Service Workshop Manual Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine Engine ID DAD A Edition 07.2017 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Service Department. Technical Information GETtheMANUALS.org Service List of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 21 - Turbocharging/supercharging 24 - Mixture preparation - injection 26 - Exhaust system 28 - Ignition system Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted Technicalwith information should respect to the correctness always of information in thisbe available document. toŠKODA Copyright by the AUTO foremen A. S.� and mechanics, because their unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2017 ŠKODA AUTO a. s. D4B8078C002 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 4 2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 4 2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.6 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.5 Assembly of radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.6 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.2 Disconnecting engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.3 Attach engine attached to engine and gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted 2.1 Summary unless authorised byofŠKODA components - assembly AUTO A. S. ŠKODA mountings AUTO A. S. . . or does not guarantee . .accept . . . any . . liability ....................... 28 2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 30 2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 2.5 Support the engine in its installed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2.6 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2.7 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3 Engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 1.1 Assembly overview - V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 1.3 Removing and installing tensioning pulley for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 43 1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1.6 Replacing crankshaft sealing ring on the belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . 48 2 Cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 2.1 Summary of components - cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . 51 2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.1 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.2 Replace the needle bearing in the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Contents i GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 4.3 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 4.4 Removing and installing oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 4.5 Check piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 4.6 Check radial clearance of connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 4.7 Position piston to TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 1.2 Summary of components - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 1.6 Checking the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 2.3 Assembly overview - Adjustment tool for control times . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 2.4 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 2.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 2.6 Pre-assembly and assembly of the adjustment tool for control times . . . . . . . . . . . . . . . . 99 2.7 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 2.8 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 2.9 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 3.2 Removing and installing bracket for radial shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 3.3 Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 3.4 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 3.5 Removing and installing cam adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 3.6 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 137 3.7 Removing and installing camshaft control valve 1 in the exhaust N318 . . . . . . . . . . . . . . 137 3.8 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 4.1 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 1.1 Assembly overview - pan/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 1.3 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 160 2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 2.1 Summary of components - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 2.2 byRemoving Protected andforinstalling copyright. Copying engine private or commercial oil cooler purposes, in part or .in.whole, . . . is. .not. .permitted ............................. 161 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability 3 with Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . .S.� respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. ............................ 163 3.1 Summary of components - crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 4.1 Summary of components - oil pressure switch/oil pressure control . . . . . . . . . . . . . . . . . . 166 ii Contents GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 4.2 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 4.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 4.4 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 167 4.5 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 1.2 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 2.1 Summary of components - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 2.3 Summary of components - coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . 182 2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 2.6 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 186 2.7 Removing and installing coolant temperature transmitter G62 . . . . . . . . . . . . . . . . . . . . . . 189 2.8 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 190 2.9 Removing and installing coolant temperature sender at engine outlet G82 . . . . . . . . . . . . 191 2.10 Removing and installing element for engine temperature control GX33 . . . . . . . . . . . . . . 192 2.11 Testing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 3.1 Summary of components - coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 4 Coolers, radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 4.2 Summary of components - fan shroud and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 4.4 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 1 Exhaust authorisedgas turbocharger . . .AUTO . . . A.. .S..does . . .not . .guarantee . . . . . or. .accept . . . any . . liability .... .................... 215 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless by ŠKODA AUTO A. S. ŠKODA 1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 215 1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 1.3 Removing and installing the exhaust gas turbocharger connection fitting . . . . . . . . . . . . . . 222 1.4 Removing and installing element for load pressure control GX34 . . . . . . . . . . . . . . . . . . 