sxopa Service Workshop Manual Fabia Il 2007 > , Fabia ll 2009 > , Octavia Il 2004 > , Octavia Il 2010 > , Roomster 2006 > . Superb || 2008 > Edition 12.2015 Service Department. Technical Information‘sxooa ® Service List of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 20 - Fuel supply system 21 - Turbocharging/supercharging 23 - Mixture preparation - injection 26 - Exhaust system 28 - Glow plug system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed, All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2016 SKODA AUTO a. s. D3E80354A2FFabia II 2007 > , Fabia II 2009 ~ , Octavia Il 2004 > , Octavia Il 2010 4.9/7 KW TDI PD Engine - Edition 12.2015 Contents 00 - Technical data 1 1 Identification 1 1.4 Engine number 1 1.2 Engine characteristics (Octavia Il, Superb I!) 1 1.3. Engine characteristics (Fabia Il, Roomster) 2 2 Safety instructions : 3 2.1. Regulations conceming safety precautions when working on the fuel system 3 22 Safety precautions when werking onthe fuel supply ofthe diesel dec injection system 4 3 Repair instructions 5 3.4 Seltdiagnosis 5 3.2 Supplementary instructions and assembly work on vehicles with en air conditioning system 5 3.3 Regulations concerning cleanness when working onthe fue auppyuel injection system 3.4. Regulations concerning cleanliness when working on the exhaust gas turbocharger 6 3.5 General instructions for charge air system with exhaust turbocharger 6 3.6 Handling the ceramic glow plugs .........2.eeecceeeeeeeeseee 7 410 - Removing and installing engine .......cseeseseeseceeeeeveseevseeseees 9 1 Removing and installing engine 9 1.4 Removing (Octavia Il, Superb Il) 9 1.2 — Removing (Fabia II, Roomster) 18 1.3. Securing the engine to the assembly stand 19 1.4 Installing (Octavia ll, Superb tI) 20 1.5 Installing (Fabia Il, Roomster) 25 4.6 Checking and adjusting the assembly bracket (Super I) ve 28 1.7 Checking and adjusting the assembly bracket (Octavia ll)... 0... viernes 82 13~- Crankshaft group .... veces tes et te tetettitettetataeeteeeenees 34 4 Removing and installing a V-bbed belt and a toothed belt 34 1.1. Summary of components - V-ribbed belt (Octavia Il, Superb I) 34 1.2 Removing and installing V-ribbed belt (Octavia II, Superb |!) 36 1.3 Summary of components - V-ribbed belt (Fabia I, Roomster) 38 1.4 Removing and installing V-ribbed belt (Fabia II, Roomster) “41 1.5 Summary of components - toothed belt (Superb I} : betes 43 1.6 Removing and installing toothed belt (Superb I!) bee tet ete e te cetetenneees 46 4.7 Summary of components - toothed belt (Octavia I!) 53 4.8 Removing and installing toothed belt (Octavia Il) ........ sees 8? 1.9 Summary of components - toothed belt (Fabia Il, Roomster) : . co 1.10 Removing and installing toothed belt (Fabia Il, Rooster) ose eee eeeeee OF 2 Removing and installing sealing flange and flywheel viet tteetteeeees Th 2.4 Summary of components (Octavia Il, Superb Il) . 74 2.2 Summary of components - (Fabis II, Roomster) 76 23. Replacing cranksheft sealing ring on belt pulley side (Octavia Il, Superb I!) 7 24 — Replacing cranksheft sealing ring on belt pulley side (Fabia lI, Roomster) 79 2.5 Removing and installing the sealing flange on the belt pulley side at 2.6 Removing and installing sealing flange on gearbox side (Octavia Il, Superb Il) 83 2.7 Removing and installing two-mass flywheel (Octavia Il, Superb Il) 90 3 Crankshaft, Piston and Conrod 93 3.1. Summary of components - Removing and installing crankshaft (Superb Il) 93 3.2 Summary of components - Removing and installing crankshaft (Octavia I!) 94 3.3. Summary of components - Removing and installing crankshaft (Fabia Il, Roomster) 95 contanis iexons, ® Fobia ! 2007 » , Fabia II 2009 > , Octavia II 2004 » , Octavia Il 2010 15 17 19 4.9/7 kW TDI PD Engine - Edition 12.2015 3.4 Disassembling and assembling pistons and conrods 3.5 Checking piston projection in TOG 3.6 Separating new conrod . 3.7 Removing and instaling drive chain sprocket. Cylinder head, valve gear .......... ceteeeteeeeee es 1 Removing and installing the eylinder head 4.1. Summary of components 1.2 Removing and installing cylinder head cover (Octavia Il, Superb I!) 1.3. Removing and installing cylinder head cover (Fabia II, Roomster) 1.4 Removing and installing cylinder head (Superb II), 1.5 Removing and installing cylinder head (Octavia lI). 1.6 Removing and installing cylinder head (Fabia'll, Roomster) 1.7 Testing compression pressure (Octavia |I, Superb I!) 1.8 Testing compression pressure (Fabia Il, Roomster) 2 Repairing Valve Gear ... 24 Valve gear - Summary of components 2.2 Checking the axial play of the camshaft . 