Service ® Workshop Manual Fabia Ill 2015 > Rapid NH 2013 > Edition 05.2019 Service Department. Technical Information® 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 21 - Turbocharging/supercharging 23 - Mixture preparation - injection 26 - Exhaust system 28 - Glow plug system Service 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 © 2019 SKODA AUTO a. s. D4Bg049C91BFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa Contents 00 - Technical data 1 1 Denomination 1 4.4. Engine number, engine data 1 2 Safety instructions 2 24 Safety precautions when working on fuel supply system 2 22 Safety precautions for working on vehicles with start-stop system 4 2.3. Safety precautions during road tests in which testing and measuring equipment is used 4 24 Safety precautions when working on cooling system cetteetet nee 5 2.5 Safety precautions when working on the exhaust system 5 3. Repair instructions... 6 3.4 Rules of cleanliness 6 32 Foreign bodies in the engine é 3.3 Contact corrosion é 3.4 Cable routing and securing 6 3.5 Assembly of radiators and condensers: 7 10 - Removing and installing engine ©... . 6. eee eee e eee e eee eee en erences B 4 Removing and installing engine -. 8 1.4 Removing engine ..... : - : we 8 112 Disconnecting engine and gearbox... - cee cece 4 113 Attach engine attached to engine end gearbox mount coves sees 16 1.4 Installing engine cote eee veeenecteeees sevens 17 2 Assembly bracket 24 2.4 Assembly overview - assembly mountings ceeeeee . 24 22 Removing and installing engine mount cece eeeeeeeeeeeeeeeeeeees 2 23 Removing and installing gearbox mount ........ cette teeeeeeeeeees 2B 24 — Removing and installing pendulum support a . 24 25 — Supportthe engine in its installed position ...... ceceeeeees ceseeees 28 3 Engine trim panel cece cette eee e eee tttettteseceseees 27 3.1 Removing and installing engine trim panel . . 2 13 - Crankshaft group see ee eee weet ee eee tense enens 28 1 Cylinder block (pulley end) 28 1.4 Assembly overview - V-ribbed belt drive 28 4.2 Summary of components - sealing flange on the belt pulley side a 30 4.3 Removing and installing V-ribbed bett . 7 4H 44 Removing and installing tensioning element for V-ribbed belt . : 33 4.5 Removing and installing bracket for auxiliary units wees : 34 1.6 Removing and installing engine support . : . 35 1.7 Removing and installing belt pulley cee so 18 Replacing crankshaft sealing ring on the belt pulley side 37 1.9 Removing and installing the sealing flange on the belt pulley side 40 2 Cylinder block on gearbox side 43 24 Summary of components - cylinder block on gearbox side 43 22 Removing and installing flywheel 44 23 Removing and installing sealing flange on gearbox side 45 3 Crankshaft 53 3.4 Summary of components - crankshaft 53 32 Crankshaft dimensions 54 3.3 Replace the needle bearing in the crankshaft 54 3.4 — Measuring axial play of crankshaft 55 4 Pistons and conrods 56 contanis i@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 4.1. Assembly overview - piston and conrod 56 4.2 Removing and instaling the piston 58 4.3 Measure piston projection in TOC . en fevers 88 44 Check piston and cylinder bore... beet eet cneeeeeee » 60 4.5 Separating new connecting rod. veces : : - 62 15 - Cylinder head, valve gear .......... rere eee - 63 1 Cylinder head 63 1.1. Summary of components - cylinder head 63 1.2. Assembly overview - cylinder head cover 65 43. Removing and installing cylinder head 66 4.4 Removing and installing cylinder head cover 73 4.5 Removing and installing gasket rings for injection units... : - . 75 4.8 Removing and installing camshaft housing wees cee 78 1.7 Checking compression. en caper Pores 79 2 Toothed belt drive. at 2.1 Summary of components - toothed belt guard - = =~ 81 22 Summary of components - toothed belt 2.0.0... ee creee vee 82 2.3. Removing and installing toothed belt guard Re 83 2.4 — Removing and installing toothed belt 85 2.5 Remove the toothed belt from the camshaft 93 3 Valve gear 96 3.1 Assembly overview - valve geer 98 3.2 Removing and installing gasket ring for camshaft ............ my... _ 7 3.3 Checking hydraulic balancing elements ........0.ccceccreeeeeeeeteereseeeess 99 3.4 Removing and instaling valve stem seals 99 4 Inlet and exhaust valves... +. 108 4.1. inspecting valve guides coves a » 106 4.2 Testing valves 108 4.3 Valve dimensions 107 17 - Lubrication feet e ee ee eee «108 1 Sump, oil pump 2 108 41 Assembly overview - panicil pump : ae + 108 1.2. Removing and instaling the bottom part of the ollsump ss rdeees ets 140 1.3. Removing and installing top part of the oll SUMP... nnuevenrernneeeeeeenenene 1 1.4 Removing and installing oll pump 28 AIA ses 0 114 1.5 Removing and installing oil level and cil temperature sender G26 417 2 Engine cil cooler ... . fee vette teeeees . 119 3. Oilfiter, i pressure awitch cece ceeeeeeees 120 3.1 Summaty of components - ol fiter housingoil pressure switch . 120 3.2 Removing and installing oil pressure switch F1 121 3.3. Testing oil pressure 122 3.4 Removing and installing oil iter housing 123 3.5 Removing and installing valve for oil pressure contro! N428 128 19-Cooling ......... - = 128 1 Cooling system, coolant = sevens settee vee 128 1.1 Connection diagram - coolent hoses feet veces 128 1.2. Check cooling system for leaks. veces vette eens 129 13. Draining and filing coolant 131 1.4 Flushing the cooling system 135 1.5 Flushing cooling system, quick stert guide 185 2 Coolant pump, regulation of cooling system . vee eeeeeeccteeeeeeeee 157 2.1. Summary of components - coolant pumpithermostat ... . 187 Ti contentsFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 2.2 Summary of components - electric coolant pump 159 2.3 Summary of components - coolant temperature transmitter 160 24 — Removing and installing electric coolant pump... cove veetetteeeteeeeees 160 2.5 Removing and installing coolant pump . fee voce eeeeee rene 162 2.6 — Removing and installing coolant regulator... voce veeteeeees ve 164 2.7 Testing the coolant regulator. bev ceete ee cneees 165 28 — Removing and installing coolant vaive for cylinder head N489 ssc cee ese. 166 2.9 Removing and installing coolant temperature transmitter G62... ee ees 166 2 Coolant pipes ....... Feet eee rc teeee ee teeer sense 169 3.1. Summary ef components - coolant pipe : : en 169 3.2 Removing and installing coolant pipes 170 4 Coolers, radiator, radiator fan 173 4.4 Assembly overview- radiator/radiator fan 173 4.2 Summary of components - fan shroud and radiator fan 175 4.3 Removing and installing radiator 175 4.4 Removing and installing fan shroud 178 45 Removing and instaling radiator fan V7 180 Turbocharging/supercharging .... 6... .s sees ee ee vee ee ee ee ee ee nena es 182 1 Exhaust gas turbocharger fetes we se 182 4.1 Summary of components - exhaust gas turbocharger... sss == ceceeees 182 1.2 Removing and installing exhaust gas turbocharger 183 13. Replacing exhaust ges turbocharger pressure box 187 2 Charge-air system eee cece cece eect eeeee tte teeeerneeeeeees 195 2.1 Summary of components - charge air system... vette tett ene n ence ere 195 2.2 Removing and installing charge air cooler... cov eeee ees ve 196 2.3 — Removing and installing charge pressure sender G31... cece se 198 24 — Removing and installing charge air temperature sender... 2... eee eee 200 25 Checking the charge-air system for leak-tightness 201 26 Leak testing the charge air cooler 203 Mixture preparation - injection... 0.0.0... 0e ccc cece ee eect nents ee eee 207 41 Injection system cece cee 4.41. Schematic overview fuel system : : : --. 207 1.2. Installation location overview fuel injection system oc... cs... ceeee eee e ees 208 1.3. Filling/bleeding the fuel system... veceeeeeeeeeeeeees - wees 21 14 Check the fuel system for tightness 212 2... Macuum system...» ceseeeneees : ceceeeeees 2.1. Connection diagram - Vacuum sytem. Me eeeceeeeeeeeeeees cee 213 22 Inspect the vacuum system 213 3 Injection units / high pressure accumulators (fuel distributors)... .....ceceeeeeeeees 215, 3.4 Summary of components - injection units (injectors) 215 3.2 Summary of components - High pressure reservoir (fuel distributor) 217 3.3 Check injection unit return quantity with engine running 218 3.4 Checking the injection units in open state 219 3.5 Removing and installing the injection units 224 3.6 Removing and installing high pressure lines 224 3.7 Removing and installing high pressure reservoir (fuel distributor) 227 4 Airfiter 230 41 Assembly overview - air filter housing 230 4.2 Removing and installing air iter housing 231 5 Intake manifold 233 5.4 Assembly overview - intake manifold 233 5.2 Removing and installing intake manifold ......... vote ceeeeeeeee ees 233 5.3.