223 2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 228 2.4 Installing and removing the air guide pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 2.5 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 2.6 Leak testing the charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 1.1 Installation location overview - fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 2 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 2.1 Summary of components - fuel distributor with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 248 2.2 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 2.4 Clean injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Contents iii GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 4.3 Removing and installing the throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . 265 4.4 Cleaning throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 5.1 Removing and installing intake manifold pressure sender GX9 . . . . . . . . . . . . . . . . . . . . 268 5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 5.3 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 5.4 Removing and installing pressure sensor for exhaust gas 1 G450 . . . . . . . . . . . . . . . . . . 273 5.5 Removing and installing valve for air mass meter GX35 . . . . . . . . . . . . . . . . . . . . . . . . . . 274 6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 6.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 7 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 7.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 7.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 7.3 Removing and installing high pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 8.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 1.2 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 1.4 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 1.5 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 2 Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 2.1 Protected Summary ofCopying by copyright. components for private or-commercial exhaustpurposes, gas cleaning . . .is. not in part or in whole, . .permitted .......................... 297 2.2 unlessRemoving and installing catalytic converter . . . . . . . . . . . .liability authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any ........................ 300 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 2.3 Removing and installing the exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . 303 28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 305 1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 1.4 Removing and installing position transmitter for inlet camshaft G1002 . . . . . . . . . . . . . . . . 308 1.5 Removing and installing position transmitter for exhaust camshaft G1003 . . . . . . . . . . . . 309 1.6 Removing and installing the engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . 310 iv Contents GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 00 – Technical data 1 Denomination (SRL001109; Edition 07.2017) ⇒ “1.1 Engine number, engine data”, page 1 1.1 Engine number, engine data Type plate on upper toothed belt guard The engine code letters and the engine number are located on the type plate, which is affixed to the sticker on the upper toothed belt guard. Each engine has its unique type plate, which can not be used for any other engine. This type plate may not be replaced by any other. The new engine is also supplied with a new type plate on the new toothed belt guard. On the new engine, the data on the type plate and on the accom‐ panying card for the engine must be checked. The information given must be the same. 1 - Information about the construction of the crankshaft. 2 - Engine number 3 - Engine codes Information about the construction of the crankshaft. ♦ Used to document the construction and commissioning. ♦ After replacing certain components, the construction data must be transferred to the engine control unit ⇒ Vehicle diag‐ nostic tester. ♦ Components that require this step are described in the work‐ flows. Engine number ♦ The engine number consists of up to nine digits (numbers and letters). ♦ The first 3 characters represent the “Engine code” . ♦ The second six -digit part represents the “current number” . ♦ If more than 999,999 engines authorisedwere produced AUTO A. S.with the same Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless by ŠKODA ŠKODA AUTO A. S. does not guarantee or accept any liability code letters, the first with of the 6 todigits respect is replaced the correctness by ain letter. of information this document. Copyright by ŠKODA AUTO A. S.� 1. Denomination 1 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Engine codes The “engine identification characters” and “serial number” are lo‐ cated on the cylinder block -arrow-. ♦ The engine identification characters are also indicated on the vehicle data sticker and the type plate. ♦ The first 3 digits of the engine identification characters refer to the displacement and the mechanical construction of the en‐ gine. ♦ The 4th digit refers to the output and torque of the engine and depends upon the engine - J623- control unit. Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet Karoq . Vehicle data carrier on the camshaft housing ♦ Used to document the construction and commissioning. ♦ After replacing the components, the construction data must be transferred to the engine control unit ⇒ Vehicle diagnostic test‐ er. ♦ Components that require this step are described in the work‐ flows. ♦ Each engine has its own unique vehicle data carrier. The data can not be usedunless for any Protected by other engine. copyright. Copying for private or commercial purposes, in part or in whole, is not permitted authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability ♦ On the left side ofwith therespect plate can be found the »Data Matrix to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Code«. This information is read ⇒ Vehicle diagnostic tester. ♦ On the right side is alphanumeric information about of the construction. This form is used for the manual entry of the data relating to construction for commissioning ⇒ Vehicle diagnos‐ tic tester. ♦ The listed data are the measured values of the components. XN1 - Cam on cylinder 1 XN2 - Cam on cylinder 2 XN3 - Cam on cylinder 3 XN4 - Cam on cylinder 4 XW1 - Sensing wheel for inlet camshaft XW2 - Encoder wheel for exhaust camshaft Engine codes DADA Manufactured 08.2017 ► Emission standards EU6 Displacement cm3 1495 Output kW at rpm 110/5000 Torque Nm at rpm 250/1500-3500 Bore ∅ mm 74.5 Stroke mm 85.7 Compression ratio 10.5 Number of cylinders/valves per cylinder 4/4 2 Rep. gr.00 - Technical data GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Engine codes DADA Fuel - RON min. 95 unleaded Ignition system/fuel injection Motronic MG 1 Firing order 1-3-4-2 Exhaust gas recirculation no Balancing shaft module no Intake