2.3 Replacing camshaft gasket ring 2.4 Removing and installing camshaft (Superb I) 2.5 Removing and installing camshaft (Octavia Il) 2.6 Removing and installing camshaft (Fabia Il, Roomster) 2.7 Testing hydraulic bucket tappets 28 Replacing the valve stem seals on the installed cylinder head 3 Inlet and exhaust valves ... 3.4 Reworking valve seats 3.2 Inspect valve guides: 33. Valve dimensions Lubrication : : 1 Removing and instling parts of the lubrication system 1.4. Lubrication system - Summary of components 12. Summary of components - oi fitter bracket (Octavia Il, Super® Il). 4.3 Summary of components - oil fer bracket (Fabia Il, Roomster) 1.4 Removing and installing oil pan (Octavia II, Superb II) 1.5 Removing and installing oil pan (Fabia Il, Roomster) ... 4.6 Removing and installing oil pump 1.7 Testing oil pressure and oil pressure switch Cooling 02.2... 1 Cooling system... 1.1 Connestion diagram for coolant hoses (Superb I) 4.2. Connection diagram for coolant hoses (Octavia I!) 4.3. Connection diagram for coolant hoses (Fabia II, Roomster) 1.4 Parts of the cooling system on engine side (Fabia Il, Roomster) 1.5 Parts of cooling system on engine side (Octavia Il, Superb Il) 4.6 Drain and fill coolant (Octavia II, Superb Il) 1.7 Draining and filing coolant (Fabia II, Rooster) 4.8 Removing and installing coolant pump 1.9 Removing and installing coolant regulator (Octavia Il, Superb Il) 4.10 Removing and installing coolant regulator (Fabia I, Roomster) 1.11 Checking the coolant eystem for leaktightness 2 Radiator and radiator fan 2.1 Parts of cooling system on body side (Octavia Il, Superb I} 2.2 Parts of cooling system on body side (Fabia Il, Roomster) 98 101 102 = 103 105 105 105 116 118 121 129 - 138 - 144 - 145 - 147 147 . 149 150 152 155 159 162 163 -. 168 . 168 171 m1 2172 . 172 172 175 .17 . 178 180 182 183 185 . 185 = 185 189 - 193 - 195 198 205 208 210 ant 213 214 217 247 220 Contents20 21 Fabia II 2007 > , Fabia II 2009 ~ , Octavia Il 2004 > , Octavia Il 2010 4.9/7 KW TDI PD Engine - Edition 12.2015 23 Removing and installing radiator (Octavia Il, Superb I!) 222 24 — Removing and installing radiator (Fabia Il, Roomster) 223 2.5 Removing and installing fen shroud for radiator fan V7 and V177 (Octavia ll, Superb Il) .. 225 Fuel supply system ..... wees ceceeeee cece eee es 227 1. Removing and instaling pers of the uel supply systern 227 1.4. Summary of components - fuel tank with attached parts (Superb II) 228 1.2 Summary of components - fuel tank with attached parts (Octavia II, Superb I) 230 1.3 Summary of components - fuel tank with attached parts, vehicles with four-wheel drive (Octavia) 232 4.4 Summary of components - fuel tank with attached parts (Fabia II) ce cos 236 4.5 Summary of components - fuel tank with attached parts (Roomster) .. 237 4.6 Summary of components. fuel filter (Superb Il) seven... eee cece enc ceees 240 4.7 Summary of components - fuel fitter (Octavia ll) ...... ce eee cee cee 2M 1.8 Summary of components fuel fiter (Fabia ll, ROOMSEN) eee cece 24M 19 Extract fuel from the fuel tank ....... rn : 2 245 1.40 Removing and installing fuel cooler (Superb I!) 2ar 4.41 Removing and installing fuel cooler (Octavia I!) 2aT 1.42 Removing and installing fuel cooler (Fabia ll; Roomster) 248 1.13 Removing and installing fuel tank (Superb I) 248 1.14. Removing and installing the fuel tank (Octavia I!) 251 1.15. Removing and installing fuel tank for vehicles with four-wheel drive (Octavia Il) 252 4.46 Removing and installing fuel tank (Fabia I!) 254 1.17 Removing and installing the fuel tank (Roomster), 255 1.48 Separating quick couplings 257 2 Fuel delivery unit, fuel gauge sender 261 24 Testing the fuel pump (Octavia II, Supert I) 261 22 Testing fuel pump (Fabia Il, Roomster) #/.... vec eeeeeeee 283 23. Removing and instaling fuel delivery unit (Superb Il). : cee eeeee ees 265 24 Removing and installing fuel delivery unit (Octavia Il) .. 268 25 Removing and instaling fuel tank for vehicles with four-wheel drive (Octavia Il, Superb Il) oro 2.6 Removing and installing fuel delivery unit (Fabia Il, Roomster) 274 27 Removing and installing the sender for fuel gauge display G (Superb Il) 276 28 — Removing and installing the transmitter for fuel gauge display G (Octavia Il)... 277 29 Removing and installing the sender for fuel gauge display G (Fabia Il, Roomster) 278 2.40 Removing and installing fuel gauge sender 2 6169 (Octavia Il, Superb II) ..... 