SKODA Fabia II 2007, Fabia II 2009, Fabia II 2011, Octavia II 2004, Octavia II 2010 Workshop Manual

Service

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Workshop Manual

Fabia II 2007 ➤ , Fabia II 2009 ➤ ,

Fab

ia II 2011 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Rapid 2011 ➤ ,
Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Roomster 2006 ➤ , Superb II 2008 ➤ ,
Superb II 2011 ➤ , Yeti 2010 ➤ ,
Yeti 2011 ➤

1.5/77; 1.6/55; 66; 77 kW TDI CR engine

Engine ID

Edition 05.2014

CAYACAYBCAYCCLNACWX

B

Service Department. Technical Information

Service

GETtheMANUALS.org

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

Re

pa ir G ro up

00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

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Contents

00 - Technical data

1 Identification

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

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Regulations concerning safety precautions when working on the fuel system . . . . . . . . . . 3

3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5 Assembly of radiators and capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.6 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.7 Supplementary instructions and assembly work on vehicles with an air conditioning

system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10 - Removing and installing engine

1 Removing and installing engine

1.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.5 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1.6 Checking and adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

13 - Crankshaft group

1 Removing and installing a V-ribbed belt and a toothed belt

1.1 Assembly overview - Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.3 Removing and installing crankshaft-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.4 Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . 68

1.5 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.6 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.7 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.1 Summary of components - sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.2 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

2.3 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 117

2.4 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

2.5 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

3.2 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3.3 Piston and conrod - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.4 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

3.5 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

3.6 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

. . . . . . . . . . . . . . . . . . . . . . . . 57

15 - Cylinder head, valve gear

1 Removing and installing cylinder head

1.1 Cylinder head cover - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1.3 Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Contents i

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1.4 Removing and installing cylinder head

1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1.6 Removing and installing the vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.7 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

2.2 Replacing camshaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

2.4 Measuring the axial play of the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

2.5 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

2.6 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

2.7 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

17 - Lubrication

1 Removing and installing parts of the lubrication system

1.1 Removing and installing parts of the lubrication system - Summary of components . . . . . . 189

1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 191

1.3 Oil filter holder - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

1.4 Removing and installing the oil filter holder with the engine oil cooler . . . . . . . . . . . . . . . . 194

1.5 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

1.6 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

1.7 Summary of components - oil feed line, oil return line and exhaust gas turbocharger

support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

1.8 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1.9 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1.10 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

. . . . . . . . . . . . . . . . . . . . . . . . . . 189

19 - Cooling

1 Cooling system

1.1 Summary of components - Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . 214

1.2 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1.4 Remove and install coolant recirculation pump 2 V178 . . . . . . . . . . . . . . . . . . . . . . . . . . 233

1.5 Replace coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

2 Coolant pump and coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

2.1 Summary of components - coolant pump and coolant thermostat . . . . . . . . . . . . . . . . . . . . 240

2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

2.4 Testing coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

3 Coolers, radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

3.2 Fan shroud with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

3.3 Removing and installing fan shroud with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

3.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

3.5 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

20 - Fuel supply system

1 Measures in case of misfuelling

1.1 Step 1, engine started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1.2 Step 2, the engine was not started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

1.3 Step 3, metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . . . 270

1.4 Step 4, no metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . 270

1.5 Step 5: Metal swarfs present in high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

1.6 Step 6: no metal swarfs are present in the high pressure pump . . . . . . . . . . . . . . . . . . . . 271

2 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 273

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

ii Contents

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2.1 Fuel tank with attached parts

2.2 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

2.3 Drain fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

2.4 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

2.5 Venting air from the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

2.6 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

2.7 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

2.8 Removing and installing the sender for fuel gauge display . . . . . . . . . . . . . . . . . . . . . . . . 300

2.9 Removing and installing suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

2.10 Separating quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

2.11 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

2.12 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

2.13 Identification mark of the different low-pressure fuel systems . . . . . . . . . . . . . . . . . . . . . . 334

3 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

3.1 Accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

3.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

3.3 Disconnect connector for accelerator pedal module and fit on . . . . . . . . . . . . . . . . . . . . . . 340

21 - Turbocharging/supercharging

1 Charge-air system - exhaust gas turbocharger

1.1 Exhaust gas turbocharger with component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

1.3 Replace vacuum positioning element for charge pressure regulation with position sender for

charge pressure regulator G581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

1.4 Removing and installing the exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . 360

1.5 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

1.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

2 Charge-air system - radiator, leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

2.1 Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

2.3 Hose connections with screw clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

2.4 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

23 - Mixture preparation - injection

1 Diesel direct injection system - fitting locations, system overview

1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

1.2 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

1.3 Filling/bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

2 Fuel system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

2.1 Fuel system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

2.2 Injection units (piezo injectors) - Summary of components and fitting position of the clamping

claw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

2.3 Removing and installing injection unit (piezo injector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

2.4 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

2.5 Installing the high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

2.6 Replace fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

2.7 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

2.8 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

2.9 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

2.10 Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

2.11 Checking return flow quantity of injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

2.12 Carry out the vacuum test of the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

2.13 Check the pressure holding valve in the fuel return-flow line . . . . . . . . . . . . . . . . . . . . . . . . 411

3 Intake manifold, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

3.1 Intake manifold with component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

. . . . . . . . . . . . . . . . . . . . 375

Contents iii

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3.2 Removing and installing intake manifold

3.3 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 422

3.4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

3.5 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

4.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

26 - Exhaust system

1 Removing and installing parts of the exhaust system

1.1 Pre-exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

1.2 Tighten exhaust temperature sender 3 G495 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

1.3 Removing and installing differential pressure sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 447

1.4 Tighten exhaust temperature sender 4 G648 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

1.5 Middle and rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

1.6 Removing and installing exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

1.7 Replacing the catalytic converter and the middle part of the exhaust system . . . . . . . . . . 472

1.8 Replacing the middle and rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . 473

1.9 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

1.10 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478

2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479

2.1 Exhaust gas recirculation with radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . 479

2.2 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 482

2.3 Check changeover of radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . 486

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

28 - Glow plug system

1 Glow Plug System

1.1 Removing and installing, testing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488

iv Contents

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00 – Technical data

1 Identification

(SRL000691; Edition 05.2014)

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

1.1 Engine number, engine data

The engine number (“engine identification characters” and “serial
number”) is located in the front at the engine/gearbox joint

-arrow-.
In addition, a sticker with the “engine identification characters”

and “serial number” is affixed to the timing belt guard.
The engine identification characters are also indicated on the ve‐

hicle data sticker.
Vehicles with four-digit engine identification characters
♦ 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.

Engine identifica‐
tion characters

Manu‐
fac‐
tured

Exhaust limit val‐
ues conforming to

Dis‐
place‐
ment

Power
output

Tor‐
que

Bore ∅ mm 79.5 79.5 79.5 79.5 77.0
Stroke mm 80.5 80.5 80.5 80.5 80.5
Cylinder / valves

per cylinder
Compression ratio 16.5 16.5 16.5 16.5 16.5
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

Fabia II 03.2010 ► 03.2010 ► 03.2010 ► ---- ----

Roomster ---- 03.2010 ► 03.2010 ► ---- ---­Octavia II ---- ---- 06.2009 ► ---- ---­Superb II ---- ---- 09.2010 ► ---- ---­Yeti ---- ---- 11.2010 ► ---- ---­Rapid In‐

dia
Rapid NH ---- 08.2013 ► 07.2012 ► 02.2013 ► ----

kW at rpm 55/4000 66/4200 77/4400 77/4000 77/3500

Nm at rpm 195/1500...2000230/1500...2500250/1500...2500 250/1500...2500 250/1500...2500

CAYA CAYB CAYC CLNA CWXB

---- ---- ---- 09.2011 ► 08.2014 ►

EU5 EU5 EU5 EU4/BS4 BS4

l 1598 1598 1598 1598 1498

4/4 4/4 4/4 4/4 4/4

1. Identification 1

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Engine identifica‐
tion characters

Cata‐
lytic
con‐
verter

Exhaust gas recir‐
culation
tor

Tur‐
bo‐
charg‐
ing

Charge air cooler yes yes yes yes yes
Diesel particle fil‐

ter
Balancing shaft

module

with radia‐

CAYA CAYB CAYC CLNA CWXB

yes yes yes yes yes

yes yes yes yes yes

yes yes yes yes yes

yes yes yes no no

no no no no no

2 Rep. gr.00 - Technical data

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2 Safety instructions

⇒ “2.1 Regulations concerning safety precautions when working
on the fuel system”, page 3

2.1 Regulations concerning safety precau‐
tions when working on the fuel system

WARNING

♦ The fuel or the fuel lines in the fuel system can become

very hot (risk of scalding)!
♦ The fuel system is under pressure!
♦ 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 cable connections. Reduce pressure by care‐

fully removing the wiring.

For reasons of safety the current supply to the fuel pump must
be interrupted before opening the fuel system. Otherwise the
fuel pump is activated when opening the driver's door. One of
the following options must be used to interrupt the current sup‐
ply:

♦ Disconnect battery

or

♦ Take out fuse for fuel pump relay - J17-

or

♦ Disconnect the plug on the flange of the fuel delivery unit.

WARNING

When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:

♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,

cooling fluid and refrigerant, brake fluid, vacuum) and

electrical

re-established.
♦ Ensure that there is adequate free access to all moving or

hot components.

lines in such a way that the original line guide is

2. Safety instructions 3

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Caution

In order to avoid the high pressure pump to run dry and to ach‐
ieve a quick engine start after parts are replaced, the following
points must be observed.

♦ If parts of the fuel system were removed or replaced, it is

necessary to initiate the basic setting “check fuel pump” in
order to vent the fuel system ⇒ Vehicle diagnostic tester.

♦ If the fuel pump, fuel line or fuel filter were removed or

replaced, the basic setting “check fuel pump” must be in‐
itiated »once« before the first engine start.

♦ If the high pressure pump is removed or replaced, the in‐

itial fuel filling of the high pressure pump must be carried
out before the first engine start ⇒ page 382 .

♦ If the high pressure system was opened, it must be

checked for tightness ⇒ page 406 .

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!
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 passen‐
ger seat, the passenger can be injured by the release of the
passenger airbag in the event of an accident.

WARNING

Secure the diagnostic device to the rear seat and operate from
that position.

4 Rep. gr.00 - Technical data

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Observe the following points to prevent injury to persons and/or
damage to the injection and preheating system:

♦ People, who have a heart pacemaker implant, should not bend

over the engine compartment when the engine is running, as

the injection units generate an output high voltage pulse.
♦ No fuel lines must be opened when the engine is running.
♦ Disconnect and connect wires of the preheating and injection

system

switched off.
♦ Do not carry out engine wash unless the ignition is switched

off.
♦ If the engine must be operated at starter speed, without it

starting, unplug the connector -5- at the fuel pressure regulat‐

ing valve - N276- .
♦ Before disconnecting the battery determine the code of the

radio fitted with anti-theft coding.
♦ Always switch off the ignition before disconnecting and re-

connecting the battery. Otherwise the engine control unit may

be damaged.
♦ After connecting the battery, carry out certain additional oper‐

ations ⇒ Electrical System; Rep. gr. 27 .

as well as measuring device wires when the ignition is

2. Safety instructions 5

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3 Repair instructions

⇒ “3.1 Rules of cleanliness”, page 6
⇒ “3.2 Foreign bodies in the engine”, page 7
⇒ “3.3 Contact corrosion”, page 7
⇒ “3.4 Cable routing and securing”, page 7
⇒ “3.5 Assembly of radiators and capacitors”, page 7
⇒ “3.6 General instructions for charge air system”, page 7
⇒ “3.7 Supplementary instructions and assembly work on vehi‐

cles with an air conditioning system”, page 8

3.1 Rules of cleanliness

⇒ “3.1.1 Regulations concerning cleanliness when working on the
fuel supply/fuel injection system”, page 6

⇒ “3.1.2 Regulations concerning cleanliness when working on the
exhaust gas turbocharger”, page 6

3.1.1 Regulations concerning cleanliness
when working on the fuel supply/fuel in‐
jection system

Carefully observe the following “rules” for cleanliness when work‐
ing on the fuel supply/injection system:

♦ Thoroughly clean the connection points and their surroundings

before releasing.

♦ Place removed parts on a clean surface and cover. Use only

lint-free cloths!

♦ Carefully cover or close opened components if the repair is not

completed immediately.

♦ Only install clean parts: Remove spare parts from their wrap‐

ping immediately before fitting. Do not use any parts which
have

been stored unwrapped (e.g. on a shelf or in a tool box).

♦ When the system is open: Avoid using compressed air when‐

ever possible. Avoid moving the vehicle.

♦ Also make sure no diesel fuel runs onto the coolant hoses. If

this is the case clean the hoses immediately. Contaminated
hoses must be replaced.