manifold change-over no Camshaft control valve, inlet / exhaust yes / yes Exhaust gas turbocharger yes Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 1. Denomination 3 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 2 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 ⇒ “2.2 Safety precautions when working on vehicles with start- stop system”, page 4 ⇒ “2.3 Safety precautions during road tests in which testing and measuring equipment is used”, page 4 ⇒ “2.4 Safety precautions when working on cooling system”, page 5 ⇒ “2.5 General safety instructions”, page 5 ⇒ “2.6 Safety precautions when working on ignition system”, page 5 2.1 Safety precautions when working on fuel supply system Fuel under very high pressure creates a risk of injury. – Wear protective gloves. – Wear safety goggles. Leaking fuel creates a fire hazard. Fuel pump is activated by switching on ignition and via driver door contact switch. Therefore, if the battery power hasn't been dis‐ connected, for safety reasons the plug of the fuel delivery unit must be disconnected, or the fuel pump fuse must be removed before opening the fuel system. – Disconnect fuse for fuel pump control unit - J538- ⇒ Current flow diagrams, Electrical fault finding and Fitting locations. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted Risk of damage to the electronic unless authorised by ŠKODA AUTO components A. S. ŠKODA AUTO when disconnecting A. S. does not guarantee or accept any liability the battery. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Only disconnect the battery when the ignition is switched off ⇒ Electrical system ; Rep. gr. 27 ; Battery; Disconnecting and con‐ necting battery . 2.2 Safety precautions when working on ve‐ hicles with start-stop system Risk of injury as a result of automatic engine start in vehicles with start/stop system. In vehicles with the start/stop system activated (identifiable by an indication in the dash panel insert) the engine can start automat‐ ically if required. – Ensure that the start-stop system is deactivated when carrying out work on the vehicle (switch ignition off, if required switch ignition on again). 2.3 Safety precautions during road tests in which testing and measuring equipment is used Risk of accident from distraction Using testers and measuring instruments during driving operation causes distraction. 4 Rep. gr.00 - Technical data GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 There is a risk of injury if testers and measuring instruments are not secured adequately. Increased risk of injury from unsecured testers and measuring instruments must be prevented. Measuring instruments can turn into dangerous projectiles on air‐ bag activation. Testers and measuring instruments must always be secured on the rear seat using a seat belt and operated by a 2nd person from there. 2.4 Safety precautions when working on cooling system Risk of injury due to hot steams. – Wear protective gloves. – Wear safety goggles. Relieve any possible pressure prior to the repair. When the engine is warm, the cooling system is under overpres‐ sure. Hot steam may escape when the expansion reservoir is opened. – Cover the cap of the coolant expansion tank with a cloth and open carefully. 2.5 General safety instructions Fuel under very high pressure creates a risk of injury. The safety measures for the pressure reduction in the high pres‐ sure system must be observed. Place a clean cleaning cloth around the connection point before detaching hose connections. Reduce pressure by carefully re‐ moving the hose. – Do not touch or disconnect ignition leads with the engine run‐ ning or at start speed. Ignition must be switched off before disconnecting and re-con‐ necting the cables of the fuel injection and the ignition system as well as of the test equipment. If the engine must be operated at start speed without it starting, as for example, when checking the compression pressure, re‐ move the fuse for the voltage supply of the injection valves and the ignition coils from the fuse holder ⇒ Current flow diagrams, Electrical fault finding and Fitting locations. 2.6 Safety precautions when working on ig‐ nition system Risk of injury due to high voltage. – Do not touch the ignition system with the engine running or at start speed. Risk of damage to injection and ignition system – Ignition must be switched off before disconnecting and re- connecting the cables of the fuel injection and the ignition system as well as of the test equipment. Switch off ignition before an engine wash. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 2. Safety instructions 5 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 3 Repair instructions ⇒ “3.1 Rules of cleanliness”, page 6 ⇒ “3.2 Foreign bodies in the engine”, page 6 ⇒ “3.3 Contact corrosion”, page 6 ⇒ “3.4 Cable routing and securing”, page 6 ⇒ “3.5 Assembly of radiators and condensers”, page 7 ⇒ “3.6 General repair instructions”, page 7 3.1 Rules of cleanliness Carefully observe the following “rules” for cleanliness when work‐ ing on the fuel supply/injection system: ♦ Thoroughly clean the connection points and their surroundings before releasing. ♦ Place removed parts on a clean surface and cover. Use lint- free cloths. ♦ Carefully cover or close open components if the repair is not completed immediately. ♦ Only install clean parts: remove spare parts from their wrap‐ ping immediately before fitting. Do not use any parts which have been stored unwrapped. ♦ When the system is open, do not work with compressed air and do not move the vehicle. ♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean the hoses immediately. ♦ Protect electrical plug connections from dirt and moisture and only connect them when dry. 3.2 Foreign bodies in the engine To prevent the penetration of foreign bodies, open channels of the inlet connection and exhaust tract must be sealed with 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 (screws, nuts, wash‐ ers, etc.) can cause contact corrosion. This is why only connection elements with a special surface coat‐ ings are fitted. Therefore, the rubber or plastic parts and the adhesives are made from electrically non-conductive materials. If there is a question mark about the suitability of parts, generally use new parts ⇒ ETKA - Electronic Catalogue of Original Parts . 3.4 Cable routing and securing Install lines of all kinds so that the original routing can be restored. ♦ Fuel feed lines ♦ Hydraulic lines Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability ♦ Brake fluid lines with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� ♦ Coolant lines ♦ Vacuum lines 6 Rep. gr.00 - Technical data GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Activated charcoal filter system lines ♦ Electrical lines To rule out mix ups and ensure the original fitting position, mark the lines before disassembly. Make photos or sketches where necessary. To avoid damage to lines, ensure sufficient clearance from all moving or hot components. Insulation or heat shield mats must be installed again in their original position. Secure all hose connections with hose clamps, assignment ⇒ Electronic Catalogue of Original Parts . When installing fit the coolant hoses free of stress, without them touching any other components (pay attention to the marking on the coolant connection and hose). 