Service: Superb II 2008 Superb II 2011

Service
Workshop Manual
Superb II 2008 ➤
Superb II 2011 ➤
2.0/103 kW TDI PD Engine
Engine ID BMP
Edition 03.2018
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

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug Protected
system by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 ŠKODA AUTO a. s. S0062090020

Superb II 2008 ➤ , Superb II 2011 ➤
2.0/103 kW TDI PD Engine - Edition 03.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Regulations concerning cleanliness when working on the fuel supply/fuel injection system
........................................................................ 4
1.6 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 4
1.7 Handling the ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 bySecuring
Protected the engine
copyright. Copying for private ortocommercial
the assembly
purposes, instand . . . . is. not
part or in whole, . . permitted
............................. 12
1.3 Installing
with respect . . . of. information
to the correctness . . . . . . in
. .this
. .document.
. . . . . .Copyright
. . . . .by. .ŠKODA
. . . .AUTO
. . . A.. .S.�
............................ 13
1.4 Unit mounting - tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Checking and adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1 Disassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 Replacing crankshaft sealing ring on the belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 34
2.3 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2 Replacing the crankshaft sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.4 Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5 inspect piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Checking the axial play of the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Replacing camshaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
2.5 Testing hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.6 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.7 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.8 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Disassembling and assembling the oil filter holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Removing and installing balancing shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.5 Install balancing shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.6 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1 Removing and installing parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Parts of the cooling system fitted to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.3 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.4 Draining andProtected
filling by
coolant . . . .for. private
copyright. Copying . . . . or. commercial
. . . . . . .purposes,
. . . . .in.part
. . or. .in .whole,
. . . is. not
. . permitted
.............. 92
1.5 Removing and installing
unless authorised byradiator
ŠKODA AUTO. A. . .S..ŠKODA
. . . . AUTO
. . . .A.. S.. .does
. . not
. . guarantee
. . . . . .or.accept
. . . .any . .liability
............ 94
1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.7 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.8 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 Fuel tank with attached parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.5 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.6 inspecting fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.7 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.8 Removing and installing the fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.9 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.10 Removing and installing suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.11 Removing and installing the tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.12 Inspecting a tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.1 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.2 Removing and installing parts of the charge air cooling system . . . . . . . . . . . . . . . . . . . . 123
1.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.4 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.5 Inspect vacuum setting element and tension rods for charge pressure control . . . . . . . . . . 126
1.6 Checking the charge-air system with turbocharger for leak tightness . . . . . . . . . . . . . . . . 127
1.7 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1 Repairing Diesel Direct Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.1 Installation location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
ii Contents
1.2 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1.3 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.4 Repairing pump nozzle units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.5 Removing and installing unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.6 Replacing O-rings for unit injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.7 Removing and installing the engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.2 Removing and installing pre-exhaust pipe with diesel particle filter . . . . . . . . . . . . . . . . . . 146
1.3 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.4 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Removing and installing parts of the exhaust gas recirculation system . . . . . . . . . . . . . . 151
2.2 Assembly overview - cooling of the exhaust gas recirculation system . . . . . . . . . . . . . . . . 152
2.3 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 153
2.4 Hose plan for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.1 Glow Plug - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.2 Removing, installing and testing the ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Contents iii
iv Contents
00 – Technical data
1 Technical data
(SRL001194; Edition 03.2018)
1.1 Engine number

The engine number (“engine identification characters” and “serial
number”) is located in the front at the engine/gearbox joint
-arrow-.
In addition, a sticker with the “engine identification characters”
and “serial number” is affixed to the timing belt guard.
The engine identification characters are also indicated on the ve‐
hicle data stickers.
1.2 Engine characteristics

Engine identification characters BMP
Manufactured 03:08 ►
Emission standards conforming to EU4
Displacement l 1.968
Output kW at rpm 103/4000
Torque Nm at rpm 320/1800…2500
Bore Protected by copyright. Copying for private or commercial purposes, in part∅or mm
in whole, is not permitted
81.0
Stroke with respect to the correctness of information in this document. Copyright bymm
ŠKODA AUTO A. S.� 95.5
Number of valves per cylinder 2
Compression ratio 18.5 : 1
Firing order 1-3-4-2
Catalytic converter yes
Exhaust gas recirculation with radiator yes
Turbocharging yes
Charge air cooler yes
Diesel particle filter yes
1. Technical data 1
01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations and direc‐
tions
1.1 Self-diagnosis
This Rep.-Gr. is deleted.
For this use the “Vehicle self-diagnosis”, “Measuring method” and
“Fault finding” ⇒ Vehicle diagnostic tester.
1.2 Supplementary instructions and assem‐

bly work on vehicles with an air condi‐
tioning system
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Note
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.
Steps which should be taken in order to remove and install the

engine without opening the refrigerant circuit:
– Unscrew the retaining clip(s) on the refrigerant lines.
– Remove V-ribbed belt ⇒ page 21 .
– Remove the air conditioning compressor ⇒ page 21 .
– Mount the air conditioning compressor and theProtected
condenser in Copying for private or commercial purposes, in part or in whole, is not permitted
by copyright.
such a way that the refrigerant lines/hoses areunless
not under ten‐
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
sion.
1.3 Safety precautions when working on

fuel supply system
WARNING
♦ On vehicles with engine with unit injectors, the tempera‐

ture of the fuel lines or of the fuel can be up to 100 °C in
an extreme case. Let the fuel cool down before opening
the lines, as otherwise there is a high risk of burning.
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
2 Rep. gr.01 - Self-diagnosis

♦ Fuel pump is activated by switching on ignition and via driver

door contact switch. Before opening the fuel system and for
reasons of safety, if the battery is not disconnected, the con‐
nector -arrow- must be disconnected from the fuel delivery
unit.
WARNING
When undertaking all installation work, particularly in the en‐

gine compartment because of its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
When removing and installing the fuel gauge sender from a full or
partly filled fuel tank, pay attention to the following:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.4 Safety precautions when working on the

injection system
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
If the test and measuring devices are operated from the passen‐
ger seat, the passenger could be injured by the release of the
passenger airbag in the event of an accident.
WARNING
Secure the diagnostic device to the rear seat and operate from
that position.
Observe the following points to prevent injury to persons and/or

damage to the injection and preheating system:
♦ Disconnect and connect wires of the preheating and injection
system as well as measuring device wires when the ignition is
switched off.
♦ If the engine should be run at the starter speed without it ac‐
tually igniting, then separate the central plug connection for
the unit injector at the cylinder head.
♦ Before disconnecting the battery determine the code of the
radio fitted with anti-theft coding.
♦ Switch off the ignition before connecting or disconnecting the
Protected bybattery
copyright. as thisforcould
Copying private otherwise damage
or commercial purposes, theor diesel
in part direct
in whole, is injec‐
not permitted
tion bysystem
unless authorised ŠKODA AUTOcontrol
A. S. unit.
ŠKODA AUTO A. S. does not guarantee or accept any liability
1. Self diagnosis, safety measures, cleanliness regulations and directions 3

♦ If the battery is disconnected and reconnected, carry out re‐

work operations ⇒ Electrical System; Rep. gr. 27 .
1.5 Regulations concerning cleanliness

when working on the fuel supply/fuel in‐
jection system
When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean the connection points and their surroundings
before disconnecting.
♦ Place removed parts on a clean surface and cover. Use lint-
free cloths!
♦ Carefully cover or seal opened or removed components if the
repair is not carried out immediately.
♦ Only install clean parts: remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately.
Protected Replace
by copyright. Copying for privateimme‐
or commercial purposes, in part or in whole, is not permitted
diately any hoses which haveunlesssuffered damage.
1.6 Regulations concerning cleanliness

when working on the exhaust gas turbo‐
charger
Carefully observe the following “5 rules” for cleanliness when
working on the exhaust gas turbocharger:
♦ Thoroughly clean the connection points and their surroundings
before disconnecting.
♦ Place removed parts on a clean surface and cover. Use lint-
free cloths!
♦ Carefully cover or seal opened or removed components if the
repair is not carried out immediately.
♦ Only install clean parts: remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
1.7 Handling the ceramic glow plugs

For ceramic glow plugs the followings points must be observed:
4 Rep. gr.01 - Self-diagnosis

Note
♦ The ceramic glow plugs are very fragile due to the used com‐
ponent materials and require utmost care when removing and
installing. When removing and installing it is essential to carry
out the specified work sequence ⇒ page 155 .
♦ The original transport packaging must be used for transport
and storage of the ceramic glow plugs or if the ceramic glow
plugs are packed in foils with insulated air cushions.
♦ Remove ceramic glow plugs from their wrapping immediately
before fitting.
♦ The pins of the ceramic glow plugs are very sensitive to im‐
pacts and flexion. For this reason never use ceramic glow
plugs that have been dropped from a low height (approx. 2
cm). Although no exterior damage is visible, dangerous hair‐
line cracks can nevertheless be present.
♦ Damage or breakage of the ceramic glow plug pin may cause
major engine damage.
♦ Always replace the ceramic glow plugs in case of doubt re‐
garding the proper state.
♦ In case of breakage of the ceramic glow plug pin all broken
pieces must be removed from the cylinder before starting the
engine, otherwise this could result in engine damage due to
seizures.
♦ The ceramic glow plugs must not be removed from the cylinder
head for testing the compression pressure.
♦ Always perform the compression pressure test on installed
ceramic glow plugs in the function “Targeted fault finding”
⇒ Vehicle diagnostic tester.
♦ Software for engine control unit is adapted to a specific type
of glow plugs (ceramic or metallic), therefore only the corre‐
sponding glow plugs must be installed.
♦ Changing the ceramic glow plugs to metal glow plugs, or vice
versa, is not permissible.
1. Self diagnosis, safety measures, cleanliness regulations and directions 5

10 – Removing and installing engine

1 Removing and installing engine
Special tools and workshop equipment required
♦ Catch pan (e.g. - VAS 6208- )
♦ Engine/gearbox jack (e.g. - V.A.G 1383 A- )
♦ Engine mount - T10012-
♦ Workshop crane (e.g. - VAS 6100- )
♦ Double ladder (e.g. - VAS 5085- )
♦ Hose clamps - MP 7-602-
♦ Supporting device - MP9-200 (10-222A)-
♦ Hook for MP9-200 - MP9-200/10 (10-222A/10)-
♦ Pliers for spring-type clips
1.1 Removing
Note
♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Collect drained coolant in a clean container for proper disposal
or reuse.
Caution
When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ To avoid damage to lines/wiring, ensure sufficient clear‐
ance to all moving or hot components.
6 Rep. gr.10 - Removing and installing engine

– Remove dipstick -1- from dipstick guide.

– Lift engine cover at the sides -arrows 2- and pull out towards
the front -arrow 3-.
– Push the dipstick back into the dipstick guide.
– Before disconnecting the battery, if necessary remove the
adapter for the anti-theft wheel bolts from the luggage com‐
partment.
WARNING
Observe necessary measures when disconnecting the battery

⇒ Electrical System ⇒ Rep. gr. 27
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System ⇒ Rep. gr. 27 .
– Remove cover and bulkhead plenum chamber ⇒ Body Work
⇒ Rep. gr. 66 .
– Remove air filter and air guide with air mass meter
⇒ page 135 .
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
gr. 27 .
– Remove both front wheels ⇒ Chassis ⇒ Rep. gr. 44 .
– noise attenuation ⇒ Bodywork - assembly work ⇒ Rep. gr.
50 and remove the complete cover on the right ⇒ Bodywork -
assembly work ⇒ Rep. gr. 66 .
– Remove right drive shaft ⇒ Chassis ⇒ Rep. gr. 40 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box.
1. Removing and installing engine 7

– Unscrew the nut from the left coupling rod -2- and press off the
coupling rod from the anti-roll bar.
– Unscrew the nuts from the left steering joint -3- and press the
steering joint out of the suspension arm.
– If present, unscrew coupling rod from front left vehicle level
sensor - G78- .
– Turn the steering to full left lock.
– Swivel the steering joint outwards and secure the drive shaft
-1- with a band -A- in the wheelhouse.
– Insert a pin screw in the suspension arm in order to stabilize
the steering joint.
WARNING
When opening the expansion reservoir, out hot steam or hot

coolant may escape. Cover the cap with a cloth and open
carefully.
– Drain coolant ⇒ page 92 .
WARNING
♦ On vehicles with engine with unit injectors, the tempera‐

ture of the fuel lines or of the fuel can be up to 100 °C in
an extreme case. Let the fuel cool down before opening
the lines, as otherwise there is a high risk of burning.
♦ Wear protective gloves.
♦ Wear safety goggles.
– Detach coolant hose, fuel intake hose -2- and fuel return-flow
hose -1- from pipes at cylinder head.

– Release screw -1- by one turn.

– Release screw -2- and nut -3-.
– Take out fuel filter with connected hoses and lay to the side.
Note
Mark the direction of rotation with chalk or a felt-tip pen before

removing the V-ribbed belt. Reversing the rotation direction of an
already used belt may destroy it.

– Remove alternator ⇒ Electrical System ⇒ Rep. gr. 27 .
WARNING

tem.
Note
In order to avoid damage to the AC condenser as well as to the

refrigerant lines and hoses, ensure that the lines and hoses are
not over-tensioned, kinked or bent.
– Remove AC compressor and bracket for auxiliary units

⇒ page 21 .
– Tie up removed AC compressor with connected refrigerant
hoses to the body.
Vehicles with auxiliary heating
– Unscrew clamp -1- and remove screw -2-.
– Detach the pre-exhaust pipe of the auxiliary heating and ad‐

ditional heating.
– Disconnect the necessary connections at the coolant pipes
and at the coolant shut-off valve of heating system - N279- .
Continued for all vehicles
– Remove charge air hoses and charge air pipe between engine
and charge air cooler ⇒ page 123 .
WARNING
Shut off the openings of the charge air cooler, e.g. with a clean
piece of foam, so that no coolant can get in.
– Remove fan shroud and radiator ⇒ page 88 .

– Remove elec. cable holder for oil level and oil temperature
sender from assembly carrier.
– Unscrew left drive shaft from the flange shaft of the gearbox
and tie up.

– Release screws -1…3- and remove pendulum support.
Note
The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
– Remove the pre-exhaust pipe from the exhaust turbocharger

⇒ page 145 .
– Disconnect the plug of the engine wiring harness from the en‐
gine control unit ⇒ page 143 .
– Release guide for engine wiring harness -2- -arrow- and pull
out upwards.
– Open cable straps -4-.
– Unscrew screws -3- at the plenum chamber partition panel
-1-.
– Lift left side of the plenum chamber partition panel and remove
the engine wiring harness.
– Unbolt the cable from the AC generator at the fuse holder

-arrow-.

– Unlatch the fuse and disconnect the plug in front from the en‐
gine control unit ⇒ page 143 , open the cable guides
-arrows-, remove the engine wiring harness and lay to the side.
– Release all remaining plugs at engine and gearbox and lay
aside the relevant lines.
Note
To release the plug for the engine speed sensor, push down on
the plug with a screwdriver while simultaneously lifting the release
button with a thin wire hook.
– Unclamp all connecting, cooling fluid, vacuum and air guide

hoses from the engine.
– Remove shift mechanism from gearbox ⇒ gearbox ⇒ Rep.
gr. 34 .
– Pull off tube-hose line for slave cylinder ⇒ transmission ⇒
Rep. gr. 34
WARNING
After separating the hydraulic line, do not operate the clutch

pedal.
– Screw engine mount - T10012- to the cylinder block with fixing

nut and bolt. Tighten screw M10x25/8.8 to approx. 40 Nm.
Note
The studs must be screwed onto the engine mount - T10012- as

shown in the figure. The stud with the thread must be positioned
on the gearbox side.
– Insert engine/gearbox jack (e.g. - V.A.G 1383 A- ) into the en‐

gine mount - T10012- and slightly raise.
Note
Use double ladder (e. g. - VAS 5085- ) to release the screws for
the engine/gearbox mounting.
– Engine mounting bolts -arrows-...

– and gearbox mounting -arrows-.
Note
♦ Check whether all hose and line connections between engine,

gearbox and body are released.
♦ When lowering carefully guide the engine with the gearbox, in
order to avoid damage.
– Carefully lower engine with gearbox.

– Remove the gearbox from the engine ⇒ gearbox ⇒ Rep. gr.
34 .
1.2 Securing the engine to the assembly

stand
♦ Lifting device - MP 9-201 (2024A)-
♦ Engine mount - MP 1-202 (VW 540)-
♦ Adapter - MP 1-202/10-
♦ Bushing - T30010 (VW 540/1B)-
♦ Assembly stand - MP 9-101-
♦ Workshop crane , e.g. -VAS 6100-
Work procedure
• Separate engine from gearbox.
WARNING
Use securing pins on the hooks and rig pins to prevent release.
– Attach lifting device - MP 9-201- at engine and at workshop

crane (e.g. - V.A.G 1202A- ).
Belt pulley side: 2nd hole of the extension in Position 1.
Flywheel side: 2nd hole of the extension in Position 8.
– Lift engine with assembled engine mount - T10012- out of the
engine/gearbox jack using the workshop crane .
– Remove engine mount - T10012-unless
.withauthorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– For carrying out assembly work, attach the engine with the
engine mount - MP 1-202- , the extension - MP 1-202/10- and
the sleeves - T30010- to the assembly stand - MP 9-101- .
(The figure shows the 1.9ltr./47kW SDI Engine; the fixing sys‐
tem is identical).
1.3 Installing
Work procedure
• Mount engine onto engine mount - T10012- .
Installation is carried out in the reverse order. When installing,
Note
♦ When undertaking assembly replace self-locking nuts and

screws which have been tightened to a torquing angle.
♦ Always replace gasket rings and seals.
♦ All cable straps should be fitted on again in the same place
when installing.
♦ Secure all hose connections with corresponding hose clips.
Engines with coupling for manual gearbox
Note
♦ Clean the serration on the drive shaft and if the clutch discs
have been used clean the hub serration, remove corrosion and
only apply a very thin layer of grease - G 000 100- . Subse‐
quently move the clutch disc up and down on the drive shaft
until the hub fits smoothly on the shaft. Always remove excess
grease.
♦ After installing the coupling,
unless authorised check the
by ŠKODA centering
AUTO ofAUTO
A. S. ŠKODA theA.clutch
S. does not guarantee or accept any liability
disc ⇒ gearbox ⇒ with
Rep. gr. 30 .
♦ Check the clutch release bearing for wear. Replace release

bearing if worn ⇒ gearbox ⇒ Rep. gr. 30 .

Engines without coupling for automatic gearbox
Note
♦ Replace needle bearing ⇒ page 47 .

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

– Check whether the dowel sleeves for centring the engine/
gearbox are present in the cylinder block; insert if necessary.
– Ensure that the intermediate plate has been inserted on the

sealing flange and is pushed onto the dowel sleeves
-arrows-.
– Screw on gearbox to engine ⇒ gearbox ⇒ Rep. gr. 34 .

– Insert engine with gearbox into the body.
– Engine mounting bolts -arrows- ...
– ... and gearbox mounting -arrows-, initially by hand. Use new

screws for attaching.
Note
Do not tighten the screws fully until the engine mount and gearbox
mount has been adjusted.
– Remove engine mount - T10012- from engine.


– Tighten pendulum support with screws -1...3- at gearbox and

at assembly carrier. Use new screws for attaching.
– Replace O-ring -1- on the right stub shaft and lubricate gearing
-2- with multipurpose grease.
– Attach the right drive shaft and screw the left drive shaft onto
the drive flange ⇒ Chassis ⇒ Rep. gr. 40 .
– Install exhaust system and align free of stress ⇒ page 149 .
– Connect hydraulic line to hydraulic clutch control cylinder and
bleed the clutch hydraulics ⇒ Gearbox ⇒ Rep. gr. 30 .
– Attach the shift mechanism to the gearbox and adjust ⇒ Gear‐
box ⇒ Rep. gr. 34 .
– Fit fan shroud and radiator ⇒ page 94 .
Vehicles with auxiliary heating
– Fit the pre-exhaust pipe of the auxiliary heating.
– Attach coolant hoses to the auxiliary heating.

– Removing and installing bracket for auxiliary units and AC
compressor ⇒ page 21 .
– Install alternator ⇒ Electrical System ⇒ Rep. gr. 27 .
– Install the V-ribbed belt ⇒ page 21 .