278 2.11 Removing and installing suction spray pump (Octavia Il, Superb Il). wees 282 2.12 Removing and installing the tandem pump 282 2.13 _ Inspecting a tandem pump 284 3 Accelerator control 288 3.4 Summary of components - accelerator pedal module (Octavia Il, Superb Il) 288 3.2 Summary of components - accelerator pedal module (Fabia ll, Roomster) ss 288 3.3 Removing and installing accelerator pedal module (Octavia Il, Superb Il) .............. 288 Turbocharging/supercharging .. 0.1... c eee ee eee e eee e etree eee eee ee 202 1 Charge-air system with exhaust gas turbocharger - Part 1 202 4.4. Connection diagram for vacuum hoses (Superb II) 292 1.2 Connection diagram for vacuum hoses (Octavia I!) 295 1.3 Connection diagram for coolant hoses (Fabia II, Roomster) 298 14 Inspect vacuum setting element and tension rods for charge pressure conto (Octavia I, Superb Il)... 302 2 Cherge-sir system with exhaust gas turbocharger Pert 2. : - +. 304 24 Summary of components - exhaust gas turbocharger (Octavia I, Superb Il)... ++... . 308 22 Summary of components - exhaust gas turbocharger (Fabia Il, Roomster) so 308 2.3 Removing and installing exhaust gas turbocharger (Octavia Il, Superb II) . 313 consents Hiiexons, ® Fabia II 2007 > , Fabia ll 2008 > , Octavia II 2004 » , Octavia Il 2010 4.9/7 kW TDI PD Engine - Edition 12.2015 2.4 — Removing and installing exhaust gas turbocharger (Fabia II, Roomster) 318 2.5 Removing and installing parts of the charge air cooler (Superb I!) 324 2.6 Removing and installing parts of the charge air cooler (Octavia Il)... 0... sees. es 326 2.7 Removing and installing parts of the charge air cooler (Fabia Il, Roomster) ............ 328 2.8 Removing and installing charge air cooler (Superb Il) ....... : : wos 330 2.9 Removing and installing charge air cooler (Octavia Il) ........ a - 332 2.10 Removing and installing charge air cooler (Fabia Il, Rooster)... 0... see. veces es 333 2.11 Hose connections ...... cecceteeeetteeeeeeseeeeeeeeees 884 2.12 Checking the charge-air system for lealtightness | 335 2.43 Replacing and adjusting the vacuum setting element for exhaust gas turbocharger on engines identification characters BLS (Octavia Il, Superb Il)... - 337 2.14 Replacing and adjusting the vacuum setting element for exhaust 92s turbocharger on eraines with identification cheracters BJB (Octavia ll)... . ~ 342 23 - Mixture preparation - injection : 1 Repairing Diesel Direct Injection system 1.4 Overview of installation locations (Octavia Il, Supert I!) 1.2. Overview of installation locations (Fabia II, Roomster) 4.3. Intake manifold - Summary of components .... 4.4 Summary of components - air fiter (Octavia Il, Superb Il) 1.5 Summary of components - air fiter (Fabia II, Roomster) 1.6 Removing and installing air fiter (Fabia Il, Roomster) 1.7 Repairing the unit injectors - Summary of components, 1.8 Removing and installing O-rings for unit injector 1.9 Removing and installing the unit injector 1.10 Removing and instaling engine speed sender G28 (Octavia Il, Superb I) 2 Engine control unit... 2.1. Removing and instling engine control unit (Superb Il) 2.2 Removing and installing engine control unit (Octavia Il) 23. Removing and instaling engine control unt J623 (Fabia Il, Roomster) 26 - Exhaust system 1 Removing and instaling parts of the exhaust eystem 1.4. Summary of components - exhaust system (Superb Il) 1.2 Summary of components - exhaust system (Octavia Il) |... 1.3 Summary of components - exhaust system (Fabia I!) 1.4 Summary of components - exhaust system (Roomster) 4.5 Removing and instaling pre-exhaust pipe with diesel particle fiter (Superb Il) - 1.6 Removing and installing pre-exhaust pipe with diesel particle fiter (Octavia I!) 1.7 Removing and installing pre-exhaust pipe for vehicles with four-wheel drive (Octavia Il) .. 403 1.8 Removing and installing pré-exhaust pipe with diesel particle filter (Fabie Il, Roomster) .. 404 1.9 Replacing middle and reer silencer (Octavia II) 408 1.10 Replacing middle and rear silencer (Fabia Il, Roomster) 407 1.11 Fitting exhaust system free of stress (Superb Il) 408 1.12 Aligning exhaust system free of stress (Octavia II) 409 1.13 Fitting exhaust system free of stress (Fabia Il, Roomster) 410 1.14 _ Inspecting the exhaust system for leaktightness ant 2 Exhaust gas recirculation system 412 2.4 Summary of components - cooling for exhaust gas recifeuation system (Octavia I, Super® i. 412 2.2 Summary of components - cooling for exhaust gas recirculation system Fabia , Roomster) ... - 415 2.3. Removing and instaling radiator for exhaust gas recirculation for engine with engine identification characters BKC, BXE (Octavia Il, Superb Il) 418 2.4 Removing and installing radiator for exhaust gas recirculation for engine with engine identification characters BLS (Octavia Il, Superb Il) 421 25 Removing and installing radiator for exhaust gas recirculation (Fabia ll, Roomster) ...... 