__ Removing and installing the throttle valve control unitJ388_ sv --evervvevvvevvevs es 288 consents Hii@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 6 Senders and sensors 240 6.1. Removing and installing the fuel pressure regulating valve N276 240 6.2 Check fuel pressure regulating valve N276 241 63 Removing and instaling fuel pressure sender G247 242 64 — Removing and instaling airflow mass meter G70... sees cece eens coves 243 65 Removing and installing differential pressure transmitter G505 veces 245 6.6 Removing and installing fuel temperature transmitter G81 : 247 6.7 Removing and installing pressure sensor for exhaust gas 1450... veces 247 7 Engine controtunit ....... vette eee ee teeeee scene 249 7.1 Removing and installing engine control unit J623 cee 249 7.2. Removing and installing engine control unt J623 with protective housing... +... 249 8 High pressure pump ...... ceeeees bo eeeee cee 253 8.1 Summary of components - high pressure pump | : 253 8.2 Removing and installing the high pressure pump 254 9 Lambda probe 258 9.1. Summary of components - lambda probe : wee 258 9.2 Removing and installing Lambda probe .... . 259 26 - Exhaust system... 0... c eee cee eee eee eee eee eeey |) 1 Exhaust pipesieilencers 263 1.1 Assembly overview - silencers 263 1.2 Separating exhaust pipesisilencers 265 1.3. Removing and installing pre-exhaust pipe 266 1.4 Removing and installing middle silencer 267 1.5 Removing and installing rear silencer .... Pee . » 268 1.6 Align exhaust system free of stress... 22.2... ceeeeeeeeeeeteeeeteeeee 270 1.7 Inspecting the exhaust system for leaks .......... eee eee e cee eeeeeeeeeeeeeeees OTH 1.8 Installation position of clamping sleeve .. : feces : an 2 Cleansing exhaust emissions lid. vee ceeeeeeeeeee 273 2.1 Summary of components - exhaust gas cleaning... .sssssvs.ss. 273 2.2 Removing and installing exhaust gas cleaning module : we : 275 2.3 Removing and installing the exhaust flap control unit J883, 279 3 Exhaust temperature regulation a vote ceeeeceee 284 3.1. Summaty of components - exhaust temperature regulation 281 3.2 Removing and installing exhaust gas temperature sender 282 4 Exhaust gas recirculation 285 4.1. Summary of components - Exhaust gas recirculation 285 4.2 Removing and installing radiator for exhaust gas recirculation 288 4.3 Test airightness of the radiator for exhaust gas recirculation 291 4.4 Removing and installing exhaust gas recirculation valve 2 GX6 201 28 - Glow plug System oc ese ecieiissssvevcuceteesseeteweecsesesess 1204 1 Glow plug system .. : : cece eee seen 294 4.1 Summary of components - Glow plug system . : 294 12 Removing and installing glow plugs 295 1.3. Removing and installing automatic glow period control unit J179 207 1.4 Removing and installing knock sensor 1 G61 297 1.5. Removing and installing Hall sender G40... voc eeee tenets e ees 208 4.8 Removing and installing the engine speed transmitter G28 fee 298 IV contantsFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa we} Technical data 1 Denomination (SRLO01380; Edition 05.2019) 1A Engine number, engine data @ The engine number (‘engine identification characters’ and ‘serial number’) is located at the front at the engine/gearbox joint -arrow.. ¢ Inaddition, a sticker with the “engine identification characters” and “serial number’ is attached to the timing belt guard, Starting with the letter °C", new four digit engine codes have been introduced, © The first 3 digits of the engine identification characters refer to the displacement and the mechanical construction of the en- gine. They are type-punched on the cylinder block including the serial number, The fourth digit refers to the output and torque of the engine. It depends upon the engine control unit. ¢ The engine identification characters are indicated on the ve- hicle data sticker. ‘¢ Maintenance ; Booklet Fabia III ‘@ = Maintenance ; Booklet Rapid NH Engine codes CUTA CUSA ‘cusB Manufactured Fabia ill 08.2014 > 07.18 112015 > 7.18 08.2014 + 07.18 Rapid NH (05.2015 ¥ 07.18 Emission U6 U6 EUS standerds con- Horming to Displacement em’ 1422 1422 1422 Output kWetrpm| 77/3500 - 3750 55/3000 - 3750 66/3000 - 3250 Torque Nm at rpm] 250/1750 ... 2500 210/500-2000 | 230/1750 ... 2500 Bore 2mm 79.5 79.5 79.5 Stroke mm 95.5 955 955 Compression 1624 16.21 1621 ratio Firing order 132 13:2 132 Exhaust gas recirculation —_ yes yes yes Exhaust temperoture regular yes yes yes ion Balancing shafts yes yes yes Exhaust gas turbocharger yes yes yes Charge air cooler yes yes yes Lambda contro! yes yes yes Particle fiter with catalyser—|yes yes yes Number of cylindersivaives per| 34 34 34 cylinder 1.Denominaton 1@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 2 Safety instructions ='2.1 Safety precautions when working on fuel supply system’, : 22.2 Safety precautions for working on vehicles with start-sto system’, page 4 2 fons dur t ‘measuring equipment is used”, page 4 ='2.4 Safety precautions when working on cooling system’, page 5 ="2.5 Sefety precautions when working’on the exhaust system’, page 5 24 Safety precautions when working on fuel supply system When undertaking all installation work, particularly in the engine compartment because ofits cramped construction, please ob- serve the following ¢ Route all the various lines (e.g. for fuel, hydraulics, activated charcoal fiter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in thelr original positions. ‘# Ensure that there is adequate free access to all moving or hot components. Fuel feed line is pressurised, + The fuel or the fuel lines in the fuel system can become very hot (risk of scalding)! + Allow the fuel to cool before opening the lines, | ¢ 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 removing the hose. For reasons of safety, the power supply to the fuel pump must be interrupted before the fuel system is opened. The fuel pump would otherwise be activated when the driver's door is opened (One of the following options must be used to interrupt the cur- rent supply: Disconnect battery or @ Take out fuse for fuel pump control unit - J538- or ¢ Pull connector off fuel delivery unit flange. 2 Rep. 07: 00- Technical dataFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa Carry out the following measures before starting work on the fuel system: © 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 racial fan (motor not in air low of fan) with a delivery volume of mors than 15.m°th must bs used. Prevent skin contact with fuel! Wear fuel-resistant gloves! Do not remove fuel hoses from the fuel fer. Do not lever the connection fittings. This leads to leaks and damage to the fuel fier top part. + Ensure that no diese! fuel gets onto other components in the engine compartment. If this happens, clean immediately! O8Ea @ Because of insufficient lubrication by diesel fuel, misfuelling can cause irreversible damage to high pressure compo- nents, particularly the high pressure pump! # Damage can be expected in the form of scoring and particle erosion Thus, free metal particles contaminate the fuel system as ‘well as the injection system, whereby further damage can be expected especially to the fuel pressure regulating valve and in the injection units. Check the filling level of the fuel tank The fuel tank must be empty for weight reasons when remov- ing it. If necessary, extract fuel from the fuel tank. @ 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, Prevent skin contact with fuel! ¢ Wear fuel-resistant gloves! When removing and installing the fuel tank, observe the following: of accident due to the fuel tank weight! The fuel tank must be empty for removal. Observe the following points to prevent injury to persons and/or damage to the injection and preheating system: People, who havea heart pacemaker implant, should not bend ‘over the engine compartment when the engine is running, as the injection units generate en output high voltage pulse. No fuel ines must be opened when the engine is running. 