– Connect all connecting, fuel, cooling fluid, oil, vacuum and

suction hoses to the engine. When installing the connecting
hose with push-fit coupling ensure that the locking clip
-arrow- interlocks behind the retaining lugs -A-.
– Adjust the assembly bracket ⇒ page 16 .
– Connect electrical connections and attach cables ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
– Install battery ⇒ Electrical System ⇒ Rep. gr. 27 .
– Install bulkhead plenum chamber and plenum chamber cover
⇒ Body Work ⇒ Rep. gr. 66 .
– Install wiper arms ⇒ Electrical System ⇒ Rep. gr. 92 .
Noise attenuation ⇒ Bodywork - assembly work ⇒ Rep. gr. 50
and install the complete cover on the right ⇒ Bodywork - assem‐
bly work ⇒ Rep. gr. 66 .
– Top up coolant ⇒ page 92 .
– Checking the oil level ⇒ Maintenance ; Booklet Superb II .
Specified torques
Module Nm
Screws/nuts M 9
6
M 13
7
M 20
8
M 40
10
M 70
12
Engine/gearbox connecting screws ⇒ gearbox
⇒ Rep. gr. 34
1.4 Unit mounting - tightening torques

Unit mounting for engine
A - 20 Nm + 90° (1/4 turn) - replace
B - 40 Nm + 90° (1/4 turn) - replace
C - 60 Nm + 90° (1/4 turn) - replace

Assembly mountings Gearbox mount

1 - 40 Nm + 90° (1/4 turn) - replace
2 - 60 Nm + 90° (1/4 turn) - replace
Pendulum support
A strength category 8.8 - 40 Nm + 90° (1/4 turn) - replace
A strength category 10.9 1) - 50 Nm + 90° (1/4 turn) - replace
B - 100 Nm + 90° (1/4 turn) - replace

Remove: First remove screw -B-, then screws -A-.
Install: First tighten screws -A-, then screw -B-.
1)On manual gearbox MQ350 (02Q), only use the screws with the
strength category 10.9 if threaded inserts (e.g. Heli Coil) -arrow-
have been installed.

1.5 Checking and adjusting the assembly

bracket
1.5.1 Checking the assembly bracket

Check dimensions on the right hanger for engine/gearbox unit:
• Between engine bracket and engine support there must be a
distance -a- of 10 ... 13 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.
Note
The distance -a- can be checked, for example with suitable round
bars.
Only if there is an acoustic complaint (engine or gearbox knock

on the frame side rail when cornering) and the dimension -a- is
outside 10 … 13 mm:
– Adjust the assembly bracket ⇒ page 18 .
1.5.2 Adjusting the unit mounting

♦ Lifting device - MP9-200 (10-222A)-
♦ Adapter - MP9-200/3 (10-222A/3)- 2x
or
♦ adapter - MP9-200/3 (10-222A/3)- 1x and adapter -
MP9-200/18 (10-222A/18)- 1x
♦ Wing plates - T10311-
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
gr. 27 .
– Remove the front stop buffers for the front flap from both upper
edges of the wings.
– Insert the wing plate - T10311- on the right vehicle side -A- in
the -direction of the arrow- up to the stop. When doing this, the
-arrow R- on the wing plate - T10311- points to the rear.
– Insert the wing plate - T10311- on the left vehicle side -B- in AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised by ŠKODA
the -direction of the arrow- up to the stop. Whenwithdoing this,
respect to the
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
-arrow L- on the wing plate - T10311- points to the rear.
Note
The wing plates - T10311- ensure that the wings do not get dam‐
aged through the weight of the engine/gearbox unit.

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

MP9-200/3- and support the engine/gearbox unit in its instal‐
led position.
– The feet of the supporting device - MP9-200 - must be pushed
as shown in the illustration up to the stop buffers -1- and placed
on the wheelhouse frame side rail at the top -2-.
– Uniformly pre-tension the engine/gearbox unit with both spin‐
dles, but do not raise.
– Release the screws -arrows- of the assembly bracket at the

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

– Move the engine/gearbox assembly with an assembly lever

between engine support -1- and supporting arm -3- for engine
mount until the following dimensions are set:
• Between engine bracket and engine support there must be a
distance -a- of 10 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.
Note
The distance -a- = 10 mm can be checked e.g. with suitable round

bars.
– Tighten the screws of the assembly bracket ⇒ page 18 .

Further installation occurs in reverse order.

13 – Crankshaft group
1 Disassembling and assembling en‐
gine
1.1 Removing and installing V-ribbed belt

♦ Locking pin - T10060A-
1 - Belt pulley
❑ with vibration damper
❑ can be installed only in
one position
2 - 10 Nm + torque a further 90°
(1/4 turn)
❑ replace
3 - Tensioning device for V-rib‐
bed belt
❑ swivel tensioning device
for V-ribbed belt with
open-end wrench to
slacken the V-ribbed
belt
❑ Tensioning device can
be locked with locking
pin - T10060A- or Allan
key.
4 - 23 Nm
5 - Bracket for auxiliary units
❑ Tightening sequence
⇒ page 22
6 - Bushing
7 - 23 Nm
8 - AC generator
❑ removing and installing
⇒ Electrical System ⇒
Rep. gr. 27
❑ to facilitate positioning,
drive the threaded bush‐
ings Protected
of the retaining
screws atauthorised
the generator
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
slightlywith
backwards
9 - 45 Nm
❑ insert using locking agent -D 000 600 A2-
❑ Observe tightening sequence ⇒ page 22
10 - Bushing
❑ 2 pieces
❑ must be inserted in the holder ⇒ Item 5 (page 21)
1. Disassembling and assembling engine 21

11 - 25 Nm
12 - AC compressor
13 - V-ribbed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
❑ do not kink
❑ Removing ⇒ page 22
❑ installing ⇒ page 22
Bolts at bracket for auxiliary units - tightening sequence

Removing
– Remove engine cover ⇒ page 6 .
– Remove fuel filter with integrated holder and place to the side.
Note

For vehicles with auxiliary heating:

– Remove the front right wheelhouse liner ⇒ Body Work ⇒ Rep.
gr. 66 .
For all vehicles:
– Swing the tensioning device in -the direction of the arrow- de‐

tention the V-ribbed belt.
– Lock the tensioning element with the locking pin - T10060A- .
– Remove the release ribbed V-belt.

Installing
Note
Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.
22 Rep. gr.13 - Crankshaft group

– First position the ribbed V-belt on the belt pulleys of the crank‐
shaft and AC compressor and on the belt pulley of the gener‐
ator last; then release the tensioning device.
– Check correct positioning of the ribbed V-belt on the belt pul‐
leys.
– Start engine and check ribbed V-belt run.
1.2 Removing and installing toothed belt
1 - Top toothed belt guard

❑ to remove, remove the
right charge air pipe
❑ when installing, careful‐
ly insert into the middle
toothed belt guard
2 - 100 Nm
❑ to release and tighten
use counterholder -
T10051-
(1/8 turn)
4 - Camshaft sprocket
❑ Mark installation posi‐
tion
5 - Hub
❑ with sensor rotor for Hall
sensor - G40-
❑ to release and tighten
use counterholder -
T10051-
❑ to remove use extractor
- T10052-
❑ Removing and installing with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6 - 10 Nm
❑ insert using locking
agent -D 000 600 A2-
7 - Rear toothed belt guard
❑ to remove, unscrew
coolant pump
❑ When installing careful‐
ly insert into the front
sealing flange
8 - 25 Nm
9 - Rubber grommet
❑ Replace if damaged.

10 - 20 Nm + torque a further 45° (1/8 turn)

11 - Tensioning pulley
❑ The eccentric of the new version has an additional hole for 6 mm hexagon socket wrench ⇒ page 24
12 - 20 Nm
13 - Guide pulley
14 - Coolant pump
❑ Removing and installing ⇒ page 95
15 - Crankshaft toothed belt sprocket
❑ there must not be any oil present on the contact surface between the pulley and the crankshaft
❑ can be installed only in one position
❑ replace
❑ do not oil
❑ to release and tighten use counterholder - T30004- or counterholder - MP 1-310-
17 - 15 Nm
18 - Bottom toothed belt guard
❑ with notch, which marks the TDC for cylinder 1
19 - V-ribbed belt pulley
❑ with vibration damper
❑ with notch, which marks the TDC for cylinder 1
❑ Adjust TDC with the vibration damper fitted ⇒ page 25
❑ replace
21 - Toothed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
❑ install (set the timing) ⇒ page 29
23 - Middle toothed belt guard
❑ with arrow indicating the TDC for cylinder 1
❑ Adjust TDC with the vibration damper fitted ⇒ page 25
❑ to remove, remove top toothed belt guard and unscrew tensioning device for ribbed V-belt.
24 - Engine mount Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Tensioning pulley
Additional hole in the eccentric of the tensioning pulley for 6 mm
hexagon socket wrench -arrow-.
Note
The tensioner pulley of the new version can be adjusted with the
special two-hole nut turner , e. g. -T10020- , or using a commer‐
cially available 6 mm hexagon socket wrench.

Adjust TDC with the vibration damper fitted

– Bring the TDC marking on the vibration damper (notch)
-large arrow- into alignment with the marking on the middle
toothed belt guard (marked arrow) -small arrow- as shown.
Note
When removing the toothed belt, it is necessary to remove the

motor support -1-.
Tightening order for engine support
Caution
The tightening sequence and the tightening torques of the fix‐

ing screws for the engine mount must definitely be respected.
Otherwise stress of the engine mount occurs, which results in
the breaking of the engine mount.
– Screw in screws -1...3- by hand first.

– Tighten screws in the order shown -1...3- to 40 Nm + torque a
further 180°(1/2 turn)
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ To do so, lift or lower the engine with the supporting device -
MP9–200- .
♦ Before the assembly carrier is installed, all the screws of the
engine holder must be tightened to the specified tightening
torque.
1.2.1 Removing
♦ Rig pin for the injection pump - 3359- or -MP 1-301 - (2x)
♦ Locking pin - T10060A-
♦ Crankshaft arrester - T10100-
♦ Counterholder - T10172-
♦ Offset screwdriver - T10264-
♦ Rig tool - T10265-
Note


– Lock the clamping device for V-ribbed belt with connecting pin
or Allen key.
– Remove ribbed V-belt tensioning device.

– Remove the right wheelhouse liner ⇒ Body Work ⇒ Rep. gr.
66 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Unscrew screws -1- and -2- and remove charge air pipe
-arrows-.
– Remove crankshaft belt pulley. To do this, counterhold at the

central screw with a ring spanner.

– Unscrew the screw on the filler neck -2- of the windscreen

washer tank.
– Unscrew the coolant expansion tank -1- and place to the side
with connected cables.
– Remove top toothed belt guard, to do so release retaining clips

-arrows-.
– Unscrew bottom and middle toothed belt guard -arrows-.
Caution
The engine may only be turned in the direction of engine rota‐

tion (clockwise) at the crankshaft.

Note
Rotate crankshaft until the marking is located at the top of the

toothed belt and the arrow on the toothed belt guard is positioned
opposite the pegs on the hub with the impulse wheel -arrows-.
– Lock hub with locking pin -MP1-301- or -3359- .

– Insert locking pin through the left slot into the hole at the cyl‐
inder head.
– Secure the crankshaft toothed belt sprocket with the crank‐
shaft arrester - T10100- .
– Insert crankshaft arrester from the front side of the timing belt
sprocket into the teeth.
Note
♦ The markings on the toothed belt sprocket and on the crank‐

shaft arrester must be in line with each other. The stud on the
crankshaft arrester must engage into the hole in the sealing
flange.
♦ The crankshaft arrester can only be fitted onto the serration of
the toothed belt sprocket from the front side.
♦ The crankshaft arrester - T10100- must not be used as a
counterholder when releasing or tightening the bolt for the
crankshaft toothed belt sprocket.
Note
Mark the direction of rotation of the toothed belt with chalk or a

felt-tip pen.
– Loosen the screws -arrows- of the camshaft sprocket.

– Loosen the fixing nut -1- of the tensioning pulley.

– Carefully turn eccentric of the tensioning pulley with offset
screwdriver - T10264- in anti-clockwise direction -arrow- until
the tensioning pulley can be interlocked with rig tool - T10265- .
– Now turn eccentric of the tensioning pulley clockwise -arrow-

as far as the stop and tighten fixing nut -1- by hand.
– First of all take toothed belt off coolant pump and then from
the other toothed belts.
1.2.2 Installing (set the timing)

• Camshaft is locked with locking pin e.g. - 3359- .
• Interlock crankshaft with crankshaft arrester - T10100- .
• Tensioning pulley is interlocked with rig tool - T10265- and
fixed at right stop with fixing nut.
Note
♦ Always perform adjusting work on the timing belt only on a cold

engine.
♦ When rotating the camshaft, the crankshaft must not be posi‐
tioned at TDC for any one piston. Risk of damaging valves and
pistons.
– Check the correct fitting of the tensioning pulley in the hole in

the rear timing belt guard -arrow-.

– Slightly screw in screws -arrows-.

• It must still be possible to turn the camshaft sprocket on the
hub, however it must not hang loose.
– Turn camshaft sprocket clockwise in the elongated holes as
far as the stop.
– Fit toothed belt onto crankshaft toothed belt sprocket, tension‐
ing pulley, camshaft and, last of all, onto the toothed belt
sprocket of the coolant pump.
Set toothed belt tension as follows:
– Pull rig tool - T10265- out of tensioning pulley.
– Loosen the fixing nut -1- of the tensioning pulley.
– Turn the eccentric of the tensioning pulley with offset screw‐

driver - T10264- clockwise -arrow- in such a way until the
pointer -2- stands in the centre of the base plate in the gap.
Note
Ensure that the fixing nut does not turn.
– Hold the eccentric of the tensioning pulley in this position and

tighten the fixing nut to 20 Nm and torque a further 45° (1/8
turn).
Note
When tightening the fixing nut, the pointer -arrow- turns max. 5
mm to the right from the gap of the base plate. This position must
not be corrected, because the toothed belt settles when running-
in.
– Insert counterholder - T10172- with bolt - T10172/4- as shown

and by pressing in the -direction of the arrow- tension the
toothed belt on the tension side.
– Tighten fixing screws -1- to 20 Nm + torque a further 45° (1/8
turn).
– Remove rig pin - 3359- and crankshaft arrester - T10100- .
Test timing:
– Turn crankshaft 2 turns in the direction of running of the engine
until the crankshaft is positioned shortly before TDC for cylin‐
der 1.
– Interlock during this motion the hub in the direction of running

of the engine with locking
Protectedpin - 3359-
by copyright. . for private or commercial purposes, in part or in whole, is not permitted
Copying

– Check if the crankshaft can be locked with the crankshaft stop

- T10100- .
If the crankshaft cannot be arrested:
– Loosen the screws -arrows- of the camshaft sprocket.
– Rotate crankshaft in direction of engine rotation until the crank‐

shaft can be locked in the hole in the sealing flange -arrow-
with the crankshaft arrester .
Note
If the crankshaft can be turned via the TDC for cylinder 1, turn
crankshaft back slightly and once again set to the TDC for cylinder
1 by turning in direction of rotation of engine.
– Tighten fixing screws -arrows- to 20 Nm + torque a further 45°

(1/8 turn).
– Remove rig pin - 3359- and crankshaft arrester - T10100- .
– Turn crankshaft 2 turns in the direction of running of the engine
until the crankshaft is again on TDC.
– Repeat timing test ⇒ page 30 .
Proceed with installation:
Further installation occurs in reverse order.

2 Removing and installing sealing

flange and flywheel
Note
Repairs to the clutch ⇒ gearbox ⇒ Rep. gr. 30 .
1 - Sealing ring
❑ Replace ⇒ page 33
❑ Neither oil nor grease
2 - Sealing flange on the belt
pulley side
❑ must be positioned on
dowel sleeves
❑ Removing and installing
⇒ page 34
3 - Cylinder block
❑ with fitted crankshaft
❑ Replace needle bearing
for crankshaft
⇒ page 47
4 - Dual-mass flywheel
⇒ page 41
❑ Assembly is only possi‐
ble in one position
through offset holes.
(1/4 turn)
❑ replace
6 - Intermediate plate
❑ must be positioned on
dowel sleeves
❑ do not damage/bend
during assembly work
❑ inserted on sealing
flange ⇒ page 33
7 - 15 Nm
❑ replace
8 - Sealing flange on the gearbox side
❑ can only be replaced complete with gasket ring and with rotor of engine speed sender - G28-
9 - engine speed sender - G28-
10 - 5 Nm

Installing intermediate plate

– Insert intermediate plate on sealing flange and push onto the
dowel sleeves -arrows-.
2.1 Replacing crankshaft sealing ring on the

belt pulley side
♦ Counterholder - T30004 - or counterholder for toothed belt
sprocket - MP 1-310 (3099)-
♦ Sealing ring extractor - MP 1-226 (3203)-
♦ Assembly tool - T10053-
Removing
• Engine installed.
– Remove toothed belt ⇒ page 23 .
– Remove crankshaft toothed belt sprocket, to this end lock
toothed belt sprocket with counterholder or counterholder for
toothed belt sprocket .
– To guide the gasket ring extractor, screw in central screw for

crankshaft toothed belt sprocket in the crankshaft by hand up
to the stop.
2. Removing and installing sealing flange and flywheel 33

– Turn inner part of gasket ring extractor - MP 1-226- two turns

(approx. 3 mm) out of the outer part and lock with knurled
screw.
– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Release knurled screw and turn the inner side against the
crankshaft until the gasket ring is pulled out.
– Clamp gasket ring extractor into the vice and remove gasket
ring with pliers.
– Clean the contact and sealing surfaces.
Installing
Note
Do not oil the sealing lip and the outer surface of the gasket ring
before the pressing in procedure.
– Remove oil residue on the crankshaft journal with a clean

cloth.
– Insert guide bushing - T10053/1- on the crankshaft bearing

pin.
– Slide gasket ring over the guide sleeve.
– Press in the gasket ring flush with the central screw for toothed
belt sprocket and with pressure bushing of -T10053- .
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ There must not be any oil present on contact surface between
toothed belt sprocket and crankshaft.
♦ Replace central screw for crankshaft toothed belt sprocket.
♦ Do not oil central screw for toothed belt sprocket of crankshaft.
– Mount crankshaft toothed belt sprocket, to this end lock tooth‐

ed belt sprocket with counterholder or counterholder for tooth‐
ed belt sprocket .
– install (set the timing) ⇒ page 23 .
2.2 Removing and installing the sealing

flange on the belt pulley side
♦ Counterholder - T30004 - or counterholder for toothed belt
sprocket - MP 1-310 (3099)-

♦ Torque wrench
♦ Sealant remover Gasket Stripper (stock code GST, stock item
No. R 34402), manufacturer Retech s.r.o.
♦ Protective goggles and gloves
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Silicone sealant - D 176 404 A2-
Removing
• Engine installed.
– Remove crankshaft toothed belt sprocket, to this end lock
toothed belt sprocket with counterholder or counterholder for
toothed belt sprocket .
– Drain engine oil ⇒ Maintenance ; Booklet Superb II .
– Removing the oil pan ⇒ page 79 .
– Unscrew the fixing screws of the sealing flange and remove
sealing flange, if necessary release by applying slight blows
with a rubber-headed hammer.
Installing
WARNING
Wear protective gloves and goggles when working with gasket

remover and degreasing agent!
– Clear sealing surface on sealing flange, cylinder block and on

the oil pan from gasket residues with chemical sealant remov‐
er.
– Degrease the sealing surfaces.
Note
Pay attention to the use by date on the silicone sealant.
– Cut off nozzle tube at the front marking (diameter of nozzle

approx. 3 mm).

– Apply silicone sealant bead -arrow- to the clean sealing sur‐

face of the sealing flange, as shown.
• Thickness of sealant bead -arrow-: 2 ... 3 mm.
Note
♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clog the strainer
in the oil suction pipe.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ When installing the sealing flange with the gasket ring fitted
place a guide sleeve - T10053/1- on the crankshaft journal.
– Carefully push the sealing flange onto the dowel sleeves at the
cylinder block and tighten new fixing bolts by hand.
– Tighten the screws of the sealing flange alternately and cross‐
wise.
– Installing the oil pan ⇒ page 79 .
– Mount crankshaft toothed belt sprocket, to this end lock tooth‐
ed belt sprocket with counterholder or counterholder for tooth‐
ed belt sprocket .
– Top up with engine oil and check the oil level ⇒ Maintenance ;
Booklet Superb II .
2.3 Replace sealing flange on the gearbox

side
♦ Screw M6x35 (3x)
♦ Screw M7x35 (2x)
♦ Feeler gauge Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Steel straightedge with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
2.3.1 Removing
• Gearbox removed
– Remove the two-mass flywheel ⇒ page 41 .
– Remove the intermediate plate from the dowel sleeves and
unhook from sealing flange -arrows-.
– Position engine on TDC cylinder 1 ⇒ page 23 .

– Remove engine speed sender -G28- -Pos. 1-.