3.5 Assembly of radiators and condensers The radiator, condenser and charge air cooler may have minor indentations on the fins, even if assembled correctly. This is not a case of damage. Radiators, condensers and charge air coolers must not be replaced because of these indentations. 3.6 General repair instructions ⇒ “3.6.1 Additional instructions when undertaking assembly work on the air-conditioning system”, page 7 ⇒ “3.6.2 General instructions for charge air system”, page 7 ⇒ “3.6.3 General notes on the ignition system”, page 8 ⇒ “3.6.4 General notes on the injection system”, page 8 3.6.1 Additional instructions when undertak‐ ing assembly work on the air-condition‐ ing system CAUTION Risk of frost due to refrigerant. Do not open the refrigerant circuit of the air conditioning system. To prevent damage to condenser or to refrigerant lines/hoses, ensureProtected that the by lines and copyright. hoses Copying are ornot for private stretched, commercial kinked purposes, orin bent. in part or whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Steps which should with respect to thebe takenofininformation correctness order to remove in this and document. install Copyright the AUTO A. S.� by ŠKODA engine without opening the refrigerant circuit – Remove the holding clamp(s) of the refrigerant lines. – Removing AC compressor ⇒ Heating, Air Conditioning ; Rep. gr. 87 ; AC compressor; installing and removing AC compres‐ sor . – Mount the AC compressor in such a way that the refrigerant lines/hoses are not under tension. 3.6.2 General instructions for charge air sys‐ tem When undertaking all installation work, particularly in the engine compartment because of its cramped construction, please ob‐ serve the following: 3. Repair instructions 7 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid, cooling fluid and refrigerant, brake fluid, vacuum) and electri‐ cal lines in such a way that the original line guide is re- established. ♦ Ensure that there is adequate free access to all moving or hot components. In case a mechanical damage to the exhaust gas turbocharger is found, for example, damage to the compressor wheel, it is not sufficient to only replace the turbocharger. In order to avoid con‐ sequential damage, perform the following tasks: ♦ Clean all oil lines. ♦ Change engine oil and oil filter. ♦ Inspect the air filter housing, the air filter element and the in‐ take hoses for contaminations. ♦ Inspect the whole charge-air routing and the charge air cooler for foreign bodies. ♦ The charge-air system must be tight. ♦ Replace self-locking nuts. ♦ Hose connections and hoses for the charge air system must be free of oil and grease before being installed. ♦ Only install approved clamps for securing the hose connec‐ tions ⇒ ETKA - Electronic Catalogue of Original Parts . ♦ Spring-type clip pliers are recommended for installation of spring-type clips. ♦ Before connecting the oil feed line, fill the exhaust turbocharg‐ er via the connection fitting with engine oil. ♦ To ensure the oil supply to the exhaust gas turbocharger, leave the engine running for about 1 minute after installing the exhaust gas turbocharger. 3.6.3 General notes on the ignition system ♦ Switch off the ignition before disconnecting and connecting the battery, as this may damage the engine control unit. ♦ The engine control unit and further components are equipped with self-diagnosis; inspect ⇒ Vehicle diagnostic tester. ♦ A minimum voltage of 11.5 V is required for perfect functioning of the electrical components. ♦ Certain inspections may cause the control unit to detect and store a fault. It is therefore necessary to query the event mem‐ ory after having completed all inspections and repairs, and if necessary, delete the entries ⇒ Vehicle diagnostic tester. Safety measures ⇒ “2.6 Safety precautions when working on ignition system”, page 5. Test data, spark-plugs ⇒ MaintenanceProtected ; Booklet Karoq by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability 3.6.4 General notes on thewithinjection system respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� ♦ The engine control unit is equipped with a self-diagnosis sys‐ tem. Before repairs and also for fault finding, first of all inter‐ rogate the event memory. Also check the vacuum hoses and connections (unmetered air). ♦ Fuel hoses in the engine compartment may only be secured with spring-type clips ⇒ ETKA - Electronic Catalogue of Orig‐ 8 Rep. gr.00 - Technical data GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 inal Parts . The use of clamp-type or screw-type clips is not allowed. ♦ A minimum voltage of 11.5 V is required for perfect functioning of the electrical components. ♦ Do not use sealants containing silicone. Traces of silicone el‐ ements drawn in by the engine are not burnt in the engine and damage the lambda probe. ♦ Certain inspections may cause the control unit to detect and store a fault. It is therefore necessary to query the event mem‐ ory after having completed all inspections and repairs, and if necessary, delete the entries ⇒ Vehicle diagnostic tester. Safety precautions when working on the injection system ⇒ “2.5 General safety instructions”, page 5 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 3. Repair instructions 9 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 10 – Removing and installing engine 1 Removing and installing engine ⇒ “1.1 Removing engine”, page 10 ⇒ “1.2 Disconnecting engine and gearbox”, page 20 ⇒ “1.3 Attach engine attached to engine and gearbox mount”, page 21 ⇒ “1.4 Installing engine”, page 22 1.1 Removing engine Special tools and workshop equipment required ♦ Disassembly tool for door panel - MP8-602/1- ♦ Extension - 2024 A /1- of lifting device - MP9-201 (2024A)- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Engine mount - T10497- ♦ Catch pan , e.g. -VAS 6208- ♦ Hose strap pliers , e.g. -VAS 6362- ♦ Locking pin - T10060A- ♦ Double ladder , e.g. -VAS 5085- ♦ Radiator protection mat - VAS 531003- ♦ Protective goggles and gloves Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability The engine is removed downwards together with the gearbox. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� • Fit all cable straps on again in the same place when installing. – Remove both front wheels ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels, tyres . – Remove the noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation . – Remove the front left and right wheelhouse liner ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheelhouse liner; remov‐ ing and installing front wheelhouse liner . – Remove air filter housing ⇒ “3.2 Removing and installing air filter housing”, page 259 . – Removing fan shroud ⇒ “4.4 Removing and installing fan shroud”, page 212 . 