3.1.2 Regulations concerning cleanliness
when

working on the exhaust gas turbo‐

charger

Carefully observe the following “rules” for cleanliness when work‐
ing on the exhaust gas turbocharger:

♦ Thoroughly clean the connection points and their surroundings

before releasing.

♦ Place removed parts on a clean surface and cover. Use only

lint-free cloths!

♦ Carefully cover or close opened components if the repair is not

completed immediately.

♦ Only install clean parts: Remove spare parts from their wrap‐

ping immediately before fitting. Do not use any parts which
have

been stored unwrapped (e.g. on a shelf or in a tool box).

6 Rep. gr.00 - Technical data

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♦ When the system is open: Avoid using compressed air when‐

ever possible. Avoid moving the vehicle.

3.2 Foreign bodies in the engine

To prevent the penetration of foreign bodies, open channels of
the

inlet connection and exhaust tract must be sealed with suita‐
ble plugs during assembly works on the engine, for example from
the screw plug set for engine - VAS 6122- .

3.3 Contact corrosion

The use of unsuitable connection elements causes contact cor‐
rosion (screws, nuts, washers, …).

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

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

If you have any doubts about the suitability of parts, please use
new parts in general ⇒ Electronic Catalogue of Original Parts
ETKA .

3.4 Cable routing and securing

♦ To ensure the original installation position, e.g. lines for fuel,

hydraulics, vacuum, activated charcoal filter system lines or
electric cables must be marked before removal. Make sketch‐
es or take photographs if necessary.

♦ Sufficient clearance from all moving or hot components must

be ensured in the engine compartment due to its cramped
construction. This prevents damage to lines.

3.5 Assembly of radiators and capacitors

The radiator, capacitor and charge air cooler may have minor in‐
dentations on the fins, even if assembly is correct. This is not a
case of damage. Radiator, capacitors or charge air cooler must
not be replaced because of these indentations.

3.6 General instructions for charge air sys‐

tem

WARNING

When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:

♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,

cooling fluid and refrigerant, brake fluid, vacuum) and
electrical lines in such a way that the original line guide is
re-established.

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

hot components.

3. Repair instructions 7

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Caution

In case a mechanical damage to the exhaust gas turbocharger
is found, for example, damage to the compressor wheel, it is
not sufficient to only replace the turbocharger. In order to avoid
consequential damage, perform the following tasks:

♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter housing, air filter element and charge air

pipes as well as charge air hoses for soiling.

♦ Check all the air guides and the charge air cooler for for‐

eign 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, check ⇒ page 372 .
♦ Replace the gaskets, the sealing rings and the self-locking

nuts.

♦ Hose connections and hoses of the charge air system must

be free of oil and grease before being installed. The gasket
ring and the sealing surface must be slightly oiled only for

push-fit couplings ⇒ page 372 .
♦ Observe markings on the hoses and components.
♦ All hose connections of the charge air system are secured with

spring strap clamps or push-fit couplings.
♦ Only install approved clamps for securing the hose connec‐

tions ⇒ ETKA - Electronic Catalogue of Original Parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Install hose connections with screw clamps ⇒ page 372 .
♦ Before screwing down the oil feed line, fill the exhaust turbo‐

charger 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.

3.7 Supplementary

instructions and assem‐
bly work on vehicles with an air condi‐
tioning 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.

8 Rep. gr.00 - Technical data

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Steps which should be taken in order to remove and install the
engine without opening the refrigerant circuit:

– Unscrew the holding clamp(s) on the refrigerent lines.
– Remove V-ribbed belt ⇒ page 63 .
– Remove AC compressor from the bracket for auxiliary units

⇒ page 57 .

– Mount the air conditioning compressor and the condenser in

such a way that the refrigerent lines/hoses are not under ten‐
sion.

3. Repair instructions 9

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10 – Removing and installing engine

1 Removing and installing engine

⇒ “1.1 Removing and installing engine trim panel”, page 10
⇒ “1.2 Removing engine”, page 11
⇒ “1.3 Securing the engine to the assembly stand”, page 28
⇒ “1.4 Installing engine”, page 29
⇒ “1.5 Assembly bracket”, page 37
⇒ “1.6 Checking and adjusting the assembly bracket”,

page 41
⇒ “1.7 Removing and installing engine support”, page 44

1.1 Removing and installing engine trim panel

Caution

The brackets of the engine cover on the cylinder head cover
can break off when they are incorrectly removed.

♦ It is therefore necessary to remove the engine cover ac‐

cording to the following instruction.

– Successively slacken the engine cover in the marked se‐

quence
cover from underneath as far as possible in the area of the

-arrows- and pull it upwards out of the attachment.

Install

Before installing the engine cover, check the correct fitting po‐
sition of the 4 fixing elements (ball sockets), if necessary move
them into the correct position. Otherwise this can lead to dam‐
age to the engine cover.

-1 ... 4- from the fixing points. To do so, grip the engine

Caution

10 Rep. gr.10 - Removing and installing engine

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– If necessary, press the ball sockets of the engine cover into

the correct position.

– Position

at the corners until it clicks into place.

the engine cover onto the fixing points and press it in

1.2 Removing engine

⇒ “1.2.1 Remove engine (Fabia II, Roomster, Rapid India, Rapid
NH)”, page 11

⇒ “1.2.2 Remove engine (Octavia II, Superb II, Yeti)”, page 19

1.2.1 Remove engine (Fabia II, Roomster, Rapid India, Rapid NH)

Special tools and workshop equipment required
♦ Engine mount - T10012­♦ Engine/gearbox jack , e.g. -V.A.G 1383 A­♦ Catch pan , e.g. -VAS 6208­♦ Step ladder
♦ Pliers for spring strap clamps

Note

If the stripped engine is replaced after engine removal, the

♦

tightening of the injection unit clamping claws on the new strip‐
ped engine must be checked. Tightening torque: Position -2-

⇒ page 388 .

♦

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.

♦

Collect drained coolant in a clean container for proper disposal
or reuse.

1. Removing and installing engine 11

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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 (for example, 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-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 supply and injection system, at the charge air system and
observe as well the rules for cleanliness ⇒ page 6 .

– If

present, take the adapter for the anti-theft wheel bolts out of

the luggage compartment.
– Remove front wheels ⇒ Chassis; Rep. gr. 44 .
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System; Rep. gr. 27 .
– Remove engine cover
– Remove

hose
– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .
– Release plug -3-

- N75- .

– Unscrew charge pressure control solenoid valve - N75 - with

fixture -2- and place it on the engine.
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.

34 .
– Remove the clutch slave cylinder from the gearbox ⇒ Gear‐

box; Rep. gr. 30 .

air filter housing with air mass meter - G70- and intake

⇒ page 426 .

⇒ page 10 .

from charge pressure control solenoid valve

Caution

After removing the slave cylinder, do not depress the clutch
pedal.

For vehicles Fabia II, Roomster

– Remove the vacuum hose -arrow- from the brake servo unit.
For vehicles Rapid India, Rapid NH

12 Rep. gr.10 - Removing and installing engine

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– Disconnect

-arrow 1-.

For Rapid India vehicles

– Disconnect the plug connection -1- for the exhaust gas tem‐

perature sender 1 - G235- and loosen from the bracket.
Continued for all vehicles
– Unlatch the fuse and disconnect the front plug from the engine

control unit ⇒ page 430 .

vacuum line behind the holder at the cylinder head

– Disconnect plug connection -arrow-.

– Carefully

-arrows-.

– Place the engine wiring harness on the engine.

slacken the engine wiring harness on its fixing points

1. Removing and installing engine 13

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– Unscrew the positive cable to the generator -1-, unclip and

place on the gearbox.

– Unscrew the cable from the starter and the gearbox and re‐

move it.

– Screws -1 ... Unscrew screw 3- and remove pendulum sup‐

port.

For vehicles Fabia II, Roomster, Rapid NH with engine identifi‐
cation characters CAYB, CAYC

– Remove pre-exhaust pipe with diesel particle filter

⇒ page 457 .

For vehicles Rapid India, Rapid NH with engine identification
characters CLNA

– Remove pre-exhaust pipe with catalytic converter, while doing

so remove the assembly carrier ⇒ page 457 .

Continued for all vehicles

– Separate fuel feed line -2- and fuel return-flow line -1-, to do

so press the release buttons. Unlock the quick coupling and

disconnect ⇒ page 303 .
– If necessary, collect the fuel which flows out with a cloth.
For vehicles Fabia II, Roomster, Rapid NH

– Unlock

valve upwards out of the guide of the coolant expansion bottle.
For Rapid India vehicles

the catch peg with a finger and pull the fuel preheating

14 Rep. gr.10 - Removing and installing engine

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– Unlock the catch peg with a finger and pull the T-piece up‐

wards out of the guide from the coolant expansion bottle.

Continued for all vehicles

– Push the catch pegs up and remove the fuel filter towards the

top.

– Place the fuel filter and the fuel hoses together with the fuel

preheating valve on the engine.
– Remove fuel filter bracket.
– Remove the right and left wheelhouse liner ⇒ Body Work;

Rep. gr. 66 .

– Unscrew the nuts from the right steering joint -arrows- and

press the steering joint out of the suspension arm.

– Unscrew screws -1- of protective plate for right drive shaft, if

present.
– Remove right drive shaft from gearbox and secure with wire

⇒ Chassis; Rep. gr. 40 .
– Remove

left drive shaft from gearbox ⇒ Chassis; Rep. gr. 40 .

1. Removing and installing engine 15

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– Unscrew

coupling rod from the anti-roll bar.

– Unscrew the nuts from 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 the wheel bearing housing to the left up to the stop.
– Swivel the steering joint outwards and secure the drive shaft

-1- with a band -A- in the wheelhouse.

– Remove right charge air hose.

the nut from the left coupling rod -2- and press off the

– Release screws -arrows-.
– Loosen hose clamp -2-.
– Disconnect the plug -1-

with intake air temperature sender - G42- and remove the right

charge air pipe.
– Drain coolant
– Remove the remaining coolant hoses from the radiator.

⇒ page 223 .

at the charge pressure sender - G31-

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– Remove the earth connection -1- from the assembly bracket.
– Remove coolant expansion bottle and place on the engine.

– Unclip

On vehicles with air conditioning
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .

the filler neck of the windshield washer reservoir -1- and

lay to the side.

WARNING

Risk of injury through refrigerant.

♦ Do not open the refrigerant circuit of the air conditioning

system.

Caution

Risk of damaging the condenser as well as the refrigerant lines
and hoses.

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

refrigerant hoses.

– Remove the AC compressor from the bracket for auxiliary

units ⇒ Heating, Air Conditioning; Rep. gr. 87 .

– Attach the AC compressor -3- e.g. behind the lock carrier as

shown in the figure. As protection put a sheet of cardbord
on the radiator wall.

Continued for all vehicles

-1-

1. Removing and installing engine 17

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– Remove noise insulation of oil pan -1-, to do so slacken the

fixing parts -arrows-.

– Unscrew screw -1- and press recirculation pump 2 - V178-

-3- (if present) to the side.

– Disconnect further necessary plug connections at the engine

and gearbox or line connections to engine and gearbox.

– Separate the quick couplings -arrows- at the heat exchanger.
– Unclamp all remaining connecting, coolant, vacuum and suc‐

tion hoses from the engine.
– Release all remaining plugs at engine and gearbox and lay

aside the relevant lines.

– Screw engine mount - T10012- to the cylinder block with nut

-2- and screw -1- to 20 Nm.

– Insert engine/gearbox jack - V.A.G 1383 A- in the engine

mount and slightly raise.

Note

Use double ladder to release the screws for the engine/gearbox
mounting.

For vehicles Fabia II, Roomster, Rapid NH

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– Release

engine support -arrows-.

For Rapid India vehicles

– Unscrew engine mounting and remove completely -arrows-.
Continued for all vehicles

the screws which connect the engine mount with the

– Remove the assembly bracket at the gearbox. Release

screws -arrows-.

Note

♦

Check whether all hose and line connections between engine,
gearbox and body are released.

♦

When lowering carefully guide the engine with the gearbox, in
order to avoid damage.

♦

Ensure the necessary space for lowering the assembly by
pressing off the assembly carrier.

– Carefully lower engine with gearbox. During this procedure,

turn or move the engine with the gearbox depending upon the
constriction.

– Remove the gearbox from the engine.

1.2.2 Remove engine (Octavia II, Superb II, Yeti)

Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel - MP 8-602/1­♦ Engine mount - T10012­♦ Engine/gearbox jack , e.g. -V.A.G 1383 A­♦ Catch pan , e.g. -VAS 6208­♦ Step ladder
♦ Pliers for spring strap clamps

1. Removing and installing engine 19

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Note

♦

If the stripped engine is replaced after engine removal, the
tightening of the injection unit clamping claws on the new strip‐
ped engine must be checked. Tightening torque: Position -2-

⇒ page 388 .

♦

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.

♦

Collect drained coolant in a clean container for proper disposal
or reuse.

