1 4 132 KW TSI Engine

Service
Workshop Manual
Fabia II 2007 ➤
Fabia II 2009 ➤
Fabia II 2011 ➤
1.4/132 kW TSI engine
Engine ID
CAV CTH
E E
Edition 12.2014
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList 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
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤
1.4/132 kW TSI engine - Edition 12.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Self diagnosis, safety measures, cleanliness regulations, directions . . . . . . . . . . . . . . . . . . 3
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Reduce pressure in the high-pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Rules of cleanliness to observe when working on the fuel supply system . . . . . . . . . . . . . . 4
1.5 Safety measures to apply when working on the fuel injection and ignition system . . . . . . 5
1.6 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.9 Additional instructions when undertaking assembly work on the air-conditioning system . . 8
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.5 Unit mounting - tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Camshaft drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2 Removing and installing the timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3 Sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Sealing flanges and flywheel - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 Replacing gasket ring on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3 Installing and removing the vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.4 Removing and installing the sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . 39
3.5 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1 Crankshaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2 Removing and installing the crankshaft needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1 Piston and conrod - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 Inspect piston, piston rings and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.4 Removing and installing oil injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Contents i
1.2 Test timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.3 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.4 Removing and installing timing chain and drive chain for oil pump . . . . . . . . . . . . . . . . . . 64
1.5 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.6 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.7 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.8 Testinf the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.1 Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.2 Checking the axial play of the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5 Replacing the valve stem seals on the installed cylinder head . . . . . . . . . . . . . . . . . . . . . . 87
2.6 Replacing the valve stem seals on the removed cylinder head . . . . . . . . . . . . . . . . . . . . . . 88
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Lubrication system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.4 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.5 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.1 Parts of cooling system on the side next to the body - Summary of components . . . . . . . . 102
1.2 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.3 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4 Coolant regulator - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.6 Removing and installing coolant recirculation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.7 Removing and installing fan shroud for radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.9 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.1 Fuel tank with component parts - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 118
1.2 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.3 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.5 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 128
1.6 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2 Separating quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4 Activated charcoal container system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1 Activated charcoal container system - Summary of components . . . . . . . . . . . . . . . . . . . . 144
4.2 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.3 Testing exhaust turbocharger pressure box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ii Contents
2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.1 Summary of components - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.2 Removing and installing the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.1 Charge air cooling system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.3 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Fitting locations of injection and ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2 The intake manifold and the bottom part of the intake manifold . . . . . . . . . . . . . . . . . . . . . . 165
2.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2 Bottom part of the intake manifold, fuel distributor and injection valve - assembly overview
........................................................................ 168
2.3 Brake vacuum pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.4 Removing and installing regulating flap control unit J808 and throttle valve control unit J338
...................................................................... 170
2.5 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3 Air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.1 Air filter housing - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.1 High pressure pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.1 Removing and installing injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.2 Replace Teflon gasket ring and supporting washer at injection valve . . . . . . . . . . . . . . . . 181
6 Testing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.1 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.1 Front part of exhaust system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.2 Removing and installing front silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.3 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.4 Replace middle and rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.6 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Ignition system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Removing and installing ignition coils with power output stages . . . . . . . . . . . . . . . . . . . . 198
Contents iii
iv Contents
00 – Technical data
1 Technical data
(SRL000770; Edition 12.2014)
1.1 Engine number

The engine number (“engine identification characters” and “serial
number”) can be found on the sticker -arrow- at the timing case.
The engine identification character is also indicated on the vehicle
data sticker and on the crankcase above the gearbox.
The engine number consists of up to nine digits (alphanumeric).
The first part represents the “engine code” (a maximum of 3 iden‐
tification letters), the second part the “serial number” (six charac‐
ters). If more than 999.999 engines with the same engine code
were produced then the first digit of the six part section will be
replaced by a letter.
Vehicles with four-digit engine identification characters
Four-digit engine identification characters are used. The first 3
digits denote the mechanical design of the engine and are stam‐
ped on the engine as before. The fourth digit refers to the output
and torque of the engine and depends upon the engine control
unit. The four digit engine identification character is indicated on
the vehicle data sticker.
Note
If the sticker does not exist, the “engine identification character”

and the “serial number” can be read on the cylinder block using
a mirror and a lamp.
Engine identification character and serial number on cylinder

block -arrow-.
1.2 Engine characteristics

Issue: 12.2014; Version: 3.0
Engine identification characters CAVE CTHE
Manufactured 05.10 ► 09.12 09.12 ► 12.14
Emission levels in accordance EU5 EU5
with
Displacement cm 3 1390 1390
Power output kW at rpm 132/6200 132/6200
Torque Nm at rpm 250/2000 … 4500 250/2000...4500
Bore ∅ mm 76,5 76,5
1. Technical data 1
Engine identification characters CAVE CTHE

Stroke mm 75,6 75,6
Compression 10:1 10:1
Cylinder / valves per cylinder 4/4 4/4
RON unleaded 98 1) unleaded 98 1)
Ignition system, fuel injection Motronic MED 17.5.5 Motronic MED 17.5.5
Type of fuel preparation Direct injection homogeneous Direct injection homogeneous
Knock control 1 sensor 1 sensor
Lambda control 2 Lambda probes 2 Lambda probes
Three-way catalytic converter yes yes
Exhaust gas recirculation no no
Intake manifold change-over no no
Camshaft adjustment yes, inlet camshaft yes, inlet camshaft
Secondary air system no no
Balancing shaft no no
Turbocharging Turbocharger and mechanical Turbocharger and mechanical
compressor compressor
1 At least 95 RON in exceptional cases, although engine output
is reduced.
2 Rep. gr.00 - Technical data

01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations, directions
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 Safety precautions when working on the

fuel supply system
WARNING
♦ The safety measures for the pressure reduction in the high

pressure system must be observed ⇒ page 4 .
♦ Lay lines of all kinds in such a way that the original line
guide is re-established.
♦ The fuel system is under pressure!
♦ Wear safety goggles and fuel-resistant gloves, in order to
avoid injuries and skin contact.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
For reasons of safety the current supply to the fuel pump must
be interrupted before opening the fuel system. Otherwise the
fuel pump is activated when opening the driver's door. One of
the following options must be used to interrupt the current sup‐
ply:
♦ Disconnect battery
or
♦ Take out fuse for fuel pump control unit - J538-
or
♦ Disconnect the plug on the flange of the fuel pump or on
the fuel pump control unit - J538- .
When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
1. Self diagnosis, safety measures, cleanliness regulations, directions 3

1.3 Reduce pressure in the high-pressure

system
Caution
♦ The injection system consists of a high pressure part

(max. pressure of 12 MPa = 120 bar) and a low pressure
part (pressure of approx. 0.6 MPa = 6 bar).
♦ Before opening the high pressure system, e.g. removing
the high pressure pump, the fuel distributor, the injection
valves, the fuel pipes or the fuel pressure sender - G247- ,
the fuel pressure in the high pressure area with a remain‐
ing pressure of approx. 0.6 MPa (6 bar) must be reduced.
The procedure for this is described below.
– Perform a vehicle diagnosis, measurement and information

system - VAS 505X- of the guided function “remove high fuel
pressure”.
– Switch off ignition.
– For safety reasons before opening the fuel system disconnect
the plug from the fuel pump control unit -2-.
WARNING
The fuel lines are pressurized! Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.
Before opening the high pressure system, lay cleaning cloths
around the connection point.
– Now lay a clean cleaning cloth around the connection point

and carefully open it up, in order to reduce the remaining pres‐
sure of approx 0.6 MPa (6 bar). Collect the fuel which flows
out.
Note
♦ Interrogate the event memory for the engine control unit at the
end of the work fort he fuel system and delete all the event
entries.
♦ After deleting the event memory of the engine control unit the
readiness code must be re-generated.
1.4 Rules of cleanliness to observe when

working on the fuel supply system
Carefully observe the following 5 rules for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
4 Rep. gr.01 - Self-diagnosis

♦ 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. in tool boxes etc.).
♦ When the system is open: Avoid using compressed air when‐
ever possible. Avoid moving the vehicle.
1.5 Safety measures to apply when working

on the fuel injection and ignition system
WARNING
♦ The safety measures for the pressure reduction in the high

pressure system must be observed ⇒ page 4 .
♦ The fuel system is under pressure! Wear safety goggles
and fuel-resistant gloves, in order to avoid injuries and skin
contact. Place a clean cleaning cloth around the connec‐
tion point before detaching wiring. Reduce pressure by
carefully removing the wiring.
Observe the following points to prevent injury to persons and/or

damage to the injection and ignition system:
♦ Do not touch or pull off ignition cables with output stage when
engine is running or turning at starter speed.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure,
open lid of fuse carrier in the engine compartment and unplug
fuse for Motronic current supply relay - J271- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
♦ The fuel delivery unit is activated when the ignition is switched
on and by the door contact switch of the driver door. Before
opening the fuel system and for reasons of safety, if the battery
is not disconnected, the plug -2- must be disconnected from
the fuel pump control unit.
Caution
When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,
activated charcoal filter, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.
If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger could be injured by the release of
the passenger airbag in the event of an accident.

1.6 General notes on the injection system

Repairing ignition ⇒ page 197 .
♦ The engine control unit is equipped with self-diagnosis. Before
repairs and also for fault finding, first of all interrogate the event
memory. Also check the vacuum hoses and connections (un‐
metered air).
♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ ETKA - Electronic catalogue of origi‐
nal parts . The use of clamp-type or screw-type clips is not
allowed.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnostic tester.
♦ When opening the driver door the fuel pump is activated for 2
seconds in order to build up the pressure in the fuel system.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety measures ⇒ page 5 .
1.7 General notes on the ignition system

♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the engine control unit.
♦ The engine control unit is equipped with self-diagnosis; in‐
spect ⇒ Vehicle diagnostic tester.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnostic tester.
Safety measures ⇒ page 5 .
Setting data, spark plugs ⇒ Maintenance ; Booklet Fabia II .

1.8 General instructions for charge air sys‐

tem
WARNING

♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,
activated charcoal filter, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ Ensure that there is adequate free access to all moving or
hot components.
Caution
In case a mechanical damage to the exhaust gas turbocharger

is found, for example, damage to the compressor wheel, it is
not sufficient to only replace the turbocharger. In order to avoid
consequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
♦ The charge-air system must be tight.

♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
♦ Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
♦ Observe the instructions for installing the charge air hoses on
the fluted pipes (tightening torque of the screw clamps)
⇒ page 160 .
♦ Observe assembly markings on the hoses and components.
♦ All hose connections of the charge air system are secured with
screw clamps.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ ETKA - Electronic Catalogue of Original Parts .
♦ After installing the exhaust turbocharger, run engine at idling
speed for about 1 minute to ensure that oil is supplied to the
turbocharger bearing.

1.9 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system
WARNING
Risk of injury through refrigerant.

♦ Do not open the refrigerant circuit of the air conditioning
system.
Caution
Risk of damaging the condenser as well as the refrigerant lines

and hoses.
♦ Do not over-tension or buckle refrigerant lines and hoses.
Steps which should be taken in order to remove and install the

engine without opening the refrigerant circuit:
– Unscrew the holding clamp(s) on the refrigerent lines
– Remove AC compressor from the bracket ⇒ page 23 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

10 – Removing and installing engine

1 Removing and installing engine
1.1 Removing and installing engine trim

panel
Removing
Caution
The bracket for the engine cover on the cylinder head cover
can break off when it is incorrectly disassembled.
♦ It is therefore necessary to remove the engine cover ac‐
cording to the following instruction.
– Pull the engine cover at the points -arrows- upwards and

through this slacken it. To do so, grasp the engine cover from
underneath as far as possible.
– Then pull the engine cover forwards out of the rear support
-1-.
Install
Caution
Before installing the engine cover, check the correct fitting po‐
sition of the 2 fixing elements (ball sockets). If necessary, move
them back into the correct position. Otherwise this can lead to
damage to the engine cover.
– If necessary, press the ball sockets of the engine cover into

the correct position.
1. Removing and installing engine 9

– Insert the engine cover into the rear support -1-.

– Then press down the engine cover at the points -2- until it
clicks into place.
1.2 Removing engine

Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Supporting device - MP9-200 (10-222A)-
♦ Engine mount - T10416- with adapter /1, /2, /3
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-
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.
♦ Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
♦ Collect drained coolant in a clean container for proper disposal
or reuse.
WARNING

hot components.
Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 3 .
WARNING
Reduce pressure in the high pressure system ⇒ page 4 .
– Remove engine cover ⇒ page 9 .
10 Rep. gr.10 - Removing and installing engine

– Before disconnecting the battery, if necessary remove the

adapter for the anti-theft wheel bolts from the luggage com‐
partment.
– Remove air filter housing ⇒ page 174 .
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Only slacken the nut of the right drive shaft.
– Remove front wheels.
– Remove the right and left wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Drain coolant ⇒ page 104 .
– Remove drive shaft to the right ⇒ Chassis; Rep. gr. 40 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box.
– Unscrew the nut from the left coupling rod -2- and press off the
coupling rod from the anti-roll bar.
– Unscrew the nuts for the left steering joint -3- and press the
steering joint out of the suspension arm.
– Unscrew the nut -2- from the track control arm on installed front
left vehicle level sensor - G78- .
– Turn steering to full left lock.

– Swivel the steering joint outwards and secure the drive shaft
-1- with strap -A- in the wheelhouse.
– Open clamp -4- and detach the hose from the pressure pipe
-8-.
– Unscrew screws -2- and -7-.
– Remove holding clamp -1- and pressure pipe -8-.
– Detach the vacuum line -1- from the el. vacuum pump -2-.
– Open the bracket for coolant line at front top frame side rail
-arrow- and loosen the coolant lines -3- and -4-.
– Detach the vacuum line -arrow- from the brake servo unit.

– Detach vacuum hose -4- from intake manifold -5-. To do so,

push the quick coupling onto the intake manifold support
-arrow 1-, press in the securing elements -arrow 2- on the left
and right forcefully and disconnect the line -arrow 3-.
– Unclip vacuum line and remove.
– Remove fuel feed line -3- ⇒ page 139 .

– Collect the fuel which flows out with a cloth.
– Detach vent line -4- ⇒ page 139 .
– Separate plug connection -2-.
– Release screws -1- and attach the expansion reservoir with
the connected refrigerant lines at the engine.
– Detach the coolant hoses at the heat exchanger -arrows-.
– Pull off coolant hoses at top of radiator -arrows-.

– Disconnect plug from coolant temperature sender at radiator
outlet - G83- .
– Remove wiring loom from starter and place down ⇒ Electrical
System; Rep. gr. 27 .
– Remove engine control unit ⇒ page 188 .
– Disconnect the plug of the engine wiring harness from the en‐
gine control unit and remove.

– Disconnect plug connection -arrow-.
– Carefully slacken the engine wiring harness on its fixing points

-arrows-.
– Place the engine wiring harness on the engine.
– Unlock the cap for the plug of the mechatronics by pulling in

-direction of arrow- and disconnect the plug.
– Remove the selector lever control cable from the gearbox ⇒
Gearbox; Rep. gr. 34 .
– Remove the right charge air hose, to do so slacken the clamps

-arrows-.
– Put lock carrier in service position ⇒ Body Work; Rep. gr. 50 .
– Removing fan shroud ⇒ page 112 .
– Remove wiring loom from alternator and place down ⇒ Elec‐
trical System; Rep. gr. 27 .
– Remove pre-exhaust pipe ⇒ page 192 .

– Unlock cable clip -5- and disconnect plug -1-.

– Pull the plug -4- out of the holder.
– Open the bracket for coolant line sideways on the rear frame
side rail.
– Disconnect plug -1- at the oil level and oil temperature sender
- G266- .
– Slacken wiring loom at cylinder block.
– Unbolt the pendulum support -arrows-.
WARNING
Bolt -1- must not be loosened.
– Remove V-ribbed belt ⇒ page 24 .
WARNING

system.
Caution
Risk of damaging refrigerant lines and hoses.


– Disconnect plug connection -1- for magnetic coupling at AC

compressor.
– Release screws -arrows- for AC compressor.
– Attach AC compressor to body.
– Position the supporting device - MP9-200- , as shown in the

figure, and hook it into the lifting eye.
– Pre-tension the engine.
Caution
The nut -2- must not be released.
– Unscrew securing bolts -arrows-.

– Remove the complete engine mounting.
– Only lower the engine/gearbox assembly by approx. 30 mm
until the engine mount - T10416- can be installed.
In order to lower the engine with the gearbox, the engine holder
- T10416- with the adapters -/1-, -/2- and -/3- is required.

– Turn the adapter - T10416/1- up to the stop in the cylinder

block.
– Fit the engine mount - T10416- with the adapters -/2- and
-/3- to the cylinder block.
– Attach the engine mount - T10416- with the screw -1- by hand
at the cylinder block.
– Tighten all screws on the engine mount - T10416- to 20 Nm.
Note
Adjust the correct angle between the bolts at the engine mount -
T10416- and engine/gearbox jack - V.A.G 1383 A- using the
adjustment nut -2-.
– Position engine and gearbox jack - V.A.G 1383 A- on engine

support - T10416- .
– Slightly raise the engine/gearbox assembly with the engine/
gearbox jack - V.A.G 1383 A- .
Note
♦ Check whether all hose and line connections between engine,

gearbox and body are released, if necessary release them.
♦ Use the double ladder - VAS 5085- in order to remove the
fixing screws for the gearbox mount.
– Remove supporting device - MP9-200- .

– Release screws -2- from gearbox mount -1-.
Note
♦ The engine/gearbox assembly should be lowered with the help

of a second mechanic.
♦ When lowering carefully guide the engine/gearbox assembly,
in order to avoid damage.
– Pull engine/gearbox unit as far forward as possible and lower

carefully and slowly downwards. During this procedure, turn
or move the engine/gearbox assembly if necessary.
– Remove the gearbox from the engine ⇒ gearbox; Rep. gr.
34 .
1.3 Securing the engine to the assembly

stand
♦ Lifting device - MP9-201 (2024 A)-
♦ Engine mount - MP1-202-
♦ Assembly stand - MP9-101-
♦ Adapter - MP1-202/8-
♦ Adapter - MP1-202/9-
♦ Workshop crane , e.g. -VAS 6100-
– Hook on the lifting device -MP9-201 (2024 A)- at the workshop
crane (e.g. -VAS 6100- ) and at the engine as shown (the fig.
shows the 1.4 ltr./90 kW TSI engine; the engine mount is iden‐
tical).
WARNING
Use securing pins on the hooks and rig pins to prevent release.
Use securing pins on the hooks and rig pins -arrows-, in order
to avoid injuries and damages to the engine.
– Lift off engine with installed engine mount - T10416- with work‐
shop crane (e.g. -VAS 6100- ) from engine/gearbox jack -
V.A.G 1383 A- .
– Remove engine mount - T10416- .

– Screw engine mount - MP1-202- with adapters - MP1-202/8-

and -MP1-202/9- to engine -arrows- and secure to the assem‐
bly stand - MP9-101- .
1.4 Installing the engine

♦ Double ladder , e. g. -VAS 5085-
♦ Engine mount - T10416- with adapter /1, /2, /3
– Check whether the dowel sleeves for centering the engine/
gearbox are present in the cylinder block; insert if necessary.
– Ensure that the intermediate plate has been inserted on the
sealing flange and is pushed onto the dowel sleeves
-arrows-.

– Replace the needle bearing -arrow- in the crankshaft

⇒ page 49 .
– Attach gearbox to engine ⇒ Gearbox; Rep. gr. 34 .
– Install engine/gearbox assembly with engine mount - T10416-
on engine and gearbox jack .
Installation is carried out in the reverse order. Pay attention to the
following:
WARNING

hot components.
Note
♦ All cable straps and heat shield foils should be fitted on again
in the same place when installing.
♦ Secure all hose connections with hose clamps ⇒ ETKA -
Electronic Catalogue of Original Parts .
♦ Replace self-locking nuts.
♦ Replace screws which have been tightened firmly to a torquing
angle.
♦ Always replace gasket rings and seals.
♦ When installing the engine/gearbox assembly, ensure clear‐
ance to the assembly carrier, the AC compressor as well as to
the radiator.
Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 3 .
– Insert engine/gearbox assembly in the body and raise until the
gearbox support bracket rests against the gearbox mount.
– Screw in new screws for gearbox mount by hand.
Note
To do so, use the double ladder - VAS 5085- .
– Install engine mount ⇒ page 22 .


• The distance from the engine mount to the timing case must
be 30 mm. Otherwise the engine mount - T10416- may tilt in
the gearbox jack.
– Lower the gearbox jack and pull it out of the engine mount -
T10416- .
– Lower the vehicle.
– Raise the engine via the spindle until the engine rests on the
engine mount.
– Screw in new screws for engine mount by hand.
– Align the engine/gearbox unit free of stress and attach firmly
⇒ page 22 .
– Remove supporting device - MP9-200- .
– Remove engine mount - T10416- from engine.
– Install pendulum support ⇒ page 22 .
– Install drive shafts ⇒ Chassis; Rep. gr. 40 .
– Install AC compressor ⇒ page 23 .
– Install the V-ribbed belt ⇒ page 24 .
– Attach the selector lever control cable at the gearbox ⇒ Gear‐
box; Rep. gr. 34 .
– Install the engine wiring harness and the engine control unit
⇒ page 188 .
– Install front silencer ⇒ page 192 .
– Install vacuum line for brake servo unit.
– Connect electrical connections and attach cables ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
– Install the left and right wheelhouse liner ⇒ Body Work ⇒ Rep.
gr. 66 .
– Install fan shroud ⇒ page 112 .
– Connect coolant hoses.
– Connect all the fuel lines ⇒ page 139 .
– Install air filter housing ⇒ page 174 .
– Install the battery and pay attention to the necessary work after
re-connecting the battery ⇒ Electrical System; Rep. gr. 27 .
– Checking the oil level ⇒ Maintenance ; Booklet Fabia II .
– Top up coolant ⇒ page 104 .
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
– Install the engine cover ⇒ page 9 .
– Interrogate all event memories and delete all fault entries
which are caused by removing and installing the engine ⇒ Ve‐
hicle diagnostic tester.
After deleting the event memory of the engine control unit the
readiness code must be re-generated ⇒ Vehicle diagnostic
tester.
– Perform a test drive.
– Then perform a vehicle system test and if necessary eliminate
the resulting faults ⇒ Vehicle diagnostic tester.