– Unscrew fixing screws on the sealing flange.
– Screw 3 screws M6x35 into the threaded bores of the sealing

flange -arrows-.
– Press out sealing flange together with rotor from the crank‐
shaft by alternately screwing the screws into the sealing
flange.
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ Do not separate or turn the sealing flange and rotor after re‐
moving them from the spare part package.

♦ The rotor gets its fitting location by fixing by fixing to the posi‐
tioning pin of the assembly tool - T10134- .
♦ Sealing flange and sealing ring form one unit and must only
be renewed together with the transmitter wheel.
♦ The rotor has an elastomer layer on its sealing surface with
the crankshaft. This layer must not be brought into contact with
dirt or grease.
♦ The assembly tool - T10134- is given its fitting location to the
crankshaft by means of a guide bolt, which is guided into the
threaded bore of the crankshaft.
2.3.2 A - Mounting the sealing flange with ro‐

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

– Grip the assembly tool on the clamping surface -B- of the

threaded spindle in a vice.
– Remove securing clip -arrow- from new sealing flange.
Note
Do not remove or turn the rotor from the sealing flange.
– Place sealing flange with front side facing down on a clean

level surface.
– Press the sealing lip supporting ring -A- -arrows-, until it rests
on the level surface.
Note
The top edge of the rotor and the front edge of the sealing flange
must be flush.
The locating hole -B- on the rotor -C- must be flush with the mark‐
ing -A- on the sealing flange.

– Lay the sealing flange with the front side on the assembly tool
in such a way that the positioning pin -A- engages into the hole
-B- of the rotor.
Note
Make sure the sealing flange lies flat on the assembly tool.
– When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly tool in such
a way that the positioning pin cannot slide out of the rotor hole.
2.3.3 B - Attach assembly tool -T10134- with

sealing flange
Protected by to theCopying
copyright. crankshaft flangepurposes, in part or in whole, is not permitted
for private or commercial
• The crankshaft flange must be free of grease and oil
• The engine is positioned on TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.
– Screw assembly tool with Allan screws -A- onto the crankshaft
flange up to the stop.
– Screw in two M7x35 mm screws -A- by about 3 turns for seal‐

ing flange guide into the cylinder block.

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

-direction of the arrow- until the rotor -B- rests on the crank‐
shaft flange -A-. Then insert the guide bolt with black ball -D-
into the threaded bore of the crankshaft up to the stop. If the
guide bolt is correctly seated, the ball is approx. 10 mm from
the assembly cup -C-. This gives the rotor its final installation
position.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.
Note
The guide bolt for petrol engines (black handle) -F- must not be
fitted into the hole of the crankshaft.
2.3.4 C - Pressing the rotor onto the crank‐

shaft flange
– Tighten the hexagon nut of the assembly tool using a torque
wrench with adapter. Tightening torque: 35 Nm.
Note
After tightening the nut to 35 mm there must still be a narrow air

gap between the cylinder block and the sealing flange.
2.3.5 D - Inspect the fitting position of the rotor

on the crankshaft
– Unscrew hexagon nut -E- up to the end of the threaded spin‐
dle.
– Release both screws -A- to the guide from the cylinder block.
– Unscrew three knurled screws -B- from the sealing flange.
– Unscrew two Allan screws and remove assembly tool.
– Remove sealing lip support ring.
The fitting position of the rotor on the crankshaft is accurate if

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

– Position the steel straight edge onto the crankshaft flange.

– Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
– Press down rotor ⇒ page 41 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing alternately cross‐
wise. Tightening torque: 15 Nm.
– Install engine speed sensor -G28- -Pos. 1-. Tightening torque:

5 Nm.
– Installing intermediate plate.
– Install flywheel with new screws. Tighten fixing bolts to 60 Nm
and torque a further 1/4 turn (90 °).
2.3.6 E - Pressing down the rotor

– Screw assembly tool - T 10134- with Allan screws up to the
stop onto the crankshaft flange.
– Screw in threebyknurled
Protected screws
copyright. Copying -B- into
for private the flange.
or commercial purposes, in part or in whole, is not permitted
– Then insert the guide bolt with black ball -D- into the threaded
bore of the crankshaft up to the stop. If the guide bolt is cor‐

rectly seated, the ball is approx. 10 mm from the assembly cup
-C-.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.
– Tighten the hexagon nut of the assembly tool using a torque

wrench with adapter. Tightening torque: 40 Nm.
– Check the fitting position of the rotor on the crankshaft again
⇒ page 40 .
If the dimension -a- is too small again:
– Tighten the hexagon nut of the assembly device to 45 Nm.
– Check the fitting position of the rotor on the crankshaft again
⇒ page 40 .
2.4 Removing and installing the two-mass

flywheel
♦ Engine mount - MP 1-202 (VW 540)-
♦ Bushing - T30010 (VW 540/1B)-

♦ Flywheel lock - MP 1-504-

♦ Counterholder - MP1-223 (3067)-
Removing
• Gearbox removed.
Engine installed
– Insert the counterholder - MP1-223 (3067)- into the bore hole
on the cylinder block.
• Fitting position of the tool:
A - for tightening
B - for slackening
Engine removed
– Secure two-mass flywheel by inserting the flywheel lock - MP

1-504- into the serration and turn sufficiently until it touches
the bushing -T30010- .
– Position the flywheel lock - MP 1-504- on the starter ring gear
and turn crankshaft until it rests against the sleeve - T30010- .
Continue for all engines

– Rotate two-mass flywheel -A- in such a way that the screws
are positioned in the middle of the holes -arrows-.
Caution
When unscrewing the screws -B-, ensure that no screw head

catches on the secondary side -A- of the two-mass flywheel,
otherwise it will be damaged.
– Release screws -B- and remove two-mass flywheel.

Installing
Note
Use new screws for attaching.

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

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

3 Crankshaft, Piston and Conrod
3.1 Removing and installing crankshaft
Note
The engine should be attached to the engine repair stand with the
engine holder - MP 1-202- for carrying out removal and installa‐
tion work.
1 - Bearing shell
❑ for cylinder block with lu‐
bricating groove
❑ do not mix up used bear‐
ing shells (mark)
2 - Drive pinion
⇒ page 45
3 - Bearing shell
❑ for bearing cap without
lubricating groove
❑ do not mix up used bear‐

ing shells (mark)
4 - Thrust washers
❑ for bearing 3
❑ different versions for
bearing cap and cylin‐
der block
❑ pay attention to locating
element
(1/4 turn)
❑ replace
6 - Bearing caps
❑ Bearing cap 1: belt pul‐
ley side
❑ bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ retaining lugs of the
bearing shells of the cyl‐
inder block/bearing cap
must be on top of one
another
7 - Needle bearing
8 - Crankshaft
❑ Axial play when new: 0.07...0.17 mm, wear limit: 0.37 mm
❑ Crankshaft bearing pin: ∅ 54.00 mm
❑ Conrod bearing pin: ∅ 50.90 mm

3.2 Replacing the crankshaft sprocket

♦ Commercially available heater unit
♦ Insertion tool - MP1-214 (10-203)-
♦ Extractor - T10392-
♦ Thrust piece - T10392/1-
♦ Multimeter in combination with temperature sender - V.A.G
1526 B-
Removing
– Remove the sealing flange on the belt pulley side
⇒ page 34 .
– Remove balancing shaft module ⇒ page 81 .
– Position the thrust piece - T10392/1- on the crankshaft.
– Insert the extractor - T10392- into the holes of the spur wheel,
turn the extractor in clockwise direction -arrow-, screw in rig
pins -A-.
3. Crankshaft, Piston and Conrod 45

– Hold the crankshaft using the ring spanner -A- and remove the
gear pinion from the crankshaft journal by screwing in the
screw using the ring spanner -B- or the ratchet.
Installing
Note
♦ Check the temperature when heating up the new drive wheel

with the temperature measuring instrument - VAS 6519- or the
hand-held multimeter - V.A.G 1526- in combination with the
sender - V.A.G 1526D/1- , to do so press the tracing point of
the temperature sender at the drive wheel.
♦ When the temperature reaches 200°C, approx. 4 seconds re‐
main for adjusting the drive wheel on the crankshaft.
♦ Higher temperatures increase the setting time (220°C = ap‐
prox. 6 seconds).
♦ Pay attention to cleanliness at crankshaft journal.
WARNING
The maximum temperature of 240°C must not be exceeded

otherwise the drive wheel changes colour or deforms.
Place the new spur wheel with the entire surface onto the com‐
mercially available heater unit and heat up to at least 200 °C,
however at a maximum of 240 °C, the legend points to thebytop.
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
WARNING
Risk of burning. You must wear suitable protective gloves for

the further work procedure.
Note
Make sure that the gear tooth system is not damaged.
– Remove the spur wheel with pliers after reaching the temper‐
ature as shown in the illustration.

– Push the gear pinion forcefully by hand onto the crankshaft

journal without deadlock up to the stop using the insertion tool
- MP1-214 (10-203)- .
– Let the spur wheel cool down for a few minutes and then install
the balancing shaft module ⇒ page 81 .
3.3 Replace needle bearing for crankshaft

Only on vehicles equipped with automatic gearbox 02E.
♦ Kukko 21/2 and Kukko 22/1
♦ Centring mandrel - T30029-
Removing
– Pull out e.g. Kukko 21/2 and Kukko 22/1 with interior extractor
-A-.
Installing
– Drive in using a centering pin - T 30029- .

♦ The marked side of the needle bearing should be legible when
in its installed condition.
Depth of installation of the needle bearing

♦ Dimension -a- = 1.5...1.8 mm

3.4 Disassembling and assembling pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ use piston ring pliers for
removing and installing
❑ marking “TOP” faces
piston crown
❑ Check ring gap
⇒ page 49
❑ Check end clearance
⇒ page 49
2 - Piston
❑ with combustion cham‐
ber
❑ Mark the installation po‐
sition and the assign‐
ment to cylinder
❑ Installation position and
assignment of piston/
cylinder ⇒ page 50
❑ arrow on piston crown
faces towards the belt
pulley side
❑ replace piston if there is
any sign of crack forma‐
tion on the piston body
❑ Inspecting piston
⇒ page 50
❑ Piston dimension: ∅
80.96 mm
❑ Install using piston ring
tensioning strap
❑ inspect piston projection
at TDC ⇒ page 51
3 - Piston pin
❑ if stiff, heat piston to approx. 60 °C
❑ use drift - VW222A- for removing and installing
4 - Circlip
5 - Connecting
Protected byrod
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ always replace
with respect as a setofonly
to the correctness information in this document. Copyright by ŠKODA AUTO A. S.�
❑ mark matching cylinder -A-

❑ Fitting position: Markings -B- point towards the belt pulley side
❑ with a split bearing cap
❑ separate new conrod ⇒ page 52
6 - Bearing shell
❑ Fitting position ⇒ page 51
❑ do not mix up used bearing shells (mark)
❑ Observe version: top bearing shell (towards the piston) must be made from a long lasting material, rec‐
ognition feature for new bearing shells: black marking on the contact surface near the separation point
❑ insert in middle ⇒ page 51
❑ check for firm seating
❑ Axial play wear limit: 0.37 mm

7 - Cylinder block
❑ Inspect cylinder ⇒ page 51
❑ Cylinder dimension: ∅ 81.01 mm
8 - Connecting rod bearing cap
❑ Check fitting position
❑ cracked cover fits only in one position at the relevant conrod
9 - Oil spray jet
❑ for cooling pistons
10 - 25 Nm
❑ install without sealant
11 - Conrod bolt, 30 Nm + torque a further + 90° (1/4 turn)
❑ replace
❑ Oil threads and contact surface.
Checking piston ring gap

♦ Feeler gauge
– Insert ring atauthorised
unless right angles
by ŠKODA from
AUTOabove down
A. S. ŠKODA AUTO into
A. S.lower cylinder
does not guarantee or accept any liability
opening, with
about 15 mm away from edge of cylinder. To insert,
use a piston without piston ring.

Piston ring New Wear limit
(dimensions in mm)
1st compression ring 0.20 - 0.40 1.00
2nd compression ring 0.20 - 0.40 1.00
Oil scraper ring 0.25 - 0.50 1.00
Checking ring-to-groove clearance

♦ Feeler gauge

– Clean before inspecting the annular grooves of the piston.

Piston ring New Wear limit
(dimensions in mm)
1st compression ring 0.06 - 0.09 0.25
2nd compression ring 0.05 - 0.08 0.25
Oil scraper ring 0.03 - 0.06 0.15
Inspecting piston

♦ External micrometer
– Measure about 10 mm from the lower edge, offset at right an‐
gles to the piston pin shaft.
• Max. deviation from specified dimension: 0,04 mm.
Installation position and assignment of piston/cylinder
Piston in cylinder 1 and 2:
• Large piston relief for inlet valve to flywheel side -arrows-.
Piston in cylinder 3 and 4:
• Large piston relief for inlet valve to belt pulley side -arrows-.
Note
♦ For new pistons the cylinder assignment is colour-coded on

thewith
piston
respect crown.
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Piston of cylinder 1 and 2: marking 1/2

♦ Piston of cylinder 3 and 4: marking 3/4

Checking cylinder bores

♦ Cylinder gauge
– Measure cylinder at 3 points crosswise in transverse direction
-A- and lengthwise -B-.
• Max. deviation from specified dimension: 0,10 mm.
Fitting position of the bearing shells in the conrods
– Insert bearing shell in the conrod or in the center of the conrod
bearing cap.
• Dimension -a- = 2.5 mm.
3.5 inspect piston projection at TDC

♦ Measuring device for piston projection - MP 1-107-
Test sequence
When fitting new pistons or a partial engine, check the piston pro‐
jection in TDC on all pistons.
Depending on the piston projection fit the relevant cylinder head
seal in accordance with the table below:
Piston projection over cylinder Marking of
block top side bores
mm
0.91 - 1.00 1
1.01 - 1.10 2
1.11 - 1.20 3

Identification of the cylinder head gasket

♦ Part number = arrow -1-
♦ Control code = -arrow 2- (ignore)
♦ Bores = -arrow 3-
Note
If different values are measured during the projection measure‐

ment of the piston, the greatest dimension applies for the seal
assignment.
3.6 Separating new connecting rod

It can happen that on new conrods, the provided separation point
is not completely cracked. If the connecting rod bearing cap can‐
not be removed by hand, then proceed as follows:
– Mark the assignment of the connecting rod to the cylinder.
– Slightly clamp the conrod, as shown in the illustration, in a vice
with aluminium protective jaws.
Note
♦ Only tension the conrod slightly in order to avoid damage on

the conrod.
♦ The conrod is clamped below the broken line.
– Unscrew both screws -arrows- by approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.

15 – Cylinder head, valve gear

1 Removing and installing cylinder
head
Note
♦ Cylinder heads with cracks between the valve seats may con‐
tinue to be used without any reduction in the life time provided
the cracks are slight and max. 0.5 mm wide.
♦ It is not permissible to rework the cylinder heads of diesel en‐
gines.
♦ Replace O-rings and gaskets.
♦ Replace cylinder head bolts and screws which have been
tightened to a torquing angle.
♦ When installing an exchange cylinder head with the camshafts
installed, it is necessary to oil the contact surfaces between
the roller arms and the cams after installing the head.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ When replacing the cylinder head, replace all the coolant
⇒ page 92 .
♦ Change
Protectedcontaminated
by copyright. Copyingengine
for privateoil ⇒ Maintenance
or commercial ; Booklet
purposes, in part or in whole, is not permitted
Superb II . to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
with respect
1.1 Summary of components - cylinder head
1. Removing and installing cylinder head 53

1 - Vacuum hose
❑ for connecting piece of
tandem pump / brake
booster
2 - Screw cap
3 - Connecting pipe
❑ for crankcase ventila‐
tion
❑ To intake hose
4 - 10 Nm
❑ Pay attention to se‐
quence for loosening
and tightening
⇒ page 56
5 - Tandem pump
⇒ page 113
6 - 20 Nm
7 - 10 Nm
8 - Coolant flange
9 - O-ring
❑ replace
10 - 10 Nm
11 - Sealing rings
❑ replace
12 - Mixing tube
❑ inserted in the head
❑unless
pull out with hook
❑ Installation
with respect to theposition
correctness of
of information in this document. Copyright by ŠKODA AUTO A. S.�
mixing tube
⇒ page 55
13 - Cylinder head gasket
14 - Hall sender - G40-
❑ for camshaft position
15 - 10 Nm
❑ mount using locking agent -D 000 600 A2-
16 - 15 Nm
17 - 100 Nm
❑ to release and tighten use the counterholder -T10051-
18 - Hub
❑ with sensor rotor for Hall sensor - G40-
❑ to remove use extractor - T10052-
❑ remove ⇒ page 67
19 - Cylinder head
❑ check for distortion ⇒ page 55
54 Rep. gr.15 - Cylinder head, valve gear

❑ After replacing, also replace coolant
20 - Cylinder head screw
❑ replace
❑ pay attention to order for slackening ⇒ page 58
❑ pay attention to order for tightening ⇒ page 61
❑ before installing, insert washers into the cylinder head
21 - Gasket for cylinder head cover
❑ replace if damaged or leaking
❑ before fitting, seal contact faces with sealant -D 454 300 A2- ⇒ page 56
22 - Fuel return-flow line
23 - fuel feed line
24 - Coolant line
25 - Cylinder head cover
Installation position of mixing tube
Checking cylinder head for distortion

♦ Feeler gauge
♦ Knife-edge straightedge
– Inspect cylinder head at several points for distortion using a
knife-edge straightedge and feeler gauge.
• Max. permissible distortion: 0.1 mm
Note
It is not permissible to Protected

reworkbythe cylinder heads of diesel engines.
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

1.2 Removing and installing cylinder head

cover
Removing
♦ Torque wrench
♦ Cleaning and degreasing agent, e.g. - D 000 401 04-
♦ Sealant -D 454 300 A2-
– Pull off hose -2- for crankcase ventilation.
– Pull off the vacuum hose to the vacuum reservoir at the cylin‐
der head.
– Release fuel hoses and coolant hoses at right charge air pipe.
– Remove charge air pipe to connection fitting,
Protectedto
by do so pull
copyright. thefor private or commercial purposes, in part or in whole, is not permitted
Copying
retaining clips. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Note
Coolant hoses as well as fuel lines remain connected.
– Remove top toothed belt guard, to do so release retaining

clips.
– Unscrew the screws for the cylinder head cover in the se‐
quence -13 ... 1- and remove the cover.
Installing
WARNING

– Clear sealing surface on bearing cap and on cylinder head

from sealant residues with chemical gasket remover.

– Apply on both edges on the sealing surfaces of the bearing

cap/cylinder head -arrows- at front ...
– ... and apply at rear a small amount of (∅ approx. 5 mm) seal‐

ant -D 454 300 A2- -arrows-.
Note
Replace the cylinder head cover gasket and the screw seal for
the cylinder head cover in the event of damage.
– Tighten the screws for the cylinder head cover in the sequence
-1…13- to 10 Nm.
1.3 Removing and installing cylinder head

♦ Hook - MP 9-200/10 (222A/10)-
♦ Supporting device - MP9-200 (10-222A)-
♦ Mounting bracket - T10014-
♦ Catch pan , e.g. -VAS 6208-
♦ Counterholder - T10051 -
♦ Locking pin - 3359- or -MP 1-301 -
♦ Crankshaft arrester - T10050- or crankshaft arrester - T10100-
♦ Workshop crane - VAS 6100 -
♦ Lifting device - MP 9-201-

1.3.1 Removing
– Switch off ignition and pull out ignition key.
– Vacuum fuel on cylinder head with hand vacuum pump
⇒ page 113 .
– Remove air filter ⇒ page 135 .
– Remove intake hose with connection piece ⇒ page 120 .
– Remove coolant hose between engine and radiator -arrows-.
– Remove charge air pipe between the exhaust turbocharger
and the charge air cooler ⇒ page 123 .
– Detach the fuel intake hose -2- and the fuel return hose -1-
from the fuel lines.
– Detach coolant hose -3-.
For vehicles with auxiliary heating: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Disconnect the fuel feed line. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
For all vehicles:

– Remove pre-exhaust pipe with diesel particle filter
⇒ page 146 .
– Disconnect plug connection at exhaust gas recirculation cool‐

er change-over valve - N345- -arrow-.

– Remove the vacuum hose -2- at the vacuum unit for charge
pressure control.
– Disconnect vacuum hose -3- at the cable for vacuum setting
element of the recirculation flap for exhaust gas recirculation.
– Disconnect vacuum line at the tandem pump.
– Loosen change-over valve for exhaust gas recirculation radi‐
ator - N345- at the bracket.
– Lay changeover valve for radiator of exhaust gas recirculation
- N345- with connected hoses to the side.
– Detach oil intake hose -1- from exhaust turbocharger.
– Remove oil feed pipe.
– Pull the vacuum hose -arrow- off the brake servo unit.
– Remove coolant hose -arrow- at coolant fitting.

