ for throttle valve control unit -J338-

218 Rep. gr.24 - Mixture preparation - injection

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18 - Connecting hose
19 - Connector
❑ for charge pressure sender -G31- with intake air temperature sender 2 -G299-

2.1.2 Part II

1 - Pressure pipe
2 - 7 Nm
3 - Retaining clip
4 - Fuel distributor
5 - Fuel pressure sender -
G247- , 22 Nm
❑ Check fuel pressure
sender -G247 -
⇒ page 239
6 - 20 Nm
7 - 30 Nm
8 - 25 Nm
9 - 25 Nm
10 - O-ring
❑ replace
11 - Spring element
❑ replace after each re‐
moval of the bottom part
of intake manifold
❑ check for correct seat‐
ing on injector
12 - Injection valve for cylinder
1 -N30-
❑ Injection valve for cylin‐
der 2 -N31-
❑ Injection valve for cylin‐
der 3 -N32-
❑ Injection valve for cylin‐
der 4 -N33-
❑ with Teflon gasket ring
and supporting washer
❑ after removing the injection valve, the Teflon gasket ring and the supporting washer must be replaced
⇒ page 235
❑ Remove and install injection valve ⇒ page 233
13 - Cylinder head
❑ removing and installing ⇒ page 94
14 - 20 Nm
15 - Intake manifold
❑ removing and installing ⇒ page 223
❑ with intake manifold pressure sender -G71-
♦ The intake manifold pressure sender -G71- is attached to the intake manifold only using a plastic clip.
♦ If the plastic clip is damaged, attach the sender to the intake manifold with screws ⇒ Electronic Catalogue
of Original Parts . Tightening torque: 3 Nm.

2. Intake manifold and fuel distributor 219

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16 - Gasket
❑ replace
17 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 220
❑ clean ⇒ page 222
❑ in case of replacement, erase initialisation values and adapt the engine control unit -J623- ⇒ Vehicle
diagnostic tester.
18 - Adapter
19 - O-ring
❑ replace
20 - O-ring
❑ replace
21 - 7 Nm
22 - O-ring
❑ replace
23 - O-ring
❑ replace
24 - Charge pressure sender -G31- with intake air temperature sender 2 -G299-
25 - 5 Nm

2.2 Removing and installing the throttle

valve control unit -J338-

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

Removing
For vehicles Fabia II, Roomster, Rapid NH
– Release screws -1- and remove retaining clip.
– Disconnect plug -2- at charge pressure sender -G31- with in‐
take air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
For the vehicles Octavia II, Yeti
– Release screws -1- and remove retaining clip.

220 Rep. gr.24 - Mixture preparation - injection

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– Disconnect plug -2- at charge pressure sender -G31- with in‐

take air temperature sender 2 -G299 - .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
Continued for all vehicles

– Disconnect the plug -1- from the throttle valve control unit -
J338 - .
– Release the fixing screws -2- and remove the throttle valve
control unit -J338- from the intake manifold.
Install
– Insert a new gasket ring in the groove of the intake manifold.

– Position the throttle valve control unit -3- together with the
adapter -2- and the fixing screws -1- onto the intake manifold
-4-.

– Tighten fixing screws -2- to 7 Nm.

– Fit the plug -1- at the throttle valve control unit -3-.

Note

Before fitting the O-rings at the exhaust turbocharger and in the

pressure pipe moisten slightly with engine oil.

For vehicles Fabia II, Roomster, Rapid NH

2. Intake manifold and fuel distributor 221

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– Fit the pressure pipe -3- at the turbocharger.

– Press the pressure pipe -3- onto the throttle valve control unit.
• During this procedure the retaining clips must click audibly into
place.
– Tighten screws -1- of retaining clip to 7 Nm.
– Connect plug -2- at charge pressure sender -G31- with intake
air temperature sender 2 -G299 - .
For the vehicles Octavia II, Yeti

– Fit the pressure pipe -3- at the turbocharger.

– Press the pressure pipe -3- onto the throttle valve control unit.
• During this procedure the retaining clips must click audibly into
place.
– Tighten screws -1- of retaining clip to 7 Nm.
– Connect plug -2- at charge pressure sender -G31- with intake
air temperature sender 2 -G299 - .
Continued for all vehicles
If a new throttle valve control unit was installed:
– Erase initialisation values and adapt the engine control unit -
J623- to the throttle valve control unit ⇒ Vehicle diagnostic
tester.

2.3 Clean throttle valve control unit -J338-

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .
♦ If a new engine control unit -J623- is fitted, the throttle valve
control unit must be adapted. The adaptation must only be
carried out with a new or cleaned throttle valve control unit,
because dirt/carbon deposits in the end stop of the throttle
valve can lead to incorrect adaptation values.
♦ The throttle valve support must not be scratched when clean‐
ing.

– Remove the throttle valve control unit ⇒ page 220 .