2, Safety instucions 3@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 # Disconnect and connect wires of the preheating and injection system as well as measuring device wires when the ignition is, ‘Switched off. # Do not carry out engine wash unless the ignition is switched off. # 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. # Some additional work must be carried out after connecting the battery = Electrical system; Rep. gr. 27 : Battery: Connecting and disconnecting battery In order to avoid the high pressure pump to run dry and to ach- ieve a quick engine start after parts are replaced, the following points must be observed. ¢ If parts of the fuel system have been removed or replaced, to bleed the fuel system itis necessary to perform the fuel system filing/bleeding process 21.3 Filingrbleeding the fuel system’, page 214 . @ Ifthe fuel pump, fuel line or fuel fiter have been removed or replaced, the fuel system filing/bleeding process must be performed. = "1.3 Filling/bleeding the fuel system’, page 211 - @ Ifthe high pressure pump is removed or replaced, the initial fuel filing of the high pressure pump must be carried out before the first engine start = '1.3 Filling/bleeding the fuel system’, page 211 © Ifthe high pressure system was opened, it must be checked for tightness = "1.4 Check the fuel system for tightness", page 212 22 Safety precautions for working on vehi- cles with start-stop system When working on vehicles with start/stop system, please observe the following: There is risk of injury from automatic engine starting on vehicles with startistop system! ¢ Invehicles with an activated start-stop system (indicated by a message in the dash panel insert), the engine can start automatically if necessary. + Itis therefore necessary to ensure that the start-stop system is deactivated when carrying out work on the vehicle (switch ignition off, if required switch ignition on again). 23 Safety precautions during road tests in which testing and measuring equipment is used 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. 4 Rp. 07:00- Technical dataFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 sepa There is a risk of accident from deflection and insufficient se- curing of testers and measuring instruments! ‘There is also a hazard from the release of the passenger airbag in the event of an accident! + Using testers and measuring instruments during driving op- eration causes distraction, + Increased risk of injury from unsecured testers and meas- uring instruments must be prevented. Testers and measuring instruments must always be secured on the rear seat using a seat belt and by a 2nd person on. the rear seat, 24 Safety precautions when working on cooling system Hot steam may escape when the expansion reservoir is opened. ¢ Wear safety goggles and safety clothing to avoid eye injuries and scalding. + Cover cap with cloth and open carefully. 25 Safety precautions when working on the exhaust system Danger of poisoning by chemical substances. Exhaust gas temperature sensors can contain chemical substan- ces. Risk of injury to the respiratory tract and poisoning, — The exhaust gas temperature encoder must not be cut or ‘opened. Risk of injury due to hot condensate and particles in the exhaust, system, = The exhaust system may contain hot condensate or particles Risk of injury to the eyes, skin and the respiratory tract ae well as danger of poisoning. ‘+ Wear protective gloves and safety goggles when discon- necting the exhaust system! @ When disconnecting, use @ suction device or provide ade- quate ventilation, Risk of damaging the decoupiing element. = Do not twist decoupling element more than 10°, — Donot load decoupling element with tensile stress. = Do not damage wire mesh on decoupling element 2, Safety instucions 5@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 3 Repair instructions = '3.1 Rules of cleantiness’, page 6 >'3.2 Foreign bodies in the engine’, page 6 > '3.3 Contact corrosion’, page 6 ='3.4 Cable routing and securing’, page 6 23.5 Assembly of radiators end condensers”, page 7 34 Rules of cleanliness Carefully observe the following “rules” for cleanliness when work- ing on the fuel supply/injection system: 4 Thoroughly clean the connection points and their surroundings before releasing, # Place removed parts on a clean surface and cover. Use lint. free cloths. # Carefully cover or close open components if the repair is not completed immediately. # Only install clean parts: remove spare parts from their wrap- ping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.). 4 When the system is opened: do no use compressed air. Do not move the vehicle. Ensure that no fuel runs onto the fuel hoses. Ifhappens, clean the hoses immediately. # Protect electrical plug connections from dirt and moisture and ‘only connect them when dry. 3.2 Foreign bodies in the engine To prevent the penetration of foreign bodies, open channels of the inlet connection and exhaust tract must be sealed with suits- ble plugs during assembly works on the engine, for example from the screw plug set for engine - VAS 6122... 3.3 Contact corrosion ‘The use of unsuitable connection elements (screws, nuts, wash- ers, etc.) can cause contact corrosion, This is why only connection elements with a special surface coat- ings are fitted Therefore, the rubber or plastic parts and the adhesives are made from electrically non-conductive materials. It there is a question mark about the suitability of parts, generally use new paris > ETKA- Electronic Catalogue af Original Parts 3.4 Cable routing and securing # To ensure the original installation position, lines such as fuel, hydraulics, vacuum, activated charcoal filter system lines or electric cables must be marked before removal. Make photos or sketches where necessary. # Sufficient clearance from all moving or hot components must be ensured in the engine compartment due to its cramped construction. This prevents damage to lines. 6 op. o:00- Technical dataFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 3.5 Assembly of radiators and condensers ‘The radiator, condenser and charge air cooler may have minor indentations on the fins, even if assembled correctly. This does ‘not constitute damage. Radiators, condensers and charge air coolers must not be replaced because of these indentations. 8.Repairinstuctions 7@® rosie 2018 ~, Rois 2019» sxova_1.4/55: 66; 77 kW TDI CR Engine - Edition 05.2019 10 1 Removing and installing engine emoving and installing e! = “1.4 Removing engine’, page 8 = "1.2 Disconnecting engine and gearbox’, page 14 =1.3 Altach engine attached to engine and gearbox mount’ page 16 = '1.4 Installing engine’, page 17 14 Removing engine ‘Special tools and workshop equipment required 4 Engine mount - T10536- @ Engine/gearbox jack , e.g. -V.AG 1383 A- 4 Hose binging claw - VAS 6362- 4 Screw plug set for engine - VAS 6122- o When installing a complete new engine and after fitting the high pressure lines, tis absolutely necessary to tighten the clamping claws of the injection units to the specified tightening torque = "3.4 Summary of components - injection units (injectors). page 215 . In order to align the injection units when fiting the high pressure lines, the clamping claws are only tightened “hand-tight" after delivery. If you do not do so, the engine may be damaged. — Remove engine cover jing and install i 7" page 27 - Remove battery and battery tray = Electrical system; Rep. ar. 27 ; Battery; Removing and installing battery tray = Remove air filter housing = "4.2 Removing and installing air iter housing’. page 234 = Release cover -1- and take off. Tana 8 op. o710- Removing and insaling engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa = Unscrew screws -1- and remove aii inlet -2- — Remove shift mechanism from the gearbox = Rep. gf. 34; Shift mechanism; removing and installing shift mechanism Vehicles fitted with a manual gearbox - Remove clutch slave cylinder = Rep. gr. 30; Clutch slave cylinder; Removing and installing clutch slave cylinder — Unlock and disconnect connectors -1-, -2- and -3.. Vehicles with automatic gearbox Risk of damaging the slave cylinder. ‘After removing the slave cylinder with connected tube-hose line, no longer press the clutch pedal - Touch a conductive component with the hands (without gloves) to discharge static electricity, — Remove the cap of the connector -1- on the double clutch ‘gearbox mechatronics - J743- and pull up the latches “arrow. = Unscrew the nuts -2- and -3- and remove bracket of the cable guide. Continued for all vehicles = Release the line and vacuum hoses -arrow- and remove hoses a (&) Note Label the connectors on the solenoid valves. There Is a risk of mix-ups. ase and pull off connectors -2- and -3- and unlatch brack- and place it on the engine with the solenoid vaives. = Disconnect vacuum line of the brake booster. = Remove engine control unit - J623- from the holder = °'7 Engine control unit”, page 249 1. Removing and instaling engine® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 = Release and pull off connector -1- for the engine control unit - J623- and pull off connector -4.. =. Slacken the wiring loom for engine control unit and place on the engine. Drain coolant = "4.3 Draining and filing coolant’, page 134 Loosen hose clamps -1- to -4-, remove coolant hoses, Loosen clamp -5- and place coolant hoses to one side. = Detach quick couplings -1- to -4- and disconnect fuel hoses and place on the engine. — Release and pull off connector -2- and unscrew screws -1-. Pull off coolant expansion tank -3- and place on the engine. 