Tightening torques
Component Nm
Screws/nuts M6 9
M7 13
M8 20
M10 40
M12 70
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. gr. 34
Screws for assembly bracket ⇒ page 22
1.5 Unit mounting - tightening torques

Assembly bracket - engine
1 - Vibration damper, not fitted on this engine
2 - 20 Nm + torque a further 90° (1/4 turn) - replace

4 - 16 Nm
Assembly bracket - gearbox
Note
Śruby -1- dokręcić w następującej kolejności: od tyłu, z przodu,

następnie od góry.
Pendulum support
– Position the screws -A- in the elongated holes of the pendulum
support in such a way that there is maximum distance between
the gearbox and the assembly carrier.
• The screw -arrow- must not be loosened.
A - 30 Nm + torque a further 90° (1/4 turn) - replace
B - 40 Nm + torque a further 90° (1/4 turn) - replace

13 – Crankshaft group
1 V-ribbed belt drive
1.1 V-ribbed belt drive - Summary of components
1 - 40 Nm + torque a further 90°

(1/4 turn)
❑ to slacken and tighten
the fixing screw, coun‐
terhold the compressor
shaft using a wrench
❑ replace
2 - Belt pulley
❑ for compressor
3 - 23 Nm
4 - Tensioning pulley
❑ for compressor's ribbed
V-belt
❑ slacken using the
wrench
❑ lock with locking pin -
T10060 A-
5 - 8 Nm
6 - Coolant pump with magnet‐
ic coupling for compressor -
N421-
❑ Removing and installing
⇒ page 108
❑ Tightening torques of
the fixing screws tooth‐
ed belt gear at the cool‐
ant pump: 24 Nm
7 - 23 Nm
❑ for the V-ribbed belt
❑ loosen with open-end
wrench SW 16 -
T10241-
❑ lock with locking pin - T10060 A-
9 - 23 Nm
10 - AC generator
11 - Belt pulley
❑ for crankshaft
❑ Clamping surfaces must be free of oil and grease.
12 - Fixing screw
❑ Removing and installing ⇒ page 37
❑ replace
❑ The clamping surface of the fixing screw must be free of grease and oil.
1. V-ribbed belt drive 23

❑ insert oiled (thread)
❑ tightening may occur in successive stages
❑ the torquing angle can be measured with a commercially available angle measuring plate, e.g. Hazet
6690
13 - 40 Nm + torque a further 90° (1/4 turn)
❑ remove and install from below
❑ replace
14 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
15 - Screw
❑ M8 = 25 Nm
❑ M10 = 45 Nm
❑ for the V-ribbed belt
❑ slacken using the wrench
❑ lock using the 4 mm hexagon wrench
17 - V-ribbed belt
❑ for generator, AC compressor and coolant pump
❑ Belt drive ⇒ page 25
❑ before removing mark running direction
18 - V-ribbed belt
❑ for compressor
❑ Belt drive ⇒ page 26
1.2 Removing and installing V-ribbed belt

♦ Locking pin - T10060 A-
♦ Open-end wrench waf 16 - T10241-
♦ 4 mm hexagon wrench
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Remove the right wheelhouse liner ⇒ Body Work; Rep. gr.
66 .
Caution
Risk of damage through reversing the rotation direction of an

already used V-ribbed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the V-ribbed belt.
24 Rep. gr.13 - Crankshaft group

– Swivel out the top tensioning pulley from above using an open-
end wrench SW 16 - T10241- in -direction of arrow-, in order
to slacken the V-ribbed belt.
– Interlock the tensioning element with the locking pin - T10060
A- .
– Swivel out the tensioning pulley from below using an open-end

wrench SW 16 in -direction of arrow-, in order to slacken the
V-ribbed belt.
– Secure tensioning device with 4 mm hexagon wrench -1-.
– Remove V-ribbed belt -2-.
Install
Belt drive for generator, AC compressor and coolant pump

1 - Belt pulley for coolant pump
2 - Vibration damper
3 - Bottom tensioning pulley
4 - Top tensioning pulley
5 - Belt pulley for generator
6 - Belt pulley for AC compressor
7 - V-ribbed belt

Belt drive for AC compressor

1 - Belt pulley for compressor
3 - Belt pulley for coolant pump with belt pulley for magnetic cou‐
pling for compressor - N421-
4 - V-ribbed belt
Note
♦ The belt pulley for the magnetic coupling for compressor -

N421- is located behind the belt pulley for coolant pump.
♦ The V-ribbed belt -4- operates on the belt pulley for the mag‐
netic coupling for compressor - N421- .
Caution
♦ Before fitting the V-ribbed belt make sure that all assem‐
blies (AC generator, AC compressor, coolant pump) are
securely mounted.
♦ Pay attention to the rotation direction and correct position
of the belt in the belt pulleys and rollers when installing an
“already used” V-ribbed belt.
– First lay the V-ribbed belt on the vibration damper. Then push
the belt onto the top tensioning pulley.
Further installation occurs in reverse order.
– Start engine and check ribbed V-belt run.
1.3 Removing and installing bracket for aux‐

iliary units
Removing
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .
WARNING

system.
Caution
Risk of damaging refrigerant lines and hoses.

– Remove AC compressor from holder ⇒ Heating, Air Condi‐

tioning; Rep. gr. 87 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

– Unscrew fixing screws -1- and remove holder with tensioning

pulley.
Install
– Fit the bracket for auxiliary units to the cylinder block.
– Tighten fixing screws -1- to 25 Nm.

Tightening torque tensioning pulley: ⇒ page 23 .

2 Camshaft drive
2.1 Camshaft drive - Summary of components
Note
♦ Before assembly oil all bearing and contact surfaces.

♦ If considerable quantities of metal swarf or abrasion is found when carrying out engine repairs, this can be
subject to damage to the crankshaft and conrod bearings. In order to avoid consequential damage, after the
repair perform the following tasks:
– Carefully clean the oil galleries.

– Replace oil spray jets.
– Replace engine oil cooler.
– Replace oil filter.
1 - Cylinder head with cam‐

shaft housing
⇒ page 76
❑ Do not rework the seal‐
ing surface
❑ with integrated cam‐
shaft bearings
2 - Cylinder block
❑ Sealing flanges and fly‐
wheel ⇒ page 34
❑ Pistons and conrods
⇒ page 50
3 - Bracket for auxiliary units
⇒ page 26
4 - Cover
5 - Sprocket
❑ for oil pump drive and
timing chain
❑ Clamping surfaces must
be free of oil and grease.
(1/4 turn)
❑ replace
7 - Sprocket
❑ Counterhold sprocket
with counterholder -
T10172-
8 - Chain
❑ mark running direction
(installed position) be‐
fore removing

9 - 25 Nm
10 - Carrier bolt for chain tensioner, 8 Nm
11 - Chain tensioner with tensioning rail
❑ for oil pump drive
12 - Oil pan
❑ clean sealing surface before installing
❑ install with silicone sealant ⇒ ETKA - Electronic catalogue of original parts
13 - 13 Nm
❑ replace
14 - Chain tensioner
15 - 9 Nm
16 - Diamond coated washer
❑ clipped onto the vibration damper
❑ replace
17 - O-ring
❑ replace
18 - Bushing
19 - Sealing ring
❑ Renew ⇒ page 35 .
❑ clipped onto the vibration damper
❑ replace
21 - Belt pulley
❑ for crankshaft
❑ Secure belt pulley with counterholder - T30004 (3415)- to prevent it from turning
❑ Removing and installing V-ribbed belt ⇒ page 24
22 - Screw
❑ Replacing
❑ Removing and installing ⇒ “3.3 Installing and removing the vibration damper”, page 37
23 - 10 Nm
24 - Support
❑ for charge air pipe
25 - 8 Nm
26 - 23 Nm
27 - Support
❑ for charge air pipe
28 - 50 Nm
29 - Timing case
2. Camshaft drive 29
❑ insert with sealant ⇒ ETKA Electronic Catalogue of Original Parts
30 - Gasket
❑ Counterhold camshaft adjuster with counterholder - T10172-
❑ Screw with left-hand thread
❑ replace
❑ replace
33 - Tensioning rail
34 - Camshaft adjuster
❑ must not be disassembled
35 - Timing chain
36 - Sprocket
❑ for exhaust camshaft
37 - Sliding rail
❑ for timing chain
38 - Guide bolt, 18 Nm
39 - Bushing
2.2 Removing and installing the timing case

♦ Counterholder - T30004 (3415)-
♦ Bolt - T30004/1 (3415/1)-
♦ Sealant ⇒ ETKA - Electronic catalogue of original parts
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
Removing

-8-.
– Pull out the ventilation pipe -5- from the timing case.
– Remove the expansion reservoir with the connected coolant
hoses and lay to the side.
– Remove holder for compressor and bottom tensioning pulley
⇒ page 26 .
– Remove AC generator and top tensioning element ⇒ Electri‐
cal System; Rep. gr. 27 .
– Unscrew the hollow screw -2- of the oil feed line -1- for the
exhaust gas turbocharger out of the timing case -3-.
– Rotate the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 57 .
– Remove vibration damper ⇒ page 37 .
Caution
Risk of engine damage.

♦ In order to avoid that the chain sprocket on the crankshaft
slides out of the driver, the crankshaft must not be turned
when the V-ribbed belt pulley is released.
– Remove coolant pump ⇒ page 108 .

– Removing the oil pan ⇒ page 94 .

– Pre-tension the engine.
Caution
The nut -2- must not be released.

– Remove the complete engine mounting.
– Unscrew bracket for charge-air pipe ( ⇒ page 28 , Pos. 30).
– Release the Allen screws -1- to -6- of the timing case and the
screws marked with the -arrows-.
– Remove timing case. To do so - if necessary - slightly raise
engine.
Note
Make sure that the bushing for the crankshaft remains in the tim‐
ing case.
– Drive gasket ring for crankshaft out of the timing case.

Install
WARNING
Wear protective gloves when working with sealant and grease

remover!
– Remove residual sealant on the sealing surfaces with chemi‐

cal sealant remover.
– Degrease the sealing surfaces.
– Insert new gasket rings -arrows- onto the reverse side of the
timing case.
– Clean the clamping surfaces of the crankshaft chain sprocket.
They must be free of oil and grease.

Note
♦ Furthermore, the timing case is sealed to the engine with a

seal and additionally with the sealant ⇒ ETKA - Electronic
Catalogue of Original Parts .
♦ The sealant should prevent leaks between the timing case and
the joints -1- and -2-.
♦ The sealant points must have a diameter of 10 mm and must
be approx. 1 mm thick.
♦ Only apply the sealant immediately before installing the timing
case.
– Apply the sealant onto the joints of the camshaft housing/cyl‐

inder head -1- and the cylinder head/cylinder block -2-.
– Carefully place the new gasket onto the dowel pins.
– For better guidance, screw 2 pin screws M6 x 80 into the cyl‐
inder head and the cylinder block.
– Position the timing case onto the pin screws and the dowel
pins.
– Tighten diagonally and evenly the fixing screws of the timing
case.
Make sure that the timing case does not tilt.
Tightening torques:
Screw M6 - 10 Nm
Screw M10 - 50 Nm
– Install gasket ring on belt pulley side ⇒ page 35 .
– Install the oscillation damper ⇒ page 37 .
– Attach the oil feed line for the exhaust gas turbocharger to the
timing case ⇒ page 146 .
– Install engine mount ⇒ page 22 .
3 Sealing flanges and flywheel
3.1 Sealing flanges and flywheel - Summary of components
1 - Screw
❑ replace
⇒ “3.3 Installing and re‐
moving the vibration
damper”, page 37
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
2 - Vibration damper
⇒ page 37
❑ clipped onto the vibra‐
tion damper
❑ replace
4 - Sealing ring
5 - Bushing
6 - O-ring
❑ replace
❑ in the spacer bush
❑ replace
8 - Cylinder head
⇒ page 76
❑ replace
10 - The two-mass flywheel
❑ Assembly is only possible in one position through offset holes.
11 - Intermediate plate
❑ must be positioned on dowel sleeves
❑ do not damage/bend during assembly work
12 - 10 Nm
❑ replace
13 - Sealing flange on the gearbox side
❑ Only replace sealing flange complete with gasket ring and rotor

14 - Engine speed sender - G28- , 5 Nm
❑ with captive screw
3.2 Replacing gasket ring on belt pulley side

♦ Gasket ring extractor - MP1-226 (3203)-
♦ Assembly device - T10053-
♦ Assembly device - T10117/2-
Removing
– Remove vibration damper ⇒ page 37 .
– Turn inner part of gasket ring extractor - MP1-226- 3 turns
(approx. 5 mm) out of the outer part and lock with knurled
screw.
3. Sealing flanges and flywheel 35

– Oil the thread head of the gasket ring extractor - MP1-226 - ,

position and forcefully screw it into the gasket ring as far as
possible.
– Release knurled screw and turn the inner side against the
bushing until the gasket ring is pulled out.
Note
♦ The diamond coated washer on the crankshaft journal must

not fall down when removing the bushing.
♦ Therefore, separate the head from the old fixing screw and
trim.
– Screw the old fixing screw without head into the crankshaft by
hand.
– Remove the bushing, O-ring and diamond coated washer from
the crankshaft journal.
– Screw out the old fixing screw without head.
– Clean the clamping surfaces of the bushing and the chain
sprocket. They must be free of oil and grease.
Install
– Screw the old fixing screw without head into the crankshaft in
order to secure the old diamond coated washer against falling
down.
– Press the new diamond coated washer onto the crankshaft
journal ( ⇒ page 34 , Pos. 7).
– Screw out the old fixing screw without head.
Note
Observe that the clamping surfaces of the belt pulley, the bushing
and the crankshaft chain sprocket are free of oil and grease.
– Press the new gasket ring up to the stop into the bushing.
– Push the bushing onto the crankshaft journal.
– Position the assembly device - T10117/2- on the bushing and

slide the gasket ring onto the sleeve.
– Remove the assembly device - T10117/2- from the bushing.

– Press the gasket ring with the assembly device - T10053- by

striking uniformly up to the stop in the timing case.
– Install the oscillation damper ⇒ page 37 .
3.3 Installing and removing the vibration

damper
♦ Bolt - T30004/1 (3415/1)-
♦ Locating screw - T10340-
♦ Adapter for dial gauge - T10170- or -T10170 A-
♦ Dial gauge , commercially available
Removing
Note
♦ In order to avoid the tightening torque of the fixing screw for

the vibration damper being altered by slip, the locating screw
- T10340- must be used in addition to the counterholder -
T30004- .
♦ The locating screw - T10340- locks the crankshaft in direction
of rotation of engine at TDC.
Caution
Risk of engine damage!

♦ The locating screw - T10340- must not be used to slacken
the fixing screw for the vibration damper - only for tight‐
ening!
♦ The locating screw - T10340- must only be screwed in the
“TDC” position of the crankshaft.

– Loosen fixing screw for vibration damper.

Counterhold vibration damper with counterholder - T30004-
with bolt - T30004/1- .
– Unscrew fixing screw and remove vibration damper.
Caution
Risk of engine damage.

♦ In order to avoid that the chain sprocket on the crankshaft
slides out of the driver, the crankshaft must not be turned
when the V-ribbed belt pulley is released.
Install
Precondition
• The gasket ring in the timing case was replaced, as described
in the chapter
⇒ “3.2 Replacing gasket ring on belt pulley side”, page 35 .
Work procedure
Note
Make sure that the clamping surfaces of the belt pulley and the
bushing are free of oil and grease.
– Press the new diamond coated washer onto the belt pulley.
– Install the vibration damper with a new fixing screw and tighten
the fixing screw by hand.

for cylinder 1 ⇒ page 57 .
– Release screw plug -arrow- at cylinder block.

– Screw the locating screw - T10340- up to the stop into the

cylinder block and tighten to 30 Nm.
Note
The crankshaft is locked in direction of rotation of engine with the

locating screw - T10340- .
– Counterhold vibration damper with counterholder - T30004-

with bolt - T30004/1- .
– Tighten fixing screw for vibration damper.
Tightening torque: 150 Nm + torque a further 180° (1/2 turn)
– Unscrew the locating screw - T10340- from the cylinder block.
– Screw the screw plug -arrow- into the cylinder block.

Tightening torque: 30 Nm
– Install the V-ribbed belt ⇒ page 24 .
3.4 Removing and installing the sealing

flange on the gearbox side
♦ Assembly tool - T10134-
♦ Feeler gauges
♦ Steel straightedge

♦ Screw M6 x 35 (3x)
3.4.1 Removing
• Gearbox is removed.
– Remove the flywheel ⇒ page 45 .
– Remove intermediate plate.
– Position engine on TDC for cylinder 1 ⇒ page 57 (do not
remove the screw cap for the camshafts).
– Remove engine speed sender - G28- -arrow-.
– Unscrew the fixing screws of the sealing flange.
Note
Sealing flange and rotor are pressed together with three M6 x 35

mm screws from the crankshaft.
– Screw 3 screws M6 x 35 mm into the threaded bores of the

sealing flange -arrows-.
– Screw the screws alternately (max. 1/2 turn per screw) into the
sealing flange and press the sealing flange together with the
rotor from the crankshaft.
3.4.2 Install
Note
♦ The sealing flange with PTFE gasket ring is provided with

sealing lip supporting ring. This supporting ring is intended as
an assembly sleeve. It must not be removed before installing.
♦ Do not separate or turn the sealing flange and rotor after re‐
moving them from the spare part package.
♦ The rotor is given its fitting location by fixing the assembly tool
- T10134- to the positioning pin.
♦ The sealing flange and sealing ring form one unit. It must only
be replaced together with the rotor.
♦ 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.

A - Mounting sealing flange with rotor 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 - T10134- on the clamping surface

-B- of the threaded spindle in a vice.
– Push assembly cup -C- down until it rests on the hexagon nut
-A-, -arrow-.
• The inner part of the assembly tool and the assembly cup must
be flush.
– Remove the securing clip -arrow- from the new sealing flange.
Note
Do not remove or turn the rotor from the sealing flange.
– Lay the front side of the sealing flange on a clean and level
surface.
– Press down sealing lips supporting ring -A- in
-direction of the arrow-, 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
- T10134- 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 -
T10134- in such a way that the positioning pin can no longer
slide out of the rotor hole.
B - Mounting the assembly tool - T10134- with sealing flange on
the crankshaft flange
• The crankshaft flange must be free of grease and oil
• Crankshaft is at TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.
– Screw assembly tool - T10134- with Allan screws -A- up to the

stop onto the crankshaft flange.

– Screw 2 screws M6 x 35 mm -A- by about 3 thread turns for

the sealing 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-. Subsequently insert the guide bolt with red
ball -F- fully into the threaded bore of the crankshaft. If the
guide bolt is correctly pushed in, then the handle has a dis‐
tance of approx. 10 mm from the assembly cup -C-. This gives
the rotor its final fitting location.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.
C - Pressing the rotor onto the crankshaft flange
– Tighten the hexagon nut of the assembly tool - T10134- 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.
D - Inspecting the fitting position of the rotor on the crankshaft
– Unscrew hexagon nut -E- up to the end of the threaded spin‐

dle.
– Release 2 screws -A- to the guide from the cylinder block.
– Release 3 knurled screws -B- from the sealing flange.
– Unscrew 2 Allan screws and remove assembly tool.
– Remove sealing lip supporting ring.

The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- = 0.5 mm between the crankshaft flange
-A- and the rotor -B-.
– Position the steel striaghtedge 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 44 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing alternately cross‐
wise. Tightening torque: 10 Nm.
– Tighten the new fixing screws of the sealing alternately cross‐
wise.
Tightening torque: 10 Nm.
– Install engine speed sender -arrow-.

– Installing the oil pan ⇒ page 94 .
– Installing intermediate plate.
– Install flywheel with new screws. Tighten the fixing screws to
60 Nm + 1/4 turn. (90°).
E - Pressing down the rotor
– Screw assembly tool - T10134- with Allan screws up to the

stop onto the crankshaft flange.
– Screw in three knurled screws -A- into the flange.
– Subsequently insert the guide bolt with red ball -E- fully into
the threaded bore of the crankshaft.
If the guide bolt is correctly positioned, then the handle has a
distance of 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.

– Tighten the hexagon nut of the assembly tool using a torque

wrench with adapter.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 43 .
If the dimension -a- is too small again:
– Tighten the hexagon nut of the assembly tool to 45 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 43 .
3.5 Removing and installing the two-mass

flywheel
♦ Flywheel lock - MP1-223 (3067)-
or
♦ Engine mount - MP 1-202 (VW 540)-

♦ Bushing - T30010 (VW 540/1B)-
♦ Flywheel lock - MP1-504-
Removing
• Gearbox is removed.
Engine installed
– Lock two-mass flywheel with counterholder - T10044- .
Engine removed
– Position the flywheel lock - MP1-504- on the starter ring gear
and turn crankshaft until it rests against the sleeve - T30010- .

Continued for all

– 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-.
Caution
When unscrewing the screws -B-, ensure that no screw head

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

Install
Installation is performed in the reverse order, pay attention to the
following points:
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.)
3.6 Removing and installing engine speed

sender - G28-
♦ Socket insert - T10370-
The fitting location of the engine speed sender - G28- is located
below the intake manifold at the sealing flange on the gearbox
side.
Removing
– Remove compressor ⇒ page 154 .

– Disconnect plug -1- from the engine speed sender - G28- .

– Take out the gasket -2- from the cylinder block and remove
the engine speed sender - G28- with the socket insert -
T10370- .
Install
– Install engine speed sender - G28- and tighten the fixing screw
to 5 Nm.
– Install compressor ⇒ page 154 .

4 Crankshaft
4.1 Crankshaft - Summary of components
Note
If considerable quantities of metal swarf or abrasion is found when carrying out engine repairs, this can be
subject to damage to the crankshaft and conrod bearings. In order to avoid consequential damage, after the
repair perform the following tasks:

– Replace oil spray jets.