422 IV contantsFabia II 2007 > , Fabia II 2009 ~ , Octavia Il 2004 > , Octavia Il 2010 4,9/77 kW TDI PD Engine - Edition 12.2015 2.6 Checking mechanical exhaust gas recirculation valve for engine wth dentfiation cherectrs AXR, BSW, BJB, BKC, BXE we 424 2.7 Checking the change-over flap of the radiator for exhaust gas. recirculation for engine with engine identification characters BKC, BXE (Octavia Il, Superb Il). . . 424 2.8 — Removing and installing exhaust gas recirculation valve N18 for engine with identification characters BLS (Fabia II, Roomster) 425 28 - Glow plug system : 427 1 Glow Plug System . ween . wee . 427 1.4 Removing and installing metal glow plugs | . wee . - wae 427 1.2 Removing and installing ceramic glow plugs. . . . wee . wee 427 1.3. Checking metal glow plugs .. - wee . . .. 428 1.4 Inspecting ceramic glow plugs 429 Contents V‘exons @ Fobie II 2007 > , Fabia Il 2009 > , Octavia II 2004 » , Octavia II 2010 4.9/77 KWTD1 PD Engine - Edition 12.2015 Vi_ contonssxopa Fabia I 2007 ~ , Fabia Il 2009 ~ , Octavia 2004 » , Octavie Il 2010 ® 4.9/7 KW TDI PD Engine - Edition 12.2015 wy} Technical data 41 Identification (SRL000892; Edition 12.2015) = ".1 Engine number’, page 1 = "1.2 Engine characteristics (Octavia Il, Superb Il)", page 4 = "1.3 Engine characteristics (Fabia Il, Roomster)", page 2 1A Engine number The engine number (“engine identification characters” and "serial number’) is located at the engine directly on the joint separating engine/gearbox In addition, the (“engine identification characters" and the ‘serial number’) are indicated on the vehicle data sticker, which is loca- ted on the timing belt guard, ‘The engine identification characters are also indicated on the ve- hicle data stickers. 1.2 Engine characteristics (Octavia II, Superb II) Engine identification BB BKC. BXE BLS [characters Manufae- Octavia i 0204" 1210 | 0804+ 05.05 | 0208+ 1210 | 0608+ 11.09 ture ‘Superb = 03.08 14.10 [03.08 > 09.10 Exhaust limit values EU3 EU-4 EU-4 EU-4 Jconforming to Displace- y 1,896 1,896 1,896 1,896 ment Power out- kWat rpm] 77/4900 7/4000 77/4000 77/4000 put Torque Nmatrpm| 250/190 2501/1900 2501/1900 250/1900 Bore mm 795 79,5 79.5 79.5 Stroke mm| 95,5 95,5 95,5 95,5 Number of cylinders / 4/2 4/2 412 4/2 valves per cylinder ‘Compres- 19,0:1 10,021 19,0:1 19,091 sion Firing order 1342 1342 1342 13-42 Selt-diagnosis yes yes yes yes Catalytic converter yes yes yes yes Exhaust gas recircula- yes yes yes yes tion Cooling of exhaust gas no yes yes yes recirculation Turbecharging yes yes yes yes Charge air cooler yes yes yes yes Diesel particle filter no. no. no. yes \donfcation 1‘exons ® Fobie II 2007 > , Fabia Il 2009 > , Octavia II 2004 » , Octavia II 2010 4.9/77 KWTD1 PD Engine - Edition 12.2015 13 Engine characteristics (Fabia II, Roomster) Engine identification charac- AXR BSW BLS ers Manufactured Fabia Il = (04.07 - 03.10 04.07 + 03.10 Roomster| 0306+ 05.06 06.08 - 03.10 17.06 + 03.10 Esha Iii vals conform. EUs U4 eu4 ing to Displacement 1 1.896 4,896 1,896 Power output KW at rpm| 7714000 714000 718000 Torque Nm at rpm) 240/1800-2200 240/1800-2200 240/1900 Bore mm 795 795 795 Stroke mm 955 955 95.5 Cylinder / valves per eylinder 42 42 4/2 |Compression 19,027 19,0:4 18,521 Firing order 1942 1342 13-42 Catalytic converter yes yes yes Exhaust gas recirculation yes yes yes Cooling of exhaust gas recircu- yes yes yes lation Turbocharging yes yes yes Charge air cooler yes yes yes Diesel particle filter no no yes 2 Rep. 07: 00- Technical dataFabia II 2007 > , Fabia II 2009 ~ , Octavia Il 2004 > , Octavia Il 2010 4,9/77 kW TDI PD Engine - Edition 12.2015 2 Safety instructions ="2.1 Regulations conceming safety precautions when workin onthe fuel system”, page 3 "2.2 Safety precautions when wotking on the fuel supply ofthe, diesel direct injection system". e 4 24 Regulations concerning safety precau- tions when working on the fuel system A WARNING * On vehicles with engine with unit injectors, the tempera- ture of the fuel lines or of the fuel can be Up to 100 °Cin an extreme case. Let the fuel coo! down before open! the nes, as otheruise there is high isk of Bumhing. % The fuel system is under pressure! % Wear safety goggles and safety clothing, in order to avoid injuries and skin contact with ¢ Place cleaning cloths around the connection point before detaching cable connections. Reduce pressure by care- fully removing the wiring. The fuel delivery unit is activated when the ignition is switched ‘onand by the