– Open the throttle valve manually and block the throttle valve
in the opened position with a suitable object (e.g. plastic or
wooden wedge)-arrow-.

WARNING

Acetone is easily inflammable. Observe the accident preven‐

tion regulations and the safety instructions when handling
easily inflammable fluids. Do not use compressed air when
cleaning the throttle valve. Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.

222 Rep. gr.24 - Mixture preparation - injection

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– Thoroughly clean the throttle valve support, in particular the

area of the closed throttle valve -arrows-, with commercially
available acetone and a paint brush.
– Wipe the throttle valve support with a lint-free cloth.
– Let the acetone dry off completely and re-install the cleaned
throttle valve control unit.
– Erase initialisation values and adapt the engine control unit -
J623- to the throttle valve control unit ⇒ Vehicle diagnostic
tester.

2.4 Removing and installing intake manifold

Special tools and workshop equipment required
♦ Pliers for spring strap clamps
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Remove top cover for ignition leads, if present.
– Remove the throttle valve control unit ⇒ page 220 .
– Disconnect the connecting hose -9- and the plug from the ac‐
tivated charcoal filter system solenoid valve 1 -N80- and re‐
move the valve from the intake manifold.
– Disconnect plug connections -1- and -4-.
– Release the fixing screws -7- and carefully place the ignition
transformer -N152- -6- onto the cylinder head cover.
– Detach connecting hose -5- from intake manifold.
– Disconnect the vacuum line of the solenoid valve for coolant
circuit -N492- -2- from the coolant pump.
– Pinch off coolant hoses for charge-air cooler with hose clamps
-MP7-601- .
– Slacken the clamps -3- and detach the coolant hoses from the
charge-air cooler.

2. Intake manifold and fuel distributor 223

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– Slacken the fixing screws -arrows- crosswise and carefully re‐

move the intake manifold upwards.

Note

Pour the residual coolant out of the charge air cooler into a col‐
lecting tank.

Install
Installation occurs in reverse order to removal.
Tightening torque of fixing screws for intake manifold: 20 Nm
Tightening torque and tightening sequence for charge-air cooler:
♦ Fabia II, Roomster, Rapid NH: ⇒ page 208 .
♦ Octavia II, Yeti: ⇒ page 209 .
– Check, top up and bleed cooling system ⇒ page 118 .

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3 Air filter

3.1 Air filter - Summary of components

(Fabia II, Roomster, Rapid NH)
Removing and installing air filter ⇒ page 226 .

1 - O-ring
❑ replace if damaged
2 - Inlet connection
3 - Spring strap clamp
❑ use hose binding claw ,
e.g. -VAS 6340- , for re‐
moving and installing
4 - Air intake hose
5 - Vacuum hose
❑ replace if damaged
❑ to cylinder head cover
6 - Intake hose with support
7 - Air filter top part
8 - 2 Nm
9 - Filter element
10 - Rubber-metal bearing
11 - Air filter bottom part
❑ removing and installing
⇒ page 226
12 - 8 Nm
13 - Rubber-metal bearing
14 - Water drain hose
15 - Intake air duct
16 - 3 Nm
17 - 10 Nm

3.2 Air filter - Summary of components

(Octavia II, Yeti)
Removing and installing air filter ⇒ page 227 .

3. Air filter 225

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1 - Air filter top part

2 - 2 Nm
3 - 2 Nm
4 - Support
5 - Filter element
6 - Rubber-metal bearing, 8
Nm
❑ with captive screw
7 - Seals
❑ replace if damaged
8 - Air filter bottom part
❑ removing and installing
⇒ page 227
9 - Rubber bearing
10 - Inlet connection
❑ with cover
11 - 2 Nm
12 - Intake air duct
13 - 2 Nm
14 - Spring strap clamp
❑ use hose binding claw ,
e.g. -VAS 6340- , for re‐
moving and installing
15 - Air intake hose
16 - Vacuum hose
❑ replace if damaged
❑ to cylinder head cover

3.3 Removing and installing air filter

(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
Removing
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew the fixing screws -arrows- of the intake air duct and
the inlet connection at the exhaust gas turbocharger.

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– Disconnect vacuum hose -1- from intake hose.

– Release the fixing screw -2- and pull the air filter housing to‐
wards the top from the bearing bolts.
Install
– Press the air filter housing from the top onto the bearing bolts.

– Tighten securing bolt -2- to 8 Nm.

– Connect vacuum hose -1- to intake hose.

– Tighten the fixing screws -arrows- of the intake air duct and
the inlet connection at the exhaust gas turbocharger.
– Install battery ⇒ Electrical System; Rep. gr. 27 .
Component Nm
Inlet connection at exhaust gas turbocharger. 10
Intake air duct 3

3.4 Removing and installing air filter

(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
Removing
– Press the catches -arrows- and take the cover -1- from the inlet
connection.
– Pull the inlet connection out of the intake air duct.
– Remove the spring strap clamp -2- with the intake hose from
the exhaust gas turbocharger.