10 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Cover radiator with radiator protection mat - VAS 531003- . WARNING Fuel under very high pressure creates a risk of injury. ♦ Before opening the injection system high-pressure system, the fuel pressure must be reduced. – Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . For vehicles with air conditioning – Remove the ribbed V-belt ⇒ “1.2.2 Removing and installing V-ribbed belt on vehicles with air conditioning system”, page 42 . CAUTION Risk of frost due to refrigerant. Do not open the refrigerant circuit of the air conditioning system. – Disconnect plug connection -1- on the control valve for the air conditioning system compressor - N280- . – Release screws -arrows- for AC compressor. NOTICE Risk of damaging AC compressor, refrigerant lines and hoses. ♦ Do not over-tension, buckle and bend refrigerant lines and ho‐ ses. – Remove AC compressor with connected refrigerant hoses and strap up to the right side. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Continued for all vehicles with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� – Drain coolant ⇒ “1.3 Draining and filling coolant”, page 174 . – Unlock catch -arrow- and remove vacuum hose -1-. – Expose vacuum hose on the air guide pipe -2-. 1. Removing and installing engine 11 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove the vacuum hose -1- from the brake vacuum pump - V192- -A-. – Remove vacuum hose from the engine mounting. – Remove the heat shield on top of the catalyst ⇒ page 219 . – Mark the position of the clamp. Note ♦ Before loosening the coupling point between catalytic con‐ verter and turbocharger, mark the position of the clamp! ♦ Re-establish the position of the clamp when assembling. – Unscrew screw -2- and remove screw clamp. – Remove screw -1-, remove nuts by Protected -arrows- and strap copyright. Copying uporcata‐ for private commercial purposes, in part or in whole, is not permitted lytic converter to the bodyshell so as not unless authorised to damage by ŠKODA AUTO A. S.theŠKODA AUTO A. S. does not guarantee or accept any liability decoupling element. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Note do not twist decoupling element in the exhaust pipe more than 10° - risk of damage – Unscrew screws -arrows- and remove holder. CAUTION Risk of injury from fuel under pressure. ♦ To relieve the fuel pressure, place a clean cloth around the connection point and loosen the connection point carefully be‐ fore opening the fuel system. NOTICE Risk of malfunctions caused by soiling. Observe safety measures and rules for cleanliness ⇒ “3.1 Rules of cleanliness”, page 6 . 12 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect the fuel feed line -1- and vent line -2- to the acti‐ vated charcoal filter. – Unscrew retaining clip -2- from hoses from the coolant tank. – Loosen hose clamp -3- and remove coolant hose. For vehicles without auxiliary heating – Raise holding clamps -arrows- and remove coolant hoses from heat exchanger for heating. Vehicles fitted with auxiliary heating – Loosen holding clamp and holding clamps and pull off both coolant hoses -arrows-. – Place a cloth below to absorb leaking coolant. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 1. Removing and installing engine 13 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen hose clamp -1- and remove coolant hose. – Raise holding clamp -arrow- and disconnect top right coolant hose from charge air cooling circuit radiator. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� – Raise holding clamp -arrow- and remove top left coolant hose from radiator. Note For the following clip unclipping procedure, use the removal tool for door panel - MP8-602/1- . – Disconnect plug -1- from the engine control unit - J623- ⇒ “6.1 Removing and installing engine control unit J623 ”, page 275 . – Take electrical plug connections -2- and -3- out of the holder and disconnect. 14 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Open the cable guide -2- upwards in -direction of arrow-. – Expose electric cables. – Disconnect plug connection -2-. – Remove B+-pole protection -1- and unscrew B+-cable from the starter magnet switch. – Unscrew the earth cable on the body. – Unlock catches -arrows-, remove cover -1- for E-box in the engine compartment. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� – Unlock catch with a screwdriver -arrow- and pull cover -1- for E-box in the engine compartment upwards. 1. Removing and installing engine 15 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew nut -arrow-, remove and expose electric cable. For vehicles with manual gearbox – Disconnect connectors -1- and -2-. – Remove shift mechanism from the gearbox ⇒ Rep. gr. 34 ; Shift mechanism; removing and installing shift mechanism . – Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch slave cylinder; Removing and installing clutch slave cylinder . For vehicles with automatic gearbox – Unlock and disconnect connectors for automatic gearbox ⇒ Rep. gr. 34 ; Removing and installing the gearbox; remove gearbox . – Remove selector lever linkage, disconnect mechatronics con‐ nector and remove all holders from the gearbox ⇒ Rep. gr. 37 ; Shift mechanism; installing and removing shift mecha‐ nism . Continued for all vehicles Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability – Disconnect electrical plugtoconnection with respect the correctness of-1- at theinoil information this level and document. Copyright by ŠKODA AUTO A. S.� oil temperature sender - G266- . – Unscrew nut arrow on left and right -1- for coupling rod -3- on anti-roll bar -2-. 16 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Undo screws -1-, -2-, -3- and remove the pendulum support. – Unscrew screws -arrows- and remove heat shield for right cardan shaft, if present. – Unscrew left and right cardan shaft from gearbox ⇒ Chassis, axles, steering; Rep. gr. 40 ; Cardan shaft; removing and in‐ stalling cardan shaft and tie up. Note Ensure that the surface protection of the drive shafts is not dam‐ aged. For vehicles with four-wheel drive – Remove angle gearbox ⇒ Rep. gr. 34 ; Angle gearbox; Re‐ move angle gearbox . Continued for all vehicles – Move lock carrier to service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Move to service position and reset . – If present, unscrew nuts -4- and screw -1- from the front left vehicle level sensor - G78- -3- and place to one side. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 1. Removing and installing engine 17 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew nuts -arrows- on right and left steering joint. – Unhook swivel hub from track control arm on left and right. – Swivel suspension strut left towards the outside and support with extension -2024 A /1- , as shown in the illustration. CAUTION There is a risk of accident from loose parts of the support. – Secure locking pin and swivel hub with plug-in lock -arrow- and nut -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� – Bolt swivel hub -2- on the right to the track control arm -1- with the nut -arrow-, as shown in the illustration. – Screw out screws -arrows- on engine mount by approximately 2 turns. 