(1/4 turn)
❑ replace
2 - Bearing caps
❑ do not mix up bearing
cap (mark)
❑ 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
3 - Needle bearing
⇒ page 49
4 - Crankshaft
❑ New axial clearance:
0.07 … 0.24 mm
Wear limit: 0.26 mm
❑ Crankshaft bearing jour‐
nals ∅ 54.00 mm
❑ Rod bearing journals: ∅
47.80 mm
5 - Sealing flange on the gear‐
box side
❑ The sealing flange can
only be replaced com‐
plete with gasket ring
and rotor
6 - 10 Nm
❑ replace
7 - Thrust washers
❑ for bearing cap 3

❑ pay attention to locating element
8 - Bearing shell
❑ in cylinder block
9 - Sprocket
❑ for oil pump drive and timing chain
10 - Bearing shell
❑ in bearing cap
❑ do not mix up used bearing shells (mark)
4.2 Removing and installing the crankshaft

needle bearing
♦ Centering mandrel - T30029 (3176)-
♦ Interior extractor - Kukko 21/2-
♦ Countersupport - Kukko 22/1-
Removing
– Pull out needle bearing with interior extractor - Kukko 21/2-
and countersupport - Kukko 22/1- .
Install
Note
The marked side of the needle bearing should be legible when in

its installed condition.
– Drive in needle bearing with centring mandrel - T30029- flush

with the crankshaft face.
4. Crankshaft 49
5 Pistons and conrods
5.1 Piston and conrod - Summary of components
Note
Before assembly oil all bearing and contact surfaces.
1 - Circlip
2 - Piston pin
❑ if stiff, heat piston to 60°
C
❑ use drift - T10046- for
removing and installing
3 - Piston
❑ mark installation posi‐
tion and matching cylin‐
der
❑ arrow on the piston
crown faces towards the
belt pulley side
❑ use piston ring tension‐
ing strap for installing
❑ check ⇒ page 52
❑ Piston and cylinder di‐
mensions ⇒ page 53
❑ Observe part number ⇒
ETKA - Electronic Cata‐
logue of Original Parts
4 - Gasket rings
❑ Offset joint 120°
❑ Use piston ring pliers for
removing and installing
compression rings
❑ Marking “TOP” faces
piston crown
❑ Inspect gap clearance
⇒ page 51
❑ Inspect end clearance
⇒ page 52
5 - Oil scraper rings
❑ carefully remove and install 3-part oil scraper rings by hand
❑ Inspect gap clearance ⇒ page 51
❑ End clearance cannot be measured
❑ replace
❑ Oil thread and contact surface
7 - Pressure relief valve, 27 Nm
❑ Opening pressure: 0.2 MPa (2.0 bar)
❑ replace after removal

8 - Oil injection nozzle

❑ for piston cooling
❑ Align guide edge of the oil spray nozzle -arrow- to the cylinder block surface.
9 - Conrod bearing cap
❑ cracked cover fits only in one position at the relevant conrod
❑ Mark the assignment of the cylinder before removal -A-
❑ Fitting position: Mark -B- points to belt pulley end (if mark is missing, mark before removing)
10 - Bearing shell
❑ do not mix up used bearing shells
❑ insert bearing shells in the centre
11 - Conrod
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Mark -B- points to belt pulley end (if mark is missing, mark before removing)
❑ located axially by pistons
❑ separate new conrod ⇒ page 53
5.2 Inspect piston, piston rings and cylinder

bore
Inspecting piston ring gap clearance

♦ Feeler gauges
– Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder. To insert
use piston without rings.
Piston ring New Wear limit
dimensions in mm
1. Compression ring 0,20 … 0,40 1,0
Oil scraper ring 0,20 … 0,8 no wear indication
possible
5. Pistons and conrods 51

Inspect piston ring end clearance

♦ Feeler gauges
– Clean ring groove before inspecting.
Piston ring New Wear limit
dimensions in mm
Oil scraper ring cannot be measured
Inspecting pistons

♦ External micrometer 75…100 mm
– Measure about 12 mm from the lower edge and offset 90° to
piston pin axis.
• Deviations from specified dimension: max. 0.04 mm.

Nominal dimension ⇒ page 53

Inspecting cylinder bore

♦ Internal precision measuring instrument 50…100 mm
– Measure at 3 points crosswise in a transverse direction -A- and
lengthwise -B-.
• Deviations from specified dimension: max. 0.08 mm.
Nominal dimension ⇒ page 53
Note
Do not measure the cylinder bore if the cylinder block is fixed to

the assembly stand - MP1-202- with the engine mount - MP9-101
- , as this may result in incorrect measurements.
5.2.1 Piston and cylinder dimensions

Grinding dimension ∅ piston mm ∅ cylinder bore
mm
Basic dimension 76,460 1) 76,51
5.3 Separating new conrod

It can happen that the predetermined breaking point on the new
conrod is not completely pierced. If the conrod bearing cap cannot
be removed by hand, proceed in the following manner:
– Mark the assignment of the conrod to the cylinder.
– Slightly tension the conrod, as shown in the illustration, in a
vice provided 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.
5. Pistons and conrods 53

– Knock against the conrod bearing cap with a plastic hammer

in -direction of arrow- in order to loosen it.
5.4 Removing and installing oil injection

nozzle
♦ Socket insert - Torx T40 - T10545-
Removing
gr. 50 .
– Remove oil pump ⇒ page 94 .
– Rotate the crankshaft with the fixing screw of the vibration
damper in direction of engine rotation until it is possible to in‐
sert the socket insert with no effort into the applicable valve.
– Loosen and remove the pressure relief valve -1-.
– Remove oil spray nozzles -2-.
Install
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
Note
Always use a new pressure relief valve when installing!
1- Pressure relief valve

2- Oil injection nozzle
• Fitting position: Align guide edge of the oil spray nozzle to the
cylinder block surface.
– Install oil pump ⇒ page 94 .
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
Tightening torques
Component Nm
Pressure relief valve 27 Nm

15 – Cylinder head, valve gear

1 Cylinder head
1.1 Cylinder head - summary of components

Testing compression pressure ⇒ page 80 .
Note
♦ When installing a replacement cylinder head, all the contact surfaces between the hydraulic supporting
elements, roller rocker arms and the cam tracks must be oiled before installing the camshaft housing.
♦ Do not remove the plastic bases supplied as a protection for the open valves until just before fitting on the
cylinder head.
♦ If the cylinder head is replaced, also the entire coolant must be replaced.
♦ Before assembly moisten all bearing and contact surfaces with oil.
♦ Removing and installing intake manifold ⇒ page 165 , part 1.
1 - 20 Nm
2 - High pressure pump
❑ for fuel supply
❑ with fuel pressure regu‐
lating valve - N276-
⇒ page 176
3 - Cable guide
❑ Screwed onto camshaft
housing to 8 Nm
(1/4 turn)
❑ replace
❑ unscrew from the out‐
side to the inside
⇒ page 71
❑ tighten from the inside to
the outside
⇒ page 71
5 - To intake hose
6 - 10 Nm
7 - 23 Nm
8 - Double screw, 10 Nm
❑ for support plate
-Pos. 12- and heat
shield
9 - Hall sender - G40-
❑ with O-ring
❑ replace the O-ring if it is
damaged
1. Cylinder head 55
10 - Ball stud, 10 Nm
❑ for top engine cover
11 - Coolant pipe
❑ for exhaust gas turbocharger
12 - Support
❑ for heat shield
13 - Camshaft housing
14 - 20 Nm
15 - Lifting eye
16 - Exhaust gas turbocharger
17 - Oil pressure switch - F1- , 20 Nm
❑ Cut open gasket ring if leaking and replace
18 - Cylinder head gasket
❑ replace
❑ metal gasket
❑ after replacing fill entire system with fresh coolant
19 - Cylinder head
❑ check for distortion ⇒ page 57
❑ Sealing surfaces to the camshaft housing must be free of oil and grease.
❑ after replacing fill entire system with fresh coolant
❑ Observe part number ⇒ ETKA - Electronic Catalogue of Original Parts
20 - Guide bolt
❑ Tightening torque: 18 Nm
21 - Screw cap
❑ replace if leaking
Removing:
– Pierce through the centre using an expanding mandrel and pull out as straight as possible using a suitable
tool.
Make sure the sealing surface on the cylinder head is not damaged.
Installing:
– Thoroughly clean the sealing surface in the cylinder head
– Thinly coat the new cap sideways all around with sealant ⇒ ETKA - Electronic catalogue of original parts .
– Screw cap with assembly mandrel, for example drive in pressure piece - MP3-410 (VW 434)- , straight
into the bore.
• The finishing edge of the screw cap must be approx. 1 mm deep in relation to the end face of the cylinder
head.
– Wipe off any sealant oozing out.
22 - Fit pin
23 - Oil strainer
❑ inserted into the cylinder head
56 Rep. gr.15 - Cylinder head, valve gear

❑ replace
24 - Hydraulic balancing element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ oil contact surfaces
25 - Roller rocker arm
❑ inspect roller bearings of roller for smooth operation
❑ for installing, clip onto the balancing element with the locking clip
26 - Sealing ring
❑ replace
❑ 4 pieces
27 - Cylinder head bolt
❑ replace
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 76 .
28 - Roller tappet
❑ Lightly moisten the contact surface with engine oil
29 - O-ring
❑ replace
❑ moisten with oil before inserting
Inspecting the cylinder head for distortion

Check with straightedge 500 mm , e. g. -VAS 6075- and feeler
gauge.
• Maximum permitted distortion: 0.05 mm
1.2 Test timing

♦ Camshaft fixer/locator - T10171 A-
♦ Dial gauge, commercially available
Test sequence
– Remove the right wheelhouse liner ⇒ Body Work; Rep. gr.
66 .
1. Cylinder head 57
– Unplug connector -2-.

– Remove oil pressure switch - F1- -1-.
– Unscrew screws for both screw caps of the camshafts -3-.

– Press out holder for engine wiring harness-1-.
– Remove coolant pipe -2- and engine wiring harness with
bracket -1- from cylinder head.
– Remove caps -3- for camshafts.
– Remove spark plug for cylinder 1 ⇒ page 197 .
– Screw adapter for dial gauge - T10170- up to the stop into the
spark plug thread.
– Insert the dial gauge -A- with extension - T10170/1- up to the
stop and fix in place using the clamping screw -arrow-.
– Turn the crankshaft in the running direction of the engine on
TDC for cylinder 1 and note down the position of the small
pointer of the dial gauge.

• The holes -arrows- in the camshafts must be positioned as

shown. If necessary rotate the crankshaft a further revolution
(360°).
Note
♦ If the crankshaft was turned more than 0.01 mm past the top
dead centre, the crankshaft must once again be turned approx
45° in the opposite direction of rotation of the engine. Then
position the crankshaft in direction of rotation of engine on top
dead centre for cylinder 1.
♦ Permissible deviation from TDC for cylinder 1: ± 0.01 mm.
Caution
♦ Before fitting on the camshaft fixer/locator - T10171 A- , it

is essential to check whether the tensioning sleeves pro‐
trude at least 7 mm.
♦ If this is not the case, then the camshaft fixer/locator is
defective and must be replaced.
♦ The camshaft fixer/locator must not be inserted using
force or for example with blows of a hammer.
– Insert camshaft fixer/locator - T10171 A- up to the stop into the

holes in the camshaft housing.
• The locking bolts -arrows 1- must engage in the holes
-arrows 2-. The inscription “TOP” -arrow 3- must be legible
from above.
If the camshaft fixer/locator - T10171 A- cannot be inserted up to
the stop in the camshaft openings, the timing is not correct and
must be set ⇒ page 59 .
The timing is O.K., if the camshaft fixer/locator - T10171 A- can
be inserted up to the stop into the camshaft openings.
Further installation occurs in reverse order. Pay attention to the
following:
♦ Replace the gasket rings for the caps of the camshafts and oil
before assembly.
♦ Install the oil pressure switch - F1- ⇒ page 91 .
1.3 Setting the timing

♦ Counterholder - T10172-
♦ Rig pin - T40011-
♦ Locating screw - T10340-
Work procedure
– Remove timing case ⇒ page 30 .
1. Cylinder head 59
– For turning the crankshaft insert the bushing, insert the vibra‐
tion damper -2- and the fixing screw -3- and tighten the fixing
screw (use counterholder - T30004 (3415)- ).

– Unscrew screws for both screw caps of the camshafts -3-.

– Press out holder for engine wiring harness-1-.
– Remove coolant pipe -2- and engine wiring harness with
bracket -1- from cylinder head.
spark plug thread.
– Turn crankshaft 45° in the opposite direction of rotation of the
engine.

– Press the tensioning rail -1- in -direction of arrow- and interlock

the piston with the rig pin - T40011- .
– Mark with a suitable felt-tip pen the direction of rotation of the

timing chain -3-.
Note
The fixing screw of the camshaft adjuster -2- has a left-hand

thread.
– Release screws -2- and -4- and remove the camshaft adjuster
-1- with the timing chain -3-. Use counterholder - T10172- to
counterhold.
– Mount again camshaft adjuster -1-.
– Replace screws -2- and -4- and tighten screw -2- to 40 Nm and
screw -4- to 50 Nm. Use counterholder - T10172- for this pur‐
pose.
Caution

– Turn the inlet and outlet camshafts with counterholder -

T10172- until the camshaft fixer/locator - T10171 A- can be
inserted up to the stop into the holes of the camshafts.

from above.
Note
When turning, the camshafts must not be moved axially.
1. Cylinder head 61
– To secure the camshaft fixer/locator - T10171 A- screw in a

M6 screw into the corresponding hole -arrows- by hand; do not
tighten.
Note
Pay attention that there are different fixing points for the camshaft
fixer/locator - T10171 A- .
– Slacken the screws of the camshaft chain sprockets. Abso‐

lutely use counterholder - T10172- .
Caution
Do not use the camshaft fixer/locator - T10171 A- as a coun‐

terholder.
– Removing the camshaft chain sprocket.
Caution
If the camshaft control was removed, the guide bushing will

need to set in the camshaft when installing.
– Place the timing chain onto the camshaft chain sprockets in

compliance with the running direction and reinsert the re‐
moved chain sprocket.
– Screw in the camshaft screws so far so that the camshaft chain
sprockets can still be turned on the camshaft.
– Tighten the timing chain, by pulling out the rig pin - T40011- .

for cylinder 1.
• Permissible deviation from TDC for cylinder 1: ± 0.01 mm.
Note
If the crankshaft was turned more than 0.01 mm past the top dead
centre, the crankshaft must once again be turned approx 45° in
the opposite direction of rotation of the engine. Then position the
crankshaft in direction of rotation of engine on top dead centre of
cylinder 1.
– Unscrew locking screw -arrow- at the crankcase.

– Screw in locating screw - T10340- as far as it can go into the
crankcase.
– Tighten locating screw - T10340- to 30 Nm.

The crankshaft is locked in direction of rotation of engine with the

locating screw - T10340- .
– Hold the camshaft chain sprockets -1- and -5- in this position
with the counterholder - T10172- and tighten the screw -2-
(left-hand thread) to 40 Nm and the screw -4- to 50 Nm.
Note
When tightening the camshaft screws, the crankshaft should not

turn. The timing chain -3- must remain tightened on both sides.
– Remove the camshaft fixer/locator - T10171 A- .

– Remove locating screw - T10340- from crankcase.
– Turn the crankshaft by 2 turns in direction of rotation of engine
on TDC for cylinder 1.
• Permissible deviation from TDC for cylinder 1: ± 0.01 mm.
– Insert camshaft fixer/locator - T10171 A - up to the stop into

the holes in the camshaft housing.
If the camshaft fixer/locator - T10171 A- is not insertable.
– Repeat setting.
If the camshaft fixer/locator - T10171 A- is insertable.
– Screw in locating screw - T10340- as far as it can go into the

crankcase.
– Tighten locating screw - T10340- to 30 Nm.
1. Cylinder head 63
– Remove camshaft clamp - T10171 A- , hold the camshaft

chain sprockets with the counterholder - T10172- and turn
screw -2- (left-hand thread) and screw -4- with a rigid wrench
90° (1/4 turn).
Note
♦ The fixing screw of the camshaft adjuster -2- has a left-hand

thread.
♦ The camshaft chain sprockets must not be turned on the cam‐
shaft when tightening.

following:
Note
The locating screw - T10340- remains in the crankcase until the

vibration damper is installed.
♦ Install timing case ⇒ page 30 .

before assembly.
1.4 Removing and installing timing chain

and drive chain for oil pump
♦ Rig pin - T40011-
Removing
– Open bracket -arrows- for wiring loom.
– Open the spring strap clamps -1- and detach the coolant hoses
from the coolant pipe -4-.
– Release screws -3- and remove coolant pipe -4-.



spark plug thread.
1. Cylinder head 65

• The holes -arrows- in the camshafts must be positioned as
shown. If necessary rotate the crankshaft a further revolution
(360°).
Note
♦ If the crankshaft was turned more than 0.01 mm past the top
dead centre, the crankshaft must once again be turned approx
45° in the opposite direction of rotation of the engine. Then
position the crankshaft in direction of rotation of engine on top
dead centre for cylinder 1.
♦ Permissible deviation from TDC for cylinder 1: ± 0.01 mm.
Caution

– Insert camshaft fixer/locator - T10171 A- up to the stop into the

holes in the camshaft housing.
from above.

tighten.
Note

– Pull off cover -1- from chain sprocket of oil pump.
– Press the tensioning rail -1- by hand in -direction of arrow- and

interlock the piston of the chain tensioner -2- with the rig pin -
T40011- .
– Remove chain tensioner -2-.

timing chain -3-.
Note
The fixing screw of the camshaft adjuster -2- has a left-hand

thread.
– Release screws -2- and -4- and remove the camshaft adjuster
-1- with the timing chain -3-. Use counterholder - T10172- to
counterhold.
– Hold the chain sprocket of the oil pump with the counterholder
- T10172- and slacken the fixing screw -1-.
1. Cylinder head 67
– Lever out tensioning spring -1- at the screw -2- with a screw‐
driver and remove tensioning spring -1-.
– Unscrew fixing screw -3- and remove the chain tensioner.

drive chain for oil pump -2-.
– Release the fixing screw of the chain sprocket -1- and remove
the chain sprockets -1- and -3- together with the drive chain of
the oil pump -2-.
Install
• The crankshaft must be positioned on TDC for cylinder 1.
– Push chain sprocket -1- in -direction of arrow- up to the stop

onto the crankshaft journal.
Caution
The integrated peg -2- of the chain sprocket -1- must fit into the
slot -3- at the crankshaft stub.
– Mark the positions of the chain sprocket and the crankshaft to

the cylinder block with a felt-tip pen.

– Fit the drive chain for oil pump -3- onto the chain sprocket
-1-.
– Place the chain sprocket of the oil pump -2- into the drive chain
of the oil pump -3- and mount it onto the drive shaft of the oil
pump.
Note
♦ Observe the marking of the running direction on the drive chain

for oil pump.
♦ The drive wheel of the oil pump only adapts to one postion on
the drive shaft of the oil pump -arrow-.
- T10172- .
– Tighten new fixing screw -1- to 20 Nm and torque a further 90°
(1/4 turn).
– Position the chain sprocket onto the drive chain for the oil
pump and tighten the fixing screw -3- to 8 Nm.
– Lever the tensioning spring -1- onto the screw -2- with a screw‐
driver.
Note
♦ Observe markings -arrows-.

♦ The crankshaft should not turn.
– Screw on the chain sprocket -3- by hand with a new fixing

screw.
– Place the timing chain -1- onto the chain sprocket of the crank‐
shaft -4- and onto the chain sprocket of the outlet camshaft
-3-.
– Screw on the camshaft adjuster -2- with a new fixing screw.
Note
♦ Observe the marking of the running direction on the timing

chain -1-.
♦ Observe that the guide sleeve is installed between the inlet
camshaft and camshaft adjuster.
thread.
1. Cylinder head 69
The timing chain must rest on the sliding rail -1- and on the chain
sprocket crankshaft -arrow-.
– Install the chain tensioner -1- and tighten the fixing screws
-2- to 9 Nm.
– Tighten the timing chain, by pulling out the rig pin - T40011-
from the chain tensioner.
– Check markings on the chain sprocket crankshaft and on the
cylinder block; they must be positioned opposite to each other.
– Tighten the fixing screw -2- to 40 Nm and the screw -4- to 50°
Nm (use counterholder - T10172- ).
Note
♦ First the fixing screws -2- and -4- are tightened to the torquing
angle (90°), after which the timing is checked.
thread.
– Screw out screw -arrows- and remove the camshaft fixer/lo‐

cator - T10171 A- from camshaft housing.
– Test timing ⇒ page 57 .
If timing is o.k.:

– Hold the camshaft chain sprockets with the counterholder -

T10172- and torque the screw -2- (left-hand thread) and the
screw -4- a further 90° (1/4 turn) with a rigid wrench.
Note

thread.
♦ The camshaft chain sprockets must not be turned on the cam‐
shaft when tightening.
– Install cover for oil pump -1-.

– Install timing case ⇒ page 30 .
– Replace the gasket rings for the caps of the camshafts and oil
before assembly.
following:
before assembly.
1.5 Removing and installing camshaft hous‐

ing
♦ 2 pin screws M6 x 80
♦ Sealant ⇒ ETKA - Electronic catalogue of original parts
Removing
Note
♦ On this engine the camshafts are located in the camshaft

housing. Before removing the camshaft housing, the timing
case must be removed ⇒ page 30 .
♦ Do not rework the sealing surface of the camshaft housing.
Observe safety measures ⇒ page 3 .

Observe rules for cleanliness ⇒ page 4 .
WARNING
– Remove exhaust turbocharger ⇒ page 148 .