3. Air filter 227

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– Detach vacuum hose -1- from air filter housing.

– Unscrew the fixing screw -2- and pull the air filter housing to‐
wards the top from the bearing bolts -3-.
Install
Installation is carried out in the reverse order. Pay attention to the
following:

– Press the air filter housing from the top onto the bearing bolts
-3-.
– Tighten securing bolt -2- to 8 Nm.
– Fit the vacuum hose -1- at the connection fitting of the air filter
housing.

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4 High pressure pump

4.1 High pressure pump - Summary of com‐

ponents

WARNING

The injection system consists of a high pressure part (max.

pressure of 12 MPa = 120 bar) and a low pressure part (pres‐
sure of approx. 0.6 MPa = 6 bar).
Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

1 - 20 Nm
2 - Fuel hose
❑ Low pressure
❑ with spring strap clamp
3 - Spring strap clamp
4 - Union nut, 25 Nm
❑ hold the connection fit‐
ting on the high pres‐
sure pump for loosening
5 - Union nut, 25 Nm
❑ hold the connection fit‐
ting on the high pres‐
sure pump for loosening
6 - High pressure pump with
fuel pressure regulating valve -
N276-
❑ removing and installing
⇒ page 230
7 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
8 - Roller tappet
❑ before fitting moisten
lightly with clean engine
oil
9 - Connector

4. High pressure pump 229

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4.2 Removing and installing the high pres‐

sure pump
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
Precondition
• The engine must be cold.
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.

WARNING

The injection system consists of a high pressure part (max.

pressure of 12 MPa = 120 bar) and a low pressure part (pres‐
sure of approx. 0.6 MPa = 6 bar).
Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

– Remove top cover for ignition leads, if present.

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– Disconnect the plug -1- and the fuel feed line -2- from the high
pressure pump.

Note

Collect the fuel which flows out with a cleaning cloth.

– Slacken the union nuts -3- at the high pressure line.

Note

Hold the screwed connections at the high pressure pump and at

the fuel distributor when slackening the union nuts with a wrench.

– Uniformly release the fixing screws -4- and remove the high
pressure pump with roller tappet from the cylinder head cover.
Install

Note

♦ Moisten the roller tappet of the high pressure pump with clean
engine oil.
♦ Always replace the O-ring of the high pressure pump.

– Slide the roller tappet -1- into the camshaft housing.

– Insert a new, oiled O-ring -2- into the slot of the high pressure
pump -3-.
– Position the high pressure pump -3- on the cylinder head cov‐
er.

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– First of all screw in the fixing screws -4- sufficiently until the
bolt heads are positioned on the flange.
– Then tighten the fixing screws -4- evenly.
Tightening torque: 20 Nm
– Screw on the union nuts of the high pressure line -3- by hand.

Note

Hold the screwed connections at the high pressure pump and at

the bottom part of intake manifold/fuel distributor when tightening
the union nuts with a wrench.

– Tighten the union nuts -3- at the high pressure line to 25 Nm.
– Attach the fuel feed line -2- and the plug -1- on the high pres‐
sure pump.
Further installation occurs in a similar way in reverse order to re‐
moval.

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5 Injection valves

5.1 Removing and installing injection valves

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .
♦ Observe the safety instructions before starting fitting work
⇒ page 6 .

Note

The Teflon gasket ring on the injection valve must be replaced

each time after removing the injection valve ⇒ page 235 .

Special tools and workshop equipment required

♦ Set of tools -T10133-
Removing
For vehicles Fabia II, Roomster, Rapid NH
– Release screws -1- and remove retaining clip.
– Disconnect plug -2- at charge pressure sender -G31- with in‐
take air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
For the vehicles Octavia II, Yeti
– Release screws -1- and remove retaining clip.

– Disconnect plug -2- at charge pressure sender -G31- with in‐

take air temperature sender 2 -G299 - .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
Continued for all vehicles
– Remove the high pressure pump ⇒ page 230 .

5. Injection valves 233

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– Release the fixing screws -arrows- and carefully remove the

fuel distributor from the injection valves.

– Press the O-ring upwards by hand as shown and remove it

from the injection valve.
– Screw the striking hammer -T10133/3- with the extractor -
T10133/15- .

– Then insert the extractor -T10133/15- into the groove -arrow-

on the injection valve.

– Pull out the injection valve with careful knocks.

Install

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– Thoroughly clean the holes of the injection valves in the cyl‐

inder head with the nylon brush -T10133/4- .
– Check the supporting washer made of plastic for damage, re‐
place if necessary ⇒ page 235 .

– Replace the spring element -arrow- as well as the Teflon gas‐

ket ring each time after removing the injection valves
⇒ page 235 .
– Replace O-rings between injection valve and bottom part of
the intake manifold and moisten lightly with clean engine oil.