Caution

When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:

♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,

cooling fluid and refrigerant, brake fluid, vacuum) and
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 supply and injection system, at the charge air system and
observe as well the rules for cleanliness ⇒ page 6 .

present, take the adapter for the anti-theft wheel bolts out of

– If

the luggage compartment.

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

trical System; Rep. gr. 27 .
– Remove engine cover
– Remove

hose
– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .

air filter housing with air mass meter - G70- and intake

⇒ page 426 .

⇒ page 10 .

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– Unplug the following plug connections at the bulkhead:
2 - Exhaust gas temperature sender 4 - G648­3 - Exhaust gas temperature sender 1 - G235- ( Temperature

sender upstream turbocharger - G507- )
4 - Lambda probe - G39­6 - Exhaust gas temperature sender 3 - G495- ( Temperature

sender downstream particle filter - G527- )
– Pull

– Remove pre-exhaust pipe with diesel particle filter

off the vacuum hose -5- from the charge pressure control

solenoid valve - N75- .

⇒ page 457 .

– Disconnect

- G266- .

– Remove bracket -2- for the wiring harness of the oil level and

oil

temperature sender - G266- from the assembly carrier and

place down on the assembly carrier.

– Remove the right and left wheelhouse liner bottom part ⇒

Body Work; Rep. gr. 66 .

– Unscrew the left drive shaft from the flange shaft of the gear‐

box.

– Unscrew

coupling rod from the anti-roll bar.

– Unscrew the nuts from the left steering joint -3- and press the

steering joint out of the suspension arm.

plug -1- at the oil level and oil temperature sender

the nut from the left coupling rod -2- and press off the

1. Removing and installing engine 21

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– 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.

– Insert a pin screw in the suspension arm in order to stabilise

the steering joint.
– Remove radiator ⇒ page 262 .

– Release screws -arrows-.
– Expose coolant hose -1-.
– Loosen hose clamp -3-.
– Disconnect the plug -2-

with intake air temperature sender - G42- and remove the right

charge air pipe.

at the charge pressure sender - G31-

– Unscrew screw -arrow- and push the coolant recirculation

pump 2 - V178- to the side.

– Remove

haust turbocharger.
– Disconnect vacuum hose -3-.

vacuum hose -2- from vacuum setting element of ex‐

22 Rep. gr.10 - Removing and installing engine

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– Remove the vacuum hose -arrow- from the brake servo unit.

– Detach fuel feed line -2- and fuel return-flow line -1-, to do so

press in securing ring. Unlock the quick coupling and discon‐
nect ⇒ page 303 .

– Disconnect plug -1- at fuel temperature sender - G81- .
– Separate

hose clamp -arrow-.

– Separate

en the hose clamp -3-.

the fuel feed line and pull it off, to do so slacken the

the fuel return-flow line and pull it off, to do so slack‐

1. Removing and installing engine 23

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– Unscrew bolt -1-.
– Push the filler tube with the filler neck -2- for the washer-fluid

reservoir to the side.

– Release screw -1- by two turns.
– Release screw -2- and nut -3-.
– Unclip bracket for coolant line at fuel filter.
– Remove

et together with the additional fuel pump - V393- .
– Remove V-ribbed belt
On vehicles with air conditioning

the fuel filter with the hoses connected and the brack‐

⇒ page 57 .

WARNING

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

Note

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

– Remove the AC compressor from the bracket for auxiliary

Continued for all vehicles
– Unlatch the fuse and disconnect the front plug from the engine

place a cardboard -A- underneath the charge air cooler

units,

for protection and secure the AC compressor with connected

refrigerant hoses to the lock carrier.

control unit

⇒ page 430 .

24 Rep. gr.10 - Removing and installing engine

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– Release duct for engine wiring harness -arrow- and pull out

upwards.

– Open the cable guides -arrows-, remove the engine wiring

harness and place down to the side.

– Expose the plug connection -1- and disconnect it.
– Open the bracket -2- lying below the cable guide.
– Remove the wiring loom to the engine control unit from the

cable guide using the removal tool for inner lining of the door
panel - MP 8-602/1- and lay it on the engine.

– Disconnect plug connection -arrow- at the bottom left frame

side rail.

Note

For purposes of presentation, the fitting position is shown from
below.

1. Removing and installing engine 25

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– Remove
– Unscrew earth strap -1-.
– Unplug connector -2-.
– Pull back the protective collar and unscrew the B+ cable from

the bracket of the solenoid switch for the starter.
– Disconnect further necessary plug connections at the engine

and gearbox or line connections to engine and gearbox.

– Separate the quick couplings -arrows- at the heat exchanger.
– Pull off coolant hose from the top and bottom of the coolant

expansion reservoir.
Vehicles with auxiliary heating
– Disconnect coolant hoses at auxiliary heating system.
Vehicles fitted with a manual gearbox
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.

34 .
– Remove pressure line from breather/slave cylinder ⇒ Gear‐

box; Rep. gr. 30 .

the cable strap for -arrow- protective collar if present.

Caution

After separating the hydraulic line, do not operate the clutch
pedal.

Vehicles with automatic gearbox
– Remove shift mechanism from gearbox ⇒ Automatic Gear‐

box; Rep. gr. 34 .
Continued for all vehicles
– Unclamp all remaining connecting, coolant, vacuum and suc‐

tion hoses from the engine.
– Release all remaining plugs at engine and gearbox and lay

aside the relevant lines.

– Unscrew screw -1- and remove pendulum support.

26 Rep. gr.10 - Removing and installing engine

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– Remove noise insulation of oil pan -1-, to do so slacken the

fixing parts -arrows-.

– Screw engine mount - T10012- to the cylinder block with nut

-2- and screw -1- to 20 Nm.

– Insert engine/gearbox jack - V.A.G 1383 A- in the engine

mount and slightly raise.

Note

Use double ladder to release the screws for the engine/gearbox
mounting.

– Successively release screws for engine mount -arrows-.
For the vehicles Octavia II

– Successively unscrew screws for gearbox mount at gearbox

0A4 -arrows- or ...

1. Removing and installing engine 27

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– ... at gearbox 02Q -arrows- or ...

– ... at gearbox 0AM -2-.
For the vehicles Superb II, Yeti

– Successively release screws for gearbox mount -arrows-.
Continued for all vehicles

Note

♦

Check whether all hose and line connections between engine,

gearbox and body are released.

♦

When lowering carefully guide the engine with the gearbox, in

order to avoid damage.

– Carefully lower engine with gearbox. During this procedure,

turn or move the engine with the gearbox depending upon the

constriction.
– Remove the gearbox from the engine.

1.3 Securing the engine to the assembly

stand

Note

The engine and gearbox support - VAS 6095- or assembly stands

- MP 9-101- with engine mount - MP 1-202- for the attachment.

Attachment to engine and gearbox mount - VAS 6095­Special tools and workshop equipment required
♦ Workshop crane , e.g. -VAS 6100­♦ Engine and gearbox support - VAS 6095­♦ Lifting device - MP 9-201 (2024A)-

28 Rep. gr.10 - Removing and installing engine

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Precondition

• Separate engine from gearbox.
– Attach lifting device - MP 9-201- at engine and at workshop

crane e.g. -VAS 6100- .
On the belt pulley side:
♦ 2. Hole of the attachment in Position 1
On the flywheel side:
♦ 4. Hole of the attachment in Position 8

Note

The illustration shows a pump injector engine. The attachment for
the Common Rail engine occurs in the same way.

WARNING

Use securing pins on the hooks and rig pins to prevent release.
Use securing pins on the hooks and rig pins in order to avoid

injuries and damage to the engine.

off engine with installed engine mount - T10012- with work‐

– Lift

shop crane from engine/gearbox jack.
– Remove engine mount - T10012- .

– Secure

mount - VAS 6095- .

engine using bolts -arrows- to the engine and gearbox

1.4 Installing engine

⇒ “1.4.1 Install engine (Fabia II, Roomster, Rapid India, Rapid
NH)”, page 29

⇒ “1.4.2 Install engine (Octavia II, Superb II, Yeti)”, page 33

1.4.1 Install

engine (Fabia II, Roomster, Rapid

India, Rapid NH)

Special tools and workshop equipment required
♦ Grease - G 000 100- for manual gearbox
Precondition

• Fit engine and gearbox using engine mount to the engine/

gearbox jack .
Installation is performed in the reverse order, pay attention to the

following points:

1. Removing and installing engine 29

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Note

♦

Observe all safety measures and notes for assembly work on
the fuel supply and injection system, at the charge air system
and observe as well the rules for cleanliness ⇒ page 6 .

♦

When undertaking assembly replace self-locking nuts and
screws which have been tightened to a torquing angle.

♦

Always replace gasket rings and seals.

♦

All cable straps should be fastened again in the same place
when installing.

♦

Secure all hose connections with corresponding hose clamps
⇒ ETKA - Electronic Catalogue of Original Parts .

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 (for example, 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-established.

♦ In order to avoid damage to the cables, ensure that there

is adequate free access to all moving or hot components.

Note

♦

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- on the serration.
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 .

– Check whether the dowel sleeves for centering the engine/

gearbox are present in the cylinder block; insert if necessary.

– 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 .
– Insert engine with gearbox into the body.
For vehicles Fabia II, Roomster, Rapid NH

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– Successively

hand.

For Rapid India vehicles

– Successively

hand.

Continued for all vehicles

screw in screws for engine mounting -arrows- by

screw in screws for engine mounting -arrows- by

– Successively

-arrows-.
– Remove engine mount - T10012- from engine.
For vehicles Fabia II, Roomster, Rapid NH with engine identifi‐

cation characters CAYB, CAYC
– Install pre-exhaust pipe with diesel particle filter

⇒ page 457 .

For vehicles Rapid India, Rapid NH with engine identification
characters CLNA

– Install exhaust pipe with catalytic converter ⇒ page 457 .
Continued for all vehicles

screw in by hand the screws for gearbox mount

1. Removing and installing engine 31

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– First

– Install the left as well as the right drive shaft ⇒ Chassis; Rep.

– Install the slave cylinder, if necessary bleed the clutch control

– Attach shift mechanism to gearbox and adjust ⇒ Gearbox;

– Install AC compressor at the bracket for auxiliary units

– Install alternator ⇒ Electrical System; Rep. gr. 27 .
– Install poly V-belt ⇒ page 63 .
– Connect all hoses to the engine.
– Connect electrical connections and attach cables ⇒ Current

– Carry out cohesive work when reconnecting the battery ⇒

– Top up coolant ⇒ page 223 .
– Checking the oil level:
♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Rapid Indie .
♦ ⇒ Maintenance ; Booklet Rapid NH .
– Install the left and right wheelhouse liner ⇒ Body Work; Rep.

– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
– Filling and bleeding the fuel system ⇒ page 382 .
– Check fuel system for tightness ⇒ page 406 .
– Perform a test drive.
– Query all fault memories, rectify any faults and delete fault

tighten pendulum support with new screws -2- and -3- at
gearbox and then tighten with new screw -1- at assembly car‐
rier.

gr. 40 .

⇒ Gearbox; Rep. gr. 30 .

Rep. gr. 34 .

⇒ page 57 .

flow diagrams, Electrical fault finding and Fitting locations.

Electrical System; Rep. gr. 27 .

gr. 66 .

memories ⇒ Vehicle diagnostic tester.

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.

Tightening torques

Component
Screws or nuts M6 10

Engine/gearbox connecting screws ⇒
Gearbox; Rep. gr. 34

32 Rep. gr.10 - Removing and installing engine

Nm

M7 15

M8 20
M10 40
M12 70

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1.4.2 Install engine (Octavia II, Superb II, Yeti)

Special tools and workshop equipment required
♦ Grease - G 000 100- for manual gearbox
♦ High temperature grease - G 052 133 A2- for automatic gear‐

box

Precondition

• Fit engine and gearbox using engine mount to the engine/
gearbox jack .

Installation is performed in the reverse order, pay attention to the
following points:

Note

♦

Observe all safety measures and notes for assembly work on
the fuel supply and injection system, at the charge air system
and observe as well the rules for cleanliness ⇒ page 6 .

♦

Always replace self-locking nuts.

♦

Replace screws which have been tightened to torquing angle.

♦

Always replace gasket rings and seals.

♦

All cable straps should be fastened again in the same place
when installing.

♦

Secure all hose connections with corresponding hose clamps
⇒ ETKA - Electronic Catalogue of Original Parts .

Caution

When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:

♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,

cooling fluid and refrigerant, brake fluid, vacuum) and
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.

For vehicles with manual gearbox

Note

♦

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- on the serration.
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 .

1. Removing and installing engine 33

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For vehicles with automatic gearbox DSG
– Replace the needle bearing -arrow- in the crankshaft

⇒ page 128 .

Note

Lubricate needle bearing and drive shaft pin with a thin layer of
high temperature grease - G 052 133 A2- . Do not grease the
serration of the drive shaft.

Continued for all vehicles
– Check whether the dowel sleeves for centering the engine/

gearbox are present in the cylinder block; insert if necessary.