1. Cylinder head 71
Note
Before the vibration damper is removed, turn the crankshaft from

the TDC for cylinder 1 in the opposite direction of rotation of the
engine by approx. 45°.
– Remove camshaft chain sprockets with timing chain

⇒ page 59 .
– Remove suction hose -1-.
– Disconnect plug for intake air temperature sender 3 - G520-

-1- and for regulating flap control unit - J808- -6-.
– Loosen hose clamp -3-.
– Release screws -arrows-.
– Remove ventilation pipe -4-.
– Remove inlet connection -2- from pressure pipe
( ⇒ page 153 , Pos. 8).
– Release screw -1-.

– Press off the coolant line -4- from the noise damper for charge
air -5-.
– Detach the ventilation pipe from the inlet connection
( ⇒ page 165 , part 1, Pos. 9).
– Lay the ventilation pipes and the connecting hoses to the side.

– Open bracket -arrows- for wiring loom.

– Separate plug connection -5-.
– Open the spring strap clamps -1- and detach the coolant hoses
from the coolant pipe -4-.
– Release screws -3- and remove coolant pipe -4-.
– Disconnect plug from camshaft adjustment valve 1 - N205- .
– Removing ignition coils ⇒ page 198 .
– Remove cable guide with wiring loom from camshaft housing.
– Disconnect the plug and the fuel feed line -arrows- from the
high pressure pump.
– Disconnect plug connection for Hall sender - G40- -4-.

– Remove cable guide -2-.
Note
Hold the screwed connections at the high pressure pump and at

the fuel distributor when slackening the union nuts with a wrench.
– Slacken the union nuts -3- and -1- at the high pressure line.
– Unscrew left lifting eye.
– Disconnect plug from camshaft adjustment valve 1 - N205- .
– Pull out oil dipstick.
1. Cylinder head 73
– Release screws for camshaft housing in the sequence

-15 … 1-.
– Carefully remove the camshaft housing.
Install
Caution
Before installing the camshaft housing, screw in the pin screws

(M 6 x 80) at the cylinder head.
The stud bolts guide the camshaft housing and prevent the
roller rocker arms sliding off from the supporting elements.
Precondition
• The pistons must not be positioned at top dead centre.
Note
Before installing the camshaft housing, the strainer for the oil cir‐
cuit will need to be installed.
WARNING

remover!
– Remove residual sealant on the cylinder head and camshaft

housing using a chemical sealant remover.
– Degrease the sealing surfaces. They must be free of oil and
grease.
– Ensure that no dirt and sealant residues get into the cylinder
head.
Caution


– Turn the inlet and exhaust camshaft until the camshaft fixer/
locator - T10171 A- can be inserted up to the stop into the
camshaft openings.

tighten.
Note
– Replace oil strainer -1- and insert in the cylinder head.

– Insert 4 new gasket rings -2- into the grooves of the cylinder
head.
– Ensure that all the roller arms are correctly positioned on the
valve stem ends -1- and are clipped in place on the relevant
hydraulic supporting elements -2-.
1. Cylinder head 75
– Apply a thin coating of sealant uniformly on the clean sealing

surface of the camshaft housing (see grid surfaces in the il‐
lustration).
– Do not apply sealant in the area of the -arrows A-. Here the
cylinder head is sealed with the inserted gasket rings.
Note
♦ No sealant must be applied in the area -arrow B-. Here the oil
strainer seals.
♦ The sealant must not be applied too thickly, as otherwise ex‐
cess sealant may penetrate into the oil bores and possibly
cause engine damage.
– To improve the routing, screw in 2 pin screws (M6 x 80) into

the cylinder head before fitting on the camshaft housing.
– Carefully place the camshaft housing vertically from above

onto the pin screws -arrows- and dowel pins of the cylinder
head.
Note
Make sure that no residues of oil drop down onto the sealing
flange and the camshaft housing does not tilt.
– Tighten the new screws for the camshaft housing in 2 stages

in the indicated tightening sequence -1…15- as follows:
1. Pre-tighten with the torque wrench to 10 Nm.
2. Using a rigid wrench torque a further 90° (1/4 turn).
Make sure that the camshaft housing does not tilt.
Note
After installing the camshaft housing, allow the sealant to dry for
about 30 minutes.
– Set the timing ⇒ page 59 .

following:
♦ Install timing case ⇒ page 30 .
♦ Install exhaust turbocharger ⇒ page 148 .
♦ Connect fuel lines ⇒ page 175 .
1.6 Removing and installing the cylinder

head
♦ Hook - MP9-200/10 (10-222A/10)-

♦ Support - T10358-
Removing
WARNING

Remove the following components:
♦ Coolant regulator housing from cylinder head
♦ Intake manifold ⇒ page 165 , part 1
♦ Exhaust gas turbocharger ⇒ page 148
– Position the supporting device - MP9-200 (10-222A)- with two
hooks - MP9-200/10- .
– Hook on the right hook into the lifting eye as shown.
– First of all do not attach the left hook.
– Support the engine in its installed position.
– Remove the timing chain from the camshaft chain sprockets
⇒ page 64 .
– Remove the tensioning rail -1- and the sliding rail -2- from the
bearing bolts.
1. Cylinder head 77
– Unscrew the fixing screw for the gearbox and screw down the
bracket - T10358- as shown.
– Hang the hook of the supporting device - MP9-200- in the
bracket - T10358- as shown.
– Turn the spindle until the hook is slightly tensioned.
– Unhook the hook -1- from the right lifting eye and push the
spindle onto the supporting device - MP9-200- on the right.
– Remove the camshaft housing ⇒ page 71 .
– Remove the roller rocker arm together with the supporting el‐
ements and lay aside on a clean surface.
– Ensure that the roller rocker arms and the balancing elements
are not mixed up.

– Release the cylinder head bolts in the specified sequence and

remove.
– Carefully remove the cylinder head.
Install
Precondition
• The pistons must not be positioned at top dead centre.
Note
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the new seal with the utmost care. Any damage will result
in leaks.
♦ There must be no oil or coolant in the blind holes of the cylinder
head bolts in the cylinder block.
– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.
WARNING

remover!
– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies 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.
– Position piston of cylinder 1 to top dead centre and slightly turn
the crankshaft anticlockwise again.
– Position the new cylinder heads. Text (part number) must be
visible.
– Insert the cylinder head. Pay attention to the dowel pins in the
cylinder block.
– Insert new cylinder head bolts and tighten by hand.
– Tighten cylinder head bolts in the tightening order shown as

follows:
♦ Tighten all bolts initially to 30 Nm.
♦ Then, torque all bolts further to 90° (1/4 turn) with a rigid
wrench.
♦ Finally, once again turn all bolts through a further 90° (1/4 turn).
♦ Finally, once again turn all bolts through a further 90° (1/4 turn).
– Insert the hydraulic balancing elements in the cylinder head

and position the relevant roller rocker arm on the valve stem
ends or balancing elements.
– Install camshaft housing ⇒ page 71 .
1. Cylinder head 79
1.7 Testing the compression

♦ Compression tester , e.g. -V.A.G 1763-
Test condition
• Engine oil temperature at least 30°C
Work procedure
– Open lid of fuse carrier in the engine compartment and unplug
the fuse for Motronic current supply relay - J271- ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
– Remove the ignition coils ⇒ page 198 and release the spark
plugs.
Note
Removing fuse interrupts the voltage supply of the injection

valves and ignition coils.
– Check compression pressure using the compression tester -

V.A.G 1763/- .
Note
Use of tester ⇒ Operating Instructions .
– Operate starter until the tester no longer indicates a pressure

rise.
Compression readings
Engine new Wear limit Difference between
cylinders
1…1.5 MPa 0,7 MPa 0.3 MPa
(10…15 bar) (7 bar) (3 bar)
If the specified values are not reached, test the combustion cham‐
ber for tightness ⇒ page 80 .
following:
– Install ignition coils ⇒ page 198 .
– Delete the contents of the event memory for the engine control
unit at the end of the work as error messages were stored due
to disconnecting the plugs ⇒ Vehicle diagnostic tester.
1.8 Testinf the combustion chamber for

tightness
♦ Pressure hose - MP1-210 (VW 653/3)- (replace gasket ring
with a spark plug gasket ring)
♦ Extractor - T10112 A-
Precondition
• Spark plugs unscrewed.

Test sequence
– Position piston of the relevant cylinder to top dead centre
(TDC).
– Screw the pressure hose MP1-210 into the spark plug thread.
– Connect pressure hose to compressed air.
– With the assistance of a second mechanic, lock the screw at
the crankshaft in order to avoid the displacement of the piston
after pressure build-up.
– Build up a pressure of approx. 0.3 MPa (3 bar) in the com‐
bustion chamber.
– Determine how the pressure escapes:
1- Via the inlet valve(s) - the pressure enters the throttle valve.
2- Via the outlet valve(s) - the pressure enters the exhaust
system.
3- Via the piston rings - the pressure enters the cylinder block.
1. Cylinder head 81
2 Valve gear
2.1 Valve gear - Summary of components

(1/4 turn)
❑ Left-hand thread
❑ replace
2 - Camshaft adjuster
❑ must not be disassem‐
bled
⇒ page 59
3 - Camshaft sprocket
❑ take note of the position
when installing the tim‐
ing chain
4 - O-ring
❑ replace if damaged
❑ before fitting moisten
lightly with engine oil
5 - Camshaft adjustment valve
1 - N205-
6 - 10 Nm
(1/4 turn)
❑ replace
❑ tighten from inside to
outside
8 - Camshaft housing
⇒ page 71
❑ remove old sealant res‐
idues
❑ before inserting, coat
with sealant ⇒ ETKA - Electronic catalogue of original parts
❑ when installing the housing, fit onto pin screws and dowel pins vertically from above
9 - 10 Nm
10 - Screw cap
❑ for inlet camshaft
❑ for exhaust camshaft
11 - Roller rocker arm
❑ inspect roller bearings
❑ for installing, clip onto the balancing element with the locking clip

12 - Valve collets
13 - Valve spring retainer
14 - Supporting element
❑ Check oil splash hole
❑ with hydraulic valve clearance compensation
❑ do not interchange
❑ before installing check axial play of the camshaft ⇒ page 84
15 - Valve spring
❑ Removing and installing on installed cylinder head ⇒ page 87
❑ Removing and installing on removed cylinder head ⇒ page 88
16 - Valve stem seal
❑ replace
17 - Valve guide
❑ not to be replaced
18 - Cylinder head
❑ Obróbka gniazd zaworowych ⇒ page 84
❑ reworking sealing surface ⇒ page 84
19 - Valves
❑ do not rework, only grinding in is permissible
❑ valve dimensions ⇒ page 84
20 - Sealing ring
❑ replace
❑ 4 pieces
21 - Oil strainer
❑ replace
22 - Exhaust camshaft
❑ do not mix up with inlet camshaft
❑ sprawdzić luz osiowy ⇒ page 84
❑ moisten with oil before installing (also axial bearing collar)
23 - Guide bushing
24 - Inlet camshaft
❑ with cam for fuel-high pressure pump -arrow-
❑ before removing, remove the bucket tappet of the fuel-high pressure pump
❑ do not mix up with exhaust camshaft
❑ sprawdzić luz osiowy ⇒ page 84
❑ moisten with oil before installing (also axial bearing collar)
2. Valve gear 83
Reworking cylinder head sealing surface

Reworking dimension of cylinder head: a = at least 108.25 mm
Note
If the sealing surface is reworked, the valves should be set lower

by the same amount (rework valve seat rings) otherwise the
valves will strike the pistons. When doing this, ensure that the
permissible minimum dimension is not exceeded ⇒ page 84 .
Valve dimensions
Note
Valves must not be reworked. Only grinding in is permissible.
Dimension Inlet valve Exhaust valve

∅a mm 29,5 26,0
∅b mm 5,973 5,953
c mm 100,9 100,5
α ∠° 45 45
2.2 Checking the axial play of the camshaft

♦ Universal dial gauge holder - MP3-447 (VW 387)-
♦ Dial gauge
Carry out measurement with the camshaft housing removed and
the end cover installed.
Checking the axial play of the camshaft
• Wear limit: 0.4 mm
2.3 Reworking valve seats

♦ Depth gauge
♦ Valve seat machining device

Note
♦ When carrying out repairs on engines with leaking valves, it is

not sufficient to machine or replace the valve seats and valves.
It is also necessary to inspect the valve guides for wear, par‐
ticularly on engines with a high mileage ⇒ page 87 .
♦ Rework valve seats only sufficiently in order to obtain a proper
contact pattern. Calculate the maximum permissible rework‐
ing dimension before commencing. If the reworking dimension
is exceeded, the proper operation of the hydraulic valve clear‐
ance compensation is no longer ensured. If this is the case
replace the cylinder head.
The maximum permissible reworking dimension can be calcula‐

ted as follows:
– Insert valve and press firmly against the valve seat.
Note
If the valve is replaced when carrying out repair work, use a new
valve for the measurement.
– Measure distance between the valve stem end and the upper
face of the cylinder head.
– Calculate max. permissible reworking dimension from the dis‐
tance measured and the minimum dimension.
Minimum dimension: Inlet valve 7,6 mm
Minimum dimension: Exhaust valve 7,6 mm
“Measured distance” - “minimum dimension” = “max. permissible
reworking dimension”.
Example:
Measured distance 8,0 mm
- Minimum dimension 7,6 mm
= max. permissible reworking dimension 1) 0,4 mm
1) The max. permissible reworking dimension is shown in the figures for reworking
the valve seats as dimension “b”.
Reworking inlet valve seat

a = ∅ 28,7 mm
b = max. permissible reworking dimension
c = 1.5…1.8 mm
Z = Bottom edge of cylinder head
α = 45° valve seat angle
β = 30° top correction angle
γ = 60° bottom correction angle
2. Valve gear 85
Reworking exhaust valve seat

a = ∅ 25,0 mm
b = max. permissible reworking dimension
c = approx. 1.8 mm
Z = Bottom edge of cylinder head
α = 45° valve seat angle
β = 30° top correction angle
γ = 60° bottom correction angle
Work procedure
Reworking can be carried out by hand while complying with the
following conditions:
• The wear limit of the valve guides must not exceed the per‐
missible dimension.
• Use NAC milling cutter with carbide metal tips (min. 90 HRC).
• Mill with the milling cutter using slight pressure in such a way
that an even removal of swarfs is ensured over the whole
working surface.
Reworking valve seats with NAC milling cutter

– Place cylinder head on a felt base and secure to prevent it from
turning.
– Match diameter of guide drift to diameter of valve guide.
Valve guide ∅ Guide drift in mm
Inlet valve 6,0 -0,01
Exhaust valve
– Match diameter of milling cutter to diameter of valve seat.
Valve seat ∅ Milling ∅ Milling cut‐ ∅ Milling
cutter 90° ter 120° cutter 60°
mm mm mm
Inlet valve 32 32 21/34
Exhaust valve 30 30 21/34
Milling sequence
1 - Mill valve seat with 90° milling cutter until a perfect contact
pattern is achieved. (Do not exceed maximum permissible re‐
working dimension!)
2 - Chamfer top correction angle with 120° milling cutter until valve
seat diameter -a- is achieved ⇒ page 85 .
3 - Mill bottom correction angle with 60° milling cutter until valve
seat width -c- is achieved ⇒ page 85 .

– Grind in valve/valve seat -arrows- with fine grinding paste so

as to achieve a perfect contact pattern.
– Check contact pattern e.g. with water colour (perfect contact
pattern over entire circumference).
– Install valve springs.
– Inspect valves for tightness.
The tightness of the valves can be checked by filling petrol into
the inlet and outlet canal (no petrol must flow out at the valve
seat).
After completing the repair measure once again the distances
between the valve stem ends and the upper face of the cylinder
head and calculate the maximum permissible reworking dimen‐
sion.
Note
If the reworking dimension is exceeded, proper operation of the

valve gear is no longer assured and the cylinder head must be
replaced.
2.4 Inspect valve guides

♦ Universal dial gauge holder - MP3-447 (VW 387)-
♦ Dial gauge
Work procedure
Note
If the valve is replaced when carrying out repair work, use a new
valve for the measurement.
– Insert valve into guide. The end of valve stem must be flush
with guide. Because of the different stem diameters only use
inlet valve in inlet guide or outlet valve in outlet guide.
– Determine the valve rock by moving back and forward
-arrows-.
• Wear limit: 0.8 mm
Note
If the wear limit is exceeded, repeat measurement with new

valves.
If the valve rock is exceeded:

– Replace the cylinder head.
2.5 Replacing the valve stem seals on the

installed cylinder head
♦ Pressure hose - MP1-210 (VW 653/3)-
♦ Valve lever - MP1-211 (VW 541/1A/5)-
2. Valve gear 87
♦ Assembly device for valves - MP1-213 (2036)-

♦ Valve supporting plate - MP1-218-
♦ Blank holder for valve spring - MP1-229 (3362)- with pressure
plate - MP 1-229/1 (3362/1)-
♦ Valve shaft pliers , e.g. -VAS 6770-
♦ Valve stem seal insertion tool - MP1-233 (3365)-
Removing
– Remove the camshaft housing ⇒ page 71 .
– Remove roller rocker arm and place on a clean surface. Make
sure that you do not mix up the roller rocker arms.
– Unscrew the spark plugs with spark plug wrench.
– Put the piston of the relevant cylinder at “bottom dead centre”.
– Screw on blank holder for valve spring - MP1-229 (3362)- with
pressure plate - MP1-229/1 (3362/1)- .
– Screw the pressure hose - MP1-210 (VW 653/3)- in the spark
plug thread.
– Connect pressure hose to compressed air of at least 0.6 MPa
(6 bar) and remove the valve springs with a blank holder for
valve spring - MP1-229 (3362)- .
– Remove valve stem seal with valve stem pliers , e.g. -VAS
6770- .
Install
– Insert the supplied plastic bushings on the relevant valve stem.
This will prevent any damage to the new valve stem seals.
– Insert the new valve stem seal -B- in the insertion tool for valve
stem seal -MP1-233 (3365)- .
– Oil the sealing lip of the valve stem seal and carefully slide
onto the valve guide -A-.
– Install camshaft housing ⇒ page 71 .
2.6 Replacing the valve stem seals on the

removed cylinder head
♦ Disassembly and assembly device for valve collets - VAS
5161- with guide plate - VAS 5161/22-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Valve shaft pliers , e.g. -VAS 6770-

♦ Valve stem seal insertion tool - 3365-

Work procedure
– Remove cylinder head ⇒ page 76 .
– Insert the cylinder head tensioning device - VAS 6419- into the
engine and gearbox jack - VAS 6095- .
– Tension the cylinder head in the cylinder head tensioning de‐
vice, as shown in the illustration.
– Connect cylinder head tensioning device to compressed air.
– Adjust the air bellows with the lever -arrow- below the com‐
bustion chamber on which the valve stem seals should be
removed.
– Allow just enough air to flow into the air bag so that it applied
to the valve disc.
– Place guide plate -VAS 5161/22- on the cylinder head and

screw on using the knurled screws -VAS 5161/12- .
– Insert the impact drift -VAS 5161/3- into the guide plate and
knock off the tightly fitted valve collets using a plastic hammer.
– Screw the detent part -VAS 5161/6- with the interlocking fork
-VAS 5161/2- into the guide plate.
– Re-insert the assembly cartridge -VAS 5161/8- into the guide
plate.
– Hook the pressure fork -VAS 5161/2- onto the detent part and
push the assembly cartridge downwards.
– Turn simultaneously the knurled screw of the assembly car‐
tridge to the right, until the tips click into the valve collets.
– Rotate the knurled screw to the left and to the right, by doing
so the valve collets are pressed apart and are installed in the
assembly cartridge.
– Release the pressure fork.
– Remove assembly cartridge.
– Unscrew guide plate and turn it to the side.
– Remove the valve spring with the valve spring retainer.
2. Valve gear 89
– Remove valve stem seal with valve stem pliers , e.g. -VAS
6770- .
Caution
Risk of damage to the valve stem seals during installation.
– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve.
If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device - VAS
5161/18- .
Note
The large diameter of the valve collets points to the top.
– Press the assembly cartridge from the top onto the insertion
device for valve collets and lift up the valve collets.
– Insert the valve spring and the valve spring retainer.
– Screw the guide plate -VAS 5161/22- back onto the cylinder
head.
– Re-insert the assembly cartridge -VAS 5161/8- into the guide
plate.
– Press down the pressure fork and turn the knurled screw to
the left and to the right while pulling it upwards, by doing so
the valve collets are inserted.
– Release the pressure fork on tightened knurled screw.
– Repeat the procedure for each valve.
– Install cylinder head ⇒ page 76 .

17 – Lubrication
1 Lubrication system
Note
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter!
♦ If considerable quantities of metal swarf or abrasion is found
when carrying out engine repairs, this can be subject to dam‐
age to the crankshaft and conrod bearings. In order to avoid
consequential damage, after the repair perform the following
tasks:

Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Booklet Fabia II .
1.1 Lubrication system - Summary of components

Fitting location of the oil pressure switch - F1- and tightening tor‐
que ⇒ page 94
1. Lubrication system 91
1 - Dipstick
❑ The oil level must not be
above the max. mark!
2 - Engine oil cooler
⇒ page 99
3 - O-ring
❑ replace
4 - Coolant pipe
❑ for engine oil cooler
❑ Bracket tightening tor‐
que to cylinder block: 20
Nm
5 - 8 Nm
6 - Screw cap
❑ Replace seal if dam‐
aged
7 - Sealing ring
8 - Oil filter, 20 Nm
❑ with gasket rings
❑ with non-return valve
❑ slacken and tighten with
oil filter wrench - 3417-
❑ Keep to change inter‐
vals ⇒ Maintenance ;
Booklet Fabia II
9 - Timing case
⇒ page 30
10 - 10 Nm
11 - Screw
❑ Replacing
❑ Removing and installing ⇒ “3.3 Installing and removing the vibration damper”, page 37
12 - Belt pulley
❑ Secure belt pulley with counterholder - T30004 (3415)- to prevent it from turning
❑ Removing and installing V-ribbed belt ⇒ page 24
❑ with the diamond coated washer
13 - Sealing ring
❑ replace
14 - Bushing
❑ The clamping surfaces of the bushing must be free of grease and oil.
15 - Gasket
92 Rep. gr.17 - Lubrication

16 - Sprocket
❑ for oil pump drive
❑ replace
18 - Sprocket
❑ for oil pump
❑ counterhold with counterholder - T10172-
19 - Chain
❑ for oil pump
❑ mark running direction (installed position) before removing
20 - 10 Nm
21 - Oil level and oil temperature sender - G266-
❑ check ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
22 - Oil drain plug, 30 Nm
❑ with captive seal
❑ replace
23 - 13 Nm
❑ replace
❑ slacken and tighten only the bolts at the gearbox side with socket insert - T10058-
24 - 40 Nm
25 - Oil pan
❑ clean sealing surface before installing
❑ install with silicone sealant ⇒ ETKA - Electronic catalogue of original parts
❑ replace
27 - Oil pump
Caution
If a new oil pump or oil
suction pipe is installed,
the oil feed line at the ex‐
haust gas turbocharger
has to be replaced.
❑ must be replaced completely

❑ Tightening torque oil intake tube: 9 Nm
28 - 5 Nm
29 - Oil separator
Fitting location of the oil pressure switch - F1- and tightening tor‐
que
The oil pressure switch - F1- -arrow- is located on the left of the
cylinder head below both camshaft caps.
– Tighten oil pressure switch - F1- -arrow- to 20 Nm.
1.2 Removing and installing oil pan

♦ Socket insert - T10058-
♦ Silicone sealant ⇒ ETKA - Electronic catalogue of original
parts
Removing
gr. 50 .
– Drain engine oil ⇒ Maintenance ; Booklet Fabia II .
– Remove front silencer ⇒ page 190 .
– Disconnect plug -1- at the oil level and oil temperature sender
- G266- .
– Release screw -arrow- and press off the charge air pipe -1-
from the oil pan to the right.

