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 ➤ 1,5/110 kW TSI EVO Engine Engine ID DAD A Edition 07.2017 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 © 2017 ŠKODA AUTO a. s. D4B8078C002 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 2.1 Summary of components - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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. � 4.1 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 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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. � 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 gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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. � 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 Summary of components - exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 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 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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 (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 were produced with the same code letters, the first of the 6 digits is replaced by a letter. Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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. � 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 used for any other engine. ♦ On the left side of the plate can be found the »Data Matrix Code«. This information is read ⇒ Vehicle diagnostic tester. ♦ On the right side is alphanumeric information about of the construction. This form is used for the manual entry of the data relating to construction for commissioning ⇒ Vehicle diagnos‐ tic tester. ♦ The listed data are the measured values of the components. XN1 - Cam on cylinder 1 XN2 - Cam on cylinder 2 XN3 - Cam on cylinder 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 cm 3 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 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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. � 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 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 1. Denomination 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. � 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. Risk of damage to the electronic components when disconnecting the battery. 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. Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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. � 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. Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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 ⇒ “3.6 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 ♦ Brake fluid lines ♦ Coolant lines ♦ Vacuum lines Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 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. � ♦ 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 s