Note

♦ The Teflon gasket ring of the injection valve must neither be

oiled nor greased.
♦ The injection valve must insert easily, if necessary wait until
the gasket ring has been drawn together sufficiently.

– Press the injection valve -1- by hand up to the stop into the
hole of the cylinder head. The injection valve should be press‐
ed evenly into the countersink -2- on the cylinder head.

Note

♦ The injection valve must never rest against the countersink

edge on the cylinder head -arrow A-, but it must always be
pressed evenly into the countersink -2- on the cylinder head.
♦ After installing, carry out a visual inspection of the fitting loca‐
tion of the injection valve.

Further installation occurs in a similar way in reverse order to re‐

moval.

5.2 Replace Teflon gasket ring and support‐

ing washer at injection valve

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

Special tools and workshop equipment required

5. Injection valves 235

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♦ Set of tools -T10133-

Work procedure
Replace Teflon gasket ring
– Remove injection valves ⇒ page 233 .
– Carefully clean the injection valve.
– Carefully cut open the gasket ring with a knife as shown
-arrow-. Absolutely try to avoid the contact of the knife blade
with the valve body.
– Remove the old gasket ring and clean the gasket ring nut in
the area of the gasket ring -arrow-. Remove the existing de‐
posits (carbon deposits) with a wire brush.

– Fit a new gasket ring -1- onto the assembly cone -T10133/5- .
Slightly push the gasket ring with the assembly sleeve -
T10133/6- (knurling points to the gasket ring -1-) as far as
possible onto the assembly cone -T10133/5 - .

– Turn the assembly sleeve -T10133/6 - around (now the knurl‐

ing points away from the gasket ring), and push the gasket ring
-1- up to the end onto the assembly cone -T10133/5 - .
– Now position the assembly cone -T10133/5- with the gasket
ring from the front onto the injection valve. Push the gasket
ring with the assembly sleeve -T10133/6- further onto the in‐
jection valve.

The gasket ring is not yet seated in its groove.

– Remove the assembly sleeve -T10133/6 - and the assembly
cone -T10133/5- .
– Push the gasket ring by hand into the annular groove.
– Fit the spacer sleeve -T10133/11 - onto the valve body.

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– Now press the calibration sleeve - T10133/7- via the gasket

ring up to the stop at the spacer sleeve -T10133/11- .
– Pull off again the calibration sleeve -T10133/7- .

– Now press the calibration sleeve - T10133/8- via the gasket

ring up to the stop at the spacer sleeve -T10133/11- .
– Pull off again the calibration sleeve -T10133/8- .
Now the Teflon gasket ring has its correct fitting dimension.
Replace supporting washer

– Remove O-ring -3-.

– Cut open the supporting washer -2- with a small side cutter
and take it off.
– Pull off the spring element at the injection valve -1- and instead
push on the lock washer -T10133/12 - .

– Mount a new supporting washer -1- on the assembly cone -

T10133/13- and fit it onto the injection valve as shown.
– Push the supporting washer -1- with the calibration sleeve -
T10133/14- (knurled side points to the injection valve) up to
the first nut -arrow- onto the injection valve.

5. Injection valves 237

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– Now turn the calibration sleeve -T10133/14- around (knurled

side points away from the injection valve). Push the calibration
sleeve via the supporting washer -1- in -direction of arrow- up
to the stop on the lock washer -T10133/12- .
– Pull off again the calibration sleeve -T10133/14- .
Now the supporting washer has its correct fitting dimension.

– Now fit a new spring element -1- for the lock washer -
T10133/12 - and push a new O-ring -3- in front of the support‐
ing washer -2-.

Note

The Teflon gasket ring -arrow- must not be oiled when installing
the injection valve.

– Install injection valves ⇒ page 233 .

Further installation occurs in reverse order to removal.

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6 Testing components

6.1 Check fuel pressure sender -G247-

Special tools and workshop equipment required
♦ Assembly device -T10118-
♦ Open ring spanner with 3/8" drive, SW 27 mm
♦ Pressure sensor tester , e.g. -VAS 6394- (includes digital
manometer -VAS 6394/1- )
♦ Adapter , e.g. -VAS 6394/3-
♦ Test adapter , e.g. -VAS 5570-

WARNING

The injection system consists of a high pressure part (max.

pressure of 12 MPa = 120 bar) and a low pressure part (pres‐
sure of approx. 0.6 MPa = 6 bar).
Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

Work procedure
– Disconnect plug -1- and remove fuel pressure sender -G247-
-2-.
For vehicles Fabia II, Roomster, Rapid NH

For the vehicles Octavia II, Yeti

– Moisten the sealing cone of the adapter -VAS 6294/3- with
clean engine oil and screw it into the fuel distributor.