door contact switch of the driver door. Before ‘opening the fuel system and for reasons of safety, ifthe battery is not disconnected, the connector -arrow- must be discon- nected from the fuel delivery unit. A WARNING When underteking all installation work, particularly in the en- gine compartment because of its cramped construction, please ‘observe the following: @ Lay lines of all kinds (for example, for fuel, hydraulic fluid, cooling fluid and refrigerant, brake fluid, vacuum) and electrical lines in such @ way that the original line guide is re-established. ¢ Ensure that there is adequate free access to all moving or hot components. SA When removing and installing the fuel gauge sender from a full or partly filled fuel tank, pay attention to the following: ¢ The extraction hose of an exhaust extraction system which is switched on, must be positioned close to the assembly open- ing of the fuel tank in order to extract the released fuel vapours, even before the work is commenced. If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a delivery volume of more than 15 m:/h must be used. Avoid skin contact with fuel! Wear fuel-resistant gloves! 2, Safety instucions 3‘exons ® Fabie II 2007 > , Febie 1 2009 > , Octavia 12004 > , Octavie I 2010 4.9/7 kW TDI PD Engine - Edition 12.2015 22 Safety precautions when working on the fuel supply of the diesel direct injection system If test and measuring devices are required during test drives ob- serve the following: + Always secure the test and measuring devices on therearseat and have a second person operate them there. If the test and measuring devices are operated from the passen= ger seat, the passenger could be injured by the release of the passenger airbag in the event of an accident. ZX weanne ‘Secure the diagnostic device to the rear seat and operate from that position. Observe the following points to prevent injury to persons and/or damage to the injection and preheating system: + Disconnect and connect wires of the preheating and injection system as well as measuring device wires when the ignition is switched off. If the engine should be run at the sterter speed without it ac- tually igniting, then separete the central plug connection for the unit injector at the cylinder heed. Before disconnecting the battery determine the code of the radio fitted with anti-theft coding, Always switch off the ignition before disconnecting and re- ‘connecting the battery. Otherwise the engine control unit may be damaged If the battery is disconnected and reconnected, carry out ad- ditional operations > Electrical System; Rep. gr. 27 4 Rp. 07:00- Technical dataFabia Il 2007 > , Fabia Il 2009 > , Octavia Il 2004 » , Octavie II 2010 4,9/77 kW TDI PD Engine - Edition 12.2015 3 Repair instructions ='3.1 Selt-diagnosis’, page 5 ="3.2 Supplementary instructions and assembly work on vehi- cles with an air conditioning system’, page 5 ="3.4 Regulations coneeming cleanliness when working on the exhaust gas turbocharger’, page 6 "3.5 General instructions for charge air system with exhaust turbocharger”, page 6 = "3.6 Handling the eeremic glow plugs’, page 7 34 Self-diagnosis This Rep.-Gr. is deleted, For this use "Vehicle self-diagnosis", "Measuring method” and “Fault finding” = Vehicle diagnostic fester. 3.2 Supplementary instructions and assem- bly work on vehicles with an air condi- tioning system A WARNING 2e net open the refigerant cicult of the ar conditioning sys- -m. [B) Note In order to avoid damage to the condenser as well as to the re- figerant lines and hoses, ensure that the lines and hoses are not overt nsioned, kinked or bent. ‘Steps which should be taken in order to remove and install the engine without opening the refrigerant circutt — Unscrew the holding clamp(s) on the refrigerent lines - Removing the V-ribbed belt: Fabia Il, Roomster = '1.4 Removing and installing V-ribbed belt (Febia Il, Room: sen page 41 @ Octavia Il, Super = "1.2 Removing and installing V-ribbed belt (Octavia Il, Su- perb Il), page 36 — Remove AC compressor = Heating, Air Conditioning; Rep. or. 87 = Mount the air conditioning compressor and the condenser in such a way that the refrigerent lines/hoses are not under ten- sion, 8.Repairinsiuctions 5‘exons ® Fabie II 2007 > , Febie 1 2009 > , Octavia 12004 > , Octavie I 2010 4.9/7 kW TDI PD Engine - Edition 12.2015 3.3 Regulations concerning cleanliness when working on the fuel supply/fuel in- jection system Carefully observe the following rules for cleanliness when working (on the fuel suppiy/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. # Only install clean components: Only unpack replacement parts immediately prior to fitting. Do not use any parts which have been stored unwrapped (@.g. on a shelf or in a tool box). 