Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � Workshop Manual Karoq 2018 ➤ 1,0/85 kW TSI engine Engine ID CHZJ DKR A DKR F Edition 04.2018 Service Service Department. Technical Information GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � List of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 21 - Turbocharging/supercharging 24 - Mixture preparation - injection 26 - Exhaust system 28 - Ignition system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. Service All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2018 ŠKODA AUTO a. s. D4B8077F854 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.2 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 3 2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 3 2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.6 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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 10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.2 Disconnecting engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.3 Attach engine attached to engine and gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2.5 Support the engine in its installed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2.6 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.7 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1.1 Assembly overview - V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1.3 Removing and installing tensioning pulley for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 37 1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 1.6 Replacing crankshaft sealing ring on the belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . 44 2 Cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 2.1 Summary of components - cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . 46 2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3.2 Replace the needle bearing in the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 4.3 Check piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 4.4 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 Contents i GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 4.5 Removing and installing oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.6 Position piston to TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1.2 Summary of components - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 1.6 Checking the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 2.3 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 2.4 Pre-assembly and assembly of the adjustment tool for control times . . . . . . . . . . . . . . . . 84 2.5 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2.6 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 2.7 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 3.3 Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 3.4 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 3.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 116 3.6 Removing and installing camshaft control valve 1 in the exhaust N318 . . . . . . . . . . . . . . 117 3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 4.1 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 1.1 Assembly overview - pan/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 1.3 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 135 2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 2.1 Summary of components - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 3.1 Summary of components - crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 4.1 Summary of components - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 4.2 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 4.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 4.4 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 145 19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 1.2 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 ii Contents GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 2.1 Summary of components - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 2.3 Summary of components - coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . 161 2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 2.6 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 166 2.7 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 2.8 Removing and installing coolant temperature transmitter G62 . . . . . . . . . . . . . . . . . . . . . . 170 2.9 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 171 3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 3.1 Summary of components - coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 4 Coolers, radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 4.2 Summary of components - fan shroud and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 4.4 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 1.3 Removing and installing charge pressure regulator V465 . . . . . . . . . . . . . . . . . . . . . . . . . . 188 2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 2.2 Installing and removing the air guide pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 2.4 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 194 2.5 Checking the charge-air system for leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 1.1 Installation location overview - fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 1.2 Reduce fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 2 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 2.1 Summary of components - fuel distributor with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 205 2.2 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 2.4 Clean injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 4.3 Removing and installing the throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . 219 4.4 Cleaning throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 5.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 5.2 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 5.3 Removing and installing intake manifold pressure sender GX9 . . . . . . . . . . . . . . . . . . . . 225 Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 Contents iii GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 5.4 Removing and installing pressure sensor for exhaust gas 1 G450 . . . . . . . . . . . . . . . . . . 226 6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 6.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 7 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 7.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 7.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 7.3 Removing and installing high pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 8.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 1.2 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 1.3 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 1.4 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 1.5 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 2 Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 2.1 Summary of components - exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 249 1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 1.5 Removing and installing the engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 iv Contents GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 00 – Technical data 1 Denomination (SRL001232; Edition 04.2018) ⇒ “1.1 Engine number, engine data”, page 1 1.1 Engine number, engine data The engine identification characters and the engine number can be found on the sticker -arrow- on the upper toothed belt guard. Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 1. Denomination 1 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 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. ♦ Starting with the letter “C”, new four digit engine codes have been introduced. ♦ 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 on the cylinder block including the serial number. ♦ The 4th digit refers to the output and torque of the engine and depends upon the engine - J623- control unit. Fitting locations for vehicle data stickers: ♦ ⇒ Maintenance ; Booklet Karoq Engine co‐ des CHZJ DKRA DKRF Karoq 07/2017 ► 07.2018 ► 07.2018 07.2018 ► Emission standards EU6 EU6 AG EU6 AG Displace‐ ment 999 999 999 Output 85/5000-5500 85/5000-5500 85/5000-5500 Torque 200/2000-350 0 200/2000-350 0 200/2000-350 0 Bore 74.5 74.5 74.5 Stroke 76.4 76.4 76.4 Compres‐ sion ratio 10.5 10.5 10.5 Number of cylinders/ valves per cylinder 3/4 3/4 3/4 Fuel - RON 95 unleaded 95 unleaded 95 unleaded Ignition sys‐ tem/fuel in‐ jection Motronic ME 17 Motronic ME 17 Motronic ME 17 Firing order 1-2-3 1-2-3 1-2-3 Exhaust gas recirculation no no no Balancing shaft module no no no Intake mani‐ fold change- over no no no Camshaft control valve, inlet / exhaust yes / yes yes / yes yes / yes Exhaust gas turbocharger yes yes yes Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 2 Rep. gr.00 - Technical data GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 2 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 3 ⇒ “2.2 Safety precautions when working on vehicles with start- stop system”, page 3 ⇒ “2.3 Safety precautions during road tests in which testing and measuring equipment is used”, page 3 ⇒ “2.4 Safety precautions when working on cooling system”, page 4 ⇒ “2.5 Safety precautions when working on ignition system”, page 4 ⇒ “2.6 General safety instructions”, page 4 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. Risk of damage to the electronic components when disconnecting the battery. Disconnect the battery only when the ⇒ Electrical System; Rep. gr. 27 battery is disconnected. 2.2 Safety precautions when working on ve‐ hicles with start-stop system Risk of injury as a result of automatic engine start in vehicles with start/stop system. In vehicles with the start/stop system activated (identifiable by an indication in the dash panel insert) the engine can start automat‐ ically if required. – Ensure that the start-stop system is deactivated when carrying out work on the vehicle (switch ignition off, if required switch ignition on again). 2.3 Safety precautions during road tests in which testing and measuring equipment is used Risk of accident from distraction Using testers and measuring instruments during driving operation causes distraction. Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 2. Safety instructions 3 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 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 scalding from hot coolant When the engine is warm the cooling system is under pressure. Hot steam may escape when the expansion reservoir is opened. – Wear protective gloves. – Wear safety goggles! – To reduce pressure: cover screw cap with a cloth and open carefully. 2.5 Safety precautions when working on ig‐ nition system Risk of injury from electric shock The ignition system is under high voltage with the engine running. There is risk of injury due to electric shock when touching the ignition system. – Do not touch or disconnect ignition leads with the engine run‐ ning or at start speed. Risk of damage to parts If the engine is running, an engine wash as well as disconnecting/ connecting electrical lines can damage components. – Switch off ignition when disconnecting/connecting electrical lines. – Switch off ignition before an engine wash. 2.6 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. Observe the following points to prevent injury to persons and (or) damage to the injection and ignition system: – 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 Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 4 Rep. gr.00 - Technical data GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � the ignition coils from the fuse holder ⇒ Current flow diagrams, Electrical fault finding and Fitting locations. Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 2. Safety instructions 5 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 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 3.1 Rules of cleanliness Observe the following “rules” when working on the fuel supply/ injection system: ♦ Thoroughly clean the connection points and their surroundings before releasing. ♦ Place removed parts on a clean surface and cover. 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 ♦ To ensure the original fitting position, e.g. lines for fuel, hy‐ draulics, vacuum, activated charcoal filter system lines or electric cables must be marked before removal. Make photos or sketches where 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. Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 6 Rep. gr.00 - Technical data GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 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. Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 3. Repair instructions 7 GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � 10 – Removing and installing engine 1 Removing and installing engine ⇒ “1.1 Removing engine”, page 8 ⇒ “1.2 Disconnecting engine and gearbox”, page 18 ⇒ “1.3 Attach engine attached to engine and gearbox mount”, page 19 ⇒ “1.4 Installing engine”, page 20 1.1 Removing engine Special tools and workshop equipment required ♦ Release lever - T10236- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Engine mount - T10483- ♦ Catch pan , e.g. -VAS 6208- ♦ Hose strap pliers , e.g. -VAS 6362- ♦ Locking pin - T10060A- ♦ Extension - 2024 A /1- of lifting device - MP9-201 (2024A)- ♦ Double ladder , e.g. -VAS 5085- ♦ Radiator protection mat - VAS 531003- ♦ Protective goggles and gloves Note The engine is removed downwards together with the gearbox. • Fit all cable straps on again in the same place when installing. – Remove both front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts . – Remove the noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation . – Remove the front left wheelhouse liner ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and installing front wheelhouse liner . – Drain coolant ⇒ “1.3 Draining and filling coolant”, page 152 . – Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . – Remove air filter housing ⇒ “3.2 Removing and installing air filter housing”, page 213 . WARNING Fuel under very high pressure creates a risk of injury. – Reduce the fuel pressure in the high pressure system ⇒ “1.2 Reduce fuel pressure”, page 203 . – Removing fan shroud ⇒ “4.4 Removing and installing fan shroud”, page 180 . Karoq 2018 ➤ 1,0/85 kW TSI engine - Edition 04.2018 8 Rep. gr.10 - Removing and installing engine GETtheMANUALS.org Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Š KODA AUTO A. S. Š KODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Š KODA AUTO A. S. � – Cover radiator with radiator protection mat - VAS 531003- . For vehicles with air conditioning – Remove V-ribbed belt ⇒ “1.2 Removing and installing V-ribbed belt”, page 35 . 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 or bend refrigerant lines and ho‐ ses. – Remove AC com