6. Testing components 239

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For vehicles Fabia II, Roomster, Rapid NH

For the vehicles Octavia II, Yeti

Continued for all vehicles
Tightening torque: 22 Nm

– Release the screw plug -2- and screw the fuel pressure sender
-G247- into the tester -VAS 6394/1- .
Tightening torque: 22 Nm
– Connect the pressure line -1- of the digital manometer -VAS
6394/1- onto the adapter -VAS 6394/3- .

– Connect the test adapter -VAS 5570- to the fuel pressure

sender -G247- -1- and to the engine plug.

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– Switch on the tester -VAS 6394/1 - , for this step, briefly press
the button -A- once.

Note

♦ If the button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If the tester -VAS 6394/1- does not indicate 0 MPa (0 bar),
carry out a zero point of the balance by means of the ⇒ op‐
erating instructions .

– Connect the vehicle diagnosis, measurement and information

system -VAS 505X- -1- to the diagnostic connection.
– Switch on ignition.
– On the display press consecutively the following buttons:
Targeted functions

CBZA,CBZB engine (UDS) ►

Reading measured value block ►

The actual value which is transmitted to the vehicle by the fuel

pressure sender -G247- is shown in the display field high pres-
sure fuel, actual value .

– Start engine.
– Compare the displayed pressure on the digital manometer -
VAS 6394/1- with the actual value on the vehicle diagnosis,
measurement and information system -VAS 505X- .
• The pressures may deviate maximum 0.5 MPa (5000 hPa)
from one another.
If the deviation is greater than 0.5 MPa (5000 hPa) oder (5 bar):
– Perform a vehicle diagnosis, measurement and information
system -VAS 505X- of the guided function “remove high fuel
pressure”.
– Replace fuel pressure sender -G247- .
– Repeat the test with the new fuel pressure sender -G247- and
compare both measured values.
If the measured values do not correspond again:
– Perform a cable testing ⇒ Vehicle diagnostic tester.

6. Testing components 241

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7 Engine control unit

7.1 Removing and installing engine control

unit -J623-
(Fabia II, Roomster, Rapid NH)

Note

♦ Before replacing the engine control unit -J623- first the control
unit identification and hence the coding of the current control
unit with the ⇒ Vehicle diagnostic tester must be interrogated.
♦ If replacing, the throttle valve control unit -J338- must be
cleaned ⇒ page 222 before adapting a new control unit.

Special tools and workshop equipment required

♦ Body saw, e.g. body saw -V.A.G 1523/A-
Removing
– Switch off ignition.
– Press the bracket -arrows- outwards and pull the engine con‐
trol unit out sideways.
For vehicles with protective cover
– Cut with body saw a slot for the cross-head screwdriver in the
heads of the pull-off screws.

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Note

It must be sawed twice with the body saw, so that the slot is wide
enough, in order to be able to unscrew the screws with a suitable
screwdriver.

– Screw out the screws.

– Remove protective cover of control unit.
For all vehicles
– Disconnect plug at engine control unit and unplug.
Install
Connect both plugs and lock.
For vehicles with protective cover
– Insert protective cover and fix with new pull-off screws at en‐
gine control unit.
For all vehicles
Insert the control unit into the pressure retaining clips on the body.
– When replacing the control unit, adapt the engine control unit
⇒ Vehicle diagnostic tester

7.2 Removing and installing engine control

unit -J623-
(Octavia II, Yeti)
Special tools and workshop equipment required
♦ Body saw, e.g. body saw -V.A.G 1523/A-

Note

♦ In order to unplug the plugs from the control unit, the control
unit must always be removed.
♦ If the engine control unit is replaced, connect the vehicle di‐
agnosis, measurement and information system -VAS 505X-
and carry out the function “replace engine control unit”.

Removing
– Switch off ignition.
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Remove bulkhead plenum chamber -arrows-.

7. Engine control unit 243

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– Open retaining clip -arrow- and remove engine control unit -

J623 - .
Vehicles with protective cover

– Cut with body saw a slot for the cross-head screwdriver in the
heads of the pull-off screws -3 and 4-.

Note

♦ In order to be able to unscrew the screws with a suitable

screwdriver, the slot must be wide enough. This is achieved
by sawing twice with the body saw.
♦ A locking agent is applied to the pull-off screws.

– Unscrew the screws and remove the protective cover for the
plug connections -2 and 5-.
Continued for all vehicles
– Unlock both plugs at engine control unit and unplug.
Install
– Connect both plugs and lock.
Vehicles with protective cover
– Fasten protective cover with new pull-off screws.
– Tighten pull-off screws evenly until the screw heads are pulled
off.
Continued for all vehicles

– Push engine control unit into the bracket and lock with retain‐
ing clip -arrow-.
– Install the plenum chamber cover ⇒ Body Work; Rep. gr. 66 .