4 When the system is open: Avoid using compressed air when- ‘ever possible. Avoid moving the vehicle, 4 Also make sure no diesel fuel runs onto the coolant hoses. If this is the case clean the hoses immediately. Replace imme- diately any hoses which have suffered damage. 3.4 Regulations concerning cleanliness when working on the exhaust gas turbo- charger Carefully observe the following rules for cleanliness when working on the exhaust turbocharger: ‘4 Thoroughly clean the connection points and their surroundings before releasing # Place removed parts on a clean surface and cover. Donotuse fuzzy cloths! Carefully covercr close opened components ifthe repairis not completed immediately. # Only install clean components: Only unpack replacement parts immediately prior to fitting. Do not use any parts which have been stored unwrapped (@.9. on a shelf or in a too! box). When the system is open: Avoid using compressed air when- ‘ver possible, Avoid moving the vehicle 35 General instructions for charge air sys- tem with exhaust turbocharger ZX wernins When undertaking all installation work, particularly in the en- gine compartment because of ts cramped construction, please ‘observe the following: Lay lines of allkinds (for example, for fuel, hydraulic Mid, cooling fluid and refrigerant, brake fluid, vacuum) and ‘electrical ines 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. 6 op. o:00- Technical dataFabia II 2007 > , Fabia II 2009 ~ , Octavia Il 2004 > , Octavia Il 2010 4,9/77 kW TDI PD Engine - Edition 12.2015 BZ cauion ‘In case a mechanical damage to the exhaust gas turbocharger ‘s found, for example, damage to the compressor wheel, itis 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 fiter. * Check air fiter housing, air fter element and charge air Pipes as well as charge air hoses for soiling. * Check all the air guides and the charge air cooler for for- eign bodies. If foreign bodies are detected in the charge air system, the complete charge-air routing must be cleaned and ifnecessary the charge air cooler must also be replaced. ‘@ The charge-air system must be tight, check ="2.12 Checking the charge-air system for leaktightness”, page 335 © Always replace self-locking nuts. ¢ Hose connections and hoses of the charge air system must be free of oil and grease before being installed. The gasket Ting and the sealing surface must be slightly oiled only for push-fit couplings > 2.11 Hose connections’, page 334 ‘@ Observe assembly markings on the hoses and components. ‘@ Allhose connections of the charge air eystem are secured with spring strap clamps or push-fit couplings. ‘¢ Only install approved clamps for securing the hose connec- tions = Electronic Catalogue of Original Parts © Use pliers for spring strap clamps to fit the spring strap clips. ‘@ Assembly of hose connections with pushsft couplings ‘= "2.11 Hose connections", page 334 Before screwing down the cil feed line, fill the exhaust turbo- charger via the connection fitting with engine oil Alter instaling the turbocharger, run engine at idling speed for about 1 minute fo ensure that ellis supplied to the turbocharg- or 3.6 Handling the ceramic glow plugs For ceramic glow plugs the followings points must be observed 8.Repairinstuctions 7exons, ® Fobia ! 2007 » , Fabia II 2009 > , Octavia II 2004 » , Octavia Il 2010 4.9/7 kW TDI PD Engine - Edition 12.2015 fw Note + The ceramic glow plugs are very fragile due to the used com- ponent materials and require utmost care when removing and instaling. Wvhen removing and installing itis essential to cay out the specified work sequence ="1.2 Removing and installing ceramie glow page 427, The original transport packaging must be used for transport and storage of the ceramic glow plugs or if the ceramic glow plugs are packed in foils with insulated air cushions. # Remove ceramic glow plugs trom their wrapping immediately before fitting. The pins of the ceramic glow plugs are very sensitive to im- pacts and flexion. For this reason never use ceramic glow. plugs that have been dropped from a low height (approx. 