– 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 .
– Insert engine with gearbox into the body.

– Successively screw in by hand the screws for engine mount

-arrows-.
For the vehicles Octavia II

– Successively

-arrows- at gearbox 0A4 -arrows- or ...

screw in by hand the screws for gearbox mount

34 Rep. gr.10 - Removing and installing engine

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– ... at gearbox 02Q -arrows- or ...

– ... at gearbox 0AM -2-.
For the vehicles Superb II, Yeti

1.5/77; 1.6/55; 66; 77 kW TDI CR engine - Edition 05.2014

– Successively

-arrows-.
For all vehicles
– Align engine and gearbox mount and tighten screws:
♦ Octavia II, Yeti
♦ Superb II ⇒ page 41 .
– Remove engine mount - T10012- from engine.
– Install pre-exhaust pipe with diesel particle filter

⇒ page 457 .

screw in by hand the screws for gearbox mount

⇒ page 43 .

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– First

– Install the left as well as the right drive shaft ⇒ Chassis; Rep.

For vehicles with manual gearbox
– Connect hydraulic line to breather/clutch slave cylinder and

– Attach shift mechanism to gearbox and adjust ⇒ Gearbox;

For models with automatic gearbox
– Attach the shift mechanism to the gearbox ⇒ Automatic Gear‐

Continued for all vehicles
– Install AC compressor at the bracket for auxiliary units

– Install poly V-belt ⇒ page 63 .
– Install radiator ⇒ page 262 .
– Install fan shroud with radiator fans ⇒ page 259 , to do so

– Connect

– Connect electrical connections and attach cables ⇒ Current

– Carry out cohesive work when reconnecting the battery ⇒

– Install bulkhead plenum chamber and plenum chamber cover

– Install wiper arms ⇒ Electrical System; Rep. gr. 92 .
– Top up coolant
– Checking the oil level:
♦ ⇒ Maintenance ; Booklet Octavia II .
♦ ⇒ Maintenance ; Booklet Superb II .
♦ ⇒ Maintenance ; Booklet Yeti .
– Install

– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
– Filling and bleeding the fuel system
– Check fuel system for tightness ⇒ page 406 .
– Perform a test drive.
– Query all fault memories, rectify any faults and delete fault

tighten pendulum support with new screws -2- and -3- at
gearbox and then tighten with new screw -1- at assembly car‐
rier.

gr. 40 .

bleed the clutch hydraulic ⇒ Gearbox; Rep. gr. 30 .

Rep. gr. 34 .

box; Rep. gr. 34 .

⇒ page 57 .

ensure adequate clearance of the blower motors.

all connecting, fuel, cooling fluid, vacuum and suction

hoses to the engine.

flow diagrams, Electrical fault finding and Fitting locations.

Electrical System; Rep. gr. 27 .

⇒ Body Work; Rep. gr. 66 .

⇒ page 223 .

the bottom part of the right and left wheelhouse liner ⇒

Body Work; Rep. gr. 66 .

⇒ page 382 .

memories ⇒ Vehicle diagnostic tester.

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.

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Tightening torques

Component Nm
Screws or nuts M6 10

Engine/gearbox connecting screws ⇒
Gearbox; Rep. gr. 34

M7 15

M8 20
M10 40
M12 70

1.5 Assembly bracket

⇒ “1.5.1 Assembly mountings (Fabia II, Roomster, Rapid NH)”,
page 37

⇒ “1.5.2 Assembly mountings (Octavia II)”, page 38
⇒ “1.5.3 Assembly mountings (Superb II, Yeti)”, page 39
⇒ “1.5.4 Assembly mountings (Rapid India)”, page 40

1.5.1 Assembly mountings (Fabia II, Room‐
ster, Rapid NH)

Tightening torques
Engine mount
1 - not fitted on this type of 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

Gearbox mount
1 -

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

2 -

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

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Pendulum support

Note

Position the screws -1- in the elongated holes of the pendulum
support in such a way that there is maximum distance between
the gearbox and the assembly carrier.

1 -

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

2 -

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

1.5.2 Assembly mountings (Octavia II)

Tightening torques
Assembly bracket

1 - 20 Nm + 90° (1/4 turn) - replace

2 - 40 Nm + 90° (1/4 turn) - replace

3 - 60 Nm + 90° (1/4 turn) - replace

Assembly bracket gearbox 0A4 and 0AM

A - 40 Nm + 90° (1/4 turn) - replace

B - 60 Nm + 90° (1/4 turn) - replace

Assembly bracket gearbox 02Q

1 - 40 Nm + 90° (1/4 turn) - replace

2 - 60 Nm + 90° (1/4 turn) - replace

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Pendulum support

A - strength class 8.8 - 40 Nm + 90° (1/4 turn) - replace

A - strength class 10.9 1) - 50 Nm + 90° (1/4 turn) - replace

B - 100 Nm + 90° (1/4 turn) - replace

Removing: First unscrew screw -B-, then screw -A-.
Installing: First tighten screw -A-, then screw -B-.

1)

On manual gearbox MQ350 (02Q), only use the screws with

strength category 10.9 if threaded inserts have been installed

the
(e.g. HeliCoil) -arrow-.

1.5.3 Assembly mountings (Superb II, Yeti)

Tightening torques
Assembly bracket

1 - 20 Nm + 90° (1/4 turn) - replace

2 - 40 Nm + 90° (1/4 turn) - replace

3 - 60 Nm + 90° (1/4 turn) - replace

Unit mounting for gearbox

A - 40 Nm + 90° (1/4 turn) - replace

B - 60 Nm + 90° (1/4 turn) - replace

1. Removing and installing engine 39

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Pendulum support

A - strength class 8.8 - 40 Nm + 90° (1/4 turn) - replace

B - 100 Nm + 90° (1/4 turn) - replace

Removing: First unscrew screw -B-, then screw -A-.
Installing: First tighten screw -A-, then screw -B-.

1.5.4 Assembly mountings (Rapid India)

Tightening torques
Engine mount

A - 20 Nm + torque a further 90° (1/4 turn) - replace

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

Gearbox mount

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

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

Pendulum support

Note

Position the screws -A- in the elongated holes of the pendulum
support in such a way that there is maximum distance between
the gearbox and the assembly carrier.

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

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

-arrow- - the screw must not be loosened

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1.6 Checking and adjusting the assembly bracket

⇒ “1.6.1 Checking and adjusting the assembly bracket (Superb
II)”, page 41

⇒ “1.6.2 Checking and adjusting the assembly mounting (Octavia
II, Yeti)”, page 43

1.6.1 Checking and adjusting the assembly bracket (Superb II)

Special tools and workshop equipment required
♦ Supporting device - MP9-200 (10-222A)­♦ Adapter - MP9-200/3 (10-222A/3)­♦ Wing plates - T10311­or

♦ Engine mount - T10012­♦ Engine/gearbox jack , e.g. -V.A.G 1383 A­Checking the assembly bracket
Check dimensions on the right hanger for engine/gearbox unit:

• Between engine bracket and engine support there must be a

distance -a- of 10...13 mm.

• The cast iron edge on the engine support -2-

to the supporting arm -1- the dimension -x- must be the same
at the front and rear.

must be parallel

Note

The distance -a- can be checked, for example 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...13 mm:

– Adjust the assembly bracket
Adjusting the unit mounting
Precondition

• Engine with gearbox supported with supporting device -

MP9-200
gearbox supported with engine mount and engine/gearbox
jack .

– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .

– Remove the front stop buffers for the front flap from both upper

edges of the wings at the front.

(10-222A)- and adapter - MP9-200/3- or engine with

⇒ page 41 .

1. Removing and installing engine 41

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– Insert

– Also insert the wing plate - T10311- on the left vehicle side

the wing plate - T10311- on the right vehicle side -A- in

-the direction of the arrow- up to the stop. When doing this, the

-arrow R- on the wing plate - T10311- points to the rear.

-B- in -the direction of the arrow- up to the stop. When doing
this, the -arrow L- on the wing plate - T10311- points to the
rear.

Note

The wing plates - T10311- ensure that the wings do not get dam‐
aged through the weight of the engine/gearbox unit.

– Position

MP9-200/3- and support the engine/gearbox unit in its instal‐
led position.

– The feet of the supporting device - MP9-200- must be pushed

as shown in the illustration up to the stop buffers -1- and placed
on the wheelhouse frame side rail at the top -2-.

– Uniformly pre-tension the engine/gearbox unit with both spin‐

dles, but do not raise.

the supporting device - MP9-200- with the adapters -

– Release the screws -arrows- of the assembly bracket at the

engine.

– Slightly

the gearbox (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.

loosen the screws -arrows- of the assembly bracket at

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– Move the engine/gearbox assembly with an assembly lever

between
mount 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 -1- the dimension -x- must be the same
at the front and rear.

engine support -2- and supporting arm -1- for engine

Note

The distance -a- = 10 mm can be checked e.g. with corresponding
round bars.

– Tighten screws for engine assembly bracket
Further installation occurs in reverse order.

⇒ page 39 .

1.6.2 Checking and adjusting the assembly mounting (Octavia II, Yeti)

Special tools and workshop equipment required
♦ Supporting device - T30099­♦ Surface - T30099/1­♦ Adapter - MP9-200/3 (10-222A/3)­or

♦ Engine mount - T10012­♦ Engine/gearbox jack , e.g. -V.A.G 1383 A­Checking the assembly bracket
Check dimensions on the right hanger for engine/gearbox unit:

• Between engine bracket and engine support there must be a

distance -a- of 10 mm.

• The cast iron edge on the engine support -2-

to the supporting arm -1- the dimension -x- must be the same
at the front and rear.

must be parallel

Note

The distance -a- can be checked, for example 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
Adjusting the unit mounting
Precondition

⇒ page 43 .

1. Removing and installing engine 43

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• Engine with gearbox supported with supporting device ­T30099- , base - T30099/1- and adapter - MP9-200/3- or
engine
gearbox jack .

The following dimensions -a- and -x- must be maintained:

• Between engine bracket and engine support there must be a
distance -a- = 10 mm.

• The cast iron edge on the engine support -2­to the supporting arm -1- the dimension -x- must be the same
at the front and rear.

with gearbox supported with engine mount and engine/

must be parallel

Note

The distance -a- = 10 mm can be checked, for example with suit‐
able round bars.

Tightening torques of the assembly bracket:

⇒ “1.5.2 Assembly mountings (Octavia II)”, page 38 .

♦
♦ ⇒ “1.5.3 Assembly mountings (Superb II, Yeti)”, page 39 .

1.7 Removing

⇒ “1.7.1 Removing and installing engine support (Fabia II, Room‐
ster, Rapid India, Rapid NH)”, page 44

⇒ “1.7.2 Removing and installing engine support bracket (Superb
II)”, page 49

⇒ “1.7.3 Removing and installing engine support bracket (Octavia
II, Yeti)”, page 53

1.7.1 Removing

and installing engine support

and installing engine support
(Fabia II, Roomster, Rapid India, Rapid
NH)

For vehicles Fabia II, Roomster, Rapid India
Special tools and workshop equipment required
♦ Supporting device - MP9-200 (10-222A)­For vehicles Rapid NH
Special tools and workshop equipment required
♦ Supporting device - T30099­♦ Surface - T30099/1­♦ Adapter - MP9-200/3 (10-222A/3)-

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Removing

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 (for example, 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-established.

♦ In order to avoid damage to the cables, ensure that there

is adequate free access to all moving or hot components.

Note

♦

Safety precautions when working on the fuel supply system

⇒ page 3 .

♦

Observe rules for cleanliness ⇒ page 6 .

– Switch off ignition and pull out ignition key.
– Remove engine cover
For vehicles Fabia II, Roomster
– Remove vacuum line from brake servo unit -arrow-.
For vehicles Rapid India, Rapid NH

– Disconnect

-arrow 1-.

For vehicles Fabia II, Roomster, Rapid India

vacuum line behind the holder at the cylinder head

⇒ page 10 .

1. Removing and installing engine 45

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– Install supporting device - MP9-200 (10-222A)- and support

the engine with spindle

-A- to hang loosely.

Note

♦

The assembly bracket must only be removed if the engine is

-B- in fitting position. Allow spindle

supported with the supporting device - MP9-200 (10-222A)- !

♦

Only release the engine support if the assembly bracket is re‐
moved.

For vehicles Rapid NH
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.

50 .

– Position the supporting device - T30099- with the base -

T30099/1- and the adapter - MP9-200/3- and support the
engine with spindle

-B- to hang loosely.

Note

-A- in its installed position. Allow spindle

♦

The assembly bracket must only be removed if the engine is
supported with the supporting device - T30099- !

♦

Only release the engine support if the assembly bracket is re‐
moved.

Continued for all vehicles
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.

gr. 66 .