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26 – Exhaust system
1 Removing and installing parts of the
exhaust system

1.1 Catalytic converter and component

parts - Summary of components
(Fabia II, Roomster, Rapid NH)

1 - Lambda probe -G39- , 50

Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for a re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3-
❑ the hot bolt paste -G 052
112 A3- must not come
into contact with the
slots of the probe body
2 - 23 Nm
❑ replace
❑ Coat pin screws of ex‐
haust manifold with ex‐
haust gas turbocharger
using hot bolt paste -G
052 112 A3-
❑ pay attention to mount‐
ing instructions and or‐
der for tightening
⇒ page 246
3 - Catalytic converter with ex‐
haust pipe
removing and installing
⇒ page 253
❑ pay attention to mount‐
ing instructions and or‐
der for tightening
⇒ page 246
❑ with decoupling element
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Secure the decoupling element with the transport device -T10403- against overtensioning and flexion
4 - Gasket
❑ replace
5 - Retaining strap
6 - Clamping sleeve, 25 Nm
❑ Tighten bolted connections evenly
❑ Fitting position ⇒ page 255

1. Removing and installing parts of the exhaust system 245

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7 - Retaining strap
8 - Gasket
❑ replace
9 - 25 Nm
❑ replace
❑ Coat pin screws of exhaust pipe with hot bolt paste -G 052 112 A3-
10 - 20 Nm
11 - Support
12 - Exhaust gas turbocharger
❑ removing and installing ⇒ page 203
❑ The exhaust gas turbocharger with charge pressure regulator -V465- and exhaust manifold can only be
replaced together
13 - Heat shield
14 - 10 Nm
❑ first of all screw in all fixing screws by hand when installing
15 - Heat shield
16 - 10 Nm
17 - 10 Nm
18 - Lambda probe downstream of catalytic converter -G130- , 50 Nm
❑ the thread of new lambda probes must be coated with assembly paste
❑ for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3- ; the paste must not
get into the slots of the probe body
19 - 10 Nm
20 - 25 Nm

Catalytic converter with exhaust pipe - mounting instructions and

order of tightening
Tighten nuts and screws in 4 stages:
Stage Screws/nuts Tightening torque
1. -Arrows- Tighten nuts by
hand up to contact
surface.
2. -1- 25 Nm
3. -2- 25 Nm
4. -Arrows- 23 Nm

1.2 Catalytic converter and component

parts - Summary of components
(Octavia II, Yeti)

246 Rep. gr.26 - Exhaust system

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1 - Lambda probe -G39- , 50

Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3- ;
the paste must not get
into the slots of the
probe body
2 - 23 Nm
❑ replace
❑ Coat stud bolts of the
turbocharger with hot
bolt paste -G 052 112
A3- .
❑ pay attention to mount‐
ing instructions and or‐
der for tightening
⇒ page 248
3 - Catalytic converter with ex‐
haust pipe
❑ pay attention to mount‐
ing instructions and or‐
der for tightening
⇒ page 248
4 - Gasket
❑ replace
5 - Gasket
❑ replace
6 - Intermediate pipe
7 - Clamping sleeve, 23 Nm
❑ Tighten bolted connections evenly
8 - 25 Nm
❑ replace
9 - Exhaust pipe
❑ with decoupling element
❑ do not twist decoupling element more than 10° - risk of damage
❑ Secure the decoupling element against over-tensioning and bending by means of the transport security
-T10403- .
10 - Hanger
11 - 25 Nm
12 - 25 Nm
❑ replace
13 - Gasket
❑ replace
14 - 25 Nm
❑ replace
❑ Coat pin screws of exhaust pipe with hot bolt paste -G 052 112 A3-

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15 - 20 Nm
16 - Support
17 - Exhaust gas turbocharger
❑ removing and installing ⇒ page 203
❑ The exhaust gas turbocharger with charge pressure regulator -V465- and exhaust manifold can only be
replaced together
18 - Heat shield
19 - 10 Nm
❑ first of all screw in all fixing screws by hand when installing
20 - Heat shield
21 - 10 Nm
22 - 10 Nm
23 - Lambda probe downstream of catalytic converter -G130- , 50 Nm
❑ the thread of new lambda probes must be coated with assembly paste
❑ for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3- ; the paste must not
get into the slots of the probe body
24 - 10 Nm
25 - 25 Nm
❑ pay attention to mounting instructions and order for tightening ⇒ page 248

Catalytic converter with exhaust pipe - mounting instructions and

order of tightening
Tighten nuts and screws in 4 stages:
Stage Screws/nuts Tightening torque
1. -Arrows- Tighten nuts by
hand up to contact
surface.
2. -1- 25 Nm
3. -2- 25 Nm
4. -Arrows- 23 Nm

1.3 Middle and rear silencer - Summary of

components
(Fabia II)

248 Rep. gr.26 - Exhaust system

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1 - Middle and rear silencer