– Unscrew the oil pan screws from the gearbox side using a
socket insert - T10058- .
Note
It is possible that the oil pan screws are not immediately acces‐
sible from the gearbox side by using a socket insert - T10058- .
In this case, turn the crankshaft in the direction of rotation of the
engine until they can be reached. The flywheel is provided with
recesses.
– Loosen crosswise and release the other oil pan screws.

– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.
WARNING

remover!
– Remove the remaining sealant on the cylinder block and on

the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
Install
Note
♦ Replace M6 oil pan bolts.

♦ Pay attention to the use by date on sealant.
♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant.
♦ For an easier and more secure attachment of the oil pan, M6
threaded pins are inserted as guides in two locations on the
flange of the cylinder block.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).
– Apply silicone sealant to the clean sealing surface of the oil
pan, as shown in the illustration. The sealant bead must be:
♦ be 2…3 mm thick
♦ run past the area around the bolt holes on the inside
-arrows-
Note
The sealant bead must not be thicker otherwise excess sealant

may get into the oil pan and block the strainer in the oil suction
pipe.
– Fit oil pan immediately and slightly tighten 2 opposite oil pan
bolts.
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.
♦ Pay attention when inserting the oil pan bolts on the flywheel
side that the oil pan bolts are inserted in the holes and not
between the cylinder block and the flywheel.
♦ If the oil pan bolts are inadvertently inserted between the cyl‐
inder block and the flywheel and can no longer be pulled out,
the oil pan must be removed again, the sealing surfaces must
be cleaned and the silicone sealant must be replaced.
– Then slightly tighten both M6 oil pan bolts on the flywheel side.
– Slightly rotate both M10 screws for oil pan/gearbox.
– Slightly tighten the remaining oil pan bolts.
– Tighten the oil pan bolts.
Screws M6: 13 Nm
Screws M10: 40 Nm
Note
After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
1.3 Removing and installing oil pump

Removing

– Unclip the cover for the chain sprocket of the oil pump -A-.
- T10172- .
– Loosen the fixing bolt of the chain sprocket.
Note
Do not unscrew the bolt yet.
– Press chain tensioner with a screwdriver in

-direction of arrow-.
– Release the fixing screw of the chain sprocket.
– Remove the chain sprocket from the oil pump and from the
chain.
– Unscrew fixing bolts of the oil pump -arrows-.

– Remove the oil pump from the cylinder block.
Install
Caution
If a new oil pump or oil suction pipe is installed, the oil feed line
at the exhaust gas turbocharger has to be replaced.
– Fit oil pump onto cylinder block.

– Tighten fixing screws of oil pump -arrows- to 14 Nm + torque
a further 90° (1/4 turn).
Tightening torque oil intake tube: 9 Nm.
– Press chain tensioner with a screwdriver in

– Insert the chain sprocket into the chain and position on the
shaft of the oil pump.
– Pay attention to the seating of the chain sprocket on the shaft

of the oil pump -arrow-.
– Screw in new fixing screw for chain sprocket.
– Counterhold the chain sprocket with the counterholder -

T10172- .
– Position the torque wrench -A- as shown.
– Tighten fixing bolt to 20 Nm + torque a further 90° (1/4 turn).

– Install the cover for the chain sprocket of the oil pump -A-.
– Installing the oil pan ⇒ page 94 .
1.4 Removing and installing engine oil cool‐

er
♦ Catch pan e.g. -VAS 6208-
Removing
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .
– Unscrew screws -arrows- for coolant pipes at cylinder block
and at engine oil cooler.
– Place a catch pan under the engine.
– Pull out the coolant pipes towards the front out of the engine
oil cooler.
– Unscrew screws -1, 2, 3- and pull off the engine oil cooler from
the cylinder block.
Note
To provide a clearer illustration, the fitting position is illustrated

with the exhaust gas turbocharger and the front silencer removed.
Install
♦ Tightening torques: ⇒ page 91
following points:
Note
Replace O-rings.
– Install alternator ⇒ Electrical System; Rep. gr. 27 .

Note
If the engine oil cooler was replaced, the coolant must be

changed.
1.5 Testing oil pressure and oil pressure

switch
♦ Flexible-head wrench SW 24 - T40175-
♦ Oil pressure tester , e.g. -V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
Conditions
• Engine oil level o.k., test ⇒ Maintenance ; Booklet Fabia II .
• Coolant temperature at least 80°C (radiator fan must have run
at least once).
Note
Functional test and repair of the visual and acoustic oil pressure
display ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations, ⇒ Vehicle diagnostic tester.
Test sequence
– Remove oil pressure switch - F1- in cylinder head left
-arrow- with the hinged wrench SW 24 - T40175- .

– Screw oil pressure switch into the test equipment.

– Screw tester in the cylinder head instead of the oil pressure
switch.
– Connect brown cable of tester to earth (-).
– Connect voltage tester to battery positive terminal (+) and to
oil pressure switch.
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch - F1- .
If the LED does not light up:
– Start engine and slowly increase engine speed.
• The LED must light up at an oil overpressure of 0.03…0.07
MPa (0.3...0.7 bar), if not replace oil pressure switch.
– Increase engine speed further.
• At 2000 rpm and an oil temperature of 80°C the overpressure
should be at least 0.2 MPa (2.0 bar).
• At a higher engine speed the overpressure must not be greater
than 0.7 MPa (7 bar).

19 – Cooling
1 Cooling system
WARNING
Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ The hose connections are secured with spring-type clips. In
case of repair assign the spring strap clamps via the ⇒ ETKA
- Electronic catalogue of original parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection).
♦ The arrows which are on the coolant pipes and the coolant
hose ends must stand opposite to each other.
1.1 Parts of cooling system on the side next to the body - Summary of compo‐
nents
Note
♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
102 Rep. gr.19 - Cooling

1 - 5 Nm
2 - Radiator bearing
3 - Radiator
⇒ page 113
❑ after replacing fill entire
system with fresh cool‐
ant
4 - Spring strap clamp
5 - Top coolant hose
❑ Connection diagram for
coolant hoses
⇒ page 104
6 - Charge air cooler
❑ can only be removed
once the radiator has
been removed
7 - Fan shroud
⇒ page 112
8 - Screw cap
❑ Check pressure relief
valve ⇒ page 115
9 - 5 Nm
10 - Expansion reservoir
❑ Sprawdzenie szczelno‐
ści układu chłodzenia
⇒ page 115
11 - Right radiator fan - V35-
⇒ page 112
12 - Radiator fan - V7-
❑ with radiator fan control unit - J293-
13 - Support
❑ for plug connection
14 - Coolant temperature sender at radiator outlet - G83- , 35 Nm
15 - Sealing ring
❑ replace
16 - Bottom coolant hose
❑ Connection diagram for coolant hoses ⇒ page 104
17 - Bottom bearing
18 - 5 Nm
1. Cooling system 103

1.2 Connection diagram for coolant hoses
1 - Expansion reservoir
2 - Coolant pump
3 - Intake manifold
4 - Cylinder head and cylinder
block
❑ fill with fresh coolant af‐
ter replacing
5 - Heat exchanger of heating
system
6 - Coolant regulator housing
7 - Top radiator connections
8 - Bottom radiator connection
9 - Coolant recirculation pump
- V50-
⇒ page 112
10 - Engine oil cooler
1.3 Draining and filling up coolant

♦ Refractometer
Draining
Note
♦ Collect drained coolant in a clean container for reuse or proper

disposal.
♦ Observe the disposal instructions.

WARNING
Hot steam may escape when the compensation bottle is

opened.
♦ Wear safety goggles and safety clothing, in order to avoid
eye injuries and scalding.
♦ Cover the cap with a cloth and open carefully.
– Open the cap of the coolant expansion reservoir.

gr. 50 .
– Remove the left charge air hose -2-, to do so slacken the
clamps -1-.
Caution
Shut off the opening of the charge air cooler, e.g. with a clean
foam piece, so that no coolant can penetrate.

– Slacken the clamp -3- and detach the bottom coolant hose
-4- from the radiator.
Filling up
– Re-connect all the coolant hoses and the left charge air hose.
Select the appropriate coolant additive from the ⇒ ETKA - Elec‐
tronic catalogue of original parts .
– In a clean reservoir mix drinking water and coolant additive in
the correct mixing ratio ⇒ Maintenance ; Booklet Fabia II .

– Top up coolant in the expansion reservoir, until the max. mark‐

ing of the coolant level is reached.
– Switch off the heating, and if present, the air conditioning sys‐
tem.
– Start engine, run for not more than 3 minutes at approx. 2000
rpm and while doing so always top up coolant in the expansion
reservoir.
– Tighten cap at expansion reservoir.
– Run engine until radiator fan starts.
WARNING

opened.
– Check the level of coolant when the expansion reservoir is

closed and top up if necessary when the engine is cooled
down.
• When engine is at operating temperature the coolant level
must be at the max. marking, when engine is cold between the
-min.- and -max.- markings.
1.4 Coolant regulator - Summary of components

1 - Inlet connections
2 - O-ring
❑ replace
3 - Pressure spring
4 - Tappet
❑ Do not cant when instal‐
ling.
5 - Coolant regulator 2
Note
Do not interchange thermo-ele‐

ments!
Start of opening: 96 ℃
6 - Coolant temperature send‐

er - G62-
❑ before removing, re‐
duce pressure in cooling
system if necessary
7 - Retaining clip
❑ check tightness
8 - Coolant regulator housing
❑ Tightening torque: 10
Nm
9 - Sealing ring
❑ replace
10 - Coolant regulator 1
Note
Do not interchange thermo-ele‐

ments!
Start of opening: 80 ℃
11 - to the expansion reservoir

13 - Coolant pipe
❑ to remove, remove coolant regulator housing -Pos. 8-
❑ to remove, remove compressor ⇒ page 154
14 - Coolant pipe
❑ to remove, remove coolant regulator housing -Pos. 8-
❑ to remove, remove compressor ⇒ page 154
15 - 5 Nm
16 - from bottom of radiator

17 - towards top radiator

1.5 Removing and installing coolant pump

♦ Torx key 30 - T10451-
♦ Locking pin - T10060A-
Removing
-8-.


– Remove inlet connection -2- from pressure pipe.
– Unclip bracket -6-.

– Remove pressure pipe -5-.
– Slacken coolant hose -7- from bracket for charge-air pipe -1-.
– Disconnect plug from charge pressure sender - G31- -8-.
– Completely slacken the screw -9-.
– Remove the right charge air hose from the charge air cooler.
– Completely slacken the screws -arrows-.
– Remove charge air pipe -1-.

– Slacken screw clamp -4- and detach the charge air hose -3-
from the throttle valve.


– Detach vent line -4-. To do so press in the securing ring.
– Carefully press the catches at the noise insulation of the com‐

pressor -arrows- towards the outside.
– Remove noise insulation.
– Swivel out the tensioning pulley for the V-ribbed belt of the
compressor clockwise using an open-end wrench SW 16 -
T10241- .
– Lock tensioning pulley with locking pin - T10060 A- .
– Unscrew fixing screws -arrows- and remove tensioning pulley.

– Release screws -5- and remove bracket -4-.

– Hold the compressor shaft using a wrench SW 16 -1-.
– Release the fixing screw -2- of the belt pulley.
– Remove the belt pulley and the V-ribbed belt for AC compres‐
sor -3-.
– Release the screws for the coolant pump with magnetic cou‐
pling for compressor - N421- -arrows- using Torx key 30 -
T10451- .
– Remove the coolant pump with the magnetic coupling for com‐
pressor - N421- from the cylinder block.
Install
Note
The gasket ring of the coolant pump is glued on. In case of dam‐
aged gasket ring the coolant pump must be replaced.

following points:
– Place the coolant pump with the magnetic coupling for com‐
pressor - N421- in the cylinder block.
– Tighten the fixing screws to 8 Nm using Torx key 30 - T10451- .
– Position the V-ribbed belt on the magnetic coupling for com‐
pressor - N421- .
– Screw on compressor belt pulley with V-ribbed belt placed on
using a new fixing screw.
– Position noise insulation on the compressor.
Note
Pay attention to the correct position of the noise insulation in the

housing.
– Press the noise insulation on the compressor, until the contact

studs -arrows- click audibly into place.

– Pay attention to the correct position of the pressure pipe -5- in

the noise damper for charge air -arrow-.
– Replace O-rings for pressure pipe -5-.
Tightening torques:
♦ V-ribbed belt drive - Summary of components ⇒ page 23
♦ Summary of components - Compressor ⇒ page 153
♦ Charge air system - Summary of components ⇒ page 160
♦ Intake manifold - Summary of components part 1
⇒ page 165
Caution
The screw clamps on the charge air pipes must be tightened

to 5.5 Nm. A too low, but also a too high tightening torque, may
result in the charge air hose falling off the charge air pipe when
driving.
1.6 Removing and installing coolant recircu‐

lation pump - V50-
♦ Hose clamps up to ∅ 25 mm - MP7-602 (3094)-
Removing
– Unscrew screw -2- and remove coolant recirculation pump -
V50- .
– Pinch off the coolant hoses with the hose clamps up to ∅
25 mm - MP7-602 (3094)- and detach them from the coolant
recirculation pump - V50- .
Install
♦ Tightening torque of screws - 2 - : 8 Nm
following points:
– Inspect coolant level, top up with coolant if necessary
⇒ page 104 .
1.7 Removing and installing fan shroud for

radiator fan
Removing

– Release screws -arrows- for the air intake -1-.
– Disconnect plug for fan -arrows-.
– Press both catch pegs (left and right) of the radiator using a
suitable tool, e.g. screwdriver, and loosen both catches.
– Push the fan shroud -1- with fans upwards and remove it to
the top.
Remove the radiator fan from the fan shroud
– Disconnect the plug connection -1- and expose cables.

– Unscrew nuts -arrows- and remove radiator fan - V7- and -
V35- .
Install
following points:
♦ Tightening torque for radiator fan: 5 Nm
– Insert fan shroud with radiator fan - V7- and -V35- from above
and slide into all 4 supports on the radiator.
• The fan shroud on the top right and left must click audibly into
place.
– Check for secure catch by tightening it in the opposite direc‐
tion.
1.8 Removing and installing radiator



Removing
– Press off the filler neck of the windscreen washer reservoir
from bracket.
– Remove bracket for filler neck of the windscreen washer res‐
ervoir.
To do so, press in the catch -direction of arrow 1- and at the
same time push the bracket upwards -direction of arrow 2-.
– Remove the right charge air hose, to do so slacken the clamps

-arrows-.
– Pull off coolant hoses at top of radiator -arrows-.

– Disconnect plug from coolant temperature sender at radiator
outlet - G83- .
– Open the bracket for coolant line at front top frame side rail
-arrow- and loosen the coolant lines -3- and -4-.
– Open the bracket for coolant line sideways on the rear frame
side rail.
– Removing fan shroud ⇒ page 112 .

– Release right and left screw -2- for radiator bearing.

– Push the radiator to the rear and remove the right and left ra‐
diator bearing ( ⇒ page 102 , Pos. 2).
– Pull the radiator -1- with the condensor on the left side approx.
4 cm upwards out of the charge air cooler -2-. To do so, press
the charge air cooler -2- towards the left and downwards.
– Remove the radiator -1- with the condensor towards the left
-direction of arrow- from the right support of the charge air
cooler -2-.
– Hold the radiator and release the screws -arrows- for the con‐
densor -2- from the radiator -1-.
– Remove radiator.
– Attach condensor to lock carrier.
Install
following points:
Tightening torques
Component Nm
Condenser on the radiator 5
Radiator at lock carrier 5
– Replenish coolant ⇒ page 104 .
1.9 Checking the coolant system for leak‐

tightness
1.9.1 Inspecting coolant system with cooling

system testing device - V.A.G 1274- for
tightness
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
Test condition
• Engine is at operating temperature.

Test sequence
WARNING

opened.
– Open compensation bottle.

– Position the cooling system testing device - V.A.G 1274- with
adapter - V.A.G 1274/8- on the coolant expansion reservoir.
– Using the hand pump of the testing device generate an over‐
pressure of approx. 0,1 MPa (1,0 bar).
If the pressure drops:
– Search position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Position the cooling system testing device - V.A.G 1274- with

adapter - V.A.G 1274/9- on the cap.
– Operate the handpump.
• 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 opens too early or too late:
– Replace cap.
1.9.2 Inspecting coolant system with cooling

system testing device - V.A.G 1274 B-
for tightness
♦ Cooling system testing device , e.g. -V.A.G 1274 B-
Test condition
• Engine is at operating temperature.

Test sequence
WARNING

opened.
– Open compensation bottle.

– Screw the adapter for cooling system testing device - V.A.G
1274/8- into the coolant expansion bottle.
– Clamp the connecting piece - V.A.G 1274 B/1- in the adapter
for cooling system testing device - V.A.G 1274/8- .
– Connect the connecting piece - V.A.G 1274 B/1- via the de‐
livered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Using the hand pump of the testing device generate an over‐
pressure of approx. 0,1 MPa (1,0 bar).
WARNING
Risk of scalding!
♦ Before the cooling system testing device - V.A.G 1274 B-
is separated from the connecting hose or the connecting
piece - V.A.G 1274 B/1- , the existing pressure must ab‐
solutely be released.
♦ For this step, press the pressure relief valve on the cooling
system testing device - V.A.G 1274 B- and hold it pressed
until the pressure gauge indicates the value »0«.
If the pressure drops:

– Search position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Screw the screw cap into the adapter for cooling system test‐
ing device - V.A.G 1274/9- .
– Clamp the connecting piece - V.A.G 1274 B/1- in the adapter
for cooling system testing device - V.A.G 1274/9- .
– Connect the connecting piece - V.A.G 1274 B/1- via the de‐
livered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Operate the handpump.
• 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 opens too early or too late:
– Replace cap.

20 – Fuel supply system

1 Removing and installing parts of the
fuel supply system
Note
♦ Fuel hoses at the engine must only be secured with spring-

type clamps ⇒ ETKA - Electronic catalogue of original parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Separate quick couplings of fuel ⇒ page 139 .
1.1 Fuel tank with component parts - Summary of components
1 - Fuel tank
❑ support with engine/
gearbox jack -
V.A.G 1383 A- when re‐
moving
⇒ page 125
2 - 25 Nm
3 - Tensioning strap
4 - Vent line
❑ to solenoid valve 1 for
activated charcoal filter -
N80- in engine compart‐
ment
5 - Fuel feed line
❑ black
❑ to fuel distributor in in‐
take manifold
6 - Fuel filter
❑ with installed pressure
limiting valve for fuel re‐
turn-flow line
Opening pressure:
0.60…0.68 MPa
(6.0 … 6.8 bar)
❑ blue return-flow line in
the middle and black
feed line on the edge
❑ Fitting position: Pin at fil‐
ter housing must en‐
gage in the recess of the
guide for the fixing
clamp
❑ the direction of flow is marked by arrow
7 - 5 Nm
❑ for collar clamp for fuel filter
118 Rep. gr.20 - Fuel supply system

8 - Sealing ring
❑ to be inserted dry into the opening of the fuel tank
❑ moisten union nuts with fuel before installing
9 - Fuel gauge sender - G-
10 - Fuel delivery unit
❑ inspecting fuel pump ⇒ page 128
❑ Clean strainer if dirty
❑ Pay attention to installation position of flange of fuel delivery unit ⇒ page 120 .
11 - Return-flow line
❑ from the fuel filter into the fuel delivery unit
❑ blue
12 - Feed line
❑ from the fuel delivery unit into the fuel filter
❑ black
13 - Union nut, 80 Nm
❑ use wrench - MP1-227 (3217)- for removing and installing
14 - 10 Nm
15 - Vent valve
❑ to remove, unclip valve at side and take out of filler neck.
❑ before installing, unscrew cap -16-
16 - Screw cap
17 - Sealing ring
18 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing ⇒ Body Work; Rep. gr. 55
19 - Gravity valve
❑ to remove, unclip valve at top and lift out of filler neck
❑ inspect valve for blockage:
♦ Valve horizontal: open
♦ Valve tilted 45°: closed
20 - Vent line
❑ between activated charcoal filter -21- and vent line -4-
21 - Activated charcoal filter
❑ schemat montażowy układu odpowietrzenia zbiornika paliwa ⇒ page 144
❑ Sprawdzenie odpowietrzenia zbiornika paliwa ⇒ page 145
22 - 10 Nm
23 - Vent line
❑ clipped in place on fuel tank
❑ check for firm seating
1. Removing and installing parts of the fuel supply system 119

Fitting location of the fuel delivery unit
Note
The fuel delivery unit can only be installed in this position.
Marking on the flange must be aligned with marking on the fuel

tank.
The -arrow- shows the direction of travel.
Connect the blue return-flow line -1- on the connection with the
marking -R-.
Connect black feed line -2- to the connection with the marking
-V-.
Inspect vent valve

Lever in zero position: Valve closed.
Lever pressed in -direction of arrow-: Valve open.
Note
Before installing the vent valve, unscrew the cap from the filler
neck.
1.2 Extract fuel from the fuel tank
1.2.1 Emptying fuel tank when fuel pump is

intact
♦ Fuel extraction device , e. g. -VAS 5190-
♦ Adapter for fuel extraction - VAS 5190/3-
♦ Disassembly wedge - 3409-
♦ Remote control - V.A.G 1348/3A-
♦ Adapter - VAS 5565-
Note
If the fuel extraction device - VAS 5190- is still fitted with an ex‐
traction hose with a fixed tip, replace it by the version with a screw-
type tip.

– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .
– Screw on fuel extraction adapter - VAS 5190/3- to extraction
house.
Note
♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .
– Pull out the supply line -1- and catch the fuel that flows out with
a cleaning cloth. Unlock the quick coupling and disconnect
⇒ page 139 .
– Connect the fuel extraction device - VAS 5190- with the adapt‐
er for the fuel extraction - VAS 5190/3- to the fuel feed line.
Caution
Secure the earth cable of the fuel extraction device to a bare

metal part of the body.
– Position right rear seat vertically ⇒ Body Work; Rep. gr. 72 .
– Unclip the cover -1- with the fuel pump control unit - J538-
-2-.

– Disconnect plug connection for fuel pump -arrow-.
– Connect adapter - VAS 5565- to fuel delivery unit -1-.

– Connect remote control - V.A.G 1348/3A- to adapter -
VAS 5565- and to battery positive terminal in engine compart‐
ment.
– Connect connection -5- (yellow) from the adapter - VAS 5565-
with adapter cables -3- from the adapter set - V.A.G 1594 C-
to the minus pole terminal on the battery.
Note
This step is only intended to ensure that the fuel pump runs when
the engine is switched off.
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew the cap from the fuel filler neck.
– Operate the remote control - V.A.G 1348/3A- and the shut-off
cock on the fuel extraction device - VAS 5190- until the fuel
tank is emptied.
Caution
The fuel pump must not run »dry«.
1.2.2 Emptying fuel tank when the fuel pump

is damaged when more than 3/4 full
Note

⇒ page 3 .

– Remove cone of valve -2- from the cylinder end piece -1- of
the fuel extraction device - VAS 5190- .
– Make a mark -arrow- on hose with insulating tape at distance

-a- = 1,180 mm from end of extraction hose.
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew the cap from the fuel filler neck.
Caution

– Screw the cylinder end piece -1- of the fuel extraction device
- VAS 5190- onto the filler tube of the fuel tank.
– Push extraction hose into fuel tank until marking -arrow- coin‐
cides with cylinder end piece -1-.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore, the hose must only be pushed in up to the previously
made marking -arrow-.
– Drain the fuel tank through the filler neck as much as possible.
– Carefully pull out the extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
♦ When working on the fuel delivery unit or on the sender for fuel
gauge display , proceed as follows ⇒ page 124 .

1.2.3 Emptying fuel tank when the fuel pump

is damaged when less than 3/4 full
♦ Wrench for union nut - MP1-227 (3217)-
♦ Disassembly wedge - 3409-
Note

⇒ page 3 .
– Switch off the ignition and all electrical components and take
out the ignition key.
-2-.
WARNING
The fuel line is under pressure! 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.
– Remove plug fuel feed line and the fuel return-flow line from
the flange on the fuel delivery unit and collect escaping fuel
with cloths. Unlock the quick coupling and disconnect
⇒ page 139 .
– Unscrew union nut with wrench for union nut - MP1-227

(3217)- .

– Carefully lift out fuel delivery unit flange -3-.
Caution

– Insert suction hose of fuel extractor - VAS 5190- as far as

possible into fuel tank.
– Extract fuel using the fuel extraction device - VAS 5190- .
If fuel tank needs only to be emptied, re-install the fuel delivery
unit ⇒ page 127 .
1.3 Removing and installing the fuel tank

Removing
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 120 .
Note

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 4 .
– Fold the underbody cover, located under the rear seat, for‐
wards.
-2-.
– Unplug the 5-pin plug from the fuel delivery unit.
– Clean around the fuel filler neck.
– Unscrew right rear wheel.
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Open fuel tank flap and unscrew cap from filler neck.

– Unscrew fixing screws on tank filler neck -arrows-.

– Remove both ventilation lines ( ⇒ page 144 , Pos. 6 and 7)
from activated charcoal filter.
– Removing rear axle ⇒ Chassis; Rep. gr. 42 .
WARNING
The fuel feed line is pressurized! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully releasing the connection
point.
– Disconnect the feed line -1- and the vent line -2-
⇒ page 139 .
– Unscrew tensioning strap for fuel tank -arrows-.

– Support the fuel tank using the engine/gearbox jack - V.A.G
1383 A- .
– Unscrew the fixing screws from the fuel tank -arrows-.
– Carefully lower the engine/gearbox jack - V.A.G 1383 A- and
remove the fuel tank with the assistance of a second mechan‐
ic.
Install
– Check both earth connections for corrosion, if necessary re‐
move corrosion.
– Check fitting position of the earth lead -1-.

• The plug -1- on the metal plate ring -2- must be placed on
firmly.
• The contact tab -4- must be hung on the fuel tank -3- and se‐
cured with the spacer bush -5-.
following:
♦ Lay the vent and fuel lines 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 line connections fit tightly.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.

1.4 Removing and installing fuel delivery

unit
♦ Wrench for union nut - MP1-227 (3217)-
Removing
• The fuel tank must not be more than 3/4 full.
Note
♦ If necessary, extract fuel from the fuel tank ⇒ page 120 .

♦ Observe the safety instructions before starting fitting work
⇒ page 3 .
wards.
-2-.
– Disconnect the plug, the feed and return flow line from the
flange of the fuel delivery unit.
Note
Press in the securing ring in order to unlock the lines.
– Unscrew union nut with wrench for union nut - MP1-227

(3217)- .
Note
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the 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.
Install
Installation of the fuel delivery unit occurs in reverse order to re‐
moval. Pay attention to the following:

Note
♦ When installing, do not bend the float arm of the fuel gauge
sender unit - G- .
♦ Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the fuel
delivery unit.
♦ Observe the fitting location of the fuel delivery unit. The mark‐
ing on the flange must be aligned with marking on the fuel tank
-arrows-.
♦ Do not interchange feed line and return-flow line.
♦ Check for firm seating at the fuel delivery unit by pulling.
♦ After installing the fuel delivery unit, check whether the lines
are still clipped in place on the fuel tank.
1.5 Removing and installing the sender for

fuel gauge display - G-
Removing
– Remove fuel delivery unit ⇒ page 127 .
– Unlock contact studs -arrows- with a screwdriver and pull out
the fuel gauge sender - G- upwards.
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the wiring and check correct installation of the plug.
– Insert the sender for fuel gauge display - G- in the guides at
the fuel delivery unit and press downwards until it latches into
position.
– Install fuel delivery unit ⇒ page 127 .
1.6 Testing fuel pump


♦ Key - T30101 (3087)-

♦ Pressure gauge , e.g. -VAS 6550-
♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g.
-V.A.G 1348/3-3-
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Multimeter , e.g. -V.A.G 1526-
♦ Adapter for measuring method/DSO (5-pin) , e.g. -VAS 5565-
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Measuring vessel
1.6.1 Inspecting proper operation and power

supply
Test conditions
• Battery voltage at least 11.5 V.
• Fuel pump fuse O.K. ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
• Fuel pump control unit - J538- O.K.
Test sequence
Note
The function of the fuel pump is tested with the actuator diagnosis.
– Connect vehicle diagnosis, measurement and information

system - VAS- .
– Switch on ignition.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”,“01 - Engine electronics” and “03 - Actuator di‐
agnosis”.
– Press right arrow button on display up to final control diagnosis
for fuel pump electronics.
• The fuel pump must now run slowly to the maximum speed.
Note
The fuel pump runs very quietly.

The fuel pump does not run:
wards.

– Disconnect plug from fuel pump control unit - J538- -2-.
– Testing the voltage supply with the voltage tester - V.A.G 1527
B- between contact -1- and -6-.
• The LED must light up.
The LED does not light up:
– Determine and remove open circuit in the wiring according to
the current flow diagram ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
The LED lights up (power supply O.K.):
-2-.
– First of all check the plug -1- for correct fit. To do so, pull on
the plug without pressing the catch.
If the plug was not correctly plugged in:
– Repeat the functional test of the fuel pump.
If the plug was correctly plugged in:
– Now unplug the plug -1-.
– Check the contacts at the plug and at the fuel delivery unit for
damage.
If no damage was detected:
– Remove fuel delivery unit ⇒ page 127 .
– Check whether the electric wiring between the flange and fuel
pump is connected.
If there is no open circuit in the wiring, the fuel pump is defective.
– Replace fuel delivery unit ⇒ page 127 .

1.6.2 Checking fuel pressure

• The function of the fuel pump was checked ⇒ page 129 .
Note

⇒ page 3 .
⇒ page 4 .

– Connect the pressure gauge - VAS 6550- with adapters - VAS

6550/1- and -VAS 6550/2- to the fuel feed line.
– Make sure that the discharge cock is closed and the shut-off
taps are opened.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.40…0.70 MPa (4.0 … 7.0 bar)
If fuel line is o.k.:
– Test holding pressure ⇒ page 133 .
If the specified pressure is exceeded:
– Check the return line between the fuel filter and fuel pump for
kinks and blockages.
If no fault is found:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.
If the measurement is less than the specification:
– Check the fuel pressure before the fuel filter, to do so proceed
as follows:

– Detach fuel feed line -arrow- at fuel filter ⇒ page 139 .
– Connect the pressure gauge - VAS 6550- with the adapter -

VAS 6550/1- and -VAS 6550/2- between the fuel filter and the
fuel feed line.
taps are opened.
– Start engine and run in idle.
– Slowly close the shutoff cock -A-.

• The pressure must rise to at least 0.7 MPa (7.0 bar).
– If the 0.7 MPa (7.0 bar) is reached, immediately open the shut-
off cock again!
If the pressure has risen, the pressure limiting valve in the fuel
filter is defective.
– Replace fuel filter.
If the pressure has not risen, the fuel pump is defective.

1.6.3 Testing holding pressure

• Fuel pressure O.K. and pressure gauge - VAS 6550- connec‐
ted in the engine compartment ⇒ page 131 .
Note

⇒ page 3 .
⇒ page 4 .
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0,3 MPa (3,0 bar) after 10
minutes.
If the pressure again drops:
– Immediately close the shut-off cock -B- of the pressure gauge

after the pressure has built up. The lever points at right angles
in the direction of flow.
Now the pressure does no longer drop:
Note
Search for leakage on the engine side. Repeat the holding pres‐
sure test. This time, close the shut-off cock -A- in order to deter‐
mine if a leak is indeed present on the engine side.
– Check the low-pressure line to the high pressure pump for

tightness.
– Replace high pressure pump ⇒ page 176 .
If the pressure again drops:
Search for leakage on the fuel tank side, to do so proceed in the
following manner:
– Check the fuel line to the fuel filter for tightness.
If the fuel line is not found to be faulty:
– Check the pressure holding valve in the fuel delivery unit. To
do so proceed in the following manner:


VAS 6550/1- and -VAS 6550/2- between the fuel filter and the
fuel feed line.
taps are opened.
– After the pressure has built up, close the shut-off cock -A-.
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0,3 MPa (3,0 bar) after 10
minutes.
If the pressure drops, the pressure holding valve in the fuel de‐
livery unit defective.
If the pressure does not drop, the pressure limiting valve in the
fuel filter is defective.
1.6.4 Check fuel flow rate
Note

⇒ page 3 .
⇒ page 4 .

wards.
-2-.
– First of all check the plug -1- for correct fit. To do so, pull on
the plug without pressing the catch. If the plug was not cor‐
rectly plugged in, it may have caused a fault.
– Now unplug the plug -1-.
– Check the contacts at the plug and at the fuel delivery unit for
damage.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect the remote control - V.A.G 1348/3A- to the adapter -
VAS 5565- and to the battery positive (+).
Note
This step is only intended to ensure that the fuel pump runs when
the engine is switched off.



VAS 6550/2- to the fuel feed line. Hold adapter - VAS 6550/1-
in a measuring container.
taps are opened.
WARNING
Danger of liquid spraying out when opening the shut-off valve.

Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact with fuel. Hold the container in front of
the free connection to the pressure gauge.
– Activate remote control - V.A.G 1348/3A - . While doing this,

slowly close the shut-off cock -arrow- until the pressure gauge
displays 0,4 MPa (4 bar) overpressure. Now do not make any
further changes to the position of the shut-off cock.
– Empty measuring glass.
– The fuel flow rate of the fuel pump is dependent on the battery
voltage. For this reason, additionally connect the multimeter -
V.A.G 1715- to the outgoing circuits -1 and 5- of the adapter
for measuring method/DSO (5-pin) - VAS 5565- .
– Activate remote control for 30 seconds while measuring the
battery voltage.
– Compare the fuel rate with the specified value.

*) minimum flow rate 1 cm3/30 s
**) Voltage at the fuel pump when engine is not running and pump
is operating.
Read out examples:
During the test a voltage of 10.5 V was measured. Thus a mini‐
mum flow rate of 580 cm3/30 s is obtained.
If the minimum flow rate is not reached:
– Check the fuel lines for possible restrictions (kinks) or block‐
ing.
– Take cap off fuel filler neck and repeat the test.
If the fuel flow rate is now reached:
– Check the ventilation of the fuel tank.
If the minimum flow rate is again not reached:
– Check the fuel filter, to do so proceed as follows:


VAS 6550/1- to the fuel feed line. Hold adapter - VAS 6550/2-
in a measuring container.
taps are opened.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and inspect the filter strainer for
soiling.
If you have still not found any fault up to this stage:
If the required fuel delivery volume has been achieved, but a fault
is still suspected in the fuel supply system (e.g. intermittent break‐
down of the fuel supply):
– Check power consumption of the fuel pump ⇒ page 137 .
1.6.5 Checking power consumption

wards.
-2-.

– Connect the current probe -A- of the vehicle diagnosis, meas‐

urement and information system - VAS- on the line -B- to
contact 1 of the 5-pin plug.
– Measure voltage consumption of the fuel pump.
Specified value: maximum 9 A
Note
If the fault in the fuel supply system is intermittent then tests can
be undertaken during a test drive but then two people are required
for this.
If the power consumption is exceeded, the fuel pump is defective.


2 Separating quick couplings

♦ Lever - T10468-
Note
♦ The quick couplings of fuel, vacuum and ventilation lines are

colour marked. Either the colour point at the quick coupling or
the release button has the corresponding colour.
♦ Observe safety measures ⇒ page 3 .
Quick coupling Colour coding at the quick cou‐

pling
Fuel feed black
line
Fuel return-flow blue
line
Vent line White, beige
Vacuum line green
WARNING
The fuel feed line is pressurized! 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 hose connections. Reduce pressure by carefully re‐
moving the hose.
Version 1
Note
When the push-fit coupling is fitted with a plastic circlip, leave it

inserted when removing and installing the quick release.
Push-on coupling with release buttons -arrows- on right and left
2. Separating quick couplings 139

The coupling point -1- in the engine compartment must be held.

– Insert the lever - T10468- between the heat shield and the stop
-arrow- of the fuel line -2- and hold it.
Continued for all socket boxes
– Press quick coupling -1- in -direction of arrow A-.

– Press the release buttons and detach the quick coupling -1- in
-direction of arrow B- from the fuel line -2-.
Pay attention to the colour assignment when installing
⇒ page 139 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 2
Push-on coupling with pull-release mechanism -arrow-

– Press quick coupling -1- in -direction of arrow A-.

– Pull on the pull release -2- in -direction of arrow B-.
– Detach the quick coupling -1- in -direction of arrow B- from the
fuel line -3-.
⇒ page 139 .
posite direction!
Version 3
Quick coupling with front release button -arrow-.

– Press the release button -arrow- and detach the quick cou‐
pling.
⇒ page 139 .
posite direction!
Version 4

– Press quick coupling in -direction of arrow A-.
– Press release buttons -arrows- and detach quick coupling.
⇒ page 139 .
posite direction!
Version 5

⇒ page 139 .
posite direction!
Version 6
2. Separating quick couplings 141


– Press push-on coupling -1- in -direction of arrow- and hold
pressed.
⇒ page 139 .
– Check the quick couplings for firm seating by pulling in the
opposite direction!
Variant 7
Quick coupling -1- with release buttons -2- right and left.
– Press push-on coupling -1- in -arrow direction A- and hold
pressed.
– Press release buttons -2- in -arrow direction B- and remove
quick coupling- 1-.
Pay attention to the assignment of the colours when installing
⇒ page 139 .
The quick coupling must be heard to click into place.
– Check the quick couplings for firm seating by pulling in the
opposite direction!

3 Accelerator pedal
3.1 Accelerator pedal module - Summary of components
1 - Bearing bracket
❑ removing and installing
⇒ Chassis; Rep. gr. 46
2 - Connector
❑ black
❑ 6-pin
3 - Accelerator pedal module
❑ with accelerator pedal
position sender -G79-
and accelerator pedal
position sender 2 -
G185-
❑ to remove the sender re‐
move the bottom part of
the dash panel on the
driver's side
❑ if the accelerator pedal
module was replaced,
an adaptation of the en‐
gine control unit has to
be performed on vehi‐
cles with automatic
gearbox ⇒ Vehicle diag‐
nostic tester
4 - 10 Nm
3. Accelerator pedal 143

4 Activated charcoal container system
4.1 Activated charcoal container system - Summary of components
Note
♦ The hose connections are secured with spring strap clips or clamp-type clips.
♦ Renew clamp-type clips with spring-type clips.
♦ Use pliers for spring strap clips to fit the spring strap clips.
♦ Safety precautions when working on the fuel supply system ⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system ⇒ page 4 .
1 - Activated charcoal filter sys‐

tem solenoid valve 1 - N80-
with ventilation line
❑ attached with bracket to
the inlet connection
❑ Valve is actuated
(pulsed) by engine con‐
trol unit - J623- when en‐
gine is warm
❑ Valve closed when igni‐
tion is switched off
2 - to pressure pipe
❑ ⇒ page 146 , Part 1,
-Pos. 9-
3 - Inlet connection
4 - 10 Nm
5 - Activated charcoal filter
❑ Fitting location: in rear
right wheelhouse
❑ attached to the vehicle
body
❑ Sprawdzenie odpo‐
wietrzenia zbiornika pal‐
iwa ⇒ page 145
❑ removing:
– Removing the rear right
wheel.
– Remove wheelhouse
liner ⇒ Body Work; Rep.
gr. 66 .
– Disconnect lines -6- and

-7-.
– Unscrew the activated charcoal filter from the body and pull out towards the bottom.
❑ Installing:
– Installation is carried out in the reverse order.

6 - Vent line
❑ to activated charcoal filter solenoid valve 1 - N80-
❑ press in securing ring in order to remove
7 - Vent line with gravity valve
❑ forcefully press securing element in order to remove
8 - to fuel filler neck
4.2 Checking the fuel tank venting

♦ Hand vacuum pump , e.g. -VAS 6213-
Test condition
• The ignition must be switched off.
– Remove the ventilation line -1- from the activated charcoal fil‐
ter on the activated charcoal filter system solenoid valve 1 -
N80- -2-.
– Connect hand vacuum pump - VAS 6213- to vent line -1- as
shown.
– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for “vacuum”.
– Operate the hand vacuum pump several times.
• No vacuum should build up.
If a vacuum builds up.
– Check the ventilation opening -3- on the activated charcoal
filter -4- for dirt and clean as required.
If no vacuum builds up:
– Shut off ventilation opening -3- on the activated charcoal filter
and once again operate the hand vacuum pump several times.
• A vacuum should build up.
If no vacuum builds up:
– Replace activated charcoal filter.
4. Activated charcoal container system 145

21 – Turbocharging/supercharging
1 Exhaust gas turbocharger
1.1 Exhaust turbocharger - Summary of components
Note
♦ The exhaust manifold and the exhaust turbocharger are one component part.
♦ Observe the general notes for assembly work on the charge air system with exhaust gas turbocharger
⇒ page 7 .
Part 1
1 - Solenoid valve for charge

pressure control - N75-
2 - 10 Nm
3 - 11 Nm
4 - Turbocharger divert air
valve - N249-
❑ for removing, the charge
air hose must be re‐
moved ⇒ page 148
5 - O-ring
❑ replace
⇒ page 148
❑ Testing exhaust gas tur‐
bocharger pressure box
⇒ page 151
7 - 9 Nm
8 - Connecting hose
9 - Connecting hose
❑ to activated charcoal fil‐
ter solenoid valve 1 -
N80- ( ⇒ page 144 ,
Pos. 2)
10 - Charge air hose
⇒ page 148
Part 2
146 Rep. gr.21 - Turbocharging/supercharging

1 - 8 Nm
2 - Coolant pipe
3 - Ball stud, 10 Nm
❑ for top engine cover
4 - O-ring
❑ replace
5 - 23 Nm
6 - Support plate
❑ for exhaust gas turbo‐
charger
❑ attached to the cam‐
shaft housing
( ⇒ page 55 , -Pos. 12-)
❑ Tightening torque for
stud bolts of catalytic
converter 20 Nm
⇒ page 148
❑ Testing exhaust gas tur‐
bocharger pressure box
⇒ page 151
8 - Gasket
❑ replace
9 - Pin screw
❑ always replace after re‐
moving the nuts
-Pos. 10-
❑ after screwing in, the pin
screws must protrude in
the cylinder head by 25
mm
10 - 25 Nm
❑ replace
❑ observe the order of tightening up ⇒ page 151
11 - 15 Nm
12 - Coolant pipe
13 - Gasket
❑ replace
14 - 8 Nm
15 - Oil return pipe
16 - Hollow screw, 20 Nm
❑ replace
❑ attached to the timing case
17 - Sealing ring
❑ replace
1. Exhaust gas turbocharger 147

18 - Oil feed pipe
Caution
The oil feed pipe must be
replaced when installing
a new exhaust gas tur‐
bocharger.
19 - Hollow screw, 30 Nm
❑ replace
1.2 Removing and installing exhaust gas

turbocharger
Caution

Removing
Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 7 .
– Open clamp -4- and detach the charge air hose -8 - from the
pressure pipe.
– Remove the holding clamp -1- and the charge air hose -8-.