– Disconnect the plug from the coolant temperature sender -
G62- and detach the electrical wiring
– Remove the release pin -arrow 1- and open the knurled nut
-arrow 2-.
– Disconnect the central plug connection for the unit injectors
and expose the wiring harness.
– Disconnect connector for fuel temperature sender -G81- .
– Disconnect the edge connector from the glow plugs.
– Unscrew the fixing screws for the oil dipstick guide tube, pull
out the oil dipstick guide tube to the top out of the cylinder
block.

– Disconnect coolant hose -1- at exhaust gas recirculation radi‐

ator.
– Remove connection pipe for exhaust gas recirculation radiator
-arrows-.
– Release screws -1-, screw -2- and hollow screw -3-.

– Remove support for exhaust turbocharger with oil return line.
– Unscrew screws out of the flange between the radiator for ex‐
haust gas recirculation and the intake manifold -arrows-.
For vehicles with auxiliary heating:
– Remove exhaust pipe of auxiliary heating ⇒ Heating, air con‐
ditioning ⇒ Rep. gr. 82 .
– Remove coolant pipe to auxiliary heating with connected cool‐
ant hoses at cylinder block.
For all vehicles:
– Remove camshaft sprocket and hub ⇒ page 67 .
– Remove timing belt tensioning pulley.

– Unscrew the rear toothed belt guard fixing screws -2- and
-4-.
– Unscrew screw -3- and remove Hall sender - G40- from cyl‐
inder head.
– Remove cylinder head cover ⇒ page 56 .
– Follow the specified order for loosening cylinder head bolts.

– Slightly raise the cylinder head with lifting device - MP 9-201-
and workshop crane - VAS 6100- and laterally remove from
the engine next to the toothed belt guard.
– Place it down on a soft surface with the sealing surface to the
top.
Note unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Engines with ceramic glow plugs: the cylinder head with in‐
stalled ceramic glow plugs must never be placed on the seal‐
ing surface, as ceramic glow plugs protrude a little and thus
can be damaged.
♦ Handling the ceramic glow plugs ⇒ page 4 .
♦ Removing and installing ceramic glow plugs ⇒ page 155 .
1.3.2 Installing
Note
♦ There must not be any oil or coolant present in the blind holes
for the cylinder head bolts.
♦ Replace cylinder head bolts.
♦ When performing installation work replace the self-locking
nuts.
♦ Replace screws which have been tightened to a torquing angle
as well as sealing rings and seals.
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the seal with the utmost care. Damage to the silicone
layer and in the area of the bead results in leakages.
♦ When installing an exchange cylinder head with the camshafts
installed, it is necessary to oil the contact surfaces between
the roller arms and the cams after installing the cylinder head.
♦ The plastic base for protecting the open valves should only be
removed immediately before attaching the cylinder head.

WARNING

– Make sure that when cleaning the cylinder head and cylinder
block no foreign particles can get into the cylinder or into the
oil and coolant galleries.
– Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.
– Before fitting the cylinder head rotate the crankshaft so that all
the pistons are almost evenly at TDC for cylinder 1.
– Pay attention to the identification of the cylinder head seal.
♦ Part number = arrow -1-
♦ Control code = -arrow 2- (ignore)
♦ Bores = -arrow 3-
Note
♦ If the cylinder head gasket or cylinder head were replaced,

install a new cylinder head gasket with the same identification
marking.
♦ If parts of the crankshaft drive were replaced, then the new
cylinder head gasket must be redefined by measuring the pro‐
trusion of the piston in TDC.
– Fit on cylinder head gasket.

• Pay attention to dowel sleeves -arrows- in cylinder block.
• Observe the installed position of the cylinder head gasket, the
marking “above” or the part number must point to the cylinder
head.
– Insert the cylinder head.

– Insert cylinder head bolts and tighten by hand.

– Tighten the cylinder head in four stages in the indicated tight‐
ening sequence:
Stage Apply
I – Tighten with the torque wrench to 35 Nm.
II – Tighten with the torque wrench to 60 Nm.
III – Using a rigid wrench torque a further 90° (1/4
turn).
IV – Using a rigid wrench torque a further 90° (1/4
turn).
Note
Tightening up the cylinder head bolts after doing repair work is

not necessary.
– Screw lifting eye of engine onto the front cylinder head.
– Insert screws -2 ... 4- with spread on locking agent -D 000 600

A2- and tighten to 10 Nm.
– Install Hall sender - G40- , insert screws -3- with spread on
locking agent -D 000 600 A2- and tighten to 10 Nm.
– Position hub onto camshaft.

– Tighten screw -1- to 100 Nm, use counterholder - T10051- to
hold.

– First of all position camshaft and then also crankshaft on TDC

for cylinder 1:
• For the camshaft, the cams of cylinder 1 must be pointing up
evenly -arrows-...
• ... and the crankshaft toothed belt sprocket must be inter‐
locked with the crankshaft arrester - T10100- .
Note
♦ Markings on the toothed belt sprocket and on the crankshaft

arrester must be in line with each other -arrow-. The stud on
the crankshaft arrester must engage into the hole in the seal‐
ing flange.
♦ The crankshaft arrester can only be fitted onto the toothed belt
sprocket from the front side of the serration.
– Push camshaft sprocket onto the hub.

• The tooth segment -arrow- of the camshaft sprocket must be
at the top.
– Slightly screw in plug -1-.
– Lock hub with locking pin e.g. - 3359-
– Install cylinder head cover ⇒ page 56 .
note the following:
– Checking the oil level ⇒ Maintenance ; Booklet Superb ll.
Note
Change contaminated engine oil ⇒ Maintenance ; Booklet Su‐

perb ll. .
1.4 Checking compression

The compression pressure is tested using a guided fault-finding
program of the vehicle diagnosis, measurement and information
system - VAS 5051 A- , under “Repair Group 15; Cylinder head/
valve gear; Particular System, Boundary Conditions; Diagnostic
Object: Poor compression pressure”.

2 Repairing Valve Gear
2.1 Summary of components
Note
♦ After installing the camshaft, the engine must not be started for about 30 minutes. The hydraulic bucket
tappets must settle (otherwise valves would strike the pistons).
♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no
valve touches the piston when the engine is started.
♦ Always replace gasket rings and seals.
♦ Removing and installing the tandem pump ⇒ page 113 .
1 - Cylinder head
2 - Bearing shell
❑ do not mix up already
used bearing shells
(mark)
❑ ensure the retaining
lugs are correctly loca‐
ted in the bearing caps
and in the cylinder head
3 - Camshaft
❑ Radial play wear limit:
0.11 mm
❑ Knock: no more than
0.04 mm
❑ Inspecting axial play
⇒ page 66
⇒ page 69
4 - Bearing shell
❑ do not mix up already
used bearing shells
(mark)
❑ ensure the retaining
lugs are correctly loca‐
ted in the bearing caps
and in the cylinder head
5 - Bearing caps
⇒ page 69
❑ Seal bearing caps 1 and
5 with sealant -D 454
300 A2-
❑ replace unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

❑ replace
2. Repairing Valve Gear 65

❑ Pay attention to sequence for loosening and tightening ⇒ page 69
8 - Valve-lever shaft
❑ do not mix up (mark)
❑ Pay attention to sequence for loosening and tightening ⇒ page 69
9 - Washer
❑ for cylinder head screws
❑ before installing the bearing caps, insert into the cylinder head
10 - Hydraulic bucket tappets
❑ Check ⇒ page 72
❑ do not mix up (mark)
❑ lay aside with contact surface facing down
❑ before installing check axial play of the camshaft ⇒ page 66
❑ oil contact surfaces
11 - Valve collets
12 - Valve spring plate
13 - Valve spring outside
14 - Valve spring inside
15 - Valve stem gasket
16 - Valve guide
17 - The unit injector
18 - Sealing ring
19 - Valve
❑ Valve dimensions ⇒ page 75
❑ do not rework, only grinding in is permissible
2.2 Checking the axial play of the camshaft

♦ Universal dial gauge bracket - MP 3-447 (VW 387)-
♦ Dial gauge

Test sequence
– Perform measurement with the bucket tappets removed and
the first and last bearing cap fitted.
• Wear limit: max. 0.15 mm.
2.3 Replacing camshaft sealing ring

♦ Insertion tool - MP 1-214 (10-203)-
♦ Sealing ring extractor - T30003 (3240)-
♦ Counterholder - T10051 -
♦ Torque wrench
♦ Screw M12x65
Removing
• Cylinder head attached at engine.
– Remove the locking pin - 3359- .
– Unscrew bolts of camshaft sprocket -arrows- and remove
camshaft sprocket from the hub.
– Loosen the fixing bolt of the hub -1- by approx. 2 turns; use
the counterholder - T10051- to do so.

– Position the extractor - T10052- and screw the screws -1- into
the hub.
– Pull off the hub, to do so counterhold the hexagonal wrench
(SW30) of the extractor and screw in the screw -2-.
– Position the inner part of the sealing ring extractor - T30003-
so that it is flush with the outer part, and lock with the knurled
screw.
– Oil the thread head of the gasket ring extractor, position and
forcibly screw into the gasket ring of the camshaft as far as
possible.
– Release knurled screw and turn the inner side against the
camshaft until the gasket ring is pulled out.
– Clamp gasket ring extractor into the vice and remove gasket
ring with pliers.
– Clean the contact and sealing surfaces.
Installing
Note
The sealing lip of the gasket ring must neither be oiled nor
greased additionally.
– Remove oil residue from the camshaft stud with a clean cloth.
– Cover slot on the camshaft cone with adhesive tape and care‐
fully push the sealing ring onto the camshaft.
– Press in the sealing ring up to the stop using thewiththrust
respectpiece
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
of the insertion tool - MP 1-214- and screw M12x 65.
– Position hub onto camshaft.

– Tighten screw -1- to 100 Nm, use counterholder - T10051- to

hold.
– Push camshaft sprocket onto the hub.

• The tooth segment -arrow- of the camshaft sprocket must be
at the top.
– Slightly screw in plug -1-.
– Lock hub with locking pin e.g. - 3359-
2.4 Removing and installing camshaft

♦ Counterholder - T10051-
♦ Silicone sealant - D 176 404 A2-
♦ Sealant - D 454 300 A2-
Removing
• Cylinder head attached at engine.
– Remove tandem pump ⇒ page 113 .
Note
The hoses can remain connected to the tandem pump.
– Remove camshaft sprocket and pull off hub ⇒ page 67 .

– Remove cylinder head cover ⇒ page 56 .

– Mark the valve-lever shafts with waterproof marker to avoid

mixing them up and to avoid destroying the basic setting of the
pump-nozzle units -arrows-.
– First release the two outer -1- and then the inner screws -2- of
the valve-lever shafts.
– Remove valve-lever shafts.
– First remove bearing caps -1-, -3- and -5-.

– Then release bearing caps -2- and -4- alternately and cross‐
wise.
Note
♦ Ensure that the bearing shells of the camshaft are not mixed
up.
♦ Mark assignment of the bearing shells for the camshaft with
waterproof marker on the reverse side.
– Take out camshaft.

Installing
– Check if the crankshaft is on TDC for cylinder 1.
• The crankshaft toothed belt sprocket is interlocked with the
crankshaft arrester - T10100- at TDC for cylinder 1.
Note
♦ Markings on the toothed belt sprocket and on the crankshaft

arrester must be in line with each other -arrow-. The stud on
the crankshaft arrester must engage into the hole in the seal‐
ing flange.
♦ The crankshaft arrester can only be fitted onto the toothed belt
sprocket from the front side of the serration.
Note
♦ Ensure that the used bearing shells of the camshaft are not
mixed up (payProtected
attention to marking).
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ When installingwith
therespect
camshaft pay attention
to the correctness toinathiscorrect
of information document.fitCopyright
of by ŠKODA AUTO A. S.�
the retaining lugs of the bearing shells in the bearing caps and
cylinder head.

– Oil contact surfaces of camshaft.

– Insert camshaft into the TDC for cylinder 1:
• The cams for cylinder 1 on the camshaft must point upwards
-arrows-.
– Then tighten bearing caps -2- and -4- alternately and cross‐
wise.
– Apply sealant -D 454 300 A2- thinly and uniformly to the
unless authorised outerAUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
by ŠKODA
bearing caps onto the surfaces -1-. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note
Make sure that sealant does not get into the grooves -arrows- or
onto the other surfaces.
– Install and tighten bearing caps -1-, -3- and -5-.

• Bearing cap -5- must fit flush with the outer edge of the cylinder
head as this may otherwise cause leaks on the tandem pump.

– Insert valve-lever shafts. While doing so, pay attention to the

markings -arrows- made when removing.
– First tighten the inner -2- and then the outer screws -1- in sev‐
eral stages.
– Install gasket ring for camshaft, hub and camshaft sprocket
⇒ page 68 .
– Lock hub of camshaft with locking pin - 3359- .
– Install tandem pump ⇒ page 113 .
– If the valve-lever shafts or ball studs have been replaced, the
unit injectors will need to be adjusted.
– Install cylinder head cover ⇒ page 56 .
Note
♦ After installing the camshaft, the engine must not be started

for about 30 minutes. The hydraulic bucket tappets must settle
(otherwise valves would strike the pistons).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.
2.5 Testing hydraulic bucket tappets

♦ Feeler gauge
♦ Wooden or plastic wedge
Note
♦ Hydraulic bucket tappets cannot be repaired.

♦ Irregular valve noises when starting engine are normal.
Test sequence
– Start engine and allow to run until the radiator fan starts. In‐
crease revolutions to about 2500 rpm for 2 minutes and un‐
dertake a test drive if necessary.
Note
If there are irregular valve noises which disappear after a long

drive but keep reappearing on short journeys then the return-flow
check tube is defective. Fitting location: in the oil filter holder. The
return-flow check tube cannot be replaced individually.
If the hydraulic bucket tappets are still loud, determine the faulty
hydraulic bucket tappets as follows:
– Remove cylinder headAUTOcover.
unless authorised by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Turn the crankshaft until the cam of the hydraulic bucket tap‐
pets to be tested is positioned on top, while doing so push the
vehicle forward in 4th gear when ignition is switched off.

– Determine the play between the cams and the bucket tappet:
– Press down the bucket tappet using a wooden or plastic
wedge.
If a 0.20 mm feeler gauge can be slipped between the camshaft
and the bucket tappet:
– Replace hydraulic bucket tappets ⇒ page 69 .
Note

2.6 Replacing valve stem seals

Cylinder head fitted
♦ Valve assembly device - MP 1-213 (2036) -
♦ Extractor - MP 1-206 (3047A)-
♦ Insertion tool - MP 1-306 (10-204)-
♦ Valve lever - MP 1-211 (VW 541/1A)-
Note with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ With cylinder head removed:

♦ Remove glow plugs from the cylinder head ⇒ page 155 .
♦ Remove unit injectors from the cylinder head ⇒ page 137 .
♦ Position cylinder head on a suitable flat valve supporting plate.
Removing
– Remove the camshaft ⇒ page 69 .
Note
♦ Ensure that the used bearing shells of the camshaft are not
mixed up (pay attention to marking).
♦ When installing the camshaft, ensure it is correctly located in
the retaining lugs of the bearing shells in the bearing caps and
in the cylinder head.
♦ Ensure that the bucket tappets are not mixed up, for this step
mark the assignment with waterproof marker on the reverse
side.
– Remove bearing shells of camshaft from the cylinder head.

– Remove bucket tappets and lay aside with the contact surface
facing down. Make sure that you do not mix up the tappets.
– Position piston of the relevant cylinder to top dead centre
(TDC).

– Insert the assembly device for valves -MP 1-213- and adjust
bearing to the stay bolt height.
– Remove valve springs with valve lever -MP 1-211- .
Note
The valves rest on the piston crown.
– Use pulling device -MP 1-206- to pull off valve stem seal.
Installing
– Insert
Protectedthe supplied
by copyright. plastic
Copying bushings
for private -A-purposes,
or commercial on theinrelevant valve
part or in whole, is not permitted
stem. Thistowill
with respect prevent ofany
the correctness damage
information to the new
in this document. valve
Copyright stemAUTO A. S.�
by ŠKODA
seals -B -.
– Insert the new valve stem seal in the insertion tool -MP 1-306- .
– Oil the sealing lip of the valve stem seal and carefully slide into
the valve guide.
– Remove plastic sleeve.
– Reinstall valve springs and secure with collets.
– Insert bucket tappets.
– Install the camshaft ⇒ page 69 .
Note


2.7 Valve dimensions

Dimension Inlet valve Exhaust valve
∅a mm 35.95 31.45
∅b mm 6.980 6.965
c mm 89.45 89.05
α ∠° 45 45
Note
Valves must not be reworked by grinding. Only grinding in with

grinding paste is permissible.
2.8 inspecting valve guides

♦ Dial gauge
Test sequence
Note
If the valves are replaced when carrying out repair work, use new
valves for the measurement.
– Insert valve into valve guide. The end of valve stem must be
flush with guide.
Valve rock: max. 1.3 mm.
Note
If the wear limit is exceeded, repeat measurement with new

valves. If the wear limit is again exceeded, replace cylinder head.
The valve guides cannot be changed.

17 – Lubrication
1 Removing and installing parts of the
lubrication system
Note
♦ If considerable quantities of metal swarf as well as abrasion is

found in the engine oil when carrying out engine repairs, care‐
fully clean the oil galleries in order to avoid consequential
damage and additionally replace the engine oil cooler as well
as the oil filter element.
♦ The oil level must not be above the max. marking - risk of
damage to catalytic converter!
Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Booklet Superb II .
1 - Oil pan
2 - 10 Nm
3 - Inlet connection
❑ Clean strainer if dirty
4 - 10 Nm
5 - O-ring
❑ replace
6 - Oil pump
⇒ page 81
❑ before installing, check
whether both assembly
sleeves for centering
the oil pump at the bal‐
ancing shaft module are
present
7 - Drive shaft for oil pump
8 - Circlip
❑ must be positioned in
the base of the groove
❑ replace damaged or
76 Rep. gr.17 - Lubrication

over-extended circlip
9 - Spur wheel for balancing shaft
❑ replace
11 - Hub
❑ for intermediate wheel
❑ replace
13 - Axial bearing disc
14 - Intermediate wheel
❑ replace
❑ to achieve the correct backlash, a coating of appropriate thickness is applied to the new intermediate
wheel, the coating is located in partial areas of the circumference on the teeth
❑ for the correct installation position, a white dot is applied
15 - Axial bearing disc
16 - Crankshaft gear
17 - Balancing shaft module
❑ install new balancing shaft module ⇒ page 82
❑ Re-install used balancing shaft module that has already been used ⇒ page 85 .
❑ before installing, check whether both assembly sleeves for centering the balancing shaft module at the
cylinder block are present
18 - Further turn M7 = 13 Nm + 90° (1/4 turn) , M8 = 20 Nm + 90° (1/4 turn.)
❑ replace
❑ observe the order of tightening up
❑ install new balancing shaft module ⇒ page 82
❑ Re-install used balancing shaft module that has already been used ⇒ page 85 .
19 - 40 Nm
20 - 45 Nm
21 - 10 Nm
❑ replace
22 - Oil level and oil temperature sender - G266 -
❑ Check ⇒ Vehicle diagnostic tester
23 - O-ring
❑ replace
❑
24 - 15 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Observe tightening sequence ⇒ page 79 in this document. Copyright by ŠKODA AUTO A. S.�
with respect to the correctness of information
25 - Oil drain plug - 30 Nm
1. Removing and installing parts of the lubrication system 77

1.1 Disassembling and assembling the oil filter holder
1 - Screw plug - 25 Nm
2 - Gasket
❑ replace
3 - Engine oil cooler
❑ Pay attention to the in‐
formation regarding a
necessary replacement.
❑ Connection diagram for
coolant hoses
⇒ page 88
4 - Gasket
❑ replace
❑ Fitting position
⇒ page 79
(1/4 turn)
❑ replace
❑ tighten crosswise
6 - Oil filter holder
❑ with return-flow check
tube
❑ Oil return-flow check
tube cannot be replaced
individually
7 - Sealing ring
❑ replace
8 - Oil pressure switch - F1- -
20 Nm
❑ 0.07 MPa (0.7 bar)
switch
9 - Screw cap - 25 Nm
❑ Loosen and tighten using an oil filter tool e.g. -3417- .
10 - O-ring
❑ replace
11 - Oil filter element
❑ remove from the cap ⇒ Item 9 (page 78)
❑ replace O-rings ⇒ Item 10 (page 78) if oil filter element is changed
❑ pay attention to change intervals ⇒ Maintenance ; Booklet Superb II
12 - Oil feed line
❑ to exhaust gas turbocharger
❑ Observe the mounting sequence:
– Screw on the union nuts first of all by hand.
– Then tightenbythe
unless authorised union
ŠKODA AUTOnuts to 22 AUTO
A. S. ŠKODA Nm.A. S. does not guarantee or accept any liability
– Subsequently secure the oil feed line in the brackets.