❑ for first equipment a
building unit
❑ Replace individually
when carrying out re‐
pairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust
system ⇒ page 255
2 - Separation point
❑ for repairs
❑ marked with recesses
around the circumfer‐
ence
3 - Rear retaining strap
❑ Pay attention to the part
number
❑ replace if damaged
4 - 25 Nm
5 - Retaining strap
❑ Pay attention to the part
number
❑ replace if damaged

1.4 Middle and rear silencer - Summary of

components
(Roomster, Rapid NH)

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1 - The middle silencer

❑ for first equipment build‐
ing unit with rear silenc‐
er; replace individually
when carrying out re‐
pairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust
system ⇒ page 255
2 - Retaining strap
❑ Pay attention to the part
number
❑ replace if damaged
3 - 25 Nm
4 - Rear silencer
❑ for first equipment build‐
ing unit with middle si‐
lencer; replace individu‐
ally when carrying out
repairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust
system ⇒ page 255
5 - Rear retaining strap
❑ Pay attention to the part
number
❑ replace if damaged

1.5 Middle and rear silencer - Summary of

components
(Octavia II)

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1 - From pre-exhaust pipe with

catalytic converter
2 - Hanger
❑ replace if damaged
3 - Retaining strap
❑ replace if damaged
4 - 23 Nm
5 - Clamping sleeve
❑ Tighten bolted connec‐
tions evenly
❑ Fitting position
⇒ page 255
6 - 23 Nm
7 - Rear silencer
❑ for first equipment build‐
ing unit with middle si‐
lencer; replace individu‐
ally when carrying out
repairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust
system ⇒ page 255
8 - Hanger
❑ replace if damaged
9 - Tunnel bridge
10 - The middle silencer
❑ for first equipment build‐
ing unit with rear silenc‐
er; replace individually
when carrying out repairs
❑ Align exhaust system free of stress ⇒ page 256
❑ Separate the exhaust system ⇒ page 255

1.6 Middle and rear silencer for vehicles

manufactured up to 06.10 - Summary of
components
(Yeti)

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1 - Hanger
❑ replace if damaged
2 - 23 Nm
3 - 20 Nm
4 - Tunnel bridge
5 - Retaining strap
❑ replace if damaged
6 - Rear silencer
❑ for first equipment build‐
ing unit with middle si‐
lencer; replace individu‐
ally when carrying out
repairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust
system ⇒ page 255
7 - Hanger
❑ replace if damaged
8 - The middle silencer
❑ for first equipment build‐
ing unit with rear silenc‐
er; replace individually
when carrying out re‐
pairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust
system ⇒ page 255
9 - Clamping sleeve, 23 Nm
❑ Tighten bolted connections evenly
❑ Fitting position ⇒ page 255
10 - 23 Nm
11 - Hanger
❑ replace if damaged

1.7 Middle and rear silencer for vehicles

manufactured as of 06.10 - Summary of
components
(Yeti)

252 Rep. gr.26 - Exhaust system

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1 - 23 Nm
2 - Hanger
❑ replace if damaged
3 - Retaining strap
❑ replace if damaged
4 - Hanger
❑ replace if damaged
5 - 23 Nm
6 - Rear silencer
❑ for first equipment build‐
ing unit with middle si‐
lencer; replace individu‐
ally when carrying out
repairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust
system ⇒ page 255
7 - Retaining strap
❑ replace if damaged
8 - Retaining strap
❑ replace if damaged
9 - The middle silencer
❑ for first equipment build‐
ing unit with rear silenc‐
er; replace individually
when carrying out re‐
pairs
❑ Align exhaust system
free of stress
⇒ page 256
❑ Separate the exhaust system ⇒ page 255

1.8 Removing and installing catalytic con‐

verter with pre-exhaust pipe
(Fabia II, Roomster, Rapid NH)
Special tools and workshop equipment required
♦ Ring spanner set for lambda probe
♦ Hot screw paste -G 052 112 A3-

1. Removing and installing parts of the exhaust system 253

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Removing
– Remove lambda probe -G39- -1-.
– Remove V-ribbed belt ⇒ page 35 .
– Unscrew top fixing screw for generator -2- and press the gen‐
erator downwards.
– Release the fixing screws -arrows- and remove the heat
shield.

– Remove securing nuts -arrows-.

– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .

– Disconnect plug connection -1- and lambda probe down‐

stream of catalytic converter -G130- .

– Loosen the nuts -arrows- at the front clamping sleeve and

push the sleeve onto the middle silencer.

Note

♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ Do not bend the decoupling element by pulling it.
♦ Do not damage the wire mesh of the decoupling element.
♦ Secure the decoupling element with the transport security -
T10403- against overtensioning.

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– Unscrew screws -1- of bracket for catalytic converter.

– Take the bolts of the exhaust pipe out of the retaining straps
-2- and remove the catalytic converter with the pre-exhaust
pipe downwards.
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ pay attention to mounting instructions and order for tightening
⇒ page 246
♦ Tightening torques ⇒ page 245 .