– Slacken clamp -1- and detach coolant hose -5-.

– Detach hoses -9- from exhaust gas turbocharger.
– Release screws -3- and remove the support plate.
– Release the ball stud -4- and the screw -8-.
– Remove coolant pipe -7-.
– Open clamp -5- and remove coolant pipe -6-.
– Release hollow screw -2-.

– Unscrew the nuts of the exhaust manifold in the sequence

-9 to 1-.
– Detach the exhaust manifold and exhaust gas turbocharger
with oil return-flow line evenly from the cylinder head (do not
tilt).
Note
If the exhaust manifold lies against the alternator, evenly swivel

the exhaust manifold and exhaust gas turbocharger upwards. The
distance to the cylinder head must be the same on the left as well
as the right.
Install
WARNING

Installation is carried out in the reverse order. When installing,

note the following:
Caution
♦ When installing the exhaust gas turbocharger, the pin

screws ⇒ Item 9 (page 147) and the nuts
⇒ Item 10 (page 147) must always be replaced.
♦ The oil feed pipe must be replaced when installing a new
exhaust gas turbocharger.
♦ Always replace seals and gasket rings.
♦ Parts for charge air system must be free of oil and grease
before installing.
♦ After installing the exhaust gas turbocharger, the turbo‐
charger with connection for oil feed line must be filled with
engine oil.
♦ After installing the turbocharger, run engine at idling speed
for about 1 minute to ensure that oil is supplied to the tur‐
bocharger.

Tightening sequence and tightening torque of exhaust gas turbo‐

charger
Tighten the nutsin the sequence -1 to 9- to 25 Nm.
Further tightening torques:
Exhaust turbocharger - Summary of components
⇒ page 146 .
1.3 Testing exhaust turbocharger pressure

box
♦ Hand vacuum pump , e.g. -VAS 6213-
– Check the correct fit of the locking clip -1- on the linkage of the
pressure box.
• The fixing nut -2- must be protected with paint.
– Detach the hose -arrow- from the pressure box.
– Fit the hose -2- for the hand vacuum pump - VAS 6213- on the
inlet connection of the pressure box.
– Slide the sliding ring -1- of the hand vacuum pump - VAS 6213-
in -direction of arrow- up to the stop.
Caution
Risk of damage to the pressure box from excessive pressure.

• The pressure must not be greater than 0.08 MPa (800
mbar).

– Operate the hand vacuum pump - VAS 6213- several times

until the pressure gauge indicates a pressure of 0.08 MPa (800
mbar). While doing so, observe the actuator rod -1- of the ex‐
haust gas turbocharger pressure box.
• The actuator rod must move at approx. 0.03 MPa (300 mbar)
• The actuator rod must be at the end of the adjustment path at
approx. 0.08 MPa (800 mbar).
– Ventilate the hand vacuum pump - VAS 6213- -arrow A-.

• The actuator rod must move in the reverse direction.
Note
Observe the motion sequence of the actuator rod over the entire
adjustment range. It must move continuously and without jolting.
If the pressure value remains at 0.08 MPa (800 mbar) and the
actuator rod moves evenly within the total range:
Pressure box is OK.
If the pressure drops or the actuator rod does not move evenly
within the total range:
– Replace exhaust turbocharger ⇒ page 148 .

2 Compressor
2.1 Summary of components - Compressor
1 - Housing with noise insula‐

tion
❑ for silencer
2 - Silencer
❑ for intake air
3 - Air intake hose
❑ secure with spring strap
clamps
4 - 7 Nm
❑ Self-tapping screw
5 - 7 Nm
6 - 7 Nm
7 - O-ring
❑ replace
8 - Pressure pipe
9 - Noise insulation
10 - Housing
❑ for noise insulation
11 - Silencer
❑ for charge air
❑ with gasket
❑ Gasket ring between
compressor and noise
insulation
12 - Belt pulley
❑ for compressor
13 - 8 Nm
14 - Coolant pump with magnetic coupling for compressor - N421-
15 - V-ribbed belt
❑ for compressor
16 - 23 Nm
❑ for compressor's ribbed V-belt
❑ loosen with open-end wrench SW 16 - T10241-
❑ lock with locking pin - T10060 A-
❑ to slacken and tighten the fixing screw, counterhold the compressor shaft using a wrench SW 16
❑ replace
2. Compressor 153
19 - Compressor
20 - 25 Nm
21 - Sealing ring
❑ replace
2.2 Removing and installing the compressor

♦ Locking pin - T10060 A-
♦ Guide bolt - T10341-
♦ Guide bolt - T10341-
Removing
system ⇒ page 7 .
– Remove drive shaft to the right ⇒ Chassis; Rep. gr. 40 .
-8-.


– Remove inlet connection -2- from pressure pipe.
– Unclip bracket -6-.

– Remove pressure pipe -5-.
– Slacken coolant hose -7- from bracket for charge-air pipe -1-.
– Disconnect plug from charge pressure sender - G31- -8-.
– Completely slacken the screw -9-.
– Remove the right charge air hose from the charge air cooler.
– Completely slacken the screws -arrows-.
– Remove charge air pipe -1-.

– Slacken screw clamp -4- and detach the charge air hose -3-
from the throttle valve.
2. Compressor 155

– Detach vent line -4-. To do so press in the securing ring.
– Release screw -1-.

– Press off the coolant line -4- from the air intake silencer -5-.
– Open the clamp -3- and detach the hose -2-.
– Detach the coolant hoses at the heat exchanger -arrows-.
– Unbolt the pendulum support -arrows-.
WARNING
Bolt -1- must not be loosened.

– Carefully press the catches at the front housing of the noise

insulation of the compressor -arrows- towards the outside.
– Remove the rear housing with the noise insulation.
– Push the engine towards the front and remove the housing
and the noise insulation.
– Swivel out the tensioning pulley for the V-ribbed belt of the
compressor clockwise using an open-end wrench SW 16 -
T10241- .
– Lock tensioning pulley with locking pin - T10060 A- .
– Unscrew fixing screws -arrows- and remove tensioning pulley.

– Hold the compressor shaft using a wrench SW 16 -1-.
– Release screws -5- and remove bracket -4-.

– Release the fixing screw -2- of the belt pulley.
– Remove the belt pulley and the V-ribbed belt for AC compres‐
sor -3-.
2. Compressor 157
– Release the bottom fixing screws -1- and screw the guide bolts
- T10341- into the threaded bores up to the stop.
– Release the top fixing screws -2- for compressor.
– Push the engine towards the front and take out the compres‐
sor.
Remove noise damper for charge air:
– Pull out the noise damper for charge air -3- with noise insula‐
tion -4- towards the front.
Install
Note
Replace the O-rings at the pressure pipe ( ⇒ page 153 , Pos. 7)

and moisten slightly with engine oil before installing.
– Replace gasket ring -1- and pay attention to the correct fitting
position of the groove of the silencer for charge air -3-.
– Slide silencer for charge air -3- with noise insulation -4- onto
the guide bolt - T10341- .
– Slide the compressor onto the guide bolts - T10341 - and

tighten the top fixing screws -2- by hand.
• The dowel sleeves of the silencer for charge air must be cor‐
rectly seated in the cylinder block and in the compressor.
– Unscrew the guide bolts - T10341- .
– Screw in the bottom fixing screws -1- by hand.
– Tighten fixing screws -1- and -2- uniformly crosswise.
– Position the rear housing with the noise insulation on the com‐
pressor.
Note
Pay attention to the correct position of the noise insulation in the

housing.

– Press the rear housing with the noise insulation on the com‐
pressor until the contact studs -arrows- on the front housing
click audibly into place.
Installation is carried out in the reverse order. When installing,
note the following:
– Replace the fixing screw for the belt pulley of the compressor.
Tightening torque: 40 Nm + torque a further 90° (1/4 turn)
– Install right drive shaft ⇒ Chassis; Rep. gr. 40 .
– Install pendulum support ⇒ page 22 .
– Pay attention to the correct position of the pressure pipe -5- in

the noise damper for charge air -arrow-.
– Replace O-rings for pressure pipe -5-.
Tightening torques:
♦ V-ribbed belt drive - Summary of components ⇒ page 23
♦ Summary of components - Compressor ⇒ page 153
♦ Charge air cooling system - Summary of components
⇒ page 160
♦ Intake manifold - Summary of components part 1
⇒ page 165
– Replenish coolant ⇒ page 104 .
2. Compressor 159
3 Charge air system with exhaust gas

turbocharger
system with exhaust gas turbocharger ⇒ page 7 .
3.1 Charge air cooling system - Summary of components
1 - Charge air cooler

⇒ page 161
❑ the radiator and the
charge air cooler are
separate parts
❑ the radiator is fitted onto
the charge air cooler
2 - Screw clamp, 5 Nm
Caution
A too low, but also a too
high tightening torque,
may result in the charge
air hose slipping off the
fluted tube of the charge
air pipe while driving.
3 - Charge air hose

4 - Charge air hose
5 - Throttle valve control unit -
J338-
❑ czyszczenie
⇒ page 172
❑ in case of replacement,
erase initialisation val‐
ues and adapt the en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester.
6 - 7 Nm
❑ with gasket rings

8 - Charge pressure sender - G31- with intake air temperature sender 2 - G299-
9 - 8 Nm
10 - 5 Nm
11 - Bearings
12 - 8 Nm
13 - 8 Nm
14 - Charge air pipe
15 - Support
16 - 8 Nm
17 - Charge air pipe
❑ to exhaust gas turbocharger
3.2 Removing and installing charge air cool‐

er
Removing
– Remove radiator ⇒ page 113 .
– Remove the charge air cooler from the bottom bearings.
Install
Installation is carried out in the reverse order.
3.3 Checking the charge-air system for

leaktightness
♦ Tester for charge-air systems - V.A.G 1687- with adapters -
V.A.G 1687/10- and -V.A.G 1687/14-
Work procedure
3. Charge air system with exhaust gas turbocharger 161

– Connect adapter - V.A.G 1687/14- with adapter - V.A.G

1687/10- at inlet connection of exhaust gas turbocharger.
– Connect hose -1- of charge air system tester to adapter -
V.A.G 1687/10- .
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-.
• The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect tester for charged-air systems - V.A.G 1687- to pres‐
sure air guide using a commercially available intermediate
piece -1-.
Note
If there is water in the inspection glass, drain water via the drain
plug -6-.
– Open valve -3-.
Caution
Risk of damage owing to pressure being set too high.

♦ The pressure must not be greater than 0.05 MPa (0.5 bar)!
– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary regulate the pressure to 0.05 MPa (0.5 bar).
– Listen to, touch or use commercially available leak search
spray or the ultrasonic measuring device - V.A.G 1842- to
check the charge-air system for leak points.
Note
♦ A small amount of air escapes via the valves into the engine.
For this reason no holding pressure test is possible.
♦ Use of ultrasonic measuring device -V.A.G 1842- ⇒ Operating
instructions .
♦ Before removing the adapter, depressurize the test circuit by
detaching the hose coupling.

24 – Mixture preparation - injection

1 Fitting locations of injection and ignition system
1 - Charge pressure sender -

G31- with intake air tempera‐
ture sender 2 - G299-
❑ at right charge air pipe
2 - Intake air temperature
sender 3 - G520- with intake
manifold pressure sender 3 -
G583-
4 - Regulating flap control unit
- J808-
5 - Control valve for fuel pres‐
sure - N276-
6 - Knock sensor 1 - G61-
❑ at rear cylinder block
7 - Solenoid valve 1 for activa‐
ted charcoal filter - N80-
8 - Pressure sensor for the
brake servo unit - G294-
9 - Intake manifold pressure
sender - G71- with intake air
temperature sender - G42-
❑ in the intake manifold
10 - Injection valves
❑ Injection valve for cylin‐
der 1 - N30-
der 2 - N31-
der 3 - N32-
der 4 - N33-
❑ in the fuel distributor
11 - Fuel pressure sender - G247-
❑ in the fuel distributor
12 - Engine control unit - J623-
13 - Coolant temperature sender at radiator outlet - G83-
❑ in the radiator
14 - Coolant temperature sender - G62-
❑ in coolant regulator housing
15 - Engine speed sender - G28-
❑ in sealing flange on gearbox side
16 - Oil pressure switch - F1-
❑ in the left cylinder head
1. Fitting locations of injection and ignition system 163

17 - Coolant recirculation pump - V50-

❑ fixed to the gearbox at the front
19 - lambda probe - G39- with heating for lambda probe - Z19-
20 - Ignition coil with a power output stage - (N70, N127, N291, N292)-
21 - Turbocharger divert air valve - N249-
22 - Camshaft adjustment valve 1 - N205-
23 - Magnetic coupling for compressor - N421-
❑ at the coolant pump
24 - Vacuum pump for brake - V192-
164 Rep. gr.24 - Mixture preparation - injection

2 The intake manifold and the bottom

part of the intake manifold
2.1 Intake manifold - Summary of components

Part 1
1 - Intake air temperature

sender 3 - G520- with intake
manifold pressure sender 3 -
G583-
2 - 5 Nm
3 - 7 Nm
5 - Sealing ring
❑ replace
lightly with clean engine
oil
6 - Regulating flap control unit
- J808-
⇒ page 170
❑ in case of replacement,
erase initialisation val‐
ues and adapt the en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester “Targeted func‐
tion”
7 - 7 Nm
10 - 7 Nm
11 - 3 Nm
12 - Intake manifold pressure sender - G71- with intake air temperature sender - G42-
13 - O-ring
❑ replace
14 - Intake manifold
❑ to remove, remove the regulating flap control unit - J808- and the throttle valve control unit - J338-
⇒ page 170
15 - 20 Nm
16 - Fuel pressure sender - G247- , 22 Nm
❑ Checking the fuel pressure in the high pressure system ⇒ page 185
2. The intake manifold and the bottom part of the intake manifold 165
17 - 80 Nm
18 - Bottom part of intake manifold
⇒ page 170 as well as the intake manifold
19 - Gasket
❑ replace
❑ Check fitting position
20 - 20 Nm
21 - Throttle valve control unit - J338-
❑ czyszczenie ⇒ page 172
❑ in case of replacement, erase initialisation values and adapt the engine control unit - J623- ⇒ Vehicle
diagnostic tester “Targeted function”
22 - 7 Nm
23 - Pressure pipe
❑ from exhaust turbocharger
24 - Retaining clip
25 - 7 Nm
Part 2
Note
♦ If hoses need to be removed during the repair, after installation, check that all hoses have been inserted
firmly.
♦ Check the hoses with catches for firm seating by pulling in the opposite direction!

1 - from the activated charcoal

filter system
❑ the fuel supply line
2 - Solenoid valve 1 for activa‐
ted charcoal filter - N80-
3 - to pressure pipe
❑ ⇒ page 146 , Part 1,
Pos. 9
4 - to inlet connection
5 - 8 Nm
6 - Fuel pipe, 25 Nm
❑ for high pressure
7 - Non-return valve
❑ for crankcase ventila‐
tion
8 - 8 Nm
9 - Connecting hose
11 - 5 Nm
12 - Connecting hose
❑ from exhaust turbo‐
charger
13 - O-ring
14 - 8 Nm
❑ in the timing case
2.2 Bottom part of the intake manifold, fuel distributor and injection valve - as‐
sembly overview
1 - O-ring
❑ replace
oil
2 - Spring element
❑ replace after removal
the fuel distributor
❑ check for correct seat‐
ing on injector
3 - Injection valve for cylinder 4
- N33-
der 1 - N30-
der 2 - N31-
der 3 - N32-
❑ with Teflon gasket ring
and supporting washer
❑ after removing the injec‐
tion valves, the Teflon
gasket ring and the sup‐
porting washer must be
replaced ⇒ page 181
❑ wymontowanie i zamon‐
towanie wtryskiwaczy
⇒ page 179
❑ Observe part number ⇒
ETKA - Electronic Cata‐
logue of Original Parts
4 - Bottom part of intake mani‐
fold
Caution
If only the bottom part of
the intake manifold
should be replaced,
make sure that the injec‐
tion valves remain in the
cylinder head. The help
of a second mechanic is
required to hold the in‐
jection valves.
Reason: After removing
the injection valve, the
Teflon gasket ring and
the supporting washer
must be replaced
⇒ page 181 .
❑ with fuel distributor

❑ Remove and install bottom part of intake manifold ⇒ page 169
❑ to remove use bit - 3320/2-

⇒ page 170 as well as the intake manifold
Removing and installing bottom part of intake manifold

– Remove fixing screw -arrow- with bit - 3320/2- .
Caution
If only the bottom part of the intake manifold should be re‐

placed, make sure that the injection valves remain in the
cylinder head. The help of a second mechanic is required to
hold the injection valves.
Reason: After removing the injection valve, the Teflon gasket
ring and the supporting washer must be replaced
⇒ page 181 .
2.3 Brake vacuum pump - Summary of components
1 - Brake servo unit

2 - Line with pressure sensor
for the brake servo unit - G294-
❑ Disconnect line from in‐
take manifold
⇒ page 170
3 - Intake manifold
4 - Support
❑ for brake vacuum pump
5 - 8 Nm
6 - 20 Nm
7 - Support
❑ for body
8 - Connector
9 - Vacuum pump for brake -
V192-
Connection at intake manifold

Detach vacuum hose -4- from intake manifold -5-:
– To do so, push the quick coupling onto the intake manifold
support -arrow 1-, press in the securing elements -arrow 2- on
the left and right forcefully and disconnect the line -arrow 3-.
2.4 Removing and installing regulating flap

control unit - J808- and throttle valve
control unit - J338-
Note
In order to remove the throttle valve control unit - J338- , first of

all remove the inlet connection of the regulating flap control unit -
J808- .
Remove throttle valve control unit - J808-

-8-.

– Disconnect plug for intake air temperature sender 3 - G520 -

– Remove the inlet connection -2- with the regulating flap control
unit - J808- from the pressure pipe.

Remove throttle valve control unit - J338- .
– Slacken the screw clamps -2 and 4-, detach the charge air
hose -3- from the throttle valve and from the charge air pipe
-1-.
– Release the fixing screws -arrows- and detach the throttle

valve control unit - J338- from the inlet connection.
Install
following points:
♦ Observe the general notes for assembly work on the charge

air system ⇒ page 7 .
If a new regulating flap control unit or throttle valve control unit
was installed:
– Erase initialisation values and adapt the engine control unit to
the throttle valve control unit ⇒ Vehicle diagnostic tester.
Tightening torques:
Intake manifold - Summary of components ⇒ page 165 .
2.5 Clean throttle valve control unit - J338-
Note

⇒ page 3 .
⇒ page 4 .
♦ If a new engine control unit - J623- is fitted, the throttle valve
control unit must be adapted. The adaptation must only be
carried out with a new or cleaned throttle valve control unit,
because dirt/carbon deposits in the end stop of the throttle
valve can lead to incorrect adaptation values.
♦ The throttle valve support must not be scratched when clean‐
ing.
– Remove the throttle valve control unit ⇒ page 170 .

– Open the throttle valve manually and block the throttle valve
in the opened position with a suitable object (e.g. plastic or
wooden wedge)-arrow-.
WARNING
Acetone is easily inflammable.

Observe the accident prevention regulations and the safety in‐
structions when handling easily inflammable fluids.
♦ Do not use compressed air when cleaning the throttle
valve.
♦ Wear safety goggles, safety gloves and safety clothing in
order to avoid injuries and skin contact.
– Thoroughly clean the throttle valve support, in particular the

area of the closed throttle valve -arrows-, with acetone and a
paint brush.
– Wipe the throttle valve support with a lint-free cloth.
– Let the acetone dry off completely and re-install the cleaned
throttle valve control unit.

3 Air filter housing
3.1 Air filter housing - Summary of components

Removing and installing air filter housing ⇒ page 174 .
1 - Spring strap clamp

❑ remove and install with
pliers for spring strap
clamps
2 - Air intake hose
❑ to inlet connection
3 - 2 Nm
4 - Air filter top part
5 - Filter element
6 - 8 Nm
7 - Rubber-metal bearing
8 - Air filter bottom part
9 - Rubber bearing
❑ seated on the ball stud
of the battery tray
❑ screwed onto lock carri‐
er
11 - 3 Nm
12 - Air intake hose
13 - Water drain hose
14 - Rubber bearing
15 - Support
❑ screwed onto the body
16 - 20 Nm
17 - Vacuum hose
❑ to cylinder head cover
3. Air filter housing 173

3.2 Removing and installing air filter hous‐

ing
Removing
– Detach the air guide hose -7- from the air filter and the inlet
connection.
– Open clamp -2- and remove air intake hose -1-.
– Completely slacken the fixing screw -5-.
– Pull off the air filter housing -4- to the top from the bearing bolt
-3- and the ball pin -6-.
Install
– Push the air filter housing -4- onto the bearing bolt -3- and the
ball pin -6-.
– Tighten securing bolt -5- to 8 Nm.
– Connect hoses -1- and -7-.