13 - Connecting piece - 35 Nm
Fitting position of gasket for engine oil cooler

– Place the gasket -2- in such a way that it can be pressed onto
all the lugs of the engine oil cooler -1-.
• The oil duct -arrow- must not be covered from the gasket.
1.2 Removing and installing oil pan

♦ Socket - T10058-
♦ Torque wrench
♦ Silicone sealant -D 176 404 A2-
♦ Cleaning and degreasing agent, e.g. - D 000 401 04-
Removing
– noise attenuation ⇒ Bodywork - assembly work ⇒ Rep. gr.
50 and remove the complete cover on the right ⇒ Bodywork -
assembly work ⇒ Rep. gr. 66 .
– Remove right charge air pipe, to do so pull the retaining clips.
– Disconnect plug at oil level and oil temperature sender -
G266- .
– Drain engine oil ⇒ Maintenance ; Booklet Superb II .
– Removing the oil pan attenuation.

– Unscrew the bolts of oil pan/gearbox -arrows-.

– Loosen crews -1... 20- crosswise and release.
– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.
Installing
WARNING

– Clear sealing surface on the oil pan from gasket residues with
chemical sealant remover.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).
– Apply silicone sealant
unless authorised beadAUTO
by ŠKODA -D 176 404 A2-
A. S. ŠKODA AUTO-arrow-
A. S. doesto
not the
guarantee or accept any liability
clean sealing surface of the oil pan, as shown.
• Thickness of sealant bead: 2 ... 3 mm.
Note
♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clog the strainer
in the oil suction pipe.
♦ Take particular care when applying the sealant bead in the
area of the rear sealing flange -arrows-.
♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant -D 176 404 A2- .
– Fit on oil pan immediately and tighten the bolts as follows:

– First of all tighten bolts -1... 20- crosswise to 5 Nm.
– Tighten the bolts of the oil pan/gearbox -arrows- to a torque of
45 Nm.
– Tighten bolts -1 ... 20- crosswise to 15 Nm.
Note
♦ When installing the oil pan with the engine removed, ensure
that the oil pan is flush with the cylinder block at the flywheel
side.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Fill with engine oil and check the oil level ⇒ Maintenance ;
Booklet Superb II .

1.3 Removing and installing oil pump

Removing
– Remove circlip -1- with circlip pliers.
– Screw in screw M3 -2- and pull out the drive shaft from the oil
pump -arrow-.
– Unscrew screws -4- and detach the connection fitting from the
oil pump.
– Release screws -3- and -5- and remove oil pump.
Caution
The screw at intermediate wheel must not be released.
Installing
Note
♦ Renew O-ring.
♦ Replace damaged or over-extended circlip.
♦ The circlip must be positioned in the
withbase
respectof thecorrectness
to the groove.of information in this document. Copyright by ŠKODA AUTO A. S.�
– Before installing the oil pump, check whether the two assem‐
bly sleeves are inserted.
Specified torques
Component Nm
Oil pump to balancing shaft module 10
Connection fitting to oil pump 10
1.4 Removing and installing balancing shaft

module
♦ Crankshaft arrester - T10100-
1.4.1 Removing
Work procedure
– Rotate the crankshaft to TDC and interlock with the crankshaft
arrester - T10100- .

– Release screws in the sequence -8 … 1- and remove balanc‐

ing shaft module with oil pump.
Note
♦ Install new balancing shaft module ⇒ page 82 .

♦ Re-install the already used balancing shaft module
⇒ page 85 .
1.5 Install balancing shaft module

♦ Rig tool - T10255-
1.5.1 Install new balancing shaft module

Work procedure
Note
♦ The spur gear drive of the balancing shaft module must be

installed with a backlash of 0.038 ... 0.072 mm.
♦ To achieve the correct backlash, a coating of appropriate
thickness is applied to the new intermediate wheel. The coat‐
ing is located in partial areas of the circumference on the teeth.
♦ The coating wears off within a short time and thus ensures
backlash.
♦ For this reason, a new balancing shaft module must always
be installed in conjunction with a new intermediate wheel with
coating.
♦ For the correct installation position, a white dot is applied on
the intermediate wheel. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Replace screws which have been tightened firmly to a torque
angle.
• Secure the crankshaft toothed belt sprocket with the crank‐

shaft arrester - T10100-
– Before installing the balancing shaft module, check that the
two assembly sleeves are inserted.

– Before positioning the balancing shaft module at the cylinder

block, slacken the screw -1- for intermediate wheel approx. 1/
4 turn.
– Check the presence of both assembly sleeves for the correct
position of the balancing shaft module on the cylinder block.
– Fit the balancing shaft module to the cylinder block, paying

attention to the correct position of the intermediate wheel:
• The white dot -arrow- on the intermediate wheel must be in the
middle of the crankshaft.
Note
Ensure that the coating of the intermediate wheel is not damaged.
– Firstly screw-in the screws by hand in the sequence -1 ... 8-.

– Tighten screws of balancing shaft module as follows:
1. Pre-tighten the screws in the sequence -1 ... 8- to 6 Nm.
2. Tighten screws -5- and -7- to 13 Nm.
3. Turn screws -5- and -7- a further 90° using a rigid wrench
(1/4 turn).
4. Screws -1... -Tighten -4-. -6- and -8- to 20 Nm.
5. Turn screws -1 ... 4-, -6- and -8- a further 90° using a rigid
wrench (1/4 turn).

– Interlock balancing shaft with rig tool - T10255- , to do so turn

the balancing shaft if necessary.
• The stud of the rig tool must grip into the groove of the bal‐
ancing shaft.
– Carefully put balancing shaft pinion onto the balancing shaft,

to do so push the intermediate wheel slightly to the side.
Note
♦ Ensure that the coating of the intermediate wheel is not dam‐

aged.
♦ If the oblong holes in the balancing shaft pinion are not aligned
with the threaded bores, the balancing shaft pinion must be
turned further by a corresponding number of teeth and put on
again.
– Tighten balancing shaft pinion -arrows-.

– Remove rig tool - T10255- .
The following 3 work steps must be carried out simultaneously

(2nd mechanic is required).
– If necessary forcefully push the intermediate wheel -3- with the
aid of a wooden rod in -direction of arrow- into the serration of
the drive pinion -2- and the balancing shaft pinion -1-.
– While doing so slightly turn the balancing shaft pinion anti-
clockwise.
– Tighten screw for intermediate wheel.
– Remove crankshaft stop.
Note
After the assembly the intermediate wheel must have no torsional

clearance. This can be checked
Protected by hand
by copyright. with
Copying littleorforce.
for private commercial purposes, in part or in whole, is not permitted

– Screw on the bottom timing belt guard -arrows-.

note the following:
– Installing the V-ribbed belt pulley.
Specified torques
Component Nm
Balancing shaft module to cylinder M7 13 + 90° 1)2)
block
M8 20 + 90° 1)2)
Balancing shaft pinion to balancing shaft 20 + 90° 1)2)
Intermediate wheel to balancing shaft module 90 + 90° 1)2)
Timing belt guard to engine 10
• 1) Replace bolts.
• 2) 90° corresponds to a quarter turn.
1.5.2 Re-install the already used balancing

shaft module
Note
♦ If the existing balancing shaft module is to be reinstalled and

neither the drive gear on the crankshaft nor the crankshaft are
to be replaced, proceed as described below. In addition, the
intermediate wheel must never have been detached.
♦ If the screw for intermediate wheel was slackened or the drive
pinion on the crankshaft or the crankshaft was replaced, a new
intermediate wheel with coating must be installed. Procedure
for installing ⇒ page 82 .
♦ Replace screws which have been tightened firmly to a torque
angle.
– Interlock balancing shaft with rig tool - T10255- , to do so turn

the balancing shaft if necessary.
• The stud of the rig tool must grip into the groove of the bal‐
ancing shaft.
– Check the presence of both assembly sleeves for the correct
position of the balancing shaft module on the cylinder block.
– Position the balancing shaft module on the cylinder block.
• If the balancing shaft is interlocked, the intermediate wheel
must grip into the drive pinion on the crankshaft.
• The intermediate wheel must have a slightly noticeable tor‐
sional clearance.

– Firstly screw-in the screws by hand in the sequence -1 ... 8-.

– Tighten screws of balancing shaft module as follows:
1. Pre-tighten the screws in the sequence -1 ... 8- to 6 Nm.
2. Tighten screws -5- and -7- to 13 Nm.
3. Turn screws -5- and -7- a further 90° using a rigid wrench
(1/4 turn).
4. Screws -1... -Tighten -4-. -6- and -8- to 20 Nm.
5. Turn screws -1 ... 4-, -6- and -8- a further 90° using a rigid
wrench (1/4 turn).
– Remove crankshaft stop.
– Screw on the bottom timing belt guard -arrows-.

note the following:
– Install vibration damper ⇒ page 21 .
Specified torques
Component Nm
Balancing shaft module to cylinder M7 13 + 90° 1)2)
block
M8 20 + 90° 1)2)
Timing belt guard to engine 10
• 1) Replace bolts.
• 2) 90° corresponds to a quarter turn.
1.6 Testing oil pressure and oil pressure

switch
♦ Oil pressure tester (e.g. - V.A.G 1342- )
♦ Voltage tester (e.g. - V.A.G 1527 B- )
♦ Auxiliary measuring set - V.A.G 1594 C-
Test conditions Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
• Oil level o.k. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
• Engine oil temperature approx. 80 C.

Test preparations
– Remove air guide to air filter.

– Remove the plug -arrow- on the oil pressure switch - F1- and
unscrew the oil pressure switch -F1- .
– Screw the oil pressure tester (e.g. - V.A.G 1342- ) into the hole
for the oil pressure switch.
– Screw oil pressure switch -2- into oil pressure tester (e.g. -
V.A.G 1342- ).
Testing oil pressure switch
– Connect brown cable -1- of oil pressure tester to earth (-).
– Unclamp the voltage tester with its auxiliary cables out of the
measuring tool set on the oil pressure switch and plus (+) ter‐
minal on the battery.
• The LED should not light up.
If the LED lights up:
– Replace oil pressure switch.
– Start the engine.
Note
Observe the testing equipment and the LED while actuating the
starter since the switching point of the oil pressure switch can
already be exceeded when starting up.
• The LED must come on at an overpressure of 0.055 ... 0.085

MPa (0.55 ... 0.85 bar).
If the LED does not light up:
– Replace oil pressure switch.
Testing oil pressure
– Start the engine.
• Oil pressure when engine idling: at least 0.08 MPa (0.8 bar).
• Oil pressure at 2000 rpm: min. 0.2 MPa (2.0 bar)
If the specified values are not reached: Oil pump defective.
– Replace oil pump ⇒ page 81 .
• Oil pressure at a higher engine speed: max. 0.7 MPa (7.0 bar).
If the specified value is exceeded: Pressure relief valve defective.
– Replace
Protected byoil filterCopying
copyright. holderfor⇒ page
private 78 . purposes, in part or in whole, is not permitted
or commercial

19 – Cooling
cooling system
WARNING

carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Replace seals and sealing rings.
♦ The arrows affixed to the coolant pipes and the coolant hoses
must stand opposite to each other.
1.1 Parts of the cooling system fitted to body
88 Rep. gr.19 - Cooling

1 - Radiator fan - V7-

❑ with radiator fan control
unit - J293-
2 - 10 Nm
3 - Fan shroud
4 - Top coolant hose
❑ To connection fitting at
cylinder head
coolant hoses
⇒ page 92
5 - O-ring
6 - Radiator
⇒ page 94
❑ After replacing, fill with
fresh coolant
⇒ page 92
7 - 5 Nm
8 - O-ring
9 - Bottom coolant hose
❑ to connection fitting of
coolant regulator at
block
coolant hoses
⇒ page 92
10 - 10 Nm
11 - 5 Nm
12 - Right radiator fan - V35-
1. Removing and installing parts of the cooling system 89

1.2 Parts of cooling system engine side
1 - to the compensation bottle

above
coolant hoses
⇒ page 92
2 - Top coolant pipe
❑ screwed onto the cylin‐
der head cover
3 - O-ring
❑ replace
4 - Retaining clip
❑ check correct fitting
5 - Coolant temperature send‐
er -G62-
6 - to radiator for exhaust gas
recirculation
coolant hoses
⇒ page 92
7 - Connection fitting
❑ for cylinder head Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
8 - 10 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
9 - towards top radiator

coolant hoses
⇒ page 92
10 - from heat exchanger
❑ Return-flow line
coolant hoses
⇒ page 92
11 - 40 Nm
12 - Distributor part
13 - from distributor part of top coolant hose
❑ Connection diagram for coolant hoses ⇒ page 92
14 - 15 Nm
15 - from the expansion reservoir below
16 - Coolant pipe
17 - Sealing ring
❑ replace
18 - Coolant temperature sender at radiator outlet -G83-
19 - 15 Nm
20 - to bottom radiator

❑ for coolant regulator
22 - Coolant regulator
❑ check: collant regulator in a water bath
❑ Start of opening approx. 87 °C
❑ Full opening approx. 102°C
❑ Stroke min. 7 mm
23 - The coolant pipe at the rear
24 - from radiator for exhaust gas recirculation
25 - to heat exchanger
26 - Coolant pump
❑ check smooth operation

1.3 Connection diagram for coolant hoses
1 - expansion reservoir
❑ with cap
❑ Check the overpressure
valve in the screw cap
⇒ page 98
2 - Radiator for exhaust gas re‐
circulation
❑ fill with fresh coolant af‐
ter replacing
⇒ page 92
⇒ page 153
3 - Heat exchanger for heating
ter replacing
⇒ page 92
4 - ATF radiator
❑ for models with an auto‐
matic gearbox
ter replacing
⇒ page 92
5 - Cylinder head/cylinder
block
ter replacing
⇒ page 92
6 - Top coolant hose
ter replacing
⇒ page 92
⇒ page 76
8 - Radiator
❑ fill with fresh coolant after replacing ⇒ page 92
9 - Bottom coolant hose
10 - Coolant pump/coolant regulator
11 - Auxiliary heating
1.4 Draining and filling coolant


♦ Refractometer - T10007-

Draining
Note
Collect drained coolant in a clean container for proper disposal or

reuse.
WARNING

carefully.
– Open the cap of the coolant expansion reservoir.

– Position drip tray (e.g. - VAS 6208- ) under the engine.
– Remove the coolant hose from the radiator; to do so pull the
retaining clip -arrow-.
– Remove the upper coolant hose on the engine oil cooler

-arrow- and drain residual coolant.
Filling up
Note
Replace O-rings.
– Connect coolant hose at bottom of radiator -arrow-.

– Connect coolant hose at top of radiator -arrow-.

Select the appropriate coolant additive from the Electronic Cata‐
logue of Original Parts Škoda or from the list of allowed coolant
additives ⇒ Maintenance ; Booklet Superb II .
– First of all prepare required quantity of coolant mixed to the
correct ratio in a suitable vessel ⇒ Maintenance ; Booklet Su‐
perb II .
– Fill the cooling system through the connection of the expan‐

sion reservoir, until the maximum marking of the coolant level
is reached.
– Start engine, run for not more than 2 minutes at approx. 1500
rpm and while doing so top up coolant in the expansion res‐
ervoir.
– Tighten cap at expansion reservoir.
– Run engine until fan starts.
WARNING

carefully.
– Check the level of coolant and top up if necessary.

• When engine is at operating temperature the coolant level
must be at the maximum marking, when engine is cold be‐
tween the minimum and the maximum markings.
1.5 Removing and installing radiator

Removing
Note

reuse.

– Disconnect the earth strap from the battery with the ignition
off.

– Remove connecting hose on left; to do so, slightly lift retaining

clips -arrows-.
– Disconnect and expose the required electrical cabling.
– Place a catch pan - VAS 6208- under the engine.
– Remove the air filter and intake air duct from the lock carrier
⇒ page 135 .
– Remove coolant hose between engine and radiator -arrows-.
– Disconnect plug connection -1-.

– Remove screws -arrows- and take out fan shroud downwards.
– Unscrew screws -arrows- and remove radiator downwards.

Installing
Note
♦ Replace gasket rings and O-rings.

♦ Secure allbyhose
Protected connections
copyright. with
Copying for private corresponding
or commercial purposes, inhose
part or clips.
in whole, is not permitted
– Top up coolant ⇒ page 92 .
1.6 Removing and installing coolant pump

Removing

– Remove V-ribbed belt tensioner and middle toothed belt guard

⇒ page 21 .
– Unscrew fixing bolts -1- of the coolant pump and remove the
coolant pump -2-.
– Remove O-ring -3-.
Installing
Note
Renew O-ring.
– Clean sealing surface for O-ring or smoothen.

– Moisten the new O-ring -3- with coolant.
– Attach the coolant pump -2-.
• Fitting position: Plug in housing points down.
– Tighten screws -1- of coolant pump to 15 Nm.
1.7 Removing and installing coolant regula‐

tor
Removing
Note

reuse.
WARNING

carefully.

WARNING

⇒ Electrical System ⇒ Rep. gr. 27 .
– Disconnect the earth strap from the battery with the ignition
off.

Note

– Unscrew the alternator and place it at the top right-hand side.

The hoses remain connected.
– Detach coolant hose -2- from connecting piece.
– Disconnect plug -1- at the coolant temperature sender at ra‐
diator outlet - G83- .
– Remove screws -arrows- and remove connecting piece.
– Turn coolant regulator -1- approx. 90° (1/4 turn) anti-clockwise

-arrow- and remove from connecting piece.
– Remove O-ring -2-.
Installing
Note
Renew O-ring.
– Clean sealing surface for O-ring or smoothen.

– Insert coolant regulator with new O-ring.
• Installation position:The bracket of the coolant regulator must
be positioned vertically.
– Moisten O-ring with coolant.
– Install the connecting
withpiece
respect on the
to the cylinder
correctness block, intighten
of information the Copyright by ŠKODA AUTO A. S.�
this document.
screws to 15 Nm and connect the hose from the radiator.
– Connect battery ⇒ Electrical System ⇒ Rep. gr. 27 .
WARNING

⇒ Electrical System ⇒ Rep. gr. 27 .
1.8 Check cooling system for leaks

♦ Cooling system testing device (e.g. - V.A.G 1274- )
♦ Adapter (e.g. - V.A.G 1274/8- )
♦ Adapter (e.g. - V.A.G 1274/9- )

Test condition
• Engine must be warm.
Test sequence
WARNING

carefully.
– Open the cap of the coolant expansion reservoir.

– Position cooling system testing device (e.g. - V.A.G 1274- )
with adapter (e.g. - V.A.G 1274/8- ) on the compensation bot‐
tle.
– Generate an overpressure of approx. 1.0 bar to test the cooling
system.
If pressure drops:
– Search position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Position cooling system testing device (e.g. - V.A.G 1274- )
with adapter (e.g. - V.A.G 1274/9- ) on the cap.
– To check the pressure relief valve, create an overpressure.
• The pressure relief valve should open at a pressure of 0.14 ...
0.16 MPa (1.4 ... 1.6 bar).
If the pressure relief valve does not open:
– Renew cap. by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised

20 – Fuel supply system

fuel supply system
Note
♦ Fuel lines are secured with quick-release couplings.

♦ Fuel hoses must be secured only with spring strap clips. The
use of clamp-type or screw-type clips is not allowed.
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
Observe safety measures ⇒ page 2 .