– Separate fuel feed line -2- and fuel return-flow line -1-, to do

so press the release buttons. Unlock the quick coupling and

disconnect ⇒ page 303 .
– Collect the fuel which flows out with a cloth.
For vehicles Fabia II, Roomster, Rapid NH

– Unlock

valve upwards out of the guide of the coolant expansion bottle.
For Rapid India vehicles

the catch peg with a finger and pull the fuel preheating

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– Unlock the catch peg with a finger and pull the T-piece up‐

wards out of the guide from the coolant expansion bottle.
Continued for all vehicles
– Unclip the fuel line from the plastic holders.

– Push the catch pegs up and remove the fuel filter towards the

top.
– Place the fuel filter and the fuel hoses together with the fuel

preheating valve on the engine.
– Remove fuel filter bracket.
– Slacken the coolant expansion bottle in such a way that there

is sufficient space for the removal of the engine support.

– Remove top part of toothed belt guard; to do so release re‐

taining clips -arrows­– Remove the earth connection from the assembly bracket.
For vehicles Fabia II, Roomster, Rapid NH

– Release fixing screws of assembly bracket/engine support

-3-, assembly bracket/body -2- and remove the complete as‐

sembly bracket.
For Rapid India vehicles

.

1. Removing and installing engine 47

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– Release fixing screws of assembly bracket/engine support

-B-, assembly bracket/body
sembly bracket.

Continued for all vehicles

– Screws -1 ... Unscrew screw 3- and remove pendulum sup‐

port.

Caution

-A- and remove the complete as‐

Make sure that no components/hoses are damaged, over‐
stretched or torn off when lifting and lowering the engine with
the supporting device - MP9-200 (10-222A)- if necessary ­T30099- .

– Pull the engine as far as possible towards the radiator.

Note

♦

Remove the fixing screw -1- together with the engine support.

♦

Raise engine and, using the spindles of the support bracket ­MP9-200 (10-222A)- if applicable -T30099- in such a way that
the screws -2- and -3- can be loosened and removed.

– Unscrew the fixing screws for the engine support in the se‐

quence -3-, -2- and -1­– Remove the engine support upwards.
Install

Caution

The tightening order and the tightening torque of the fixing
screws for the engine support must definitely be respected.
Otherwise engine support tensioning may occur, resulting in
engine support breakage.

Installation is carried out in reverse order. However, pay attention
to the following:

– Place the engine support from the top.

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Note

♦

Install the fixing screw -1- together with the engine support.

♦

Raise engine and, using the spindles of the support bracket ­MP9-200 (10-222A)- if applicable -T30099- in such a way that
the screws -2- and -3- can be inserted and tightened.

– Tighten screws in two stages in the following sequence:

Stage

1. -1-, -2-, -3- 7 Nm

2. -1-, -2-, -3-

– Install engine mounting with new screws.
– Tighten screws for engine mount.
Further installation occurs in reverse order. However, pay atten‐

tion to the following:
♦ Make sure the fuel lines fit tightly.
♦ Do not mix-up the feed line and the return-flow line (the return-

flow line is blue or has a blue marking, the feed line is black).
Tightening torques
♦ ⇒ “1.5.1 Assembly mountings (Fabia II, Roomster, Rapid NH)”,

page 37 .

♦ ⇒ “1.5.4 Assembly mountings (Rapid India)”, page 40 .

1.7.2 Removing

Screws Tightening torque/torquing angle

40 Nm + 180° (1/2 turn).

and installing engine support

bracket (Superb II)

Special tools and workshop equipment required
♦ Supporting device - MP9-200 (10-222A)­♦ Adapter - MP9-200/3 (10-222A/3)­♦ Wing plates - T10311­Removing

Caution

When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:

♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,

cooling fluid and refrigerant, brake fluid, vacuum) and
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 49

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Note

♦

Safety precautions when working on the fuel supply system

⇒ page 3 .

♦

Observe rules for cleanliness ⇒ page 6 .

– Switch off ignition and pull out ignition key.
– Remove engine cover
– Detach fuel feed line -2- and fuel return-flow line -1-, to do so

press in securing ring. Unlock the quick coupling and discon‐
nect ⇒ page 303 .

⇒ page 10 .

– Unscrew bolt -1-.
– Push the filler tube with the filler neck -2- for the washer-fluid

reservoir to the side.

– Disconnect the plug from the differential pressure sender -

G505- and unscrew the fixing screws

-1-.

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– Slacken line -1- for differential pressure sender - G505- with

bracket from top timing belt guard.
– Remove the bracket with the differential pressure sender -

G505- and place it to the rear.

Caution

Risk of damage!

♦ The differential pressure indicator - G505- is very sensitive

and must not touch somewhere when laying it down with
the bracket.

– Unplug connector from compensation bottle.
– Unscrew screw for compensation bottle.

– Release screw -1- by two turns.
– Release screw -2- and nut -3-.
– Unclip bracket for coolant line at fuel filter.
– Lay

– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.

the compensation bottle with the hoses connected and the

fuel filter with the hoses connected onto the engine.

66 .

– Insert

– Also insert the wing plate - T10311- on the left vehicle side

the wing plate - T10311- on the right vehicle side -A- in

-the direction of the arrow- up to the stop. When doing this, the

-arrow R- on the wing plate - T10311- points to the rear.

-B- in -the direction of the arrow- up to the stop. When doing

this, the -arrow L- on the wing plate - T10311- points to the

rear.

Note

The wing plates -T10311- ensure that the wings do not get dam‐
aged through the weight of the engine/gearbox unit.

1. Removing and installing engine 51

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– Position

MP9-200/3- and support the engine/gearbox unit in its instal‐
led position.

– Uniformly pre-tension the engine/gearbox unit at both spin‐

dles, do not raise.
– Remove engine mounts.
– Remove the sound dampening system ⇒ Body Work; Rep.

gr. 50 .
– Remove the right wheelhouse liner bottom part ⇒ Body Work;

Rep. gr. 66 .
– Remove the coolant pipe from the engine support.

Make sure that no components as well as hoses are damaged,
overstretched or torn off when lifting and lowering the engine
with the supporting device - MP9-200- .

The fixing screw -1- is accessible through the hole in the wheel‐
house. If necessary, raise or lower the engine via the spindles of
the supporting device - MP9-200- so that the screws -2- and -3­can be removed.

the supporting device - MP9-200- with the adapters -

Caution

Note

– Unscrew the fixing screws for the engine support in the se‐

quence -3-, -2- and -1­– Remove engine support upwards.
Install

Caution

The tightening order and the tightening torque of the fixing
screws for the engine support must definitely be respected.
Otherwise engine support tensioning may occur, resulting in
engine support breakage.

Installation is carried out in reverse order. However, pay attention
to the following:

– Insert engine support from above.

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Note

The installation of the fixing screw -2- is possible through the hole
in the wheelhouse. If necessary, raise or lower the engine via the
spindles of the supporting device - MP9-200- so that the screws

-1- and -3- can be inserted.

– Tighten screws in two stages in the following sequence:

Stage

1. -1-, -2-, -3- 7 Nm

2. -1-, -2-, -3-

– Install engine mounting with new screws.
– Check the setting of the assembly bracket at the engine

⇒ page 41 .

– Tighten screws for engine mount.
Further installation occurs in reverse order. However, pay atten‐

tion to the following:
♦ Make sure the fuel lines fit tightly.
♦ Do not mix-up the feed line and the return-flow line (the return-

flow line is blue or has a blue marking, the feed line is black).
Tightening torques
♦ ⇒ “1.5.3 Assembly mountings (Superb II, Yeti)”, page 39

1.7.3 Removing

Screws Tightening torque/torquing angle

40 Nm + 180° (1/2 turn).

and installing engine support

bracket (Octavia II, Yeti)

Special tools and workshop equipment required
♦ Supporting device - T30099­♦ Surface - T30099/1­♦ Adapter - MP9-200/3 (10-222A/3)­Removing

Caution

When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:

♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,

cooling fluid and refrigerant, brake fluid, vacuum) and
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 53

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Note

♦

Safety precautions when working on the fuel supply system

⇒ page 3 .

♦

Observe rules for cleanliness ⇒ page 6 .

– Switch off ignition and pull out ignition key.
– Remove engine cover
– Detach fuel feed line -2- and fuel return-flow line -1-, to do so

press in securing ring. Unlock the quick coupling and discon‐
nect ⇒ page 303 .

⇒ page 10 .

– Unscrew bolt -1-.
– Push the filler tube with the filler neck -2- for the washer-fluid

reservoir to the side.

– Disconnect the plug from the differential pressure sender -

G505- and unscrew the fixing screws

-1-.

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– Slacken line -1- for differential pressure sender - G505- with

bracket from top timing belt guard.
– Remove the bracket with the differential pressure sender -

G505- and place it to the rear.

Caution

Risk of damage!

♦ The differential pressure indicator - G505- is very sensitive

and must not touch somewhere when laying it down with
the bracket.

– Unplug connector from compensation bottle.
– Unscrew screw for compensation bottle.

– Release screw -1- by two turns.
– Release screw -2- and nut -3-.
– Unclip bracket for coolant line at fuel filter.
– Lay

– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.

the compensation bottle with the hoses connected and the

fuel filter with the hoses connected onto the engine.

66 .

– Position the supporting device - T30099- with the base -

T30099/1- and the adapter - MP9-200/3- and support the

engine in its installed position.
– Uniformly pre-tension the engine/gearbox unit at both spin‐

dles, do not raise.
– Remove engine mounts.
– Remove the sound dampening system ⇒ Body Work; Rep.

gr. 50 .
– Remove

Rep. gr. 66 .
– Remove the coolant pipe from the engine support.

the right wheelhouse liner bottom part ⇒ Body Work;

Caution

Make sure that no components as well as hoses are damaged,
overstretched or torn off when lifting and lowering the engine
with the supporting device - T30099- .

1. Removing and installing engine 55

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Note

The fixing screw -1- is accessible through the hole in the wheel‐
house. If necessary, raise or lower the engine via the spindles of
the supporting device - T30099- so that the screws -2- and -3­can be removed.

– Unscrew the fixing screws for the engine support in the se‐

quence -3-, -2- and -1­– Remove engine support upwards.
Install

Caution

The tightening order and the tightening torque of the fixing
screws for the engine support must definitely be respected.
Otherwise engine support tensioning may occur, resulting in
engine support breakage.

Installation is carried out in reverse order. However, pay attention
to the following:

– Insert engine support from above.

Note

The installation of the fixing screw -2- is possible through the hole
in the wheelhouse. If necessary, raise or lower the engine via the
spindles of the supporting device - T30099- so that the screws

-1- and -3- can be inserted.

– Tighten screws in two stages in the following sequence:

Stage

1. -1-, -2- , -3- 7 Nm

2. -1-, -2- , -3-

– Install engine mounting with new screws.
– Check the setting of the assembly bracket at the engine

⇒ page 43 .

– Tighten screws for engine mount.
Further installation occurs in reverse order. However, pay atten‐

tion to the following:
♦ Make sure the fuel lines fit tightly.
♦ Do not mix-up the feed line and the return-flow line (the return-

flow line is blue or has a blue marking, the feed line is black).
Tightening torques
♦ ⇒ “1.5.2 Assembly mountings (Octavia II)”, page 38 .
♦ ⇒ “1.5.3 Assembly mountings (Superb II, Yeti)”, page 39 .

Screws Tightening torque/torquing angle

40 Nm + 180° (1/2 turn).

56 Rep. gr.10 - Removing and installing engine

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13 – Crankshaft group

1 Removing and installing a V-ribbed

belt and a toothed belt

⇒ “1.1 Assembly overview - Poly V-belt”, page 57
⇒ “1.2 Removing and installing V-ribbed belt”, page 63
⇒ “1.3 Removing and installing crankshaft-belt pulley”,

page 67
⇒ “1.4 Removing and installing tensioning element for V-ribbed

belt”, page 68
⇒ “1.5 Removing and installing bracket for auxiliary units”,

page 75
⇒ “1.6 Assembly overview - toothed belt drive”, page 82
⇒ “1.7 Removing and installing toothed belt”, page 90

1.1 Assembly overview - Poly V-belt

⇒ “1.1.1 Summary of components - Vehicles without air condi‐
tioning”, page 57

⇒ “1.1.2 Summary of components - Vehicles with air conditioning
and guide pulley”, page 59

⇒ “1.1.3 Summary of components - Vehicles with air conditioning
system and tensioning element”, page 61

1.1.1 Summary of components - Vehicles without air conditioning

1. Removing and installing a V-ribbed belt and a toothed belt 57

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1 - Crankshaft-belt pulley

❑

with vibration damper

❑ pay attention to correct

installation position

⇒ page 58

❑

removing and installing

⇒ page 67

2 - Screw

❑

25 Nm

3 - Alternator

❑ removing and installing

⇒ Electrical System;
Rep. gr. 27

4 - Bracket for auxiliary units

❑ wymontowanie i zamon‐

towanie

❑

kolejność dokręcania

⇒ page 59

5 - V-ribbed belt

❑ wymontowanie

towanie

❑

pay attention to the cor‐
rect position on the belt
pulley when installing it

⇒ page 75

i zamon‐

⇒ page 63

Fitting position of the crankshaft belt pulley

• The hole -arrow- in the crankshaft belt pulley must be posi‐

tioned above the peg on the crankshaft timing belt sprocket.