2 om). Although no exterior damage is visible, dangerous hair- line cracks can nevertheless be present. Damage or breakage of the ceramic glow plug pin may cause ‘major engine damage. + Alays replace the ceramic glow plugs in case of doubt re- garding the proper state. # incase of breakage of the ceramic glow plug pin all broken pieces must be removed from the cylinder before starting the engine, otherwise this could result in engine damage due to seizures. The ceramic glow plugs must not be removed from the cylinder head for testing the compression pressure. # Alnays pertorm the compression pressure test on installed ceramic glow plugs in the function “Targeted fautt nding” = Vehicle diagnostic tester. The software version of the engine control unit is matched to. the glow plug type (ceramic or metal), therefore only the rele- vant glow plugs must be installed. # Changing the ceramic glow pligs to metal glow plugs, or Vice versa, is not permissible. 8 Rep. 0: 00- Technical datasxopa Fabia I 2007 ~ , Fabia Il 2009 ~ , Octavia 2004 » , Octavie Il 2010 ® 4.9/7 kW TDI PD Engine - Edition 12.2015 moving and installing e1 1 Removing and installing engine "1.4 Removing (Octavia Il, Superb Il), page 8 ="1.3 Securing the engine to the assembly stand’, page 19 = "4.4 Installing (Octavia Il, Superb IN". page 20 = 1.5 Installing (Fabia lI, Roomster)", page 25 >1.8 Checking and adjusting the assembly bracket (Superb Il) page 29 21.7 Checking and adjusting the assembly bracket (Octavia It page 32 14 Removing (Octavia II, Superb II) ‘Special tools and workshop equipment required Catch pan . e.g. -VAS 6208- Engine/gearbox jack ,€.¢. -V.AG 1383/4- Pliers for spring strap clamps Double ladder Engine mount - 710012 Wire . . . . . . © The engine is removed downwards together with the gearbox. ¢ Allcable straps that have been loosened or cut open when the engine was removed must be attached again in the same lo- cation when the engine is installed again. © Collect arained coolant ina elean container for proper disposal or reuse. AY owen When undertaking all installation work, particularly in the en. gine compartment because of is cramped construction, please ‘observe the following: # Lay lines of all kinds (for example, for fuel, hydraulic fluid, cooling fluid and refrigerant, brake fluid, vacuum) and electrical lines in such a way that the original line guide is re-established. # Inorder to avoid damage to the cables, ensure that there is adequate free access to all moving or hot components. Observe all safety measures and notes for assembly work on the fuel supply and injection system, at the charge air system and observe as well the rules for cleanliness. 22 Safety instn 3 1. Removing and insaling angina 9)‘exons ® Fabia II 2007 > , Fabia ll 2008 > , Octavia II 2004 » , Octavia Il 2010 4.9/7 kW TDI PD Engine - Edition 12.2015 = Lift the engine cover at the sides -arrows 1- and pull out to- wards the front -arrow 2-. = Remove air fiter and intake air duct = 1.4 Summary of components - air filter (Octavia Il, Super ID, page 364 ZV wasn Observe measures when disconnecting the battery » Electri- cal System; Rep. gr. 27 ~ Remove bettery and battery tray = Electrical System: Rep or - Remove cover and bulkhead plenum chamber = Body Work; Rep. gr. 66 — Remove both front wheels + Chassis; Rep. gr. 44 = Remove the sound dampening system = Body Work; Rep. gr. 50 Remove the front right and left whesthouse liner => Body Work; Rep. or. 66 A WARNING Hot steam or hot coolant may escape When the compensation bottle is opened. Cover the cap with a cloth and open carefully. t and fill coolant (Octavia Il, Superb I)", A WARNING '# On vehicles with engine with unit injectors, the tempera- ture of the fue! ines or of the fuel can be up to 100 °C in an extreme case. Let the fue! cool down before opening the lines, as otherwise there is a high risk of burning. ¢ Wear protective gloves. + Wear safety goggles. = Detach coolant hose, fuel intake hose -2- and fuel return-flow hose -1- from pipes at cylinder head, 10 ep. o.10-Removing and insaling engine4,9/77 kW TDI PD Engine - Edition 12.2015 For the vehicles Octavia Il up to 08.05 — Unlatch fuses, remove fuel fter with its connected lines up- wards from bracket -errow- and lay to the side. Fabia II 2007 > , Fable Il 2009 ~ , Octavia l 2004 > , Octavie I! 2010 ® 1. Removing and instaling engine 11‘exons ® Fabie II 2007 > , Febie 1 2009 > , Octavia 12004 > , Octavie I 2010 4.9/7 kW TDI PD Engine - Edition 12.2015 For Octavia Il vehicles as of 08.05 and Superb II vehicles. — Release screw-1- by one turn. — Release screw -2- and nut-3. = Take out fue! filter with connected hoses and lay to the side. Continued for all vehicles (Fro Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it = Remove V-ribbed belt = '1,.2 Removing and installn perb Il), page 36 — Remove alternator = Electrical System; Rep. gr. 27 bed belt (Octavia II, Su: For vehicles with air conditioning ZX ween Do not open the refrigerant circuit of the air