Observe rules for cleanliness ⇒ page 2 .
1.1 Fuel tank with attached parts
1 - Return-flow line
❑ from fuel cooler
❑ clipped in place on fuel
tank
❑ blue (blue marking)
2 - Feed line
❑ to fuel filter
❑ clipped in place on fuel
tank
❑ black
3 - Sealing ring
❑ replace
❑ to be inserted dry into
the opening of the fuel
tank
❑ only moisten with fuel
from the inside for instal‐
ling the flange
4 - Fuel pump
❑ with fuel gauge sender -
G-
⇒ page 107
❑ Note installation posi‐
tion on the fuel tank
⇒ page 100
❑ inspecting fuel pump
1. Removing and installing parts of the fuel supply system 99

⇒ page 105
❑ Clean strainer if dirty
the fuel gauge sender - G- ⇒ page 110
5 - Lock ring, 110 Nm
❑ use wrench -T30101- or -3087- for removing and installing
6 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work ⇒ Rep. gr. 55
7 - Screw cap
8 - Mounting part
9 - Earth connection
10 - 10 Nm
11 - Suction spray pump
❑ connected to the fuel gauge sender 2 - G169-
12 - Fuel gauge transmitter 2 - G169-
❑ Note installation position on the fuel tank ⇒ page 100
13 - Fuel tank
❑ when removing support, for example with the engine/gearbox jack -V.A.G 1383 A-
14 - Tensioning strap
15 - 25 Nm
❑ replace
16 - 23 Nm
17 - Heat shield
18 - Fuel cooler
19 - to fuel filter
20 - 20 Nm
Fitting position of the flange of the fuel delivery unit (with fuel
gauge sender - G- ) and the flange with fuel gauge sender 2 -
G169-
The markings on the flanges must be aligned with markings on
the fuel tank -arrows-.
Note
The markings on the
unless authorised fuel AUTO
by ŠKODA tankA.are hardly
S. ŠKODA visible.
AUTO A. S. does not guarantee or accept any liability
100 Rep. gr.20 - Fuel supply system

1.2 Removing and installing fuel filter

The fuel flow direction is indicated with arrows on the hoses and
on the fuel filter.
1 - Return-flow hose
❑ to fuel cooler
❑ blue/blue marking
2 - 5 Nm
3 - Washer
❑ integrated with screw
⇒ Item 2 (page 101)
4 - Intake hose
❑ from fuel tank
❑ white or white marking
5 - Return-flow hose
❑ from the tandem pump
❑ blue marking
❑ with connection fitting
for fuel temperature
sender - G81-
6 - Intake hose
❑ to the tandem pump
❑ white marking
7 - Fuel filter - top part
8 - Fuel temperature sender -
G81-
9 - Sealing ring
❑ replace
10 unless
- Fuel filter element
❑ pay attention to change
intervals ⇒ Mainte‐
nance ; Booklet Superb
ll.
11 - Fuel filter - lower part
12 - 10 Nm
13 - Connecting piece of fuel temperature sender G81
14 - Retaining clip
15 - Sealing ring
❑ replace
1.3 Extract fuel from the fuel tank

♦ Hose adapter , e. g. -V.A.G 1318-16-
♦ Adapter e.g. -V.A.G 1318-17-
♦ Auxiliary measuring set, , e. g. -V.A.G 1594 C-

♦ Battery
♦ Fuel tank
Note
If there are functional problems of the fuel delivery unit suction off
fuel with fuel extraction device, e.g. -VAS 5190- .
Work procedure
Note
Observe the regulations concerning cleanliness when working on

the fuel supply/injection system ⇒ page 4 .
– Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 .

– Remove the cover from the fuel delivery unit.
Note
On vehicles with auxiliary heating, the plug connection for the

dosing pump - V54- must also be disconnected.
WARNING
Fuel feed line is pressurised. Wear safety goggles and safety

clothing, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
cable connections. Reduce pressure by carefully removing the
wiring.
– Unplug the 5-pin connector -1- and the black feed line -2-.
Note
Always press in the securing ring in order to unlock the lines.

– Connect adapters -V.A.G 1318/16- and -V.A.G 1318/17- and

fit this “drain pipe” onto the feed support of the fuel delivery
unit.
– Hold the “drain pipe” in a suitable catch pan for fuel.
– Using auxiliary cables -A- from the measuring tool set - V.A.G
1594/C- connect up the battery through contacts of the fuel
pump as follows:
Battery positive terminal (+) to contact -1- of the fuel pump.
Battery negative terminal (-) to contact -5- of fuel pump.
The fuel pump runs and suctions off fuel.
WARNING
In order to avoid fuel overflow due to the fuel tank not being
sufficiently large enough, the fuel pump must not run unatten‐
ded.
1.4 Removing and installing fuel cooler

♦ Torque wrench
Note
The fuel cooler is located at the return-flow line to the fuel tank. It
is attached to the underfloor of the vehicle body.
– Observe rules for cleanliness ⇒ page 2 .

Removing
– Removing the right underfloor trim panel.
– Separate fuel lines at fuel cooler.
– Unscrew fixing nuts for fuel cooler -arrows- and remove fuel
cooler.
Installing
The installation occurs in reverse order:
Tighten fixing nuts for the fuel cooler to 15 Nm.
1.5 Removing and installing the fuel tank

♦ Engine/gearbox jack (e.g. -V.A.G 1383 A- )
♦ Torque wrench

Removing
Note
Observe the safety instructions before starting fitting work

⇒ page 2 .

– Drain the fuel tank ⇒ page 101 .
– Remove the covers from the fuel delivery unit and from the fuel
gauge sender 2 - G169- .
Note

– Disconnect the plug from the flange of the fuel delivery unit
and from the flange of the fuel gauge sender 2 - G169-
-arrows-.
– Remove right rear wheel ⇒ Chassis ⇒ Rep. gr. 44 .
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
gr. 66 .
– Unscrew fixing bolts on filler neck -arrows-.
Note
♦ On vehicles with auxiliary heating, the fuel line for the dosing
pump - V54- must also be disconnected.
♦ Press down the securing rings in order to unlock the connec‐
tions of the fuel lines.
– Disconnect vent line -1- and fuel feed line -2- (black) at the
connection point.
– Remove rear tunnel bridge for exhaust system ⇒ page 145 .
– Remove the rear silencer ⇒ page 145 .
– Unscrew the suspension bolt on the middle silencer
⇒ page 145

– First of all screw out the screws -2- and -5-.
– Support the fuel tank using the engine and gearbox jack -
V.A.G 1383 A- .
– Screw out the screws for the tensioning straps -1, 3, 4- and
-6-.
– Slightly lower the fuel tank using the engine and gearbox jack
- V.A.G 1383 A- .
– Then remove the fuel tank from the engine/gearbox jack -
V.A.G 1383 A- and pull through the filler neck between the
body and the rear axle with the help of a second mechanic.
Installing
– Support fuel tank with engine/gearbox jack, e.g. -
V.A.G 1383 A- .
– Raise fuel tank in its installation position and install.
Further installation occurs in reverse order to removal. Pay at‐
tention to the following:
♦ Lay the vent and fuel hoses without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the fuel line connections fit tightly.
♦ Check feed line, return-flow line and ventilation line at fuel tank
for firm seating.
♦ Check earth connection of fuel tank/body at filler neck.
1.6 inspecting fuel pump

Special tools
withand workshop
respect equipment
to the correctness required
of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Remote control, e.g. -V.A.G 1348/3A-

♦ Measuring tool set, e.g. - V.A.G 1594 C-
♦ Adapter, e.g. - V.A.G 1318/16-
♦ Adapter, e.g. - V.A.G 1318/17-
♦ Measuring vessel
Checking the function and supply voltage
Test conditions
• Battery voltage at least 11.5 V
• Fuses o.k. (No. 27).
• All electrical components such as lights and rear window heat‐
er must be switched off.

Test sequence
– Switch on ignition. The fuel pump must be heard to start run‐
ning.
– Switch off ignition.
If the fuel pump does not run:
– Continuing searching for faults using a multimeter (e.g. -
V.A.G 1715- ) ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
Check fuel flow rate
Test conditions
Note
♦ Safety precautions when working on the fuel supply system

⇒ page 2 .
♦ Observe the regulations concerning cleanliness when working
on the fuel supply/injection system ⇒ page 4 .
• Supply voltage o.k.

• Battery voltage at least 11.5 V
• Fuel temperature 15…30 °C.
• Fuel tank at least 1/4 full. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Test sequence
– Unscrew the cap from the filler neck.
– Disconnect the 5-pin plug from the fuel pump.
– Connect remote control -V.A.G 1348/3A- with connection lines
from measuring tool set to contact -1- of the fuel pump and to
battery positive terminal.
– Use connection lines from the measuring tool set to connect
the contacts -5- to the plug and to the fuel pump.
– Connect adapter -V.A.G 1318/17- and -V.A.G 1318/16- to the
fuel delivery unit and hold in the measuring vessel.
– Activate remote control -V.A.G 1348/3A- for 30 seconds.

– Compare the amount of the fuel pumped to the specified value

(the amount of the fuel pumped is dependent on the voltage
at the fuel delivery unit).
If the minimum fuel flow rate is not reached:
– Remove the fuel delivery unit and check that the preliminary
stage screen is not clogged up.
If no fault was detected until now:
– Replace fuel delivery unit.
1.7 Removing and installing fuel delivery

unit
♦ Key - T30101 (3087)-
♦ Fuel suction device (e.g. -VAS 5190- )
Condition
• The fuel tank must not be more than 1/4 full.
Removing
Note
♦ Observe the safety instructions before starting fitting work

⇒ page 2 .
♦ Observe rules for cleanliness ⇒ page 2 .
♦ Switch off ignition and pull out ignition key.

Note

– Disconnect the plug as well as the black feed line -1- and the
blue return-flow line -2- from the flange.
Note
♦ Press in the securing ring in order to unlock the line.

♦ For vehicles with auxiliary heating the unless
suction line by
authorised forŠKODA
the dos‐
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ing pump - V54- must be pulled out additionally (open lower
clamp).

– Unlock lock ring with wrench -T30101- .
– Slightly raise the closing flange and check if the spring -2- is
still fastened on the flange -1-.
If the spring -2- is loose on the guide pipe -3-, hold it with your
fingers while removing the closing flange.
– Pull closing flange and gasket ring for fuel pump out of the
opening of the fuel tank and place to the side with the con‐
nected lines.

– Through the opening of the fuel tank, disconnect the fuel line
-1- to the vacuum pump by pressing the release button.
– Disconnect the fuel delivery line -2- from the fuel delivery unit.
Note
♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Remove fuel pump from the fuel tank so that the electric cables
and fuel hoses are not damaged and the float arm of the send‐
er for fuel gauge display - G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Installing
The fuel delivery unit is installed in the reverse order. However,
pay attention to the following:
– Insert the fuel delivery unit into the fuel tank with the closing
flange placed to the side. Do not bend the float arm of the fuel
gauge sender unit - G- while doing so.
– Install the fuel delivery unit and the fuel line.
– Insert the new dry gasket ring for the flange into the opening
of the fuel tank and moisten only from the inside with fuel for
installing the closing flange.
• The spring -2- must be fastened to the retaining lugs -1- of the
closing flange.
– First of all guide the guide pipe -3- into the guide bore -4-.
– Then lower the closing flange in such a way that the guide pipe
-6- locks into the guide bore -5-.

Note
Pay attention that the electrical cables -1- and the fuel feed line
-3- are routed according to the illustration and the float arm -2- is
not blocked.
– Press the closing flange down and bring it into the installation
position.
Further information:
♦ Fitting position of the fuel delivery unit: The peg -2- at the clos‐
ing flange must be located between the pegs -1- and -3-. The
-thick arrow- points in the direction of travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
line and the return-flow line are still clipped in place on the fuel
tank.
1.8 Removing and installing the fuel gauge

sender - G-
Removing
– Remove fuel delivery unit ⇒ page 107 .
– Unlock the securing tabs -arrows- using a screwdriver and pull
the fuel gauge sender - G- up and out.

– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Installing
– Connect the wiring and check correct installation of the plug.
– Insert the fuel gauge sender - G- into the guides on the fuel
delivery unit and press down until it engages.
– Install fuel delivery unit.
1.9 Removing and installing fuel gauge

sender 2 - G169-
• The fuel tank must not be more than 1/2 full.
Note
♦ Empty the fuel tank if necessary ⇒ page 101 .

♦ Observe the safety instructions before starting fitting work
⇒ page 2 .
♦ Observe rules for cleanliness ⇒ page 4 .
♦ Make sure that the sender for fuel gauge display is not bent.
Removing
Switch off ignition and pull out ignition key.

– Remove left cover and disconnect plug from fuel gauge sender
2 - G169- .
– Unlock lock ring at flange with wrench -T30101- .

– Pull lightly Fuel gauge transmitter 2 - G169- out of the opening

of the fuel tank, unlock the securing tabs -arrows- and discon‐
nect the pump.
Installing
– The installation occurs in reverse order. Pay attention to the
following:
WARNING
When installing do not bend the float arm of the fuel gauge
sender 2 - G169- .
– Insert the fuel gauge sender 2 - G169- into the fuel tank.
– Fit the suction jet pump in the fuel tank onto the fuel gauge
sender 2 - G169- and push it in until the securing tabs
-arrows- latch into position.
– Insert new dry sealing ring for the flange into the opening of
the fuel tank and only moisten the inside (towards the flange)
with fuel.
– Check the fitting position ⇒ page 100 and insert the flange of
the fuel gauge sender 2 - G169- into the opening of the fuel
tank.
– Check correct positioning of sealing ring.
– Tighten the lock ring with wrench -T30101- to 110 Nm.

– Fit on plug and install left cover.

1.10 Removing and installing suction jet

pump
Note
♦ The fuel tank is subdivided in a left and a right chamber. In

order to pump the fuel out of the left chamber -3- of the fuel
tank into the right chamber to the housing of the delivery unit
-2-, a suction jet pump -1- is required.
♦ The version of the fuel tank requires that the fuel is pumped
from the area of the fuel gauge sender 2 - G169- with a suction
jet pump to the fuel delivery unit.
♦ A check is only to be carried out, if the engine stops because
of fuel shortage, although the fuel gauge still indicates a fuel
tank which is 1/4 full.
Work procedure
– Remove fuel delivery unit ⇒ page 107 .
– Remove fuel gauge sender 2 - G169- ⇒ page 111 .
– Now the suction jet pump can be pulled out from the side of
the fuel gauge sender 2 - G169- (left vehicle side).
– Check, if the fuel lines on the suction jet pump are placed on
firmly and not damaged.
– Check the suction jet pump additionally for possible contami‐
nation.
1.11 Removing and installing the tandem

pump
♦ Hand vacuum pump (e.g. -V.A.G 1390- or -VAS 5226- )
♦ Drain container - V.A.G 1390/1-
Removing
WARNING
The tandem pump must on no account be disassembled, oth‐

erwise the proper operation of the pump vacuum part is no
longer assured. This will result in a failure ofbythe
Protected brake
copyright. booster.
Copying for private or commercial purposes, in part or in whole, is not permitted
Caution
Observe instructions for re-installing a used tandem pump

⇒ page 116 .

– Separate feed hose -1- (marked in white) and return-flow hose

-2- (marked in blue) from the fuel filter.
– Connect the diesel extractor - VAS 5226- to the return-flow
hose -2-.
– Create a vacuum with the diesel extractor - VAS 5226- until
no more fuel flows out of the return-flow hose.
– Unplug connector -1- from the air mass meter -G70- .
– Detach vacuum hose -5-, intake hose -2- and air guide -4-.
– Slacken screw -3- and remove air filter housing.
– Separate vacuum line -1- for brake servo unit from tandem
pump -4-.
– Detach feed hose -2- (marked in white) and return-flow hose
-3- (marked in blue) from the tandem pump -4-.
– Unscrew fixing screws -arrows- and remove tandem pump
-4- from the cylinder head.
Installing
♦ Ensure that the coupling of the tandem pump is correctly seat‐

ed in the camshaft.
♦ Always replace the tandem pump seals.
– Install tandem pump and fixing screws -arrows- to torque M8.

20 Nm, tighten to M6...10 Nm.
– Connect return-flow hose (marked in blue) to the return-flow
coupling -3- of the tandem pump.
– Connect the feed hose (marked in white) to the feed connec‐
tion -2- and the vacuum line of the brake servo unit -1- to the
tandem pump -4-.

– Connect the diesel extractor - VAS 5226- to the return-flow

hose -2-.
– Operate the diesel extractor - VAS 5226- until fuel comes out
of the return-flow hose.
– Connect return-flow hose -2- (marked in blue) to fuel filter.
1.12 Inspecting a tandem pump

Check feed pressure
♦ Pressure gauge appliance (e.g. -VAS 5187- )
♦ Tandem pump tester , e. g. -VAS 5187-
♦ Hose clamp - MP7-602 (3094)-
Test conditions
• The coolant temperature must be at least 85 °C.
• Unit injectors O.K.
• Fuel filter and fuel line must not be blocked.
Work procedure
– Unplug connector -1- from the air mass meter -G70- .
– Detach vacuum hose -5-, intake hose -2- and airA.guide -4-.
unless authorised by ŠKODA AUTO S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Slacken screw -3- and remove air filter housing.
– Release screw plug -arrow-.

– Connect pressure gauge appliance -VAS 5187- as shown.

– Install air filter and connect suction hose and air guide.
– Start engine and engine speed must increase to 4000 rpm.
– Note the pressure shown on the pressure gauge.
Specified value: min. 0,75 MPa (7,5 bar).
If the set value is not reached:
– Close return-flow line between tandem pump and fuel filter
with hose clamp -MP 7-602- .
– Start engine and engine speed must increase to 4000 rpm.
– Note the pressure shown on the pressure gauge.
Specified value: min. 0,75 MPa (7,5 bar).
If the specified value is reached:
Pressure loss at the unit injectors.
– Replace O-rings for unit injectors ⇒ page 140 .
If the set value is not reached:
– Replace tandem pump ⇒ page 113 .
Note
After removing the pressure gauge, tighten the screw plug to 25

Nm. Always replace the gasket ring.
Check tightness (internally)
Note
After re-installing a used tandem pump e.g. after changing or re‐

pairing a cylinder head and/or after changing a hopper motor the
tandem pump must absolutely be checked for internal tightness
between fuel and oil side. In case of leakage this can lead to a
fuel/oil mixing, which can cause an engine damage.

♦ Tester, e.g. -V.A.G 1687-
Work procedure
– Disconnect the fuel intake hose (white marking) and the fuel
return-flow hose (blue marking) from the tandem pump.
– Close the return-flow connection at the tandem pump with a
dummy plug. Secure the dummy plug with a spring strap
clamp.
Prepare tester e.g. -V.A.G 1687- as follows:

– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
– Connect the testing device -5- with a commercially available
connection for compressed air and a piece of fuel hose to the
connection of the fuel feed line for the tandem pump. To se‐
cure, use a spring strap clamp.
Note
The rotary knob must be slightly pulled to the top in order to rotate
the pressure control valve -2-.
– Connect hose with compressed air -1- (compressed air sup‐

ply) to tester e.g. -V.A.G 1687- .
Note
If there is water in the transparent drain container, drain water via

the drain plug -6-.
– Open valve -3-.

– Set the pressure to 1.0 bar with the pressure control valve
-2-.
WARNING
The maximum test pressure is 1.3 bar and must not be excee‐
ded.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 1.0 bar.
– Close the valve -3- to maintain the pressure and observe the
drop in pressure over a period of 1 minute.
If no drop in pressure is detected, the tandem pump can be used
again; in case of drop in pressure replace the tandem pump.

2 Accelerator control
2.1 Assembly overview - accelerator module
1 - Connector
❑ black
❑ 6-pin
2 - Accelerator pedal module
❑ with accelerator pedal
position encoder - G79-
and accelerator pedal
position encoder 2 -
G185-
❑ for vehicles with auto‐
matic gearbox 02E with
kick-down switch
❑ not adjustable
❑ -A- openings for release
tool - T10238- or -
T10240-
⇒ page 118
❑ When replacing, adapt
the engine control unit
⇒ Vehicle diagnostic
tester
3 - 10 Nm
4 - Cap
2.2 Removing and installing accelerator

pedal module
♦ Release tool - T10238- (for left-hand drive vehicle)
♦ Release tool - T10240- (for right-hand drive vehicle)
Removing
– Remove cover in footwell.
– Disconnect connector from accelerator pedal module.
– Remove cap in module upwards.
– Remove securing screw.

– Insert release tool -T10238- (on vehicles with right-hand drive,

release tool -T10240- ) in the corresponding openings up to
the stop.
– Remove accelerator pedal module.
Installing
– Fit the plug -2- onto the accelerator pedal module -5-.
The locking of the connector must be audible.
– Push again rubber grommet -1- onto the connector -2-.
– Push accelerator pedal module onto the securing bolt -6-.
– Insert the centering pin -7- into the hole in the underbody.
– Screw on accelerator pedal module with fixing screws -3-,
tighten to 10 Nm and push on cap -4-.
– Install steering column cover.
– If the accelerator pedal with
module was
respect to replaced,
the correctness the engine
of information in this con‐
document. Copyright by ŠKODA AUTO A. S.�
trol unit has to be adapted ⇒ Vehicle diagnostic tester.
– On vehicles with automatic gearbox, adapt the kick-down
function after replacing the accelerator pedal module ⇒ Vehi‐
cle diagnostic tester.
2. Accelerator control 119

21 – Turbocharging/supercharging
1 Charge air system with exhaust gas
turbocharger
Note
♦ Observe rules for cleanliness.