58 Rep. gr.13 - Crankshaft group

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Bracket for auxiliary units - tightening order and tightening torques

• A dowel sleeve must be located between the bracket for aux‐
iliary

units and the cylinder block in the area of the screw hole

-6-.

– Insert new fixing screws for the bracket for auxiliary units as

follows:

♦ Screws -1- and -2- M10 x 52
♦ Screws -3- and -4- M10 x 30
♦ Screws -5- and -6- M10 x 60
– Tighten securing bolts for bracket for auxiliary units step by

step in the following order:

Stage

1. -1 … 6- by hand as far as the stop

2. -1 … 6- 40 Nm

3. -3- and -4-

4. -1-, -2-, -5- and

Screws Tightening torque/torquing angle

45° (torque a further 45° (1/8 turn)
90° (torque a further 90° (1/4 turn)

-6-

1.1.2 Summary of components - Vehicles with air conditioning and guide pulley

1 - V-ribbed belt

❑ wymontowanie

towanie

❑

check for wear

❑ mark the direction of ro‐

tation with chalk or a felt-

tip pen before removing
❑ do not kink
❑ pay attention to the cor‐

rect position on the belt

pulley when installing it

2 - Guide pulley for V-ribbed
belt

❑ wymontowanie i zamon‐

towanie

3 - Crankshaft-belt pulley

❑

with vibration damper
❑ pay attention to correct

installation position

⇒ page 60

❑

removing and installing

⇒ page 67

4 - Screw

❑

replace
❑ 10 Nm + torque a further

90° (1/4 turn)

⇒ page 63

⇒ page 63

5 - Fitting sleeve

❑ pay attention to correct

fit in the bracket for aux‐

iliary units
❑ The dowel sleeve is lo‐

cated in the top right

i zamon‐

1. Removing and installing a V-ribbed belt and a toothed belt 59

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screw hole ⇒ page 61

6 - Screw

❑

replace

❑

20 Nm + torque a further 45° (1/8 turn)

7 - Screw

❑ replace
❑

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

8 - Guide pulley

❑ for toothed belt

9 - Screw

❑ 15 Nm

10 - Guide pulley

❑ for toothed belt

11 - Bracket for auxiliary units

❑ wymontowanie i zamontowanie
❑

kolejność dokręcania

12 - High pressure pump

❑

wymontowanie i zamontowanie

13 - Screw

❑

kolejność dokręcania

14 - Alternator

❑

removing and installing ⇒ Electrical System; Rep. gr. 27

15 - Screw

❑ 25 Nm

16 - AC compressor

❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87

17 - Screw

❑ M8 = 25 Nm
❑ M10 = 45 Nm

18 - Fitting sleeve

❑ pay attention to correct fit in the bracket for auxiliary units
❑ The dowel sleeve is located in the bottom right screw hole

19 - Screw

❑

Tightening torque

⇒ page 61

⇒ page 61

⇒ page 63

⇒ page 75

⇒ page 400

⇒ page 61

Fitting position of the crankshaft belt pulley

• The hole -arrow- in the crankshaft belt pulley must be posi‐
tioned above the peg on the crankshaft timing belt sprocket.

60 Rep. gr.13 - Crankshaft group

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Bracket for auxiliary units - tightening order and tightening torques

• A dowel sleeve must be located between the bracket for aux‐
iliary

units and the cylinder block in the area of the screw hole

-6-.

– Insert new fixing screws for the bracket for auxiliary units as

follows:

♦ Screws -1- and -2- M10 x 52
♦ Screws -3- and -4- M10 x 30
♦ Screws -5- and -6- M10 x 60
– Tighten securing bolts for bracket for auxiliary units step by

step in the following order:

Stage

1. -1 … 6- by hand as far as the stop

2. -1 … 6- 40 Nm

3. -3- and -4-

4. -1-, -2-, -5- and

Screws Tightening torque/torquing angle

45° (torque a further 45° (1/8 turn)
90° (torque a further 90° (1/4 turn)

-6-

1.1.3 Summary of components - Vehicles with air conditioning system and ten‐

sioning element

1. Removing and installing a V-ribbed belt and a toothed belt 61

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1 - Crankshaft-belt pulley

❑

with vibration damper

❑ pay attention to correct

installation position

⇒ page 62

❑

removing and installing

⇒ page 67

2 - Screw

❑

25 Nm

3 - AC generator

❑ removing and installing

⇒ Electrical System;
Rep. gr. 27

4 - Bracket for auxiliary units

❑ order of tightening

⇒ page 63

5 - Screw

❑

replace

❑ 20 Nm + torque a further

180° (1/2 turn)

6 - Tensioner for V-ribbed belt
7 - AC compressor

❑ removing and installing

⇒ Heating, Air Condi‐
tioning; Rep. gr. 87

8 - Screw

❑ M8 = 25 Nm
❑ M10 = 45 Nm

9 - Dowel sleeves

❑ pay attention to correct

fit in the holder

10 - V-ribbed belt

❑ wymontowanie i zamontowanie
❑

check for wear
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ do not kink
❑ pay attention to the correct position on the belt pulley when installing it

Fitting position of the crankshaft belt pulley

• The hole -arrow- in the crankshaft belt pulley must be posi‐
tioned above the peg on the crankshaft timing belt sprocket.

⇒ page 63

62 Rep. gr.13 - Crankshaft group

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Bracket for auxiliary units - tightening order and tightening torques

• A dowel sleeve must be located between the bracket for aux‐
iliary

units and the cylinder block in the area of the screw hole

-6-.

– Insert new fixing screws for the bracket for auxiliary units as

follows:

♦ Screws -1- and -2- M10 x 52
♦ Screws -3- and -4- M10 x 30
♦ Screws -5- and -6- M10 x 60
– Tighten securing bolts for bracket for auxiliary units step by

step in the following order:

Stage

1. -1 … 6- by hand as far as the stop

2. -1 … 6- 40 Nm

3. -3- and -4-

4. -1-, -2-, -5- and

Screws Tightening torque/torquing angle

45° (torque a further 45° (1/8 turn)
90° (torque a further 90° (1/4 turn)

-6-

1.2 Removing and installing V-ribbed belt

⇒ “1.2.1 Removing and installing V-ribbed belt for vehicles without
air conditioning system”, page 63

⇒ “1.2.2 Remove and install poly V-belt for vehicles with air con‐
ditioning unit and guide pulley (Fabia II, Roomster, Rapid NH,
Octavia II, Superb II, Yeti)”, page 64

⇒ “1.2.3 Removing and installing V-ribbed belt for vehicles with
air conditioning system and tensioning element”, page 65

1.2.1 Removing and installing V-ribbed belt

for vehicles without air conditioning sys‐
tem

Note

The repair kit includes the V-ribbed belt, the assembly tool ­T10367- and an illustrated work sequence ⇒ ETKA - Electronic
Catalogue of Original Parts .

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

gr. 50 .

– Remove

Rep. gr. 66 .

– Cut through V-ribbed belt.
Install
Installation is performed in the reverse order, pay attention to the

following points:
– The following work procedure is described in the illustrated

work procedure from the repair kit.

– Start engine and check ribbed V-belt run.

the right wheelhouse liner bottom part ⇒ Body Work;

1. Removing and installing a V-ribbed belt and a toothed belt 63

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1.2.2 Remove and install poly V-belt for vehi‐
cles with air conditioning unit and guide
pulley (Fabia II, Roomster, Rapid NH,
Octavia II, Superb II, Yeti)

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

gr. 50 .
For vehicles Fabia II, Roomster, Rapid NH
– Removing

gr. 66 .
– Unscrew screws -3-, -4- and -6-.
– Carefully push the coolant line -5- to the side so that there is

adequate space for loosening the screw -2- for the guide pulley

of the V-ribbed belt.
For vehicles Octavia II, Superb II, Yeti
– Remove the right wheelhouse liner bottom part ⇒ Body Work;

Rep. gr. 66 .
For all vehicles

the right wheel-well inner panel ⇒ Body Work; Rep.

Caution

Risk of damage through reversing the rotation direction of an
already used V-ribbed belt.

♦ If it is intended to re-install the V-ribbed belt, mark the di‐

rection of rotation with chalk or a felt-tip pen before re‐
moving it.

– Slacken the screw for the guide pulley/V-ribbed belt -arrow-

until the V-ribbed belt can be easily removed.
– Remove the V-ribbed belt.
Install
Installation is performed in the reverse order, pay attention to the

following points:

Note

Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.

64 Rep. gr.13 - Crankshaft group

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– First

1 - Crankshaft-belt pulley
2 - Guide pulley
3 - AC generator
4 - AC compressor
– Coat the guide surfaces for the guide pulley with the grease G

– Guide the guide pulley with the bolt into the guide in the brack‐

– Screw

–

position the V-ribbed belt on the belt pulleys of the crank‐
shaft and AC compressor and last on the belt pulley of the
generator.

052 751 A1 .

et for auxiliary units.

in the screw for the guide pulley -arrow- until the bolt of
the guide pulley is located at the stop (this tensions the V­ribbed belt).

Subsequently slacken the screw -arrow- again by 1/4 turn,
tighten again to 30 Nm + torque a further 90° (1/4 turn).

– Check whether the end of the screw for the guide pulley/V-

ribbed belt protrudes beyond the contact surface of the guide
pulley. Dimension

– Check correct positioning of the V-ribbed belt.
– Start engine and check ribbed V-belt run.

-a- = approx. 2.5 mm.

1.2.3 Removing and installing V-ribbed belt
vehicles with air conditioning system

for
and tensioning element

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

gr. 50 .

– Remove

Rep. gr. 66 .

the right wheelhouse liner bottom part ⇒ Body Work;

1. Removing and installing a V-ribbed belt and a toothed belt 65

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Caution

Risk of damage through reversing the rotation direction of an
already used V-ribbed belt.

♦ If it is intended to re-install the V-ribbed belt, mark the di‐

rection of rotation with chalk or a felt-tip pen before re‐
moving it.

– Swing the tensioning element in -the direction of the arrow-

detension the V-ribbed belt.

– Align

– Remove the V-ribbed belt.
Install
Installation is performed in the reverse order, pay attention to the

following points:

Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.

– Lay the V-ribbed belt onto the V-ribbed belt pulleys.
1 - Crankshaft
2 - Tensioning element
3 - AC generator
4 - AC compressor

the holes -arrows- and lock the tensioning element using

the locking pin - T10060 A- .

Note

66 Rep. gr.13 - Crankshaft group

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– Hold

– Release the tensioning element.
– Check correct positioning of the V-ribbed belt.
– Start engine and check ribbed V-belt run.

the tensioning element with the ring spanner and pull out

the locking pin - T10060 A- .

1.3 Removing and installing crankshaft-belt

pulley

Removing
– Remove V-ribbed belt
– Loosen

so hold the screw for the crankshaft timing belt sprocket using
the ring spanner.

the screws -arrows- of the crankshaft belt pulley, to do

⇒ page 57 .

– Release screws and remove crankshaft-belt pulley.
Install
Installation is performed in the reverse order, pay attention to the

following points:

Note

♦

Pay attention to the fitting position of the crankshaft belt pulley

⇒ page 62 or ⇒ page 58 .

♦

Replace the screws of the crankshaft belt pulley.

Tightening torques
♦

⇒ “1.1 Assembly overview - Poly V-belt”, page 57

1. Removing and installing a V-ribbed belt and a toothed belt 67

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1.4 Removing and installing tensioning ele‐
ment for V-ribbed belt

⇒ “1.4.1 Remove and install tensioner link for Poly V-belt (Fabia
II, Roomster, Rapid NH)”, page 68

⇒ “1.4.2 Remove and install the tensioner link for poly V-belt (Oc‐
tavia II, Superb II,Yeti)”, page 70

⇒ “1.4.3 Removing and installing tensioner link for poly V-belt
(Rapid India)”, page 71

1.4.1 Remove and install tensioner link for Poly V-belt (Fabia II, Roomster, Rapid NH)

For vehicles Fabia II, Roomster
Special tools and workshop equipment required
♦ Supporting device - MP9-200 (10-222A)­For vehicles Rapid NH
Special tools and workshop equipment required
♦ Supporting device - T30099­♦ Surface - T30099/1­♦ Adapter - MP9-200/3 (10-222A/3)­Removing
– Remove V-ribbed belt ⇒ page 63 .
– Remove right charge air hose.

– Unlock the catch peg with a finger and pull the fuel preheating

valve upwards out of the guide of the coolant expansion bottle.

68 Rep. gr.13 - Crankshaft group

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– Unscrew
– Disconnect the plug -1- from the expansion bottle and remove

the coolant expansion bottle and place it on the engine.

For vehicles Fabia II, Roomster

– Install supporting device - MP9-200 (10-222A)- and support

the engine with spindle -B- in fitting position. Allow spindle

-A- to hang loosely.
For vehicles Rapid NH
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.