1.9 Replacing middle or rear silencer

Special tools and workshop equipment required
♦ Body saw e.g. -V.A.G 1523 A -
♦ Protective goggles

Note

♦ For individually replacing the front or rear silencer, a separa‐

tion point is provided in the connecting pipe.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.

WARNING

In order to avoid injuries from metal swarfs, wear safety gog‐

gles and safety clothing.

– Separate exhaust pipe at right angles at the separation point

-arrow 2- with body saw.
For the vehicles Fabia II, Roomster

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For the vehicles Octavia II, Yeti

Continued for all vehicles
– When installing, position clamping sleeve -4- at the side mark‐
ings -arrow 1- and -arrow 3-.

– Turn the clamping sleeve in such a way that the ends of the
screws -arrow- do not protrude beyond the bottom edge of the
clamping sleeve.
– Align the rear silencer horizontally and tighten the clamping
sleeve to 23 Nm.
– Align exhaust system in cold condition free of stress
⇒ page 256 .

1.10 Aligning exhaust system free of stress

• The exhaust system is aligned when cold.
– Slacken the nuts at the clamping sleeve -1- and align the in‐
termediate pipe -2- (-arrow- points in direction of travel).
-a- = 5 mm

The fixing screws must be located on the right. The screws must
not protrude beyond the bottom edge of the clamping sleeve
-arrow-.
– Tighten the front nut by hand.
For the vehicles Fabia II, Roomster

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– Push the middle and rear silencer forward until the dimension
-a- = 3 … 7 mm is obtained on the retaining strap/middle si‐
lencer.
For the vehicles Octavia II, Yeti

– Push the exhaust system so far forward until the dimension

-a- of 7…9 mm is achieved between hanger/body and hanger/
middle silencer.
Continued for all vehicles
– Tighten bolted connections of the clamping sleeve evenly to
23 Nm.
For the vehicles Octavia II, Yeti

Align the exhaust tailpipe version l.

– Align rear silencer in such a way that there is an equal distance
-a- right and left between bumper opening and exhaust tail‐
pipe.
– For centering the exhaust tailpipe, if necessary loosen the
suspension of the rear silencer.
Align the exhaust tailpipes version ll.

– Align rear muffler in such a way that there is

• an equal distance -a- between bumper opening and exhaust
tailpipe.
• the distance -b- from the bumper opening to the exhaust tail‐
pipes is equal.
For centering, if necessary the hangers of the exhaust system
must be loosened.

1.11 Inspecting the exhaust system for leak‐

tightness
– Start engine and run in idle.
– Seal off exhaust tailpipes for the duration of the leak check
(e.g. with cloth or plug).

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– Inspect connection points of cylinder head/exhaust manifold,

exhaust gas turbocharger/exhaust pipe etc. for tightness by
listening and visual inspection.
– Eliminate any leak found.

258 Rep. gr.26 - Exhaust system

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28 – Ignition system
1 Ignition system

1.1 Ignition system - Summary of components

1 - Cable guide
2 - 8 Nm
3 - Cap
❑ mounted up to
06.11.2011
❑ the cover for the ignition
leads is installed as of
07.11.2011
4 - Connector
5 - Hall sender -G40-
6 - 10 Nm
7 - Ignition cable with spark
plug connector
❑ Remove the spark plug
connector from the
spark plugs using the
extractor -T10112 A- .
♦ D ignition transformer = ig‐
nition cable cyl. 1
♦ B ignition transformer = ig‐
nition cable cyl. 2
♦ C ignition transformer = ig‐
nition cable cyl. 3
♦ A ignition transformer = ig‐
nition cable cyl. 4
8 - Spark plug, 25 Nm
9 - Knock sensor 1 -G61-
❑ at rear cylinder block
❑ 20 Nm
10 - Connector
11 - 20 Nm
❑ the tightening torque influences the knock sensor function
12 - Ignition transformer -N152-
♦ D ignition transformer = ignition cable cyl. 1
♦ B ignition transformer = ignition cable cyl. 2
♦ C ignition transformer = ignition cable cyl. 3
♦ A ignition transformer = ignition cable cyl. 4
13 - Engine speed sender -G28-
❑ removing and installing ⇒ page 260

1. Ignition system 259

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14 - 5 Nm
15 - 7 Nm

1.2 Removing and installing engine speed

sender -G28-
Special tools and workshop equipment required
♦ Socket insert -T10370-
Removing
– Disconnect plug -arrow- from engine speed sender -G28- .
– Unscrew fixing screw of engine speed sender -G28- with sock‐
et insert -T10370 - .
– Remove engine speed sender -G28- from cylinder block.
Install
– Install engine speed sender -G28- and tighten the fixing screw
to 5 Nm.
Further installation occurs in a similar way in reverse order to re‐
moval.

260 Rep. gr.28 - Ignition system