♦ The charge-air system must be tight.
♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
1.1 Removing and installing exhaust gas turbocharger
1 - 10 Nm
2 - Mounting bracket
3 - Heat shield
4 - Oil supply hose
❑ to connection fitting of
oil feed line for exhaust
turbocharger
❑ Check oil feed line for
continuity before instal‐
ling.
❑ Fill the exhaust turbo‐
charger with engine oil
through the connection
fitting of the oil feed line
before installing
5 - Vacuum setting element
❑ for charge pressure with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
control
❑ Component part of the
exhaust turbocharger,
not replaced separately
6 - Vacuum hose
7 - Gasket
❑ replace
8 - for diesel particle filter
9 - Clamp - 7 Nm
❑ for exhaust gas turbo‐
charger and diesel par‐
ticle filter
❑ replace
10 - Exhaust turbocharger with exhaust manifold
❑ can only be replaced as one part
❑ Check vacuum actuator ⇒ page 126
120 Rep. gr.21 - Turbocharging/supercharging

11 - 25 Nm
❑ replace
12 - 25 Nm
13 - Gasket
❑ replace
14 - Connecting pipe
❑ for exhaust gas recirculation
15 - 25 Nm
❑ replace
16 - 15 Nm
17 - O-ring
❑ replace
18 - Hollow screw - 60 Nm
19 - Countersupport
❑ for exhaust gas turbocharger
❑ for oil return-flow line
20 - Exhaust gas temperature sender 1 - G235- ( Temperature sender upstream turbocharger - G507- ) - 45
Nm
❑ the thread of new temperature transmitters must be coated with assembly paste
❑ Grease only the thread with hot bolt paste - G 052 112 A3- for re-used temperature sender.
21 - Heat shield
❑ for intake hose between air filter and exhaust turbocharger
23 - 9 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
24 - 10 Nm

Caution
In case of mechanical damage to the exhaust gas turbocharg‐

er, e.g. damage of the compressor wheel, it is not sufficient to
only replace the exhaust gas turbocharger. In order to prevent
consequential damage to the engine, perform the following
tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter housing, air filter element and charge air
pipes as well as charge air hoses for soiling.
♦ Check all the air guides and the charge air cooler for for‐
eign bodies.
If soiling or foreign bodies are detected in the filling system, all
air guides must be carefully cleaned and if necessary replace
the charge air cooler.
1. Charge air system with exhaust gas turbocharger 121

Removing
⇒ page 146 .
– Unplug connector at air mass meter -G70- ⇒ page 131 .
– Remove the connection pipe ⇒ page 135 .
– Remove intake hose.
– Remove connection fitting ⇒ page 120 .
– Remove vacuum line for vacuum setting element
⇒ Item 5 (page 120) .
– Remove oil supply hose ⇒ Item 4 (page 120) .
– Disconnect and unhook cables to exhaust gas temperature
sender 1 - G235- ( temperature sender upstream turbocharger
- G507- ).
– Detach the connecting hose from the turbocharger
⇒ page 123 .
– Remove the connection pipe ⇒ page 152 .
– Release screws -1-, screw -2- and the hollow screw -3-.
– Remove left heat shield at exhaust manifold -arrows-.

– Unscrew holder for diesel particle filter.

– Unscrew nuts -arrows- and remove exhaust manifold with ex‐

haust turbocharger downwards.
Installing
Note
♦ Replace the gaskets, the sealing rings and the self-locking

nuts.
♦ Fill exhaust turbocharger with engine oil through the connec‐
tion fitting of the oil feed line.
♦ Hose connections and hoses for the charge air system must
be free of oil and grease before being installed.
– When installing the connecting hose with push-fit coupling en‐

sure that the locking clip -arrow- interlocks behind the retaining
lugs -A- ⇒ page 125 .
– Checking the oil level ⇒ Maintenance ; Booklet Superb II .
Note
after installing the exhaust turbocharger run the engine approx. 1

minute in idle and do not increase speed immediately in order to
ensure the supply of oil to the turbocharger.
1.2 Removing and installing parts of the charge air cooling system
Note
♦ Before testing or repairing, check all hoses and lines for tight connection and leaks.
♦ Hose connections and hoses for the charge air system must be free of oil and grease before being installed.

1 - 7 Nm
3 - Charge air cooler
⇒ page 124
4 - top seal
❑ fitted onto charge air
cooler
5 - bottom seal
❑ fitted onto charge air
cooler
6 - Connecting hose
7 - 8 Nm
8 - to exhaust gas turbocharger
9 - Charge air pipe
10 - to inlet connection
11 - 15 Nm
12 - 3 Nm
13 - Charge pressure sender -
G31- / intake air temperature
sender - G42-
1.3 Removing and installing charge air cool‐

er
Removing
– Remove coolant radiator ⇒ page 94 .
– Remove front bumper ⇒ Body Work ⇒ Rep. gr. 63 .
– Remove the connecting hoses on the left and right from the
charge air cooler.
WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
tem.
Note
To avoid damaging the condenser, wiring and air conditioning

hoses make sure the lines and hoses are not excessively expan‐
ded, buckled or bent.

– Release fixing screws -1- at charge air cooler:
Note
For the following operations a second mechanic is required to

hold the charge air cooler.
– Swivel the charge air cooler towards the rear, remove the lat‐
eral bearings and unhook out of the lower bearings.
– Release the securing bolts -arrows- of the condenser.

– Remove charge air cooler downwards.
Installing
Note
Replace O-rings.
– Observe the assembly instruction for hose connections with

push-fit couplings ⇒ page 125 .
1.4 Hose connections
1.4.1 Assembly of hose connections with

push-fit couplings
Caution
The gasket ring for the push-fit coupling can be damaged, if

the locking clip is in the lock position during the assembly. The
connection would leak. Observe the assembly instruction.
Note
All hose connections of the charge air system are secured with
spring strap clamps or push-fit couplings. For the push-fit cou‐
plings pay attention to the following points:

Removing
– Release push-fit coupling by pulling the locking clip -arrow-.
Disconnect hose/pipe without auxiliary tool.
Installing
– Observe that the retaining lugs latch when installing -A-.
– When replacing the sealing ring, place the sealing ring in the
groove of the charge air hose. Make sure that the gasket ring
if fully seated all round in the groove.
– Oil the sealing surface and the sealing ring.
– Put the securing clamp into the release position -1-.

– Insert the charge air hose up to the stop into the coupling.
– Put the locking clip into the lock position -2- and then press
down once again the charge air hose.
– Check hose for tight connection by pulling on it and check the
quick coupling is locked correctly.
1.4.2 Hose connections with spring strap ring
Note
After disassembling and assembling the charge air lines with

spring strap clamps, there is a risk of the “hose slipping off” when
driving. For this reason, spring strap rings are installed, which can
only be opened when there is a defect of the appropriate charge
air line. When carrying out repairs, the spring strap ring must be
destroyed using a suitable tool and replaced by a spare part ac‐
cording to the ⇒ Electronic Catalogue of Original Parts .
1.5 Inspect vacuum setting element and

tension rods for charge pressure control

♦ Hand vacuum pump , e.g. -VAS 6213-
Faults at tension rods or at vacuum setting element of charge
pressure control lead to the following faults:
♦ Specified values for charge pressure are not reached.
♦ Poor performance.

♦ Irregular performance in the partial load region.

♦ Engine jerk in change-over.
Test sequence
• Check vacuum piping for tightness and completeness
⇒ page 127 .
• Charge-air system was checked for tightness ⇒ page 127 .
– Connect the connecting hose -2- to the vacuum setting ele‐
ment and to the hand vacuum pump - VAS 6213- .
– Slide the sliding ring -1- of the hand vacuum pump - VAS 6213-
in the -direction of arrow- for “vacuum”.
Note
For the following test a second mechanic is required.
– Generate vacuum with the hand vacuum pump - VAS 6213-

and observe the tension rod of exhaust turbocharger.
Note
For the inspection use a mirror. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Nominal values:
• At a vacuum of 0.05...0.120 bar (0.005…0.012 MPa), the ten‐
sion rod must move upwards.
• At a vacuum of 0.550...0.620 bar (0.055…0.062 MPa), the
tension rod must rest at the top against the stop.
– Remove the connecting hose from the hand vacuum pump -
VAS 6213- and at the same time observe the tension rod over
the entire adjustment range.
• The tension rod must move without jolting over the entire ad‐
justment range.
If the specified values are not achieved or the tension rod moves
with jolt:
– Replace exhaust turbocharger ⇒ page 120 .
Note
♦ If the measuring accuracy of the vacuum at the hand vacuum

pump - VAS 6213- is not adequate, a turbocharger tester e.g.
-V.A.G 1397 A- can be used for a more accurate measure‐
ment.
♦ Connection of the turbocharger tester ⇒ Owner's Manual .
1.6 Checking the charge-air system with tur‐

bocharger for leak tightness
♦ Charge-air system testing device , e. g. -V.A.G 1687-
♦ Adapter e.g. -V.A.G 1687/10-

Test sequence
– Remove intake hose -1- from air filter.
– Fit adapter - 1687/10- into the intake hose -1- and secure with
a clamp.
Prepare tester for charge air system - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.

– Connect tester - V.A.G 1687- as shown to adapter - 1687/10- .

– Connect the pneumatic hose -1- (pneumatic support) at tester.
Note
If there is water in the transparent drain container, drain water via

the drain plug -6-.
– Open valve -3-.

– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
Caution
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 0.05 MPa (0.5 bar).
– Listen to, touch or use commercially available leak search
spray or the ultrasonic measuring device e. g. -V.A.G 1842- to
check the charge-air system with exhaust gas turbocharger for
leak points.
Note
♦ Minor leaks are permissible on the suction side of the turbo‐

charger, because the intake hoses are not designed for over‐
pressure.
♦ A small amount of air escapes via the valves into the engine.
For this reason no pressure test is possible.
♦ Using the ultrasonic tester - V.A.G 1842- ⇒ Owner's Manual .
♦ In case of a leak point, observe the assembly instructions for
charge air system.
♦ Before removing the adapter, depressurize
Protectedthe test circuit
by copyright. Copyingby
for private or commercial purposes, in part or in whole, is not permitted
detaching the coupling from the adapter
unless- authorised
1687/10- .
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
1.7 Connection diagram for vacuum hoses

1 - Exhaust gas turbocharger

2 - Charge air cooler
3 - intake hose
4 - Non-return valve
5 - Brake servo
6 - Solenoid valve for charge
pressure control -N75-
7 - Air filter
8 - Changeover valve for radi‐
ator of exhaust gas recircula‐
tion -N345-
9 - Tandem pump
10 - Cylinder head
11 - Intake manifold
12 - Vacuum reservoir
13 - Exhaust pipe
❑ for recirculation flap
❑ always replace together
with radiator for exhaust
gas recirculation
15 - Exhaust gas recirculation
valve -N18- with EGR potenti‐
ometer -G212- and EGR con‐
trol motor -V338-
16 - Non-return valve
❑ white connection to sol‐
enoid valve for charge
pressure limitation
⇒ Item 6 (page 130) and
to vacuum reservoir
❑ for charge pressure control
❑ Component part of the exhaust turbocharger, not replaced separately

23 – Mixture preparation - injection

1 Repairing Diesel Direct Injection sys‐
tem
The control unit is equipped with event memory. Before repairs,
setting operations and fault finding, query the event memory and
run self-diagnosis ⇒ Vehicle diagnostic tester.
Note
♦ Faults can be detected by the control unit as checking and

adjustment work is being undertaken and then saved. It is
therefore essential to delete the event memory after complet‐
ing all checking and adjustment work ⇒ Vehicle diagnostic
tester
♦ Safety precautions when working on the injection system
⇒ page 3 .
1.1 Installation location overview
Note
Some components are mounted under the engine cover. Removing ⇒ page 6 .
The components A through G are not represented in the overview

figure.
1. Repairing Diesel Direct Injection system 131

A - Warning light for engine

electronics - K149-
❑ on the dash panel insert
B - Accelerator pedal position
sender - G79- with accelerator
pedal position sender 2 -
G185-
❑ in footwell on the accel‐
erator pedal
C - The brake light switch - F-
and brake pedal switch - F63-
❑ in footwell on the brake
pedal
D - Fuel pump relay - J17-
❑ on relay carrier
E - Clutch position sender -
G476-
❑ at master cylinder
F - Automatic glow period con‐
trol unit - J179-
❑ below E-box in the en‐
gine compartment
G - Relay and fuse carrier
❑ with terminal 30 voltage
supply relay - J317-
❑ with terminal 15 voltage
supply relay - J329-
❑ E-box in the engine
132 Rep. gr.23 - Mixture preparation - injection

compartment
1 - Intake manifold flap motor - V157-
2 - Exhaust gas temperature sender 3 - G495- ( Temperature sender downstream particle filter - G527- )
3 - Lambda probe -G39- with heating for lambda probe -Z19-
4 - Exhaust gas recirculation valve -N18- with EGR potentiometer -G212- and EGR control motor -V338-
5 - Engine control unit -J248-
6 - Exhaust gas temperature sender 2 - G448- ( Temperature sender upstream particle filter - G506- )
7 - Pressure sensor 1 for exhaust gas -G450-
8 - Exhaust gas temperature sender 1 - G235- ( Temperature sender upstream of turbocharger - G507- )
9 - The unit injectors
❑ Unit injector solenoid valve cyl. 1 - N240-
❑ Removing and installing unit injectors ⇒ page 137
10 - Changeover valve for radiator of exhaust gas recirculation -N345-
11 - Coolant temperature sender -G62-
12 - Solenoid valve for charge pressure control -N75-
13 - Connector
❑ at the front wall on the left
❑ Summary of components ⇒ page 134
14 - Air mass meter -G70-
15 - Tandem pump
16 - Multipin plug connection
❑ central for unit injectors
17 - Engine speed sender - G28-
18 - Fuel temperature sender -G81-
19 - Glow plugs
❑ Glow plug 3 - Q12-
❑ Glow plugAUTO4 - Q13-
unless authorised by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ Removing and installing glow plugs ⇒ page 155
20 - 3-pin connector
Hall sender - G40-
21 - Coolant temperature sender at radiator outlet - G83-

22 - Glow plugs
❑ Removing and installing glow plugs ⇒ page 155
23 - Intake manifold pressure sender -G31- with intake manifold temperature sender -G42-
24 - Hall sender - G40-
❑ for camshaft position

Summary of components - plug on the front wall

1 - Solenoid valve for charge pressure control -N75-
2 - Plug (orange) for exhaust gas temperature sender 3 - G495-
( temperature sender downstream particle filter - G527- )
3 - Plug for exhaust gas temperature sender 2 - G448- ( temper‐
ature sender upstream of particle filter - G506- )
4 - Connector for lambda probe -G39- and heating for lambda
probe -Z19-
5 - Plug for exhaust gas temperature sender 1 - G235- ( temper‐
ature sender upstream of turbocharger - G507- )
1.2 Assembly overview - intake manifold
1 - Gasket
❑ replace
2 - Intake manifold
3 - Sealing ring
❑ replaceunless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
4 - Supports
5 - Intake manifold flap motor -
V157-
❑ The intake manifold flap
is closed for about 3
seconds after switching
off the engine and then
opens again. This re‐
duces the switch-off im‐
pact.
6 - from charge-air cooler
7 - 10 Nm
trol motor -V338-
sealing surfaces at in‐
take manifold for dirt
and clean as required
Note
♦ After replacing, adapt new part

as follows:
♦ Switch ignition on and off; then
wait 1 minute for the afterrun of
the control units,
♦ Start engine and run in idle for at
least 1 minute,

♦ Interrogate event memory ⇒ Ve‐

hicle diagnostic tester, no fault
should be stored in the event
memory.
♦ If a fault occurs, erase the event
memory and repeat the entire
work procedure.
9 - Gasket
❑ replace
10 - Radiator
11 - 22 Nm
13 - 22 Nm
1.3 Removing and installing air filter
1 - intake hose
❑ to exhaust gas turbo‐
charger
2 - Air mass meter -G70-
3 - O-ring
4 - Vacuum hose Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ to the solenoid valve for unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
charge pressure limita‐ with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
tion -N75-
5 - 2 Nm
6 - Air filter top part
❑ if during repairs the air
filter housing is opened
(except for air filter ele‐
ment change), it should
be entered in the Serv‐
ice Schedule (change
interval for air filter ele‐
ment is shortened)
7 - Intake air duct
❑ bolted to the lock carrier
8 - 2 Nm
9 - Air deflector
10 - Drain pipe
11 - Air filter bottom part
❑ with supports for drain
pipe

12 - 8 Nm
13 - Filter element
14 - 2 Nm
❑ from cylinder head cover
❑ for crankcase ventilation
1.4 Repairing pump nozzle units

♦ Always replace gasket rings and O-rings.
1 - 20 Nm + torque a further 1/
4 turn (90 °)
❑ replace
2 - Valve-lever shaft
❑ with valve levers
3 - Counternut, 30 Nm
4 - Adjusting screw
❑ replace
❑ Grease the contact sur‐
face of the unit injector
to the ball pin using
grease -G 000 100-
5 - Ball stud
❑ replace
6 - The unit injector
❑ Check ball pins for wear
marks and replace if
necessary
❑ Grease the contact sur‐
face to the adjusting
screw using grease -G
000 100-
⇒ page 137
7 - O-ring
8 - O-ring
9 - O-ring
❑ Replace ⇒ page 140 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
10 - Heat-protection seal
❑ replace
11 - Circlip
12 - Cylinder head
13 - Clamping pad
14 - 12 Nm + torque a further 3/4 turn (270°)
❑ replace

1.5 Removing and installing unit injectors

♦ Dial gauge
♦ Torque wrench
1.5.1 Removing
– Remove top toothed belt guard and cylinder head cover
⇒ page 56 .
Note
Turn engine at hexagonal head of central screw at front end of

the crankshaft, if necessary using counterholder - T10172- or us‐
ing counterholder - MP 1-216- at camshaft sprocket.
– Turn the crankshaft until the corresponding cam pair of the

relevant unit injector to be removed points uniformly upwards.
– Release the counternuts of the adjusting screws -1- and un‐
screw the adjusting screws until the valve lever rests against
the ball pin of the unit injectors.
– Screw out fixing screws -2- for the valve-lever shaft from the
outside to the inside and remove the valve-lever shaft.
– Set the camshaft in such a way that the cam for Cylinder 2
points in -direction of arrow-. All clamping pads can be re‐
moved in this position.
– Unplug the connector from the unit injector.
Protected Support
by copyright.the op‐for private or commercial purposes, in part or in whole, is not permitted
Copying
posite side of the connector with yourunless
finger in order
authorised to avoid
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
twisting the connector.
– Screw out fixing screw -3- of the clamping pad and remove the
pad in the direction towards the camshaft.

– Insert extractor - T10055- in direction of the camshaft instead

of the clamping pad in the slot of the unit injector.
– Remove the unit injector through movements of the sleeve at
the nut up to the stop in -direction of arrow-.
Note
Do not interchange the unit injectors, if necessary mark the as‐

signment to each cylinder.
1.5.2 Installing
Note
♦ For any work procedure involving an adjustment of the unit

injector it is necessary to replace the adjusting screw in the
valve lever and also the ball pin of the unit injector. If there is
any wear replace the ball pin and the adjusting screw.
♦ Grease the contact surfaces between the ball pin and the ad‐
justing screw using -G 000 100- .
♦ New unit injectors are supplied with O-rings and heat-protec‐
tion seal.
♦ If the old unit injectors are installed again, all O-rings and the
heat-protection seal must be replaced.
– Before installing the unit injector, check the correct position of

the three O-rings, the heat-protection seal and the circlip.
The O-rings must not be twisted.
– Oil the O-rings and place the unit injector with the greatest of
care into the cylinder head.
– Slide the unit injector into the cylinder head seat up to the stop
by exerting a uniform pressure.
– Place the clamping pad in the side slot of the unit injector.
Note
If the unit injector is not perpendicular to the clamping pad the

fixing screw may loosen and cause damage to the unit injector or
cylinder head.
– Align the unit injector as follows:

– Screw the new fixing screw in the clamping pad until the unit
injector can still easily be turned.

– Set unit injector at a right angle to the bearing shell of the

camshaft.
– Using a caliper gauge, check dimension -a- from the outer side
of the cylinder head to the cylinder surface of the unit injector.
Cylinder Dimension -a-
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
– Adjust the unit injector if required, tighten the fixing screw to a
torque of 12 Nm and then torque a further 270° (3/4 turn).
Tightening may occur in successive stages.
– Mount valve-lever shaft and tighten up the new fixing screws

as follows:
– First tighten the inside -2- then both outside -1- screws by
hand. In the same sequence tighten to 20 Nm and torque a
further 90° (1/4 turn).
1.5.3 Setting
– Place a dial gauge on the adjusting screw of the unit injector.
Note
Turn engine at hexagonal head of central screw at front end of

the crankshaft, if necessary using counterholder - T10172- or us‐
ing counterholder - MP 1-216- at camshaft sprocket.
– Turn the crankshaft in the running direction of the engine until

the roller of the valve lever is on the drive cam tip.
♦ Roller side -arrow A- is on the highest point.
♦ Dial gauge -arrow B- is on the lowest point.
– Remove the dial gauge.
– Turn the adjusting screw in the valve lever until one feels a
significant resistance (the unit injector is against the stop).