50 .

the screws of the coolant expansion bottle -arrows-.

– Position the supporting device - T30099- with the base -

T30099/1- and the adapter - MP9-200/3- and support the
engine with spindle

-B- to hang loosely.
Continued for all vehicles

– Remove the earth connection -1- from the assembly bracket.
– Remove the screws -arrows- of the assembly bracket

⇒ page 44 .

– Carefully lower the engine sufficiently so that the tensioning

element can be taken out.

-A- in its installed position. Allow spindle

1. Removing and installing a V-ribbed belt and a toothed belt 69

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– Release screws -arrows-.
– Loosen hose clamp -2-.
– Disconnect the plug -1-

with intake air temperature sender - G42- and remove the right
charge air pipe.

at the charge pressure sender - G31-

– Unscrew

ribbed belt.
Install
Installation is performed in the reverse order, pay attention to the

following points:

– Install the screws -arrows- of the assembly bracket

⇒ page 44 .

– Replace the screw of the tensioning element for the V-ribbed

belt.
– Install poly V-belt ⇒ page 63 .
Tightening torques
♦ ⇒ “1.1.3 Summary of components - Vehicles with air condi‐

tioning system and tensioning element”, page 61

screw -2- and remove tensioning element -1- from V-

1.4.2 Remove

poly V-belt (Octavia II, Superb II,Yeti)

Removing
– Remove V-ribbed belt

70 Rep. gr.13 - Crankshaft group

and install the tensioner link for

⇒ page 63 .

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– Remove right charge air hose.
– Remove fan shroud with radiator ⇒ page 259 .

– Release screws -arrows-.
– Expose coolant hose -3-.
– Loosen hose clamp -2-.
– Disconnect the plug -1- at the charge pressure sender - G31-

with intake air temperature sender - G42- and remove the right
charge air pipe.

– Unscrew

ribbed belt.
Install
Installation is performed in the reverse order, pay attention to the

following points:
– Replace the screw of the tensioning element for the V-ribbed

belt.
– Install poly V-belt
Tightening torques
♦ ⇒ “1.1.3 Summary of components - Vehicles with air condi‐

tioning system and tensioning element”, page 61

screw -2- and remove tensioning element -1- from V-

⇒ page 63 .

1.4.3 Removing and installing tensioner link

for poly V-belt (Rapid India)

Removing
– Remove V-ribbed belt ⇒ page 63 .

1. Removing and installing a V-ribbed belt and a toothed belt 71

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– Slacken clamps -1- and -2- and remove the charge air hose.

– Unscrew screws -3-, -4-, -6-.
– Carefully press off the coolant line -5- to the side.

– Unscrew the fixing screws -arrows- from the charge air pipe

and disconnect the plug -1- at the charge pressure sender ­G31- with intake air temperature sender - G42- .

72 Rep. gr.13 - Crankshaft group

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– Open the clamp -2-,

the charge air pipe.
– Remove AC compressor, do not loosen the coolant line at the

AC compressor.
– The refrigerant circuit remains closed.
– Hang the AC compressor at the body using suitable auxiliary

tools ⇒ Rep. gr. 87 ; Removing and installing AC compressor .

– Release fixing screw -2-.

expose the coolant hose -3- and remove

– Push the tensioning element slightly forwards.

– Rotate the tensioning element 180° clockwise.

1. Removing and installing a V-ribbed belt and a toothed belt 73

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– Pull

Install
The installation of the tensioning element occurs in reverse order.

Pay attention to the following:

– Rotate the tensioning element below the AC generator in its

the tensioning element below the AC generator obliquely

towards the bottom out of the support.

support.

– Rotate the tensioning element 180° clockwise.

– Insert the tensioning element in its support.
♦ Replace the screw for the tensioning element.

74 Rep. gr.13 - Crankshaft group

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– Bring coolant line -5- back into the fitting position, tighten

screws -3-, -4-, -6- to the following tightening torque: 8 Nm.
– Install poly V-belt ⇒ page 63 .
Tightening torques
♦ ⇒ “1.1.3 Summary of components - Vehicles with air condi‐

tioning system and tensioning element”, page 61

1.5 Removing

and installing bracket for aux‐

iliary units

⇒ “1.5.1 Removing and installing bracket for auxiliary units (Fabia
II, Roomster, Rapid India, Rapid NH)”, page 75

⇒ “1.5.2 Removing and installing bracket for auxiliary units (Oc‐
tavia II, Yeti)”, page 77

⇒ “1.5.3 Removing and installing bracket for auxiliary units (Su‐
perb II)”, page 80

1.5.1 Removing

and installing bracket for aux‐
iliary units (Fabia II, Roomster, Rapid
India, Rapid NH)

Removing
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .
– Wymontować pompę wysokociśnieniową
On vehicles with air conditioning

WARNING

Risk of injury through refrigerant.

♦ Do not open the refrigerant circuit of the air conditioning

system.

⇒ page 400 .

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 ⇒ Heating, Air Conditioning; Rep. gr. 87 .

1. Removing and installing a V-ribbed belt and a toothed belt 75

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– Attach the AC compressor -3- e.g. behind the lock carrier as

shown in the figure. As protection put a sheet of cardbord
on the radiator wall.

– Release screw -arrow-.
– Release

drives.

screws -1- and -2- and remove toothed belt camshaft

-1-

76 Rep. gr.13 - Crankshaft group

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– Release
Install
Installation is performed in the reverse order, pay attention to the

following points:

screws -1 ... 6- and remove bracket for auxiliary units.

Note

Replace screws which have been tightened to a torquing angle.

– If no dowel sleeves are present on the top right between the

bracket for auxiliary units and the cylinder block, insert dowel

sleeves.
– Tighten the fixing screws for the bracket for auxiliary units.
– Install high pressure pump
– Installing the timing belt ⇒ page 95 .
– Install engine support and engine mount ⇒ page 44 and

⇒ page 37 .

– Install alternator ⇒ Electrical System; Rep. gr. 27 .
On vehicles with air conditioning
– Install AC compressor at the bracket for auxiliary units

⇒ page 57 .

– Filling and bleeding the fuel system ⇒ page 382 .
– Check fuel system for tightness ⇒ page 406 .
Tightening torques
♦ ⇒ “1.1 Assembly overview - Poly V-belt”, page 57

⇒ page 400 .

1.5.2 Removing

and installing bracket for aux‐

iliary units (Octavia II, Yeti)

Special tools and workshop equipment required
♦ Supporting device - T30099­♦ Surface - T30099/1­♦ Adapter - MP 9-200/3 (10-222/3)­♦ Ring bolt - 3368­♦ Collar nut M10
Removing
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .
– Wymontować pompę wysokociśnieniową
On vehicles with air conditioning

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

WARNING

⇒ page 400 .

1. Removing and installing a V-ribbed belt and a toothed belt 77

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Note

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

– Remove the AC compressor from the bracket for auxiliary

units and attach to the lock carrier.
Continued for all vehicles
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.

66 .
– Insert the supporting device - T30099- with the base -

T30099/1- and the adapter - MP9-200/3- and attach the spin‐

dle -B-.

WARNING

Risk of accident due to loosened screwed connection.

♦ The collar nut must be screwed in by at least 6 turns so

that the ring bolt - 3368- is held securely.

– Tighten the ring bolt - 3368- with the collar nut M10 or the nut

with the washer -arrow- at the engine support, as shown in the

illustration.
– Hook spindle -A- onto ring bolt - 3368- .
– Uniformly pre-tension the engine with both spindles, but do not

raise.

– Release screws -1- and -2-, remove connecting stud.
– Release screws -3...6- and remove engine mounting.

78 Rep. gr.13 - Crankshaft group

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– Release screw -3- on engine support.

– Release screw -arrow-.
– Release

drives.

screws -1- and -2- and remove toothed belt camshaft

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– Unscrew
Install
Installation is performed in the reverse order, pay attention to the

following points:

screws -1 ... 6- and remove bracket for auxiliary units.

Note

Replace screws which have been tightened to torquing angle.

– If no dowel sleeves are present on the top right between the

bracket for auxiliary units and the cylinder block, insert dowel

sleeves.
– Tighten the screws for the bracket for auxiliary units.
– Install engine support and engine mount

⇒ page 37 .

– Install high pressure pump ⇒ page 400 .
– Installing the timing belt ⇒ page 90 .
– Install alternator ⇒ Electrical System; Rep. gr. 27 .
On vehicles with air conditioning
– Install AC compressor at the bracket for auxiliary units

⇒ page 57 .

– Filling and bleeding the fuel system ⇒ page 382 .
– Check fuel system for tightness ⇒ page 406 .
Tightening torques
♦ ⇒ “1.1 Assembly overview - Poly V-belt”, page 57

⇒ page 44 and

1. Removing and installing a V-ribbed belt and a toothed belt 79

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1.5.3 Removing and installing bracket for aux‐
iliary units (Superb II)

Special tools and workshop equipment required
♦ Supporting device - MP9-200 (10-222A)­♦ Adapter - MP 9-200/3 (10-222A/3)­♦ Wing plates - T10311­♦ Ring bolt - 3368­♦ Collar nut M10
Removing
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .
– Wymontować pompę wysokociśnieniową ⇒ page 400 .
On vehicles with air conditioning

WARNING

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

Note

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

– Remove the AC compressor from the bracket for auxiliary

units and attach to the lock carrier.
Continued for all vehicles
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.

66 .
– Insert the wing plate - T10311- on the right vehicle side -A- in

-the direction of the arrow- up to the stop. When doing this, the

-arrow R- on the wing plate - T10311- points to the rear.

– Also insert the wing plate - T10311- on the left vehicle side

-B- in -the direction of the arrow- up to the stop. When doing

this, the -arrow L- on the wing plate - T10311- points to the

rear.

Note

The wing plates -T10311- ensure that the wings do not get dam‐
aged through the weight of the engine/gearbox unit.

80 Rep. gr.13 - Crankshaft group

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– Position

MP9-200/3 - and support the engine/gearbox unit in its instal‐
led position.

the supporting device - MP9-200- with the adapters -

WARNING

Risk of accident due to loosened screwed connection.

♦ The collar nut must be screwed in by at least 6 turns so

that the ring bolt - 3368- is held securely.

– Tighten

with the washer -arrow- at the engine support, as shown in the

illustration.
– Hook spindle -A- onto ring bolt - 3368- .
– Uniformly

raise.

the ring bolt - 3368- with the collar nut M10 or the nut

pre-tension the engine with both spindles, but do not

– Release screws -1- and -2-, remove connecting stud.
– Release screws -3...6- and remove engine mounting.

– Release screw -3- on engine support.

1. Removing and installing a V-ribbed belt and a toothed belt 81

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– Release screw -arrow-.
– Release

drives.

screws -1- and -2- and remove toothed belt camshaft

– Unscrew
Install
Installation is performed in the reverse order, pay attention to the

following points:

Replace screws which have been tightened to torquing angle.

– If no dowel sleeves are present on the top right between the

bracket for auxiliary units and the cylinder block, insert dowel

sleeves.
– Tighten the screws for the bracket for auxiliary units.
– Install engine support and engine mount

⇒ page 37 .

– Install high pressure pump ⇒ page 400 .
– Installing the timing belt.
– Install alternator ⇒ Electrical System; Rep. gr. 27 .
On vehicles with air conditioning
– Install AC compressor at the bracket for auxiliary units

⇒ page 57 .

– Filling and bleeding the fuel system ⇒ page 382 .
– Check fuel system for tightness ⇒ page 406 .
Tightening torques
♦ ⇒ “1.1 Assembly overview - Poly V-belt”, page 57

screws -1 ... 6- and remove bracket for auxiliary units.

Note

⇒ page 44 and

1.6 Assembly overview - toothed belt drive

⇒ “1.6.1 Summary of components - Toothed belt drive (Fabia II,
Roomster, Rapid India, Rapid NH)”, page 82

⇒ “1.6.2 Summary of components - Toothed belt drive (Octavia
II, Superb II, Yeti)”, page 86

1.6.1 Summary of components - Toothed belt drive (Fabia II, Roomster, Rapid

82 Rep. gr.13 - Crankshaft group

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1 - Toothed belt

❑

before removing mark

running direction
❑ check for wear
❑ do not kink
❑ wymontowanie i zamon‐

towanie

⇒ page 90

Note

If the toothed belt is replaced when
carrying out engine repair (apart
from regular change interval), it
should be entered in the Service
Schedule!