4 High pressure pump
4.1 High pressure pump - Summary of components
Caution
1 - Roller tappet
oil
2 - O-ring
❑ replace
oil
3 - High pressure pump with
fuel pressure regulating valve -
N276-
⇒ page 176
Caution
Risk of damage!
Do
♦ not disassemble the
high pressure pump, only
remove completely and
install again, if necessary
replace.
4 - 20 Nm
❑ Tighten screws uniform‐
ly
❑ for high pressure
6 - Union nut, 25 Nm
❑ Observe safety meas‐
ures ⇒ page 3 .
❑ do not change bending
form
❑ Check for any damage before reinstalling
❑ Moisten union nuts with fuel.
❑ hold the connection fitting on the high pressure pump for loosening
7 - Fuel hose
❑ for low pressure
❑ with spring strap clamp
❑ for low pressure
4. High pressure pump 175

4.2 Removing and installing the high pres‐

sure pump
Condition
• The engine must be cold.
Removing
Note

⇒ page 3 .
⇒ page 4 .
Caution

ing pressure of approx. 0.6 MPa (6 bar) must be reduced
⇒ page 4 .
– Remove inlet connection with regulating flap control unit -

J808- ⇒ page 170 .
– Turn the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 57 (do not drain coolant and do not re‐
move the cap for the camshafts).
– Disconnect the plug and the fuel feed line -arrows- from the
high pressure pump.

– Disconnect the wiring -2- and remove the clip -4- from the high
pressure line.
Note
Hold the connection fittings at the high pressure pump and at the
fuel distributor when slackening the union nuts with a wrench.
Caution
Risk of damage!
♦ Do not disassemble the high pressure pump, only remove
completely and install again, if necessary replace.
– Slacken the union nuts -1 and 3- at the high pressure line.
– Uniformly release the fixing screws -arrows-.
– Remove the high pressure pump -3- with the roller tappet -1-
from the camshaft housing.
Install
Caution
Only grab the high pressure pump at the housing when re‐
moving and installing!
♦ If the spring set of the piston for high pressure pump is
slackened, there would be a leak in the high pressure
pump and it must be replaced.
Note
♦ Moisten the roller tappet of the high pressure pump with clean
engine oil.
♦ Always replace the O-ring of the high pressure pump.
– Slide the roller tappet -1- into the camshaft housing.
4. High pressure pump 177

– Insert a new, oiled O-ring -2- into the slot of the high pressure
pump -3-.
– Position the high pressure pump -3- onto the camshaft hous‐
ing.
– First of all screw in the fixing screws -arrows- sufficiently until

the screw heads touch the flange.
– Then uniformly tighten the fixing screws -arrows-.
– Screw on the union nuts -1 and 3- of the high pressure line by

hand.
– Install the line -2- and press the support -4- onto the high pres‐
sure pump.
Tightening torque of power attachment screw: 8 Nm
Note
Hold the connection fittings at the high pressure pump and at the
fuel distributor when tightening the union nuts with a wrench.
– Tighten the union nuts -1 and 3- at the high pressure line to

15 Nm.
– Connect the fuel feed line and the plug -arrows- on the high
pressure pump.

5 Injection valves
5.1 Removing and installing injection valves
Note

⇒ page 3 .
⇒ page 4 .
♦ Observe the safety instructions before starting fitting work
⇒ page 5 .
Note
The Teflon gasket ring on the injection valve must be replaced

each time after removing the injection valve ⇒ page 181 .

♦ Extractor - T10133-
Removing
– Remove the regulating flap control unit - J808- and the throttle
valve control unit - J338- ⇒ page 170 .
– Removing the intake manifold ⇒ page 165 .
– Remove intake manifold bottom part ⇒ page 168 .
– Press the O-ring upwards by hand as shown and remove it
from the injection valve.
– Screw striking hammer - T10133/3- with extractor -
T10133/15- .
5. Injection valves 179

– Then insert the extractor - T10133/15- into the groove

-arrow- on the injection valve.
– Pull out the injection valve with careful knocks.

Install
– Thoroughly clean the holes of the injection valves in the cyl‐

inder head with the nylon brush - T10133/4- .
– Check the supporting washer made of plastic for damage, re‐
place if necessary ⇒ page 181 .

– Replace the spring element -arrow- as well as the Teflon gas‐

ket ring each time after removing the injection valves
⇒ page 181 .
– Replace O-rings between injection valve and fuel distributor
and moisten lightly with clean engine oil.
Note
The Teflon gasket ring of the injection valve must neither be oiled
nor greased.
– Press the injection valve by hand up to the stop into the hole
of the cylinder head.
Note
The injection valve must insert easily, if necessary wait until the
gasket ring has been drawn together sufficiently.
– Pay attention to the correct seating and fitting position of the

injection valves in the cylinder head.
5.2 Replace Teflon gasket ring and support‐

ing washer at injection valve
Note

⇒ page 3 .
⇒ page 4 .

♦ Extractor - T10133-
Work procedure
Replace Teflon gasket ring
– Remove injection valves ⇒ page 179 .
– Carefully clean the injection valve.
– Carefully cut open the gasket ring with a knife as shown
-arrow-. Absolutely try to avoid the contact of the knife blade
with the valve body.
– Remove the old gasket ring and clean the gasket ring nut in
the area of the gasket ring -arrow-. Remove the existing de‐
posits (carbon deposits) with a wire brush.

– Fit a new gasket ring -1- onto the assembly cone - T10133/5- .
Slightly push the gasket ring with the assembly sleeve -
T10133/6- (knurling points to the gasket ring -1-) as far as
possible onto the assembly cone - T10133/5- .
– Turn the assembly sleeve - T10133/6- around (now the knurl‐

ing points away from the gasket ring), and push the gasket ring
-1- up to the end onto the assembly cone - T10133/5- .
– Now position the assembly cone - T10133/5- with the gasket
ring from the front onto the injection valve. Push the gasket
ring with the assembly sleeve - T10133/6- further onto the in‐
jection valve.
The gasket ring is not yet seated in its groove.

– Remove the assembly sleeve - T10133/6 - and the assembly
cone - T10133/5- .
– Push the gasket ring by hand into the annular groove.
– Fit the spacer sleeve - T10133/11- onto the valve body.
– Now press the calibration sleeve - T10133/7- via the gasket

ring up to the stop at the spacer sleeve - T10133/11- .
– Pull off again the calibration sleeve - T10133/7- .

– Now press the calibration sleeve - T10133/8- via the gasket

ring up to the stop at the spacer sleeve - T10133/11- .
Now the Teflon gasket ring has its correct fitting dimension.
Replace supporting washer
– Remove O-ring -3-.

– Cut open the supporting washer -2- with a small side cutter
and take it off.
– Pull off the spring element at the injection valve -1- and instead
push on the lock washer - T10133/12- .
– Mount a new supporting washer -1- on the assembly cone -

T10133/13- and fit it onto the injection valve as shown.
– Push the supporting washer -1- with the calibration sleeve -
T10133/17- (knurled side points to the injection valve) up to
the first nut -arrow- onto the injection valve.
– Now turn the calibration sleeve - T10133/17- around (knurled

side points away from the injection valve). Push the calibration
sleeve via the supporting washer -1- in -direction of arrow- up
to the stop on the lock washer - T10133/12- .
Now the supporting washer has its correct fitting dimension.

– Now fit a new spring element -1- for the lock washer -
T10133/12- and push a new O-ring -3- in front of the support‐
ing washer -2-.
Note
The Teflon gasket ring -arrow- must not be oiled when installing
the injection valve.
– Install injection valves ⇒ page 179 .


6 Testing components
6.1 Check fuel pressure sender - G247-

♦ Open ring spanner with 3/8" drive, SW 27 mm
♦ Pressure sensor tester , e.g. -VAS 6394- (contains pressure

manometer - VAS 6394/1- )
♦ Adapter , e.g. -VAS 6394/2-
♦ Test adapter , e.g. -VAS 5570-
♦ Vehicle diagnosis, measurement and information system -
VAS-
Caution

ing pressure of approx. 0.6 MPa (6 bar) must be reduced
⇒ page 4 .
Work procedure
– Remove fuel pressure sender - G247- -1-.
6. Testing components 185

– Screw in the adapter - VAS 6294/2- instead of the fuel pres‐

sure sender - G247- and tighten it to the tightening torque of
22 Nm.
– Release the screw plug -2- and screw the fuel pressure sender
- G247- into the tester - VAS 6394/1- .
– Screw pressure line -1- of the pressure gauge - VAS 6394/1-
onto the adapter - VAS 6394/2- until hand-tight.
– Connect the test adapter - VAS 5570- to the fuel pressure

sender - G247- -1- and to the plug.
– Switch on the tester - VAS 6394/1- , for this step, briefly press
the button -A- once.
Note
♦ If the button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If the tester - VAS 6394/1- does not indicate 0 MPa (0 bar),
carry out a zero point of the balance by means of the ⇒ op‐
erating instructions .

– Connect the vehicle diagnosis, measurement and information

system - VAS- -1- to the diagnostic connection.
– Switch on ignition.
– On the display press consecutively the following buttons:
Vehicle self-diagnosis
Self-diagnosis ►
01 - Engine Electronics ►
011 - Measured values ►
– Select measured value block 1 4 0 and confirm with Q .

The actual value which is transmitted to the vehicle by the fuel
pressure sender - G247- is shown in the display field 3.
– Start engine.
– Compare the displayed pressure on the digital manometer -
VAS 6394/1- with the actual value on the vehicle diagnosis,
measurement and information system - VAS- .
• The pressures may deviate maximum 0.5 MPa (5 bar) from
one another.
If the deviation is greater than 0.5 MPa (5 bar):
– Perform a vehicle diagnosis, measurement and information
system - VAS- of the guided function “remove high fuel pres‐
sure”.
– Replace fuel pressure sender - G247- .
– Repeat the test with the new fuel pressure sender - G247- and
compare both measured values.
If the measured values do not correspond again:
– Perform a cable testing ⇒ Vehicle diagnostic tester.
6. Testing components 187

7 Engine control unit
7.1 Removing and installing engine control

unit - J623-
Note
♦ If the engine control unit must be replaced, connect ⇒ Vehicle

diagnostic tester and perform the function “replace engine
control unit”.
♦ If replacing, the throttle valve control unit - J338- must be
cleaned ⇒ page 172 before adapting a new control unit.

♦ Body saw e.g. -V.A.G 1523/A-
Removing
– Open the catches -arrows- of the bracket and remove the en‐
gine control unit.
Vehicles without protective cover
– Disconnect both plugs at the engine control unit - J623- and
remove.
Vehicles with protective cover

– Cut with body saw a slot for a cross-head screwdriver in the

heads of the pull-off screws.
Note
♦ It must be sawed 2x with the body saw, so that the slot is wide
enough, in order to be able to unscrew the screws with a suit‐
able screwdriver.
♦ A locking agent is applied to the pull-off screws.
– Disconnect both plugs at the engine control unit - J623- and

remove.
Install
– 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.
Continued for all vehicles
– Insert engine control unit - J623- in the bracket and lock se‐
curely.
– When replacing the control unit, adapt the engine control unit
⇒ Vehicle diagnostic tester.
– Interrogate the even memory again ⇒ Vehicle diagnostic test‐
er.
Note
After deleting the event memory of the engine control unit the
readiness code must be re-generated.
– Install air filter housing ⇒ page 174 .
7. Engine control unit 189

26 – Exhaust system
1 Removing and installing parts of the
exhaust system
1.1 Front part of exhaust system - Summary

of components
Note
♦ After working on the exhaust system, ensure that the system

is not under tension
♦ and that there is sufficient clearance to the bodywork.
♦ If necessary, loosen clamp(s). Align exhaust system in such a
way that sufficient clearance is maintained to the bodywork
and the support rings are evenly loaded.
♦ Always replace self-locking nuts.
♦ The decoupling element in the pre-exhaust pipe should not be
bent by more than 10° - risk of damage.
♦ Neither bend nor over-tension the decoupling element.
♦ Do not damage the wire mesh of the decoupling element.
♦ Coat the stud bolts with hot bolt paste - G 052 112 A3- before
installing the counternuts.
190 Rep. gr.26 - Exhaust system

1 - Heat shield
2 - 10 Nm
3 - Clamping sleeve, 23 Nm
❑ Tighten bolted connec‐
tions evenly
❑ Fitting position
⇒ page 195
4 - Exhaust pipe with catalytic
converter
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Remove the protection
for the decoupling ele‐
ment on the spare part
as late as possible
⇒ page 192
5 - Retaining strap
6 - Support
7 - 23 Nm
8 - 9 Nm
9 - Lambda probe - G39- , 50
Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste - G 052 112 A3- ;
the paste must not get
into the slots of the
probe body
❑ carry out the removal using the set of tools - T10395-
10 - Lambda probe downstream of catalytic converter - G130- , 50 Nm
❑ the thread of new lambda probes must be coated with assembly paste
❑ for re-used lambda probe, only coat the thread with hot bolt paste - G 052 112 A3- ; the paste must not
get into the slots of the probe body
❑ carry out the removal using the set of tools - T10395-
11 - 23 Nm
❑ replace
❑ before installing, coat pin screws of exhaust manifold with exhaust gas turbocharger using hot bolt paste
- G 052 112 A3-
12 - Nut
❑ tightening order and tightening torque ⇒ page 148
Caution
The oil feed pipe must be
replaced when installing
a new exhaust gas tur‐
bocharger.
1. Removing and installing parts of the exhaust system 191

❑ The exhaust gas turbocharger and the exhaust manifold can only be replaced together
14 - Gasket
❑ replace
1.2 Removing and installing front silencer

Removing
– Unscrew the screws and the nuts -arrows- of the heat shield
above the exhaust gas turbocharger.
gr. 50 .
– Disconnect both bottom plug connections -arrows- from the

lambda probe - G39- and the lambda probe downstream of
catalytic converter - G130- .
– Slacken the wiring loom of the generator, the lambda probe

downstream of catalytic converter - G130- and the lambda
probe - G39- from the supports -arrows-.

– Slacken clamps -1- and -3-.

– Unscrew the screws -2- from the bracket of the front silencer
and remove the bracket.
– Release the screws -5- of the front silencer -6-.
– Unscrew nuts -4- from exhaust gas turbocharger.
– Loosen the nuts -arrows- at the clamping sleeve and push the
clamping sleeve onto the middle silencer.
Note
♦ When re-fitting the exhaust pipe, note the following:

♦ The decoupling element in the pre-exhaust pipe should not be
bent by more than 10° - risk of damage.
♦ Do not damage the wire mesh of the decoupling element.
♦ The assistance of a 2nd mechanic is required for removing
and installing, so that the front silencer is not damaged.
– Press off the retaining straps -2- from the bolts of the front
silencer and remove the front silencer.
Install
following points:
– Replace gaskets and nuts of exhaust gas turbocharger.

– First fasten the front silencer loosely to the exhaust gas tur‐
bocharger. While doing so, ensure that the centreing -1- of the
catalytic converter -2- grips into the opening -3- of the cylinder
block.
– Position the charge air pipe and screw the screws into the cyl‐
inder block by hand.
– Tighten the nuts at the exhaust gas turbocharger by hand.
– Tighten the screws in the cylinder block.
– Then tighten the nuts at the exhaust gas turbocharger.
Tightening torques: ⇒ page 190
♦ Observe the general notes for assembly work on the charge
air system ⇒ page 7 .
♦ Check the exhaust system for leaktightness ⇒ page 196 .
1.3 Middle and rear silencer - Summary of components
1 - Middle and rear silencer

❑ individually replace the
middle and rear silenc‐
ers when carrying out
repairs ⇒ page 194
❑ The separation point is
marked by indentations
on the exhaust pipe
❑ fitting on the exhaust
system free of stress
⇒ page 195
2 - Separation point
❑ for repairs
❑ marked with recesses
around the circumfer‐
ence
3 - Rear retaining strap
❑ Pay attention to the part
number
4 - 23 Nm
5 - Retaining strap
❑ Pay attention to the part
number
1.4 Replace middle and rear silencer


♦ Body saw e.g. -V.A.G 1523 A-

♦ Protective goggles
Work procedure
For separating the middle and rear silencer, a separation point is
provided on the exhaust pipe, which is marked with recesses.
WARNING
In order to avoid injuries from metal swarfs, wear safety gog‐

gles and safety clothing.
– Separate exhaust pipe at the separation point -arrow 1- with

body saw (right-angled).
– When installing, position clamping sleeve -4- at the side mark‐
ings -arrow 2- and -arrow 3-.
– Install clamping sleeve in such a way that the ends of the

screws do not protrude beyond the bottom edge of the clamp‐
ing sleeve.
• The bolted connection points to the right.
– Tighten bolted connections of clamping sleeve evenly to 23
Nm.
– Align exhaust system free of stress ⇒ page 195 .
1.5 Aligning exhaust system free of stress

Condition
• The exhaust system is aligned when cold.
– Slacken the clamping sleeve -1- and align to pre-exhaust pipe
-2- (-arrow- points in direction of travel).
-a- = 5 mm

• The fixing screws must be located on the right. The screws

must not protrude beyond the bottom edge of the clamping
sleeve -arrow-.
– Tighten the front nut of the clamping sleeve by hand.
– Push the middle and rear silencer so far forward until the initial
load -dimension a- on the retaining strap is 3…7 mm.
– Tighten nuts of clamping sleeve evenly to 23 Nm.
Align exhaust tailpipes
– Align the middle and rear silencer in such a way that there is
an equal distance -a- on the left and right between bumper
opening and exhaust tailpipes.
At the same time there must be an equal distance -b- from the
bumper opening to the exhaust tailpipes.
For centering, if necessary the hangers of the exhaust system
must be loosened.
1.6 Inspecting the exhaust system for leak‐

tightness
– Seal off exhaust tailpipes for the duration of the leak check
(e.g. with cloth or plug).
– Inspect connection points of cylinder head/exhaust manifold,
exhaust gas turbocharger/exhaust pipe etc. for tightness by
listening and visual inspection.
– Eliminate any leak found.

28 – Ignition system
1 Ignition system
1.1 Ignition system - Summary of components
1 - Connector
❑ black, 4 pin
❑ release with assembly
device - T10118-
2 - Ignition coil with a power
output stage - (N70, N127,
N291, N292)-
⇒ page 198
3 - Connector
❑ for knock sensor 1 -
G61-
❑ black, 2 pin
❑ Contacts of plug gilded
4 - Knock sensor 1 - G61-
❑ Contacts of plug gilded
❑ to remove, remove com‐
pressor ⇒ page 154
5 - 20 Nm
❑ the tightening torque in‐
fluences the knock sen‐
sor function
6 - Connector
❑ for hall sender - G40-
❑ black, 3 pin
8 - O-ring
9 - 10 Nm
10 - Spark plug, 30 Nm
❑ use spark plug wrench - 3122 B- for removing and installing
❑ Type and electrode spacing ⇒ Maintenance ; Booklet Fabia II
11 - Cable guide
❑ Screwed onto camshaft housing to 5 Nm
12 - Earth lead
❑ only loosen or tighten with the ignition off
13 - 10 Nm
❑ only loosen or tighten with the ignition off
1. Ignition system 197

1.2 Removing and installing ignition coils

with power output stages
♦ Extractor - T10094 A-
Removing
Only for cylinder 1:
– Release fixing screws -1- from the connection fitting of the
crankcase ventilation and from the non-return valve.
– Disconnect plug -2- from turbocharger divert air valve - N249-
and hose connection -3-.
– Push ventilation pipe with hoses to the side.
For all cylinders:
– Position extractor - T10094 A- onto the ignition coil with power

output stage -arrow-.
– Slightly pull out the ignition coil with power output stage.
– Position the assembly device - T10118- as shown.
– Carefully unlock the plug lock and disconnect the plug.
Install
– Insert all ignition coils loosely into the relevant spark plug shaft.
– Align the ignition coils to the plug connections.
– Push the plugs onto the ignition coils with power output stage
until they audibly click into place.
– Position extractor - T10094 A- onto the ignition coil with power
output stage.
– Press the ignition coil with power output stage into the cylinder
head -arrow-.
198 Rep. gr.28 - Ignition system

– Insert the rubber grommet -1- into the hose -2-.

– Fit the hose -2- onto the intake manifold support -3-.
♦ Tightening torque of fixing screws for connection fitting of
crankcase ventilation and non-return valve: 10 Nm
1. Ignition system 199

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1.2 Test timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1.1 Engine number

If the sticker does not exist, the “engine identification character”

Engine identification character and serial number on cylinder

1.2 Engine characteristics

Engine identification characters CAVE CTHE

2 Rep. gr.00 - Technical data

1.2 Safety precautions when working on the

♦ The safety measures for the pressure reduction in the high

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

1.3 Reduce pressure in the high-pressure

♦ The injection system consists of a high pressure part

– Perform a vehicle diagnosis, measurement and information

– Now lay a clean cleaning cloth around the connection point

1.4 Rules of cleanliness to observe when

4 Rep. gr.01 - Self-diagnosis

1.5 Safety measures to apply when working

♦ The safety measures for the pressure reduction in the high

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

When undertaking all installation work, particularly in the en‐

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

1.6 General notes on the injection system

1.7 General notes on the ignition system

6 Rep. gr.01 - Self-diagnosis

1.8 General instructions for charge air sys‐

When undertaking all installation work, particularly in the en‐

In case a mechanical damage to the exhaust gas turbocharger

♦ The charge-air system must be tight.

1. Self diagnosis, safety measures, cleanliness regulations, directions 7

1.9 Additional instructions when undertak‐

Risk of injury through refrigerant.

Risk of damaging the condenser as well as the refrigerant lines

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

8 Rep. gr.01 - Self-diagnosis

10 – Removing and installing engine

1.1 Removing and installing engine trim

– Pull the engine cover at the points -arrows- upwards and

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

1. Removing and installing engine 9

– Insert the engine cover into the rear support -1-.

1.2 Removing engine

♦ The engine is removed downwards together with the gearbox.

When undertaking all installation work, particularly in the en‐

Reduce pressure in the high pressure system ⇒ page 4 .

– Remove engine cover ⇒ page 9 .

10 Rep. gr.10 - Removing and installing engine

– Before disconnecting the battery, if necessary remove the

1. Removing and installing engine 11

12 Rep. gr.10 - Removing and installing engine

– Detach vacuum hose -4- from intake manifold -5-. To do so,

– Remove fuel feed line -3- ⇒ page 139 .

– Detach the coolant hoses at the heat exchanger -arrows-.

– Pull off coolant hoses at top of radiator -arrows-.

1. Removing and installing engine 13

– Disconnect plug connection -arrow-.

– Carefully slacken the engine wiring harness on its fixing points