10 ep. o.10-Removing and insaling engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa ~ Release nuts -1- and remove earth cable -2- — Pull connecter off exhaust gas temperature transmitter 1 - 6235. and lambda probe 1 in front of the catalytic converter - GX10- -arrowe. = Pull off cap -2- of line 30/8+ -1-. = Unscrew nut and remove line 30/B+ -1-. Disconnect plug connections -3-, — Loosen hose clamp -1- and disconnect coolant hoses. — Remove the front left and right wheelhouse liner > General body repairs, exterior; Rep. gr. 66 ; Wheelhouse liner; remov- ing and installing front wheelhouse liner 1. Removing and instaling engine 11® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 — Unscrews screws -1- for electrical coolant pumps and release and pull off connectors -4- and -6-. = Loosen retaining clips -2- and remove cover for noise insula- tion 3. — Remove pre-exhaust pipe = "1,3 Removing and installing pre-exhaust pil ~ Remove the assembly carer > Chassis, axles, steering: Rep. gr. 40; Assembly carrier: Removing and installing assembly carrier without steering gear Unscrew drive shaft left and right from the gearbox = Chassis, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in- stalling the drive shaft and strap it up towards the rear. = Release retaining clips -1-and-2-, release hose clamp -3- and disconnect coolant hoses. = Unscrew nuts -1- and remove cover -2- = Pull off connector -1- and undo line of lambda probe, = Remove V-ribbed belt = 1,3 Removing and installing V-ribbed belt”, page 31 Risk of injury through refrigerant! Do not open the refrigerant circuit of the air conditioning system, 12 Rep. o.10-Removing and insaling engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soo Release and pull off connector-3- for throttle valve control unit. — Unscrew screws -2- and -4-, remove air conditioner compres- sor with connected coolant hoses from bracket and strap up to the right (CF) ne When attaching the engine mount, take note of the gap at the bolt _[[05265.. The gap must polnt towards the ollpan. f necessary, Joasen and tun the bolt — Fit the engine mount - 710536- as shown and secure with, screw -110536/5- and nut -T10536/4- . Insert the engine/gearbox jack - V.AG 1383 A- into the engine mount - T10536- and raise the enginelgearbox unit slightly. (B) note Use the double ladder to release the screws for the assembly bracket. - Completely unscrew engine mount screws -3- for engine mounting ~ = Completely unscrew screws -1- for gearbox mount -4. Risk of damaging vacuum lines or electric cables and the en- gine compartment! @ Check that all vacuum lines and electric cables between en- gine, gearbox and body have been loosened. @ Guide the engine/gearbox unit out of the engine compart- ment carefully when lowering. — Carefully lower the engine with gearbox. 1. Removing and instaling engine 13,® Fabia Ill 2015 > , Rapid NH 2013 > sxona_1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019 12 Disconnecting engine and gearbox 21.2.1 Disconnect the engine from the gearbox - vehicles with manual geerbox’”. page 14 > "1.2.2 Disconnect the engine from the gearbox - vehicles with ‘automatic gearbox’. page 15 1.2.1 Disconnect the engine from the gearbox - vehicles with manual gearbox Special tools and workshop equipment required + Workshop crane , e.g. -VAS 6100- @ Shackle - 10-222 A/12- Work procedure + Engine/gearbox unit removed and attached to engine mount - T10536- - Remove starter = Electrical system: Rep. or. 27 ; Starter; Removing and installing starter — Release screws -arrows- and remove gearbox support brack- et = Attach the gearbox with the clevis - 10-222 A/12- to the work- shop crane ~ VAS 6100- 14 ep. o.10-Removing and instaling engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa = Unscrew the connecting screws -1-, -2-, -5,-6-, con- necting the gearbox/engine. = Remove the gearbox from the engine, taking care with the in- termediate plate. 1.2.2 Disconnect the engine from the gearbox - vehicles with automatic gearbox . En nel gearbox unit removed and attached to engine mount - - Disconnect coolant hoses from gearbox oil cooler and loosen hose clamps. = Move the engine/gearbox unit with enginelgearbox jack - \V.A.G 1383 A- to @ work bench and lower the until in such @ ‘way that the gearbox is positioned on the support — Expose electrical cables on the bracket -arrow- and place plug-in connection =1- on the bracket. = Unscrew screws -1- and -2- and starter from the gearbox. 1. Removing and instaling engine 15)® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edi = Unscrew the connecting screws 1-, -3, 5+, <6 ~10- connecting the gearbox/engine. (B) now Screw -3- is only accessible after removing the starter. ~ Remove the gearbox from the engine. 13 Attach engine attached to engine and gearbox mount ‘Special tools and workshop equipment required 4 Workshop crane - VAS 6100- 4 Engine and gearbox mount - VAS 6095- @ Lifting device - MP9-201 (2024A)~ Work procedure + Separate engine from gearbox Use securing pins on the hooks and rig pins to prevent release! = Hook lifting device - MP9-201 (2024 A)- to engine and to the workshop crane - VAS 6100 [E) Nore For cooraination with the unit centre of gravity, the perforated rails of the lifting hook must be placed as shown, ‘There is @ risk of accident from loose parts of the lifting device! @ The suspension hooks and locking pins on the lifting device must be secured with plug-in locks -arrows-. Remove the engine with the workshop crane - VAS 6100- from the engine and gearbox jack - V.AG 1383 A- VAS 6100 20240 16 ep. o.10-Removing and instaing engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa = Screw on engine with the gearbox side to the engine and ‘gearbox jack- VAS 6095- as shown. 14 Installing engine Note © Tightening torques apply only for lightly greased, oiled, sphatized or blackened nuts and screws. ¢ Other lubricants such as engine and gearbox oil are allowed. However, do not use lubricants containing graphite. ¢ Donotuse degreased parts. Work procedure (&) note ¢ Screws which have been tightened firmly to a torquing angle must be replaced. ¢ Replace self-locking nuts and screws as well as seating rings, gaskets and O-rings. ¢ Hose connections and air guide pipes and hoses must be free of oil and grease before being installed. ¢ Secure all hose connection with spring-type clips that comply with the series design > ETKA.- Electronic Catalogue of Onbg- inal Par ¢ Fitall cable straps on again in the same place when installing. — Install intermediat 22.1 Summary of components - cylinder block on gearbox side’, page 43, 1. Removing and instaling engine 17@® rosie 2015 ~, Ronis 2019 ~ sxooa_1,4/55; 66; 77 kW TDI CR Engine - Edition 05.2019 — If there are no dowel sleeves -A- are available in the cylinder block for centering the engine and gearbox, insert dowel sleeves. @ Note A vehicle with manual gearbox is shown as an example. Vehicles fitted with a manual gearbox ~ Ifa needle bearing is installed in the crankshaft, remove the needle bearing "3.3 Replace the needle bearing in the crankshaft’ page 54 — Ifthe clutch release bearing is worn, replace the clutch release bearing = Rep. gr. 30 ; Clutch mechanism ~ Lightly grease the gearing of the gearbox drive shaft using lu- bricating grease for spline = ETKA - Electronic Catalogue of Original Parts = Check the centering of the clutch dise. Vehicles with automatic gearbox = Ifno needle bearings installed in the crankshaft, install needle bearing 23.3 Replace the needle bearing in the crankshaft’. Continued for all vehicles ‘Secure gearbox to engine. Install gearbox support bracket Lift engine/gearbox unit with the engine mount - T10536- Insert engine/gearbox assembly in the body. Initially insert screws -3- for engine mount by hand as far as the stop. 5 18 ep. o.10-Removing and insaling engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa Initially insert screws -arrows- for gearbox mount -1- by hand. as far as the stop. = Remove engine mount - 710536- from engine. — Install starter > Electrical system; Rep. gr. 27 ; Starter; Re- moving and installing starter Install pre-exhaust pipe = "13 Removing and installing pre-exhaust pips page 266 = Inetall lefty and right drive shaft > Rep. gr. 40 ; Drive shaft; Removing ang installing drive shaft — Install assembly carrier> Rep. gr. 40 : Assembly carrier: Re- moving and installing assembly cerrier without steering gear = Install AC compressor > Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; Removing and installing AG. compressor. = Install the V-ribbed belt "13 Removing and installing V-ribt page 31, = Tighten engine and gearbox mount = "2.4 Assembly overview - assembly mountings” page 21 Install engine control unit "7 Engine control unit’, page 249 Vehicles fitted with a manual gearbox - Remove clutch slave cylinder: > Rep. gr. 30 ; Clutch slave cylinder; Removing and installing clutch slave cylinder Continued for all vehicles — Install shift mechanism on gearbox => Rep. gr. 34 ; Shift mechanism; Removing and installing shift mechanism - Remove battery and battery tray = Electrical system; Rep. gr. 27 ; Battery; Removing and instelling battery tray = Electrical connections and proper routing = Electrical System; Rep. gr. 97 ; Relay carrer, fuse holder, E-boxes; Removing and installing E-box Checking the oll level: ‘@ = Maintenance ; Booklet Fabia Ill ‘@ = Maintenance ; Booklet Rapid NH Risk of damaging control units as a resuit of overvoltage. # Do not use charger for jump starting! = Venting air from the fuel system ing/bleeding the fuel system’, page 211 = Top up coolant = page 132 = Install the front left and right wheelhouse liner > Exterior body work; Rep. gr. 66 : Wheelhouse liner; Removing and installing the front wheelhouse liner . 1. Removing and instaling engine 19)@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 [F) Note After instaling new parts (engine/partial engine, cylinder heed, ‘camshaft housing or exhaust gas turbocharger), the oil pres- ‘sure control must be limited 0 the high pressure level for ‘approx. 1000 km. This takes into account the higher friction when running in new components and ensures optimum evac- uation of particles from running.in wear. The function to increase oil pressure does not always have to be available on the engine contro! unit. In this case, the oil pressure is not increased. — Connect diagnostic unit = Vehicle diagnostic tester. = Switch on the ignition and select * (loss ° Tightening torques - summaries of components ¢ When installing @ complete new engine and afer fitting the high pressure lines, itis absolutely necessary to tighten the ‘clamping claws of the injection units to the specified tight- ‘ening torque ='3.4 Summary of components - injection units (injectors)’, page 215 ¢ In order to align the injection units when fitting the high pres- sure lines, the clamping claws are only tightened "hand- tight" after delivery. if you do not do so, the engine may be damaged. [Component Nm [Screwe/nuts M6 10 MT 5 MB 20 M0 40 M12 65 (a) Note Replace boits /nuts that are tightened at an angle of rotation, as well as replacement components after removal + Assembly bracket page 21 # Attach gearbox to engine + Rep. gr. 34; Removing and in- stalling gearbox 20 0p. or.10- Removing and installing engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 2 Assembly bracket 2'2.1 Assembly overview - assembly mountings", page 21 ='2.2 Removing and installing engine mount’, page 22 3 Removing and installing gearbox mount’, page 23 "2.4 Removing and installing pendulum su age 24 ='2.5 Support the engine in its installed position”, page 25 24 Assembly overview - assembly mountings 4--Screw Gearbox mount Replace after disas- sembly 2 40. Nm + 90° 2- Screw 2 Gearbox mount to body 2 Replace after disas- sembly 50. Nm + 90°. 3- Gearbox mount Removing and installing =!2.3 Removing and in- stalling gearbox mount Gearbox bracket = Gearbox; Rep. gr. 34; Assembly bracket rew = Set for pendulum support to assembly carrier a Replace after disas- sembly 2 30Nm + 90° 7+ Screw for pendulum support Replace after disas- sembly 2 40 Nm + 90°, 8 - Pendulum support Removing and installing = *2.4 Removing and installing pendulum support’, page 24 9- Engine mounting Removing and installing = *2.2 Removing and installing engine mount’, page 22 10- Screw for engine mounting 2 Replace after disassembly 20 Nm + 90°. 2. assembly bracket 21® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 11 - Double screw Q for engine mounting G Replace after disassembly 1 30Nm +90", 12- Screw for engine mounting Replace efter disassembly O 30Nm +90". 22 Removing and installing engine mount Removing = Remove engine cover "3.1 Removing and installing engine trim panel’ page 27 = Disconnect quick couplings -1- and lay fuel hoses on the en- gine. = Release and pull off connector -2: and unscrew screws -1- Remove the coolant expansion tank -3- and pull up laterally. = Support the engine and gearbox in installed pos "2.5 Support the engine in its installed pos! page 25 = Uniformly pre-tension the engine/gearbox unit with spindles, but do not raise. = Release nuts -1- and remove earth cable -2.. 22 ep. or.10- Removing and installing engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa = Unscrew screws -3- and -1- and remove engine mounting -2- towards the top, Installing The installation occurs in reverse order. However, pay attention to the following: summaries of components Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after remove @ Assembly bracket = "2:1 Assembly overview - assembly mountings’, page 21 23 Removing and installing gearbox mount Removing = Remove battery and battery tray = Electrical system; Rep. gf. 27 ; Battery; Removing and installing battery tray — Support the engine and gearbox in installed position =."2'5 Support the engine in its installed position’, page 25, 2. Assembly brackst 23,® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 = Unscrew screws ~1-, -2- and -3- for gearbox mount Remove gearbox mount -4.. Installing ‘The installation occurs in reverse order. However, pay attention to the following: [F) Nore Replace screws which have been tightened firmly to a torque an- gle. = Fix the gearbox mount to the longitudinal beam. ‘There is a risk of damaging the thread in the gearbox support bby tightening the bolts obliquely! ¢ Before the screws are turned, the gearbox supports and ‘supporting arm must be absolutely parallel to each other. If necessary, push up gearbox using a hydraulic trolley jack. # Do not remove support bracket unti the bolts securing the ‘assembly mounting have been tightened to specified torque. = Raise the gearbox with the hook - 10-222A/32- so thet the gearbox support bracket is resting on the supporting arm of the gearbox mount. = Remove supporting device - MP9-200 (10-222A)- Tightening torques - summaries of components (B) woe Replace boits /nuts that are tightened at an angle of rotation, as well as replacement components after removal # Assembly bracket 4 Assembly over + Battery = Electrical system; Rep. gt. 27 ; Battery; Removing and installing battery ssembly mountings’, page 21 24 Removing and installing pendulum sup- port Removing = Remove the noise insulation = General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise ineuletion 24 ep. or.10- Removing and installing engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66: 77 kW TDIGR Engine - Edition 05.2019 soa — Unscrew screws -1- and -2- and remove the pendulum sup- port. Installing The installation occurs in reverse order. However, pay attention to the following: (re Replace screws which have been tightened firmly to 8 torque an- gle. Tightening torques - summaries of components, [F) Note Replace bots / nus that ar tightened at an angle of rotation, as well as replacement components after removal. Noise insulation > General body repairs, exterior ; Rep. gr. 66 ; Noise insulation: Summary of components- noise insula- tion . @ Assembly bracket ‘= '2.1 Assembly overview - assembly mountings”, page 21 25 Support the engine in its installed posi- tion ‘Special tools and workshop equipment required + Supporting device - MP9-200 (10-222). Adapter - T10540- Hook - MP9-200/10 (10-2224/10)- Hook - 10-2228/32- Shackle - 10-2228/12- Adapter - MP9-200/18 (10-222A/18)- = present, release connector -2- and pull off. = Press release buttons on the hose -1-for crankcase ventilation ‘and remove from cylinder head, ee eee Fit supporting device - MP9-200 (10-222A)- 2. Assembly bracket 25)® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 4 MP9-200 (10-2228) 2-MP9-200/10 3 MP9-200/18 (10-2218) 4 10-222032 5 - T10540/1 6 - T1054072 7-10-2212 Arrow - hexagon bolt — Secure the support bracket - MP8~200 (10 - 222 A)-on both sides to the lid hinges with the tensioning strap - T10038- = Uniformly pre-tension the engine/gearbox unit with both spin- dies, but do not raise. 