2 - Screw

❑ replace
❑ to release and tighten

use counterholder -

3415­❑ Neither oil nor grease

thread or collar

Tighten in three stages as fol‐
lows
♦ 1. stage 180 Nm

♦ 2. Continue to turn stage by

90° (1/4 turn)

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♦ 3. Continue to turn stage by

45° (1/8 turn)

3 - Crankshaft - toothed belt
sprocket

4 - Nut

❑ 20 Nm

5 - Guide pulley
6 - Nut

❑

20 Nm + torque a further 45° (1/8 turn)

7 - Tensioning pulley

❑ pay attention to different versions
❑

for removing and installing, remove engine support

8 - Screw

❑

replace
❑

20 Nm + torque a further 45° (1/8 turn)

9 - Camshaft sprocket
10 - Screw

❑ 15 Nm

11 - Screw

❑ to release and tighten use counterholder - T10051­❑ 100 Nm

12 - Hub

❑ for camshaft

⇒ page 85

⇒ page 44

1. Removing and installing a V-ribbed belt and a toothed belt 83

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❑ to release and tighten use counterholder - T10051­❑

to remove use extractor - T10052-

❑ wymontowanie i zamontowanie
13 - Rear toothed belt guard
14 - Screw

❑

replace
❑ Attach high pressure pump
❑

20 Nm + torque a further 45° (1/8 turn)

15 - Screw

❑ replace
❑ 10 Nm

16 - Guide pulley
17 - Screw

❑ replace
❑

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

18 - Hub

❑ for high pressure pump
❑ to release and tighten use counterholder - T10051­❑ to remove use extractor - T40064­❑ wymontowanie i zamontowanie

19 - Nut

❑

95 Nm

20 - Toothed belt gear on the high pressure pump
21 - Screw

❑ replace
❑ 20 Nm

22 - Coolant pump

❑ wymontowanie i zamontowanie

23 - Screw

❑

15 Nm

24 - Timing belt guard - top part
25 - Timing belt guard - bottom part

❑ wymontowanie i zamontowanie

26 - Screw

❑

9 Nm

27 - Screw

❑ replace
❑

10 Nm + torque a further 90° (1/4 turn)

⇒ page 178

⇒ page 400

⇒ page 241

⇒ page 86

28 - Crankshaft-belt pulley

❑ with vibration damper
❑ Assembly only possible in one position, holes offset
❑ removing and installing

29 - Screw

❑

5 Nm

84 Rep. gr.13 - Crankshaft group

⇒ page 67

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30 - Protection plate

31 - Screw

❑

replace
❑ wymontowanie i zamontowanie
❑

40 Nm + 180° (1/2 turn).

32 - Engine support bracket

❑

removing and installing

Different versions of tensioning pulleys

Note

♦

There are 2 versions of tensioning pulleys installed, which can

⇒ page 44

⇒ page 85

be exchanged.

♦

The versions differ by the reverse direction of rotation when
tensioning. During adjusting work, first check which version of
tensioning pulley is installed and then ensure the correct ro‐
tation direction of the eccentric element when tensioning the
belt.

Tensioning pulley A
♦ Use the rig tool - T10265- for installing.
♦ When installing, ensure that the peg of the base plate of the

tensioning pulley is correctly positioned in the opening in the
rear timing belt guard.

♦ Tensioning the timing belt is carried out by turning the eccen‐

tric element of the tensioning pulley »clockwise«.
Tensioning pulley B
♦ It is not necessary to use a rig tool for installing.
♦ The tensioning pulley does not have a peg on the base plate

and is not tied up at the opening in the rear timing belt guard

(its fitting position is free).
♦ Tensioning the timing belt is carried out by turning the eccen‐

tric element of the tensioning pulley »anti-clockwise«.

Secure the engine support

Note

Replace screws for engine support.

– Tighten screws in 3 stages in the following sequence:

Stage

1. -1 … 3- 7 Nm

2. -1 … 3- 40 Nm

3. -1 … 3-

Bolts Torque/torquing angle

180° (1/2 turn)

1. Removing and installing a V-ribbed belt and a toothed belt 85

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Attach toothed belt guard - bottom part
– Tighten screws -arrows-: 9 Nm.

1.6.2 Summary of components - Toothed belt drive (Octavia II, Superb II, Yeti)

1 - Toothed belt

❑

before removing mark
running direction

❑ check for wear
❑ do not kink
❑ wymontowanie i zamon‐

towanie

2 - Screw

❑ replace
❑ to release and tighten

use counterholder ­3415-

❑ Neither oil nor grease

thread or collar

Tighten in three stages as fol‐
lows
♦ 1. stage 180 Nm

♦ 2. Continue to turn stage by

90° (1/4 turn)

⇒ page 90

Note

If the toothed belt is replaced within
the scope of engine repair (apart
from change intervals), it should be
entered in the Service Schedule!

♦ 3. Continue to turn stage by

45° (1/8 turn)

3 - Crankshaft - toothed belt
sprocket

4 - Nut

❑ 20 Nm

86 Rep. gr.13 - Crankshaft group

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5 - Guide pulley
6 - Nut

❑

20 Nm + torque a further 45° (1/8 turn)

7 - Tensioning pulley

❑

pay attention to different versions

❑

for removing and installing, remove engine support:
♦ Octavia II, Yeti
♦

Superb II

8 - Screw

❑

replace

❑

20 Nm + torque a further 45° (1/8 turn)

9 - Camshaft sprocket
10 - Screw

❑ 15 Nm

11 - Screw

❑ to release and tighten use counterholder - T10051­❑ 100 Nm

12 - Hub

❑ for camshaft
❑ to remove use extractor - T10052-

❑ wymontowanie i zamontowanie
13 - Rear toothed belt guard
14 - Screw

❑

replace
❑ Attach high pressure pump
❑

20 Nm + torque a further 45° (1/8 turn)

⇒ page 53

⇒ page 49

⇒ page 89

⇒ page 178

15 - Screw

❑ replace
❑ 10 Nm

16 - Guide pulley
17 - Screw

❑ replace
❑

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

18 - Hub

❑ for high pressure pump
❑ to release and tighten use counterholder - T10051­❑ to remove use extractor - T40064­❑ wymontowanie i zamontowanie

19 - Nut

❑

95 Nm

20 - Toothed belt gear on the high pressure pump
21 - Screw

❑ replace
❑ 20 Nm

⇒ page 400

1. Removing and installing a V-ribbed belt and a toothed belt 87

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22 - Coolant pump

❑

wymontowanie i zamontowanie

23 - Screw

❑

15 Nm
24 - Timing belt guard - top part
25 - Timing belt guard - bottom part

❑ wymontowanie i zamontowanie

26 - Screw

❑

9 Nm
27 - Screw

❑ replace
❑

10 Nm + torque a further 90° (1/4 turn)

28 - Crankshaft-belt pulley

❑ with vibration damper

29 - Screw

❑ 5 Nm
30 - Protection plate
31 - Screw

❑ replace

❑ wymontowanie i zamontowanie
32 - Engine support bracket

❑

wymontowanie i zamontowanie

⇒ page 241

⇒ page 90

⇒ page 89

⇒ page 44

88 Rep. gr.13 - Crankshaft group

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Different versions of tensioning pulleys

Note

♦

There are 2 versions of tensioning pulleys installed, which can
be exchanged.

♦

The versions differ by the reverse direction of rotation when
tensioning. During adjusting work, first check which version of
tensioning pulley is installed and then ensure the correct ro‐
tation direction of the eccentric element when tensioning the
belt.

Tensioning pulley A
♦ Use the rig tool - T10265- for installing.
♦ When installing, ensure that the peg of the base plate of the

tensioning pulley is correctly positioned in the opening in the
rear timing belt guard.

♦ Tensioning the timing belt is carried out by turning the eccen‐

tric element of the tensioning pulley »clockwise«.
Tensioning pulley B
♦ It is not necessary to use a rig tool for installing.
♦ The tensioning pulley does not have a peg on the base plate

and is not tied up at the opening in the rear timing belt guard

(its fitting position is free).
♦ Tensioning the timing belt is carried out by turning the eccen‐

tric element of the tensioning pulley »anti-clockwise«.

Secure the engine support

Note

Replace screws for engine support.

– Tighten screws in 3 stages in the following sequence:

Stage

1. -1 … 3- 7 Nm

2. -1 … 3- 40 Nm

3. -1 … 3-

Bolts Torque/torquing angle

180° (1/2 turn)

1. Removing and installing a V-ribbed belt and a toothed belt 89

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Attach toothed belt guard - bottom part
– Tighten screws -arrows-: 9 Nm.

1.7 Removing and installing toothed belt

⇒ “1.7.1 Removing and installing toothed belt (Fabia II, Roomster,
Rapid India, Rapid NH)”, page 90

⇒ “1.7.2 Removing and installing toothed belt (Octavia II, Superb
II, Yeti)”, page 101

1.7.1 Removing and installing toothed belt (Fabia II, Roomster, Rapid India, Rapid NH)

Special tools and workshop equipment required
♦ Rig pin - 3359- (2x)
♦ Crankshaft arrester - T10050­♦ Locking pin - T10060 A­♦ Counterholder - T10172- with stud - T10172/4- and stud -

T10172/9­♦ Offset screwdriver - T10264- (tensioning pulley A)
♦ Rig tool - T10265- (tensioning pulley A)
♦ Offset screwdriver - T10409- (tensioning pulley B)
♦ Socket insert XZN 10 - T10385­♦ Pliers for spring strap clamps

90 Rep. gr.13 - Crankshaft group

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Removing

Caution

When undertaking all installation work, particularly in the en‐
gine compartment due to its cramped construction, please
observe the following:

♦ If the toothed belt is replaced when carrying out engine

repair (apart from regular change interval), it should be
entered in the Service Schedule!

♦ Lay lines of all kinds (for example, 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-established.

♦ In order to avoid damage to the cables, ensure that there

is adequate free access to all moving or hot components.

Note

♦

Safety precautions when working on the fuel supply system

⇒ page 3 .

♦

Observe rules for cleanliness ⇒ page 6 .

– Put the shift lever into Neutral in order to turn the crankshaft.
– Switch off ignition and pull out ignition key.
– Remove engine cover
– Remove V-ribbed belt ⇒ page 57 .
For vehicles Fabia II, Roomster, Rapid NH with engine identifi‐

cation characters CAYB, CAYC
– Disconnect

sender - G505- .

– Release screw -3- and remove differential pressure sender -

G505- from bracket.

– Place the differential pressure sender - G505- with line to the

rear.

Continued for all vehicles

the plug connection -2- at the differential pressure

⇒ page 10 .

1. Removing and installing a V-ribbed belt and a toothed belt 91

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– Separate fuel feed line -2- and fuel return-flow line -1-, to do

so press the release buttons. Unlock the quick coupling and

disconnect ⇒ page 303 .
– Collect the fuel which flows out with a cloth.
For vehicles Fabia II, Roomster, Rapid NH

– Unlock

valve upwards out of the guide of the coolant expansion bottle.
For Rapid India vehicles

– Unlock the catch peg with a finger and pull the T-piece up‐

wards out of the guide from the coolant expansion bottle.
Continued for all vehicles
– Unclip the fuel line from the plastic holders.

the catch peg with a finger and pull the fuel preheating

– Push

– Place the fuel filter and the fuel hoses together with the fuel

– Remove fuel filter bracket.

the catch pegs towards the outside and remove the fuel

filter towards the top.

preheating valve on the engine.

92 Rep. gr.13 - Crankshaft group

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– Unscrew
– Remove the plug -1- from the expansion bottle and push the

expansion bottle to the side.

– Remove top part of toothed belt guard; to do so release re‐

taining clips -arrows-.

– Remove crankshaft-belt pulley ⇒ page 67 .

the screws of the coolant expansion bottle -arrows-.

Note

Do not lock tensioning element for V-ribbed belt.

– Release screws -arrows-.
– Remove bottom toothed belt guard.

• Remove the engine support before exchanging the tensioning
pulley and removing and installing the toothed belt.

Note

The assembly bracket must only be removed if the engine is

♦

supported with the supporting device - MP9-200 (10-222A)- ,
if necessary -T30099- !

♦

Only release the engine support if the assembly bracket is re‐
moved.

– Remove engine support

– Rotate the crankshaft on TDC in direction of rotation of the

engine
crankshaft arrester - T10050- . Slide the crankshaft arrester
from the front side of the toothed belt sprocket into its teeth.

and remove the crankshaft timing belt sprocket with the

Note

⇒ page 44 .

The markings on the crankshaft - toothed belt sprocket -2- and on
the crankshaft arrester - T10050- -1- must be aligned. While doing
so, the stud of the crankshaft arrester - T10050- must engage in
the hole of the sealing flange.

1. Removing and installing a V-ribbed belt and a toothed belt 93

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The arrow on the camshaft sprocket must be close to the »12
o'clock« position.

– Slacken the screws -arrows- for the camshaft sprocket by ap‐

prox. 90°.

– Slacken the screws -2- for the toothed belt sprocket at the high

pressure pump by approx. 90° using the socket insert XZN 10

- T10385- .

Tensioning pulley A

– Loosen nut -1- for tensioning pulley.
– Turn the eccentric of the tensioning pulley with the offset

screwdriver - T10264- in
until the tensioning pulley can be interlocked with the rig tool

- T10265- .

-direction of arrow- (anti-clockwise),

94 Rep. gr.13 - Crankshaft group