18 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 2 screws – Screw out screws -arrows- on gearbox mount by approxi‐ mately 2 turns. Gearbox mount with 3 screws – Screw out screws -arrows- on gearbox mount by approxi‐ mately 2 turns. Continued for all vehicles – Position clamping piece T10497/2 on the housing fin of the cylinder block, as shown in the illustration. – Position engine mount - T10497- with bolts T10497/1 at the cylinder block. – Screw clamping piece T10497/2 with screw -1- onto the en‐ gine mount T10497 and tighten it to 20 Nm. – Fit the adapter - T10497/3- to the engine mount - T10497- and tighten screw -1- to 20 Nm. – Insert engine mount - T10497- onto the engine and gearbox jack - V.A.G 1383A- and lift engine/gearbox unit a little. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Note with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� To remove the screws for the assembly mountings, use a com‐ mercially available double ladder , e. g. -VAS 5085- . 1. Removing and installing engine 19 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Screw out engine mount screws -arrows- fully. Gearbox mount with 2 screws – Screw out gearbox mount screws -arrows- fully. Gearbox mount with 3 screws – Screw out gearbox mount screws -arrows- fully. Continued for all vehicles NOTICE Risk of damaging vacuum lines or electric cables and the engine compartment. – Check that all vacuum lines and electric cables between en‐ gine, gearbox, assembly mountings and body have been loos‐ ened. – Drain engine/gearbox Protected by copyright. Copyingunit a little. for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability – Push with the gearbox respect side of to the correctness the engine/gearbox of information unit forwards in this document. Copyright by ŠKODA AUTO A. S.� and drain it slowly and carefully. 1.2 Disconnecting engine and gearbox Special tools and workshop equipment required ♦ Additional hook - MP9-200/10 (10-222A/2)- ♦ Workshop crane , e.g. -VAS 6100- ♦ Shackle - 10-222A/12- • Engine/gearbox unit removed and attached to engine mount - T10497- . – Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and installing starter . 20 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Install shackle - 10-222A/12- on gearbox. – Hook additional hook - MP9-200/10 (10-222A/2)- with shackle - 10-222A/12- onto the workshop crane - VAS 6100- . Note Pre-load the workshop crane - VAS 6100- slightly, but do not raise the gearbox. – Unscrew engine/gearbox connecting screws ⇒ Rep. gr. 34 ; Removing and installing gearbox . – Remove the gearbox from the engine. 1.3 Attach engine attached to engine and gearbox mount Special Protected toolsCopying by copyright. and for workshop equipment private or commercial required purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with♦respect Supporting device to the correctness - MP9-201 of information (2024 Copyright in this document. A)- by ŠKODA AUTO A. S.� ♦ Engine and gearbox mount - VAS 6095- ♦ Workshop crane , e.g. -VAS 6100- • Gearbox disconnected from engine ⇒ “1.2 Disconnecting engine and gearbox”, page 20 . – Suspend lifting device - MP9-201 (2024 A)- -A- from the en‐ gine and workshop crane - VAS 6100- -B- as shown in the illustration. – For coordination with the unit centre of gravity position the perforated rails must be placed as shown in the illustration. CAUTION There is a risk of accident from loose parts of the lifting device. – The suspension hooks and locking pins on the lifting device must be secured with plug-in locks -arrows-. – Remove engine from engine mounting - VAS 6100- using workshop crane - T10497- . 1. Removing and installing engine 21 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Secure engine using bolts -arrows- to the engine and gearbox mount - VAS 6095- . 1.4 Installing engine Special tools and workshop equipment required ♦ Extension - 2024 A /1- of lifting device - MP9-201 (2024A)- ♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931- ♦ Engine mount - T10497- ♦ Hose strap pliers , e.g. -VAS 6362- ♦ Locking pin - T10060A- ♦ Double ladder , e.g. -VAS 5085- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted ♦ Protective goggles and gloves unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� ♦ Grease - G 000 100- Note ♦ When installing a new engine, make sure that the supplied toothed belt guard is installed at the top. ♦ The type plate for the new engine is attached to the toothed belt guard at the top. ♦ Only this type plate contains the correct information about the engine. ♦ After installing new parts (engine/partial engine, cylinder head, camshaft housing or exhaust gas turbocharger), the oil pres‐ sure control must be limited to the high pressure level for approx. 1000 km. This takes into account the higher friction when running in new components and ensures optimum evac‐ uation of particles from running-in wear ⇒ page 26 . ♦ The function to increase oil pressure does not always have to be available on the engine control unit. In this case, the oil pressure is not increased. For vehicles with manual gearbox – Clean the serration of the drive shaft and if the clutch disc has been used clean the hub serration, remove any corrosion present and only apply a very thin layer of grease - G 000 100- to the serration of the drive shaft. – Move clutch plate to and fro on input shaft until the hub moves freely on shaft. Always remove excess grease. – Check centring of driven plate assembly ⇒ Rep. gr. 30 ; Clutch; removing and installing clutch . 22 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Check the clutch release bearing for wear. Replace release bearing when worn ⇒ Rep. gr. 30 ; Clutch control; Summary of components- Clutch release mechanism . For vehicles with automatic gearbox – Replace the needle bearing -arrow- in the crankshaft ⇒ “3.2 Replace the needle bearing in the crankshaft”, page 63 . Continued for all vehicles Installation is performed in the reverse order; pay attention to the following points: – Screws which have been tightened firmly to a torquing angle must be replaced. – Replace self-locking nuts, sealing rings, gaskets and O-rings. • Secure all hose connection ends with spring-type clips that comply with the series design ⇒ ETKA - Electronic Catalogue of Original Parts . • Fit all cable straps on again in the same place when installing. – Installing intermediate plate ⇒ Fig. ““Installing intermediate plate”“ , page 52 . – If there are no dowel sleeves in the cylinder block for centering the engine and gearbox, insert dowel sleeves -A-. – Screw gearbox securely onto engine at positions -1-, -2-, -3-, -6-, -7-, -8- and -9-. – Attach engine/gearbox unit to engine mount - T10497- . – Insert engine/gearbox assembly in the body. – Initially insert screws -arrows- for engine mount by hand as far as the stop. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 1. Removing and installing engine 23 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 2 screws – Initially insert screws -arrows- for gearbox mount by hand as far as the stop. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 24 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 3 screws – Initially insert screws -arrows- for gearbox mount by hand as far as the stop. Note The screws must not be permanently tightened until the assembly bracket is adjusted ⇒ “2.6 Adjusting the unit mounting”, page 34 . – Remove engine mount T10497 from engine. – Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐ moving and installing starter . For vehicles with manual gearbox – Remove clutch slave cylinder: ⇒ Rep. gr. 30 ; Clutch slave cylinder; Removing and installing clutch slave cylinder . – Install linkages with cable support ⇒ Rep. gr. 34 ; Shift mech‐ anism; installing and removing shift mechanism . For vehicles with automatic gearbox – Install assembly carrier ⇒ Running gear, axles, steering; Rep. gr. 40 ; Assembly carrier; ProtectedRemoving and for by copyright. Copying installing assembly private or commercial purposes, in part or in whole, is not permitted carrier with steering unless box . authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� – Install selector lever linkage, install mechatronics connector and install holders to the gearbox ⇒ Rep. gr. 37 ; Shift mech‐ anism; installing and removing shift mechanism . For vehicles with four-wheel drive – Install angle gearbox ⇒ Rep. gr. 34 ; Angle gearbox; Remove angle gearbox . Continued for all vehicles – Install pendulum support ⇒ “2.4 Removing and installing pendulum support”, page 32 . – Install exhaust pipe with catalytic converter ⇒ “2.2 Removing and installing catalytic converter”, page 300 . – Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft . – Install nuts for axle joint/ left and right wheelhouse ⇒ Chassis, Axles, steering; Rep. gr. 40 ; Bottom track control arm, steer‐ ing joint; Removing and installing the bottom track control arm . For vehicles with air conditioning – Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; Removing and installing AC compressor . – Install the V-ribbed belt ⇒ “1.2 Removing and installing V-ribbed belt”, page 41 . Continued for all vehicles Electrical connections and proper routing ⇒ Current flow dia‐ grams, Electrical fault finding and Fitting locations. – Connect plug of the engine wiring harness to engine control unit ⇒ “6.1 Removing and installing engine control unit J623 ”, page 275 . 1. Removing and installing engine 25 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Connect the remaining electric cables to the engine and gear‐ box. – Connect coolant hoses. – Install the front left and right wheelhouse liner ⇒ Exterior body work ; Rep. gr. 66 ; Wheelhouse liner; Removing and installing the front wheelhouse liner . – Install the front wheels ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels, tyres . – Adjust the assembly bracket ⇒ “2.6 Adjusting the unit mounting”, page 34 . – Install battery tray and battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . – Install air filter housing ⇒ “3.2 Removing and installing air filter housing”, page 259 . – Checking the oil level ⇒ Maintenance ; Booklet Karoq . – Top up and bleed cooling system ⇒ “1.3 Draining and filling coolant”, page 174 . – Interrogate all event memories and delete all event entries which are caused by removing and installing the engine ⇒ Ve‐ hicle diagnostic tester. After deleting the event memory of the engine control unit the readiness code must be re-generated. NOTICE Risk of damaging control units as a result of overvoltage. ♦ Do not use charger for jump starting! In the event that a new complete engine has been installed: Note ♦ After installing new parts (engine/partial engine, cylinder head, camshaft housing or exhaust gas turbocharger), the oil pres‐ sure control must be limited to the high pressure level for approx. 1000 km. This takes into account the higher friction when running in new components and ensures optimum evac‐ uation of particles from running-in wear. ♦ The function to increase oil pressure does not always have to be available on the engine control unit. In this case, the oil pressure is not increased. – Connect the diagnostic device ⇒ Vehicle diagnostic tester and carry out the function 0001 - Activate engine inlet . Comply with the information given in the type plate ⇒ page 1 . – Check the information on the vehicle type plate with the ac‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability companying engine identity card. The information withgiven must respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� be the same. – Carry out function 0001 - Replace the engine ⇒ Vehicle diagnostic tester. 26 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Tightening torques Note ♦ Tightening torques apply only for lightly greased, oiled, phosphatized or blackened nuts and screws. ♦ Other lubricants such as engine and gearbox oil are allowed, but no lubricants containing graphite. ♦ Do not use degreased parts. Component Tightening torque Screws/nuts M6 9 Nm M7 15 Nm M8 20 Nm M10 40 Nm M12 65 Nm deviations: Connecting screws for engine to gearbox ⇒ Rep. gr. 34 ; In‐ stalling and removing gearbox; tightening torques for gearbox . ♦ Cardan shaft guard ⇒ Chassis, axles, steering ; Rep. gr. 40 ; Cardan shaft; Removing and installing cardan shaft. Screws for assembly bracket ⇒ “2.1 Summary of components - assembly mountings”, page 28 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 1. Removing and installing engine 27 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 2 Assembly bracket ⇒ “2.1 Summary of components - assembly mountings”, page 28 ⇒ “2.2 Removing and installing engine mount”, page 30 ⇒ “2.3 Removing and installing gearbox mount”, page 30 ⇒ “2.4 Removing and installing pendulum support”, page 32 ⇒ “2.5 Support the engine in its installed position”, page 33 ⇒ “2.6 Adjusting the unit mounting”, page 34 ⇒ “2.7 Check assembly bracket setting”, page 36 2.1 Summary of components - assembly mountings 1 - Screw ❑ Replace after removal ❑ Tightening sequence ⇒ Fig. ““Engine support bracket - tightening tor‐ que and tightening or‐ der”“ , page 29 ❑ 40 Nm + 90° 2 - Engine support bracket ❑ Tightening torque and tightening order ⇒ Fig. ““Engine support bracket - tightening tor‐ que and tightening or‐ der”“ , page 29 ❑ Removing and installing ⇒ “1.5 Removing and in‐ stalling engine support”, page 45 3 - Engine mounting ❑ with supporting arm ❑ Removing and installing ⇒ “2.2 Removing and in‐ stalling engine mount”, page 30 4 - Screw ❑ Replace after removal ❑ 40 Nm + 90° 5 - Screw ❑ Replace after removal ❑Protected 20 Nm + 90° by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability 6 - Screw with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� ❑ 8 Nm 7 - Mounting bracket 8 - Screw ❑ Replace after removal ❑ 60 Nm + 90° 28 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 9 - Pendulum support ❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 32 10 - Screw ❑ Replace after removal ❑ Tightening torque and tightening order ⇒ Fig. ““Pendulum support - tightening torque and tightening order”“ , page 30 11 - Screw ❑ Replace after removal ❑ Tightening torque and tightening order ⇒ Fig. ““Pendulum support - tightening torque and tightening order”“ , page 30 12 - Screw ❑ Replace after removal ❑ Tightening torque and tightening order ⇒ Fig. ““Pendulum support - tightening torque and tightening order”“ , page 30 13 - Screw ❑ Replace after removal ❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Summary of components - assembly bracket 14 - Screw ❑ Replace after removal ❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Summary of components - assembly bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability 15 - Screw with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� ❑ Replace after removal ❑ 50 Nm + 90° 16 - Gearbox mount ❑ with supporting arm ❑ Removing and installing ⇒ “2.3 Removing and installing gearbox mount”, page 30 Engine support bracket - tightening torque and tightening order Note Screws which have been tightened firmly to a torquing angle must be replaced. – Tighten screws gradually in the given sequence: Level Screws Tightening torque/torquing angle 1. -1…3- 40 Nm 2. -1…3- Turn 90° further 2. Assembly bracket 29 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Pendulum support - tightening torque and tightening order Note Screws which have been tightened firmly to a torquing angle must be replaced. – Tighten screws gradually in the given sequence: Level Screws Tightening torque/torquing angle 1. -2-, -3- 50 Nm 2. -1- 130 Nm 3. -1…3- Turn 90° further 2.2 Removing and installing engine mount Removing – Unscrew the vacuum pump for brake - V192- together with the bracket from the motor bearing ⇒ Braking systems; Rep. gr. 47 ; Vacuum system; Removing and installing electric vacuum pump . – Disconnect plug connection -1-. – Unscrew retaining clip -2- from hoses from the coolant tank. – Unlock catches using a screwdriver -arrow- and lay coolant expansion tank to the side. – Suspend engine into the installation position ⇒ “2.5 Support the engine in its installed position”, page 33 . – Unscrew screws -arrows- and remove engine mount -1-. Installing Installation is performed in the reverse order; pay attention to the following points: Note Screws which have been tightened firmly to a torquing angle must be replaced. – Check assembly mounting adjustment ⇒ “2.7 Check assembly bracket setting”, page 36 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted Tightening torques unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� • Assembly bracket ⇒ “2.1 Summary of components - assembly mountings”, page 28 . 2.3 Removing and installing gearbox mount Removing – Remove air filter housing ⇒ “3.2 Removing and installing air filter housing”, page 259 . 30 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . – Remove the engine control unit ⇒ “6.1 Removing and installing engine control unit J623 ”, page 275 . – Unscrew the nuts -arrows- and remove holder -1-. Note Holders are installed differently according to build version. – Unscrew screw -1-, unclip upwards -arrows- and push slightly to the side. – Suspend engine into the installation position ⇒ “2.5 Support the engine in its installed position”, page 33 . Gearbox mount with 2 screws – Unscrew screws -arrows- and remove the gearbox mount -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 2. Assembly bracket 31 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 3 screws – Unscrew screws -2- and then screws -arrow-. – Remove gearbox mount -1-. Installing Installation is performed in the reverse order; pay attention to the following points: Note Screws which have been tightened firmly to a torquing angle must be replaced. NOTICE There is a risk of damaging the thread in the gearbox support bracket by positioning the bolts obliquely. ♦ Before screwing in the screws -arrows- the gearbox support bracket and supporting arm of the gearbox mount must be absolutely parallel to each other. If necessary, push up gear‐ box at the rear using a hydraulic trolley jack. ♦ Do not remove supporting device - MP9–200 (10 - 222 A)- until the bolts securing the gearbox mount have been tightened to specified torque. – Lift gearbox with the support bracket spindle until the gearbox support bracket is touching the supporting arm of the gearbox mount. – Check assembly mounting adjustment ⇒ “2.7 Check assembly bracket setting”, page 36 . – Remove supporting device - MP9–200 (10 - 222 A)- . Tightening torques ♦ Assembly bracket ⇒ “2.1 Summary of components - assembly mountings”, page 28 . 2.4 Removing and installing pendulum sup‐ port – Remove the noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation . – Remove screws -1-, -2- and -3-. – Remove pendulum support -4- from assembly carrier -5-. Installing The installation occurs in reverse order. Tightening torques ♦ Screws for pendulum support ⇒ “2.1 Summary of components - assembly mountings”, page 28 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 32 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 2.5 Support the engine in its installed posi‐ tion Special tools and workshop equipment required ♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)- ♦ Supporting device - MP9–200 (10 - 222 A)- ♦ Adapter - 10 - 222 A /13- ♦ Shackle - 10 - 222 A /12- ♦ Lever - MP8-602/1- or -80 200- – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 37 . – Push out insert -1- with lever - MP8-602/1- or -80 200- on both sides. – Fit the supporting device as shown and place on the vehicle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 2. Assembly bracket 33 GETtheMANUALS.org Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note The figure shows the suspension of the 1.4 TSI engine. The suspension of the 1.5 TSI engine is identical. • Adapter - 10 - 222 A /13- with the inscription L located on the right side of the vehicle. • Adapter - 10 - 222 A /13- with the inscription R located on the left side of the vehicle. • Arrows on the adapters - 10 - 222 A /13- point forwards in the direction of travel. – Insert hooks to MP9-200 and T30099 - MP9-200/10 (10-222A/ 10)- with shackles - 10 - 222 A /12- into the suspension lugs of the motor – Slightly pre-tension the engine/gearbox unit via hooks MP9-200 and T30099 - MP9-200/10 (10-222A/10)- , but do not raise. 2.6 Adjusting the unit mounting – Remove air filter housing ⇒ “3.2 Removing and installing air filter housing”, page 259 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 34 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org
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