26 op. or.10- Removing and installing engineFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 3 Engine trim panel 23.1 Removing and installing engine trim panel’, page 27 34 Removing and installing engine trim panel Removing Carefully pull the engine cover off the rubber bolts one after ‘another -arrows-. DO not pull engine cover off in jerks or on one side. Installing = To avoid damage, do not strike the engine cover with the fist ora tool, — Position the engine cover paying attention to the oil fill sup- ports and dipstick. Press the engine cover into the rubber bolts at the top, first on the left, then on the right, 3. Engine tim panet 27@® rosie 2018 ~, Rois 2019» sxova_1.4/55: 66; 77 kW TDI CR Engine - Edition 05.2019 LE} Crankshaft grou 1 Cylinder block (pulley end) 21.4 Assembly overview V-ibbed belt drive", page 28 ="1,2 Summary of components - sealing flange on the belt pulley side’, page 30 = '1.3 Removing and installing V-ribbed belt’, page 34 ="1.4 Removing and installing tensioning element for V-ribbed belt’. page 33 ="1.5 Removing and installing bracket for auxiliary units", page 34 = "4.6 Removing and installing engine support”, page 35 = “LZ Removing and installing belt pulley”, page 37 2 "1,8 Replacing crankshaft sealin A ley si page 37. = 1.9 Removing and installing the sealing flange on the belt pul- ley side”, page 40 1.1 Assembly overview - V-ribbed belt drive 28 op or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 1-V-ribbed belt check for wear before removing, mark out the rotation direction with chalk or felt pen (tisk of damage through, reversing the rotation d- rection of an already used belt) do net kink Routing of the ribbed V- belt = page 32 2 Removing and installing 31.3 Removing and in- stalling V-ribbed belt’ page 31 Pay attention to the cor- tect poston ofthe Vtb- bed beltin the belt pulley when installing it 2+ Screw a Replace after disas- sembly 2 10Nm + 90° 3- V-ribbed belt pulley Removing and installing solr nee 4 - Mounting bracket @ for generator 2 installed on crankcase Removing and installing 31.5.2 Removing and installing bracket for alternator’, page 35 5- Screw Replace after disassembly 2 20.Nm + 180" 6 - AC generator Removing end installing = Electrical system; Rep. gt. 27 ; Alternator; Removing and installing alternator 7- Screw Tightening torque > Electrical system; Rep. of. 27 ; Alternator; Removing and ins 8- AC compressor Do not open refrigerant circuit 2 installing and removing > Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; installing and re- moving AC compressor 9- Screw Tightening torque = Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; installing and removing AC compressor 10- Tensioner for V-ribbed belt before installing, check whether both dowel sleeves for centering the tensioning element at the cylinder block are present Removing and installing 51.4 Removing and installing tensioning for V-ribbed belt’, page 33, lling alternator . 1.Oyfinder tock (puey enc) 2Q@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 11- Screw 20Nm +90", 12 Summary of components - sealing flange on the belt pulley side 1-Screw 1D Tightening torque Pos. = Item 4 (page 82) 2 - Crankshaft toothed belt ‘sprocket there must not be any oil present on the contact surface between the pulley and the erank- shaft 1D can be installed only in one position 3 Sealing ring for crankshaft on the belt pulley side Replace sealing ring 31.8 Replacing crank- haf sealing ring on the belt pulley side” page 37 4 Screw Tightening torque and tightening order = Fig. “*Sealing flange ‘on the belt pulley side - jhtening torque and {gntening orer~_ page 5-Fitpin Different versions = ET- KA Electronic Cata- logue of Original Parts 6 - Fitpin Different versions = ET- KA- Electronic Catalogue of Original Parts 7 - Sealing flange on the belt pulley side Removing and installing .9 Removing and installing the sealing flange on the belt pulley sid ye 40 30 op. 9:15- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa Sealing flange on the belt pulley side - tightening torque and tight- ‘ening order = Tighten screws in steps in the given sequence: Level screws [Tightening torque 1. -1-to-10-_ [Tighten by hand as far as the stop 2. =1-t0-6- [crosswise in steps up to 13 Nm 3. -7-to-10-_[13Nm 1.3 Removing and installing V-ribbed belt =".3.1 Removing and installing V-ribbed belt - Vehicles without ‘itconditioning’, page 31 = ".3.2 Removing and installing V-tibbed belt - Vehicles with air ‘conditioning’, page 31 1.3.4 Removing and installing V-ribbed belt - Vehicles without air conditioning (F) see The repair kit includes the V-ribbed belt, the assembly tool - 110367- and an illustrated work procedure = ETKA- Electronic Catalogue of Original Parts Removing — Remove the noise insulation = General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation . ~ Remove the front right wheelhouse liner > General body re- pairs, exterior: Rep. gr. 68 ; Wheelhouse liner, Removing and installing the front wheelhouse liner = Cut through V-ribbed belt. Installing Assembly is carried out serve the following: = The following work procedure is described in the illustrated work procedure from the repair Kit. Start engine and check ribbed V-belt run, 1.3.2 Removing and installing V-ribbed belt - Vehicles with air conditioning ‘Special tools and workshop equipment required # Locking pin - 710060 A- the reverse order. When installing, ob- 1. Oyinder block (puileyena) 31® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 Removing — Remove the noise insulation > General body repairs, exterior; Rep. gr. 66 : Noise insulation; Summary of components = noise insuletion — Remove the front right wheelhouse liner + General body re- pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; Removing and installing the front wheelhouse liner . Risk of damage by reversing the direction of rotation of a V- ribbed belt that has already been used. Mark the direction of rotation with chalk or a felt-ip pen be- fore removing the V-tobed belt so that can be reinatalled again. = Swivel tensioning device in -direction of arrow- to slacken the \V-ribbed belt. — Secure tensioning device with locking pin - 10060 A- . — Remove the V-ribbed belt Installing ‘The installation occurs in reverse order. However, pay attention to the following: Lay the V-ribbed belt in stages, as shown: = Vetibbed belt pulley + Tensioning pulley for V-ribbed belt Belt pulley for generator + Belt pulley for AC compressor — Tum the tensioning element in the -direction of the arrow- and pull out the locking pin - T1060 A- . Check that the V-ribbed belt is positioned correctly. = Start engine and check the that the V-ribbed belt is running correctly. 32 Rep or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 14 Removing and installing tensioning ele- ment for V-ribbed belt Removing — Remove V-tibbed belt = "1.3 Removing and installing V-ribbed belt’, page 31 — Remove alternator = Electrical system ; Rep. gr. 27 ; Alter- nator, Removing and installing alternator = Unscrew screw -2-, loosen screws 4. — Remove the air conditioner compressor from the engine. = Unscrew screw -2- and remove tensioning roller -1-. Installing ‘The installation occurs in reverse order. However, pay attention to the following: (E) ne Insert the dowel sleeves for centering the tensioning element {or Vetbbed bet > ETKA- Electronic Cailogue of Original ats © Replace screws Which have been tightened firmly to @ torque angle. Tighten air conditioner compressor. = Insiall the V-ribbed belt. 21.3 Removing and installing V-ribbed belt”, page 31, Tightening torques - summaries of components: Cows Replace bolts /nuts that are tightened at an angle of rotation, as well as replacement components after removal. © V-ribbed belt drive 2 "1.1 Assembly overview - V-ribbed belt drive’, page 28 1.Oyfinder tock puey enc) 33® Fabia Ill 2015 > , Rapid NH 2013 > sxona_1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019 15 Removing and installing bracket for aux- iliary units 