– Turn the adjusting screw in the opposite direction from the stop
by about 180°
– Hold the adjusting screw in this position and tighten up the lock
nut using a torque of 30 Nm
– Fit the plug of the unit injector and install the cylinder head
cover and the top toothed belt guard.
1.6 Replacing O-rings for unit injectors.

Removing
– Lever off the O-rings from the grooves of the unit injector with
extreme care.
– Make sure, above all, that the contact surfaces in the grooves
for the O-rings are not damaged.
Installing
Note
♦ Always use the assembly sleeves to install the O-rings. If they

are not used there is a risk that the O-rings may become dam‐
aged.
♦ Observe the correct allocation of the O-rings to the slots: The
ring thickness reduces in the direction of the injection nozzle.
♦ Avoid rolling the O-rings when sliding them on. The O-rings
must not be turned inwards on the groove of the unit injector.
– Remove the heat-protection seal along with the circlip.

– Clean the contact surfaces for the O-rings in the grooves of
the unit injector with great care.
– Insert the assembly sleeve -T10056/1- on the unit injector up
to the stop.
– Carefully slide the upper, thicker O-ring onto the assembly
sleeve and in the groove of the unit injector.
– Remove assembly sleeve.


to the stop.
– Carefully slide the middle, thinner O-ring onto the assembly
sleeve and in the groove of the unit injector.

to the stop.
– Carefully slide the lower O-ring onto the assembly sleeve and
insert it in the groove of the unit injector.
– Slide on a new heat-protection seal together with the circlip.
1.7 Removing and installing the engine

speed sender - G28-
♦ Hose clamps up to ∅ 25 mm - MP7-602 (3094) -
Removing
– Unclip the coolant hoses at the engine oil cooler with hose
clamps and remove the coolant hoses.
– Remove oil filter holder ⇒ page 78 .
– Remove the plug -arrow- on the engine speed sender - G28-
with the assembly device - T10118 - and lay the electrical
cable to the side.
Note
To unlock the plug without using the assembly device - T10118- ,

the unlock button must be pressed at the plug using a screwdriver
and at the same
Protected time unlock
by copyright. Copying the unlock
for private buttonpurposes,
or commercial with ainthin wire
part or in whole, is not permitted
hook. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

– Unscrew the fixing screw -2- for the engine speed sender -
G28- -1-.
Installing
– Install oil filter holder ⇒ page 78 .
Tightening torque
Component Nm
Engine speed sender - G28- on the sealing 5
flange

2 Engine control unit
2.1 Removing and installing engine control

unit
♦ Body saw, e.g. -V.A.G 1523 A-
Note
♦ In order to be able to unplug the connector from the control

unit, the control unit must always be removed.
♦ If the engine control unit is being replaced, connect the vehicle
diagnosis, measurement and information system - VAS
5051B- and carry out the guided function “replace engine con‐
trol unit”.
Removing
– Switch off ignition.
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
gr. 66 .
– Open retaining clip -arrow- and remove the engine control unit
- J623 - .
Vehicles with protective cover
2. Engine control unit 143

– Cut with body saw a slot for the cross-head screwdriver in the
heads of the pull-off screws -3- and -4-.
Note
♦ It must be sawed twice with the body saw, so that the slot is
wide enough, in order to unscrew the screws with a suitable
screwdriver.
♦ The pull-off screws until are inserted with locking agent.
– Unscrew the screws and remove the protective cover -2- and
-5-.
– Unlock both plug connectors at engine control unit and remove
them.
Installing
– Connect both plugs and lock.
Vehicles with protective cover
– Fasten protective cover with new pull-off screws.
– Tighten pull-off screws evenly until the screw heads are pulled
off.
– Push engine control unit into the bracket and lock with retain‐
ing clip -arrow-.
– Install water box cover ⇒ Body Work ⇒ Rep. gr. 66 .

26 – Exhaust system
exhaust system
Note
♦ The decoupling element in the pre-exhaust pipe should not be

♦ Replace the gaskets and the self-locking nuts.
♦ After performing installation work on the exhaust system,
make sure the exhaust system is not mounted under tension
and has adequate clearance from the vehicle body. If
necessary ,slacken the clamping sleeve and align the silenc‐
ers and exhaust pipe so as to create adequate clearance
between these components and the vehicle body, and to en‐
sure that the weight of the exhaust system is evenly distributed
over the hangers.
1.1 Summary of components
1 - Pressure sensor 1 for ex‐

haust gas -G450- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
2 - Mounting bracket with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ for pressure line

3 - Pressure line - 45 Nm
4 - 10 Nm
5 - lambda probe - G39- - 50
Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ if a re-used lambda
probe is installed, only
coat the thread with hot
bolt paste - G 052 112
A3- ; the hot bolt paste -
G 052 112 A3- must not
get into the slots of the
probe body
6 - Exhaust gas temperature
sender 2 - G448- ( Tempera‐
ture sender upstream particle
filter - G506- )
❑ Tightening torque 45
Nm
❑ the thread of new tem‐
perature transmitters
must be coated with as‐
sembly paste
❑ Grease only the thread
with hot bolt paste - G
052 112 A3- for re-used
temperature sender.
1. Removing and installing parts of the exhaust system 145

7 - Pre-exhaust pipe with diesel particle filter

8 - Identification
❑ for clamping sleeve
9 - Clamping sleeve
❑ align exhaust system free of stress before tightening ⇒ page 149
❑ Tighten bolted connections evenly
10 - 23 Nm
11 - Front tunnel bridge
12 - Retaining strap
❑ Pay attention to the part number
13 - Exhaust gas temperature sender 3 - G495- ( Temperature sender downstream particle filter - G527- )
❑ Tightening torque 45 Nm
❑ the thread of new temperature transmitters must be coated with assembly paste
❑ Grease only the thread with hot bolt paste - G 052 112 A3- for re-used temperature sender.
14 - from exhaust turbocharger
15 - Rear silencer
❑ replace complete when carrying out repairs
❑ Installing the exhaust system without tension ⇒ page 149
16 - Rear tunnel bridge
17 - Shackle
18 - 23 Nm
19 - Clamp - 7 Nm
❑ replace
20 - Gasket
❑ replace
21 - 25 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ screwed onto the cylinder block
23 - 8 Nm
1.2 Removing and installing pre-exhaust

pipe with diesel particle filter
♦ Tool set SW 17 - T 10395-
Removing
146 Rep. gr.26 - Exhaust system

– Release fuel hoses and coolant hoses at right charge air pipe.
– Remove right charge air pipe.
– Remove intake manifold flap motor -V157- ⇒ page 151 .
– Remove exhaust gas recirculation valve -N18- with EGR po‐
tentiometer -G212- and EGR control motor -V338-
⇒ page 151 .
– Disconnect el. plug -4- to lambda probe -G39- .
– Unscrew lambda probe -3-.

– Remove exhaust gas temperature sender 2 - G448- ( temper‐
ature sender upstream particle filter - G506- ).
– Unbolt bracket -2- for pressure lines.
– Unbolt pressure line -4- at diesel particle filter.
– Remove fixing clamp -1- for diesel particle filter.
– Remove right front wheel.
– Remove noise insulation ⇒ Body Work; Rep. gr. 50 and right
wheelhouse liner ⇒ Body Work; Rep. gr. 66 .
– Disconnect plug from oil level and oil temperature sender -
G266- ⇒ page 76 .

– Unscrew exhaust gas temperature sender 3 - G495- ( tem‐

perature sender downstream particle filter - G527- ) -Pos. 1-
from exhaust pipe downstream diesel particle filter.
– Unscrew pressure line -2- for exhaust gas pressure sensor 1
-G450- .
– Disconnect plug -arrow- for remove exhaust gas pressure

sensor 1 -G450- with pressure lines.
– Unscrew the right drive shaft from the gearbox flange.
– Release screws -2unless
andauthorised
3-. by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove drive shaft screening from the engine (if present).
– Remove front tunnel bridge ⇒ Item 11 (page 146) .
Note
The decoupling element in the pre-exhaust pipe should not be

– Slacken nuts of clamping sleeve ⇒ Item 9 (page 146) .
– Unscrew hanger of exhaust system -arrows-.

– Release cover for left underbody.
– Release retaining loop ⇒ Item 12 (page 146) on rear silencer.
– Unscrew heat shield for underbody and push towards fuel
tank.

– Release screws -arrows- at holder for diesel particle filter.

– Remove the pre-exhaust pipe with diesel particle filter by turn‐
ing clockwise 180°; to do so slightly push the engine/gearbox
assembly towards the front.
Installing
following:
Note

♦ All cable straps which are detached when removing, should
be attached again in the same place when installing.
– When installing the connecting hose with push-fit coupling en‐

sure that the locking clip -arrow- interlocks behind the retaining
lugs -A-.
– Align exhaust system free of stress ⇒ page 149 .
– After replacing the diesel particle filter, an adaption must be
performed in the function “Targeted functions” ⇒ Vehicle di‐
agnostic tester.
1.3 Inspecting the exhaust system for leaks
– Start engine and run in idle.

– Seal off exhaust tailpipe for the duration of the leak check (e.g.
with cloths or plugs).
– Inspect connection points of cylinder head/exhaust manifold,
exhaust gas turbocharger/pre-exhaust pipe etc. for leak-tight‐
ness by listening.
– Eliminate any leak found.
1.4 Align exhaust system free of stress

• The exhaust system is aligned when cold.
– Slacken front clamping sleeve -1- and align opposite exhaust
pipe -2- (-arrow- in direction of travel).
-a- = 5 mm
The fixing screws must be located on the right. They must not
protrude beyond the bottom edge of the clamping sleeve.
– Tighten front nut by hand.

– Push the rear silencer so far forward until the pre-tensioning

on the rear retaining strap on the middle silencer is -a- = 7...9
mm.
– Tighten the nuts of the front double clamp evenly to 23 Nm.
Align exhaust tailpipe

– Align rear silencer in such a way that there is an equal distance
-a- and -b- between bumper opening and exhaust tailpipes.
– For aligning the exhaust tailpipes, if necessary loosen hanger
on the rear silencer.

2 Exhaust gas recirculation system
2.1 Removing and installing parts of the ex‐

haust gas recirculation system
Note
♦ The actuation of the exhaust gas recirculation system is per‐

formed by the engine control unit -J248- for the EGR valve -
N18- with EGR potentiometer -G212- and EGR control motor
-V338- .
♦ The mechanical exhaust gas recirculation valve with cone-
shaped valve plunger makes it possible to achieve different
opening cross-sections at different opening strokes.
♦ Always replace self-locking nuts.
1 - Gasket
❑ replace
2 - Intake manifold
3 - Sealing ring
❑ replace
4 - Supports
5 - Intake manifold flap motor -
V157-
❑ The intake manifold flap
is closed for about 3Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
seconds after switching
off the engine and thenwith respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
opens again. This re‐

duces the switch-off im‐
pact.
6 - from charge-air cooler
7 - 10 Nm
trol motor -V338-
sealing surfaces at in‐
take manifold for dirt
and clean as required
Note
♦ After replacing, adapt new part

as follows:
♦ Switch ignition on and off; then
wait 1 minute for the afterrun of
the control units,
♦ Start engine and run in idle for at
least 1 minute,
2. Exhaust gas recirculation system 151

♦ Interrogate event memory ⇒ Ve‐

hicle diagnostic tester, no fault
should be stored in the event
memory.
♦ If a fault occurs, erase the event
memory and repeat the entire
work procedure.
9 - Gasket
❑ replace
10 - Radiator
11 - 22 Nm
13 - 22 Nm
2.2 Assembly overview - cooling of the exhaust gas recirculation system
1 - Coolant hose
❑ to connection fitting
coolant hoses
⇒ page 88
2 - Gasket
❑ replace
3 - 22 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
4 - Connecting pipe with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
5 - From exhaust manifold

6 - 25 Nm
❑ replace
7 - to connection of exhaust
gas recirculation valve -N18-
with EGR potentiometer -
G212- and EGR control motor
-V338-
8 - Radiator
❑ for exhaust gas recircu‐
lation
⇒ page 153
9 - 10 Nm
10 - Coolant hose
❑ from the coolant pipe at
the rear
coolant hoses
⇒ page 88

11 - Connecting hose
12 - Changeover valve for radiator of exhaust gas recirculation -N345-
❑ for recirculation flap
❑ always replace together with radiator for exhaust gas recirculation
❑ Connection diagram ⇒ page 154
2.3 Removing and installing radiator for ex‐

haust gas recirculation
⇒ page 146 .
– Place a catch pan under the engine.
– Detach coolant hoses from radiator for exhaust gas recircula‐
tion.
– Unscrew connection pipe for exhaust gas recirculation radiator
-arrows-.
– Release screws -1-, screw -2- and hollow screw -3-.

– Remove support for exhaust turbocharger with oil return line.
2. Exhaust gas recirculation system 153

– Unbolt bracket -2- for diesel particle filter.

– Disconnect the vacuum line -1- and remove.
– Release screws -arrows- and remove radiator for exhaust gas
recirculation.
Installing
following:
Note

2.4 Hose plan for exhaust gas recirculation

Summary of components ⇒ page 129

28 – Glow plug system

1 Glow Plug System
1.1 Glow Plug - Overview

For glow plugs see ⇒ Parts Catalogue .
Note
Safety regulations must be observed when handling the ceramic

glow plugs ⇒ page 4 .
1.2 Removing, installing and testing the ce‐

ramic glow plugs
♦ Handheld multimeter - V.A.G 1526 B-
♦ Hose - N 020 150 5- approx. 250 mm
♦ Flexible-head wrench SW 10. - 3220-
♦ Torque wrench
♦ Means for loosening the screwed connections
For ceramic glow plugs the followings points must be observed:
1. Glow Plug System 155

Note
♦ The ceramic glow plugs are very sensitive because of their

special material properties and special handling is required
during removal and installation.
♦ They must only be transported and stored in original transport
containers or wrapped individually in air cushion foil.
♦ Remove ceramic glow plugs from their wrapping immediately
before fitting.
♦ The ceramic glow plugs are very sensitive to impacts and
bending. For this reason never use glow plugs that have been
dropped from a low height (approx. 2 cm). Even if no damage
is evident, dangerous hairline cracks might be present.
♦ Always replace the ceramic glow plugs in case of doubt re‐
garding the proper state.
♦ In the event of damage to, or breakage of, the ceramic glow
plugs, this will result in engine damage.
♦ In case of breakage of the ceramic glow plug pin all broken
pieces must be removed from the cylinder before starting the
engine, otherwise this could result in engine damage due to
seizures.
♦ The ceramic glow plugs must not be removed in order to test
the compression pressure.
♦ Always perform the compression pressure test on installed
ceramic glow plugs in the function “Targeted fault finding”
⇒ Vehicle diagnostic tester.
♦ Software for engine control unit is adapted to a specific type
of glow plugs (ceramic or metallic), therefore only the corre‐
sponding glow plugs must be installed.
♦ Changing the ceramic glow plugs to metal glow plugs, or vice
versa, is not permissible.
1.2.1 Removing
– Before removing, check the ceramic glow plugs in the function
“Actuator diagnosis” ⇒ Vehicle diagnostic tester.
– Slacken fuel filter from bracket and lay to the side with con‐
nected hoses.
– Disconnect electrical plug connections at the glow plugs.
Note
♦ When slackening the ceramic glow plug the maximum per‐

missible torque of 20 Nm must not be exceeded.
♦ Always slacken ceramic glow plug with recommended socket
insert and torque wrench.
– Carefully slacken glow plug in compliance with the maximum

permissible torque of 20 Nm.
If the glow plug can be slackened with max. 20 Nm torque
– Use commercially available tool to slacken the screwed con‐
nections and repeat the slackening procedure.
156 Rep. gr.28 - Glow plug system

Note
If the glow plug cannot be slackened with a torque of max. 20 Nm

using the tool for slackening, remove the cylinder head and then
unscrew the plug.
– Put hose -N 020 150 5- with a length of approx. 250 mm onto

the loosened glow plug and carefully unscrew without tilting.
– Pull up the unscrewed ceramic glow plug with hose to avoid
any contact and carefully place down.
1.2.2 Installing
Note
Threads of cylinder heads and glow plugs must be clean and dry,
free from oil and lubricant.
– Clean holes for glow plugs in cylinder head from fixed com‐
bustion residues.
– Screw ceramic glow plugs into the holes and lightly tighten by
hand.
Note
♦ The tightening torque of the ceramic glow plugs must be strict‐

ly observed: max. 12 Nm (for clean, dry, oil-free and grease-
free threads).
♦ In case by
Protected ofcopyright.
non compliance there
Copying for private is a risk
or commercial of breakage
purposes, of the
in part or in whole, is not permitted
pin,withwhich
respect can always lead
to the correctness to severe
of information engineCopyright
in this document. damage.
by ŠKODA AUTO A. S.�
– Tightening ceramic glow plugs with recommended socket in‐

sert, max. tightening torque 12 Nm.
Inspect the installed ceramic glow plugs before the first engine
start.
– Connect hand-held multimeter - V.A.G 1526 B- for resistance
measurement between contact and glow plug housing.
• Specified value: less than 1Ω
If the specified value is exceeded (greater than 1 Ω):
– Remove ceramic glow plug and check if the pin is not broken
off.
Note
In case of breakage of the ceramic glow plug pin all broken pieces
must be removed from the cylinder before starting the engine,
otherwise this could result in engine damage due to seizures. If
required, the cylinder head must be removed.
– Re-connect electrical plug connections for glow plugs.

– Before the first engine start check the installed ceramic glow
plugs via the self-diagnosis ⇒ Vehicle diagnostic tester.
1. Query and erase event memory of engine control unit. Do
not start the engine!
1. Glow Plug System 157

2. Perform self-diagnosis.
3. Query the event memory of the engine control unit again.
Do not start the engine!
Note
The engine must not be started as long as a fault concerning the

ceramic glow plugs is stored in the event memory!
– Check electrical wiring and plug connections for glow plugs.
158 Rep. gr.28 - Glow plug system

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Service

Service Department. Technical Information

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Copyright © 2018 ŠKODA AUTO a. s. S0062090020

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.5 Testing hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.2 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.1 Engine number

1.2 Engine characteristics

1.2 Supplementary instructions and assem‐

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

To prevent damage to condenser or to refrigerant lines/hoses,

Steps which should be taken in order to remove and install the

1.3 Safety precautions when working on

♦ On vehicles with engine with unit injectors, the tempera‐

2 Rep. gr.01 - Self-diagnosis

♦ Fuel pump is activated by switching on ignition and via driver

When undertaking all installation work, particularly in the en‐

1.4 Safety precautions when working on the

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

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

♦ If the battery is disconnected and reconnected, carry out re‐

1.5 Regulations concerning cleanliness

1.6 Regulations concerning cleanliness

1.7 Handling the ceramic glow plugs

4 Rep. gr.01 - Self-diagnosis

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

10 – Removing and installing engine

♦ The engine is removed downwards together with the gearbox.

6 Rep. gr.10 - Removing and installing engine

– Remove dipstick -1- from dipstick guide.

Observe necessary measures when disconnecting the battery

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

1. Removing and installing engine 7

When opening the expansion reservoir, out hot steam or hot

– Drain coolant ⇒ page 92 .

♦ On vehicles with engine with unit injectors, the tempera‐

8 Rep. gr.10 - Removing and installing engine

– Release screw -1- by one turn.

Mark the direction of rotation with chalk or a felt-tip pen before

– Remove V-ribbed belt ⇒ page 21 .

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

In order to avoid damage to the AC condenser as well as to the

– Remove AC compressor and bracket for auxiliary units

– Detach the pre-exhaust pipe of the auxiliary heating and ad‐

– Remove fan shroud and radiator ⇒ page 88 .

1. Removing and installing engine 9

– Release screws -1…3- and remove pendulum support.

The decoupling element in the pre-exhaust pipe should not be

– Remove the pre-exhaust pipe from the exhaust turbocharger

– Unbolt the cable from the AC generator at the fuse holder

10 Rep. gr.10 - Removing and installing engine

– Unclamp all connecting, cooling fluid, vacuum and air guide

After separating the hydraulic line, do not operate the clutch