condltioning sys~ tem. a Note In order to avoid damage to the AC compressor as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent — Remove AC compressor + Heating, Air Conditioning; Rep gr. 87 = Tie up removed AC compressor with connected refrigerant hoses to the body. Continued for all vehicles ~ Remove charge air hoses and charge air pipe between engine and charge air cooler © Octavia ll = °2.6 Removing and installing parts of the charge air cooler (Octavia il)" page 326 + Superb II ="2.5 Removing and installing parts of the charge eit Gooler (Superb il)", page 324 — Remove fan shroud and radiator 32.3 Removing and installing radiator (Octavia lI, Superb I)” page 222 For vehicles with auxiliary heating = Separate coolant hoses on the auxiliary heating ~ Remove exhaust pipe of auxiliary heating (only for vehicles with extended exhaust pipe)= Heating, Alr Conditioning: Rep. gr. 82 12 Rep. o.10-Removing and instaing engineFabia II 2007 > , Fabia II 2009 ~ , Octavia Il 2004 > , Octavia Il 2010 4.9/7 KW TDI PD Engine - Edition 12.2015 Continued for all vehicles — Remove drive shaft to the right > Chassis; Rep. gr. 40 — Unscrew left drive shaft from the flange shaft of the gearbox and tie up. = Unscrew screws -1 ... 33- and remove pendulum support. Vehicles with four-wheel drive = Remove the assembly carrier > Chassis; Rep. gt. 40 = Remove propshaft from gearbox > Chassis; Rep. gr. 39 Continued for all vehicles (F) re The decoupling element in the pre-exhaust pipe should not be bent by more than 10° «risk of damage. — Remove the pre-exhaust pipe from the exhaust turbocharger >"t Removing and installing parts of the exhaust system’ = Unlatch the fuse and disconnect the plug from the engine con- trol unit, open the cable guides -arrows-, remove the engine wiring harness and lay to the side. = Release all remaining plugs at engine and gearbox and lay aside the relevant lines, = Unclamp all connecting, coolant, vacuum and suction hoses from the engine. = Remove shift mechaniem from gearbox > Chassis; Rep. of. 34 — Remove hydraulic clutch control from gearbox > Chassis: Rep. gr. 34 A WARNING After removing the slave cylinder or after separating the hy- araulic line, do not depress the clutch pedal. 1. Removing and instaling engine 13;‘exons ® Fabia II 2007 > , Fabia ll 2008 > , Octavia II 2004 » , Octavia Il 2010 4.9/7 kW TDI PD Engine - Edition 12.2015 = Screw on -110012- engine mount to the cylinder block with fxing nut and bol. Tighten serew M10 x 258.8 to approx. 40 Nm. @ Note The studs must be screwed onto the engine mount -T10012-, as shown in the figure. The stud with the thread must be positioned on the gearbox side. = Insert engine/gearbox jack at engine mount VAG 1383/A- — (e.g. -T10012-) and slightly raise, V.A.G 1383A[Sm=7 ff Note Use the double ladder to release the screws for the assembly bracket. Successively release screws for assembly bracket at engine “arrows. — Successively release screws at gearbox OA4 -arrows- or =... at gearbox 02 -arrows- or 14 ep. o.10-Removing and instaling engineFabia II 2007 > , Fabia II 2009 ~ , Octavia Il 2004 > , Octavia Il 2010 4,9/77 kW TDI PD Engine - Edition 12.2015 at gearbox 02E -2. (F) note © Check whether all hose and line connections between engine, gearbox and body are released. © When lowering carefully guide the engine/gearbox jack unit, in order to avord damage. ¢ Ensure adequate clearance to the AC compressor or espe- cially ensure free passage between drive shaft and turbo- charger. — First of all slightly lower the engine/gearbox unit. Then push engine/gearbox unit forwards and only then lower further ~ Remove the geerbox fom the engine = gearbox: Rep a. 1.2 Removing (Fabia II, Roomster) ‘Special tools and workshop equipment required # Catch pan , e.g. VAS 6208- Engine/gearbox jack, ¢.9)-VAG 1383/A- Pliers for spring strap clamps Double ladder Engine mount - 710012- Wire [F) Note ¢ The engine is removed downwards together with the gearbox. ¢ Allcable straps that have been laosened or cut open when the ‘engine was removed must be attached again in the same lo- cation when the engine is installed again. © Collect arained coolant in a clean container for proper disposal or reuse. ee eee — Lift the engine cover at the sides -arrows A- and pull out to- wards the front -arrow B-. A WARNING Observe measures when aisconnecting the battery = Electri- cal System; Rep. gr. 27. ~ Remove battery and battery tray = Electrical System Rep. or — Remove air filter with intake hose and hose to turbocharger ="1.6 Removing and installing air fiter (Fabia II, Roomster)” 1. Removing and instaling engine 15)