21.5.1 Removing and installing bracket for high pressure pump", page 34 > '1.5.2 Removing and installing bracket for alternator’ page 35 1.5.1. Removing and installing bracket for high pressure pump Removing = Remove engine cover 33.1 Removing end installing engine trim panel’, page 27 Remove the toothed belt from the camshaft ='2.4 Removing and installing toothed belt’, page 85 . = Remove high pressure pump 3_).2Remoung anc insteling the high pressure pump’ page = Unscrew pin screw -1- and screw -3: for the fuel return-flow Tine -2- — Unscrew screws -1- and remove bracket for high pressure pump -2-. Installing The installation occurs in reverse order. However, pay attention to the following: —_ Install high pressure pump 3g}-2 Removion and instaling the hich pressure puro’ page = Install the toothed belt Removing and installing toothed belt’, page 85 . Tightening torques [F) Nove Replace bolts / nuts that are tightened at an angle of rotation, as weil as replacement components after removal. summaries of components # Cylinder head = "1.4 Summary of components - cylinder head’, page 63 34 op or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 1.6.2 Removing and installing bracket for al- ternator Removing — Remove the bracket for high pressure pump = "1.5.1 Removing and installing bracket for high pressure pump’. page 34 — Remove V-ribbed belt ="1.3 Removing and installing V-ribbed belt’, page 31 . — Remove alternator = Electrical system ; Rep. gr. 27; Alter- nator, Removing and installing alternator = Unscrew screw -2- and remove bracket for alternator -1- Installing ‘The installation occurs in reverse order. However, pay attention to the following: = Install the bracket for high pressure pump. = "1.5.1 Removing and installing bracket for high pressure pump” page 34 — Install high pressure pump 254 ~ Install the toothed belt ='2.4 Removing and installing toothed belt’, page 85 ~ Install alternator > Electrical system; Rep. or. 27 ; Alternator; Removing and installing alternator = Install the V-ribbed belt = "1.3 Removing and installing V-ribbed belt”. page 31 Tightening torques - summaries of components, (B) Note Replace bolts / nuts that are tightened at an angle of rotation, as wel as replacement components after remove ¢ V-ribbed belt drive = "1.4 Assembly overview - V-ribbed belt drive", page 28 1.6 Removing and installing engine support Removing — Remove top toothed belt guard Be it gua . B = Remove bottom toothed belt guard ="2.3.2 Removing and installing bottom toothed belt guard’, page 84 = Remove engine mounts = "2.2 Removing and installing engine mount’, page 22 Raise (lower) engine/gearbox unit with the spindle uniformly ‘so that the screws for the engine support bracket are acces- sible, 1Oyfinder tock puay enc) 3B® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 = Unscrew and remove nuts -1- and remove refrigerant lines -2-from the double screws. — Release screws -A- by one tum and unscrew screws -B-. = Unscrew screws -2-, -4- and -5- and remove engine support bracket -3- upwards, Installing The installation occurs in reverse order. However, pay attention to the following: = Insert engine support bracket -3- and first tighten screws -2-, -4-, 5: by hand, then tighten to specified torque. = Tighten the screws -A- and -B-, = Install engine mount ='2.2 Removing and installing engine mount’, page 22 ~_ Install bottom toothed belt guard ='23.2 Removing and installing bottom toothed belt guard page 84 = Install top toothed belt guard gg25.1 Removing andinstaling tp toothed bet guard page [&) Nove Replace screws which have been tightened fly to # torque ar gle. = Tighten screws in steps in the given sequence: Engine support bracket - tightening torque and tightening order Leve screws [Tightening torque/torque angle 1 7 Nm 2. 50 Nm 3. [Turn 480° further 36 op or-13- crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 17 Removing and installing belt pulley Removing — Remove the noise insulation + General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation — Remove the front right wheelhouse liner = General body re- pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; Removing and installing the front wheelhouse liner = Remove V-ribbed belt = page 31 = Release the holding clamps -1- and push the refrigerant line -2:toone side - Hold the screw for crankshaft sprocket with the socket insert and release the screws -arrow.- for the belt pulley. = Unscrew screws and remove belt pulley. Installing The installation occurs in reverse order. However, pay attention to the following: (Dm Assembly of the belt pulley is only possible in one position. = Inetall vibration damper and tighten the new screws = ETKA Electronic Catalogue of Original Parts Tightening torques - summaries of components, (CF) nee Replace bolts /nuts that are tightened at an angle of rotation, as well as replacement components after removal. © V-ribbed belt drive 2 "1.1 Assembly over ibbed belt drive". page'28 18 Replacing crankshaft sealing ring on the belt pulley side Special tools and workshop equipment required Counterholder - T30004 (3415)- @ =Extractor - T10443~ 4 Guide bushing-110117- oF 14014 7Aewith serew-T10117/2- (see) 1.Oyfinder tock puey enc) 37® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edi Work procedure — Remove top toothed belt guard ='2.3.1 Removing and installing top toothed belt guard”, page a3 — Remove bottom toothed belt guard ="2.3.2 Removing and installing bottom toothed belt guard’ page 84. — Remove the toothed belt from the camshaft, "2.5 Remove the toothed belt from the camshat page 93. = Crankshaft arrester - 710490- for crankshaft. Risk of damage to vaives and piston crowns! ‘© The crankshaft must not be tumed any further when the’ toothed belt has been removed and the camshafts are mounted, Risk of damage to the toothed belt! Do not over-tension or Kink the toothed belt. — Unscrew screw -1- for crankshaft-toothed belt sprocket with. the counterholder - 130004 (3415)- . — Unscrew screws and remove crankshaft-belt pulley. Ifitis turned back too much, the inner pressure plate loosens - 710443. from the pressure screw. ‘The pressure plate must then be pressed onto the pressure screw once again. = Carefully tur back set screw -arrow- of the extractor-710443- until a slight resistance is noticeable, 38 op or-15- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa = Place extractor - T10443- straight, as shown in the illustration, and lock by tightening the set screw -2-. = Screwin the pressure screw -1- until the gasket ring is pulled out. — Clean the contact and sealing surfaces. (F) ne The seating lip of the gasket ring must not be olled or greased additionally. — Position the guide sleeve - 10117/1- on the crankshaft — Carefully slide the new gasket ring for crankshaft -1- over the guide bushing onto the camshaft + The labelled side of the gasket points outwards. + The guide sleeve - T10117/1- remains fitted on the crankshaft while the gasket is being pressed in. = Place guide sleeve - 110117- with screw - T10117/3- onto the crankshaft. — Press in gasket ring -1- to stop. ri0117.4 Position toothed belt pulley on the crankshaft The contact surface between the V-ribbed belt pulley and the toothed belt pulley must be free of oil and grease. The surface -arrow- on the toothed belt pulley must be placed in contact with the crankshaft journal, as shown in the figure. oO Risk of damage to valves and piston crowns! @ The crankshaft must not be turned any further when the toothed belt has been removed and the camshafts are mounted, 1. Cytnder block putey ena) 3Q® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 = Tighten screw--1- for crankshaft-toothed belt sprocket with the counterholder - T30004 (3415). Lock the crankshaft toothed belt sprocket using the crankshaft arrester - T10490- + The studs of the crankshaft arrester -110490- must reach into the threaded bores of the toothed belt pulley. + Therrigpin of the crankshaft arrester-T40480- must reach into the bores at the sealing flange. install (get the timing) = page 88 Tightening torques - summaries of components: [E) note Replace bolts /nuts that are tightened at an angle of rotation, as well as replacement components after removal. # Toothed belt 22.2 Summary of components. othed belt" page 82 19 Removing and installing the sealing flange on the belt pulley side Special tools and workshop equipment required # Counterholder - T30004 (3415)= 4 Assembly tool -T10053- '# Cleaning and degreasing agent , ¢.9. -D 009 401 04- @ Silicone sealant > ETKA - Electronic catalogue of original parts Removing = Remove the front right wheelhouse liner = Generel body re- pairs, exterior, Rep. gt. 66 ; Wheelhouse liner; Removing and installing the front wheelhouse liner ~ Remove toothed belt 40 op or-13- crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa - Unscrew screw for crankshaft-toothed belt sprocket with the counterholder - T30004 (3415)- . = Remove crankshaft toothed belt sprocket. — Remove sump top part 3,8 Removing and instaling too part ofthe’ sumo’ pan a — Unscrew the remaining screws and release the sealing flange from the bonding, = Carefully drive out the sealing ring from the removed sealing flange. Installing — Remove residual sealant on the cylinder head and sump top Part using a chemical sealant remover. Clean sealing surfaces, they must be free of oil and grease. = Fitthe assembly tool - T10053/1- onto the crankshaft journal. (8) note Pay attention to the use by date on sealant. Risk of blockage of the lubrication system through excess seat- ant! ‘# The sealant bead must not be thicker than specified. + Thickness of sealant beads: 2-3 mm. 1. Oyinder block (puiley ena 41® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 ~ Apply sealant bead -2- to the clean sealing surface as shown. — Apply a thin coat of sealantto the lower sealing surface -1- on the sealing flange. (B) wwe The sealing flange must be installed within § minutes after apply- ing the sealant Install sealing flange with builtin sealing ring — Insert the new sealing flange using the assembly tool - T10083/1- = Remove assembly tool - 710053/1- and tighten screws for ‘sealing flange by hand as far as the stop. = Tighten screws for sealing flange crosswise. Tightening torque and tightening order > Fig. “'Sealing flange on the belt pulley side - tightening tor- {que and lightening order”, page 31 Install sealing flange without installed sealing ring — Push sealing flange onto the dowel pins on the cylinder block. = Tighten screws for sealing flange crosswise. Tightening torque and tightening order = Fig. “'Sealing flange on the belt pulley side - tightening tor- ‘que afd tightening order”, page 31 = Installing seal > "1.8 Replacing crankshaft sealing ring on the belt pulley side", page 37 Continued = Install sump top part ="1.3 Removing and installing top part of the oil sump’, page: it install (set the timing) > page 88 Further installation occurs in reverse order. However, pay atten- tion to the following Tightening torques - summaries of components 4G) Note Replace bolts /nuts that are tightened at an angle of rotation, as well as replacement components after removal # Sealing flange ="1.2 Summary of components - sealing flange on the belt Dulley side", page 30 42 Rep or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 2 Cylinder block on gearbox side "2.1. Summary of components - cylinder block on gearbox side", age 43 ='2.2 Removing and installing fivwhee'", page 44 24 ‘Summary of components - cylinder block on gearbox side 1-Serew Replace after disas- sembly 2 60Nm + 20" 2 Flywheel Removing and installing ='2.2 Removing and in- stalling flywheel" pages 2 Pre-tension geering in the flywheel 32.2 Removing and in- i e page 44 Can only be installed in one position 3. Engine speed transmitter - G28. 2 Summary of compo- nents 24.1 Summary of com ponents - Glow plug system’, page 294 4- Screw 2 Tightening torque 24.1 Summary of com- ponents - Glow plug system’, page 294 5- Intermediate plate must be positioned on dowel sleeves: do not damage/bend during assembly work 6 - Fitting sleeve D 2units 7 - Sealing flange on the gearbox side with integrated sealing ring Replace after disassembly Removing and installing = ‘2.3 Removing and installing sealing flange on gearbox side", pace 45 8- Screw Tightening torque and tightening order = Fig, “Sealing flange on the gearbox side tightening torque and tightening order”, page 44 2. Cylinder back on goatbarsids 43@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 Sealing flange on the gearbox side - tightening torque and tight- ening order = Tighten screws in steps in the given sequence: Level screws __|Tightening torque 1. -1- to -6-__|Tighten by hand as far as the stop 2. -1- to -6-_|crosswise in steps up to 13 Nm. 2.2 Removing and installing flywheel ='2.2.1 Pre-tension gearing in the flywheel - vehicles with auto- matic gearbox’, page 44 2'2.2.2 Removing and installing flywheel”, page 44 2.2.1 Pre+tension gearing in the flywheel - ve- hicles with automatic gearbox (Fre In vehicles with automatic gearbox, the gearing of the gearbox in the flywheel must be pre-tensioned and secured. Pre-tensioning is intiated when the engine 1s started for the first time and it se- cures the gearing between flywheel and gearbox. = Insert screwdriver into the recess and turn by 90° in direction of arrow -A- 80 that the locking clutch -1- is exposed above the recess, — Press in the locking clutch with a tool in direction of arrow -B- and loosen the screweriver. Repeat the procedure for the other locking clutch. ‘The gearing in the flywheel is now pre-tensioned and ready for installation, 2.2.2 Removing and installing flywheel ‘Special tools and workshop equipment required © Flywheel lock - MP1-223 (3067)- Removing + Gearbox removed Ve = Remove the clutch + Rep. gf. 30 ; Clutch mechanism icles fitted with a manual gearbox 44 op or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa For all vehicles Insert counterholder - MP1-223 (3067)- into the bore on the cylinder block Pos. -B-. — Loosen and remove all flywheel bolts. Installing ‘The installation occurs in reverse order. However, pay attention to the following: © In vehicles with automatic gearbox, the gearing of the gearbox in the flywheel must be pre-tensioned and secured. Pre-tensioning s initiated when the engine is started for the first time and it secures the gearing between flywheel and gearbox = '2.2.1 Pre-tension gearing in the flywheel - vehicles with au- tomatic gearbox’, page 44 (F) ne Assembly of flywheel is only possible in one position. Insert counterholder - MP1-223 (3087)- into the bore on the cylinder block Pos. -A.. Tightening torques - summaries of components! (B) note Replace bolts /nuts that are tightened at an angle of rotation, as Well as replacement components after removal. Cylinder block ‘Summary of components - cylinder block on gearbox side", page 43 23 Removing and installing sealing flange on gearbox side ‘Special tools and workshop equipment required # Tool insert SW 24-V.AG 1932/11- @ Assembly tool - T10134- @ Depth gauges , e.g. -VAS 6082- @ 3x screw M6x35, @ 2x screw M7x35_ Press out sealing flange with rotor + Gearbox removed — Remove the flywheel = mi aes For clearer illustration, the following work sequences are shown ‘on the removed engine. 2. Cylinder back on goatbaxsids 45® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 Remove intermediate plate -1- from the dowel sleeves arrows Ae = Move intermediate plate -1- upwards. arrow -B- of the inter- — Atthe same time, pull the retaining ind the sealing flange. meciate plate -1- out of the recess — Tum the crankshaft at the screw for toothed belt pulley until the crankshaft is positioned on “TDG” as shown in the Mustra- tion. - Removing the oil pan 373 Removing end inetalingtonipertof hes ~ Remove engine speed transmitter - G28- = "4.6 Removing and installing the engine speed transmitter G28" page 298 ; — Unscrew screws -arrows- on sealing flange -1-. = Sealing flange and rotor are pressed together with 3 M6x35 mm screws from the crankshaft — Alternating, screw in three screws -arrows- (max. 1/2 turn (180°) per screw) into the threaded holes of the sealing flange =1- and remove the sealing flange together with the rotor -2- from the crankshaft -3-. Remove sealing flange -1- with rotor -2- G6 op or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa Sealing flange with rotor (8) note ¢ The sealing flange with PTFE sealing ring Is provided with sealing lip supporting ring -2-. This support ring serves as a fitting sleeve and must not be removed prior to installation. © Do not separate or turn the sealing flange and rotor -1- after removing them from the spare part package. ¢ The rotor -1- is brought to its installation position on the as- sembly tool - T10134- by a locating pin > page 47 ¢ Sealing flange and sealing ring form one unit and must only be renewed together with the transmitter wheel. ¢ The assembly too! - T10134. is brought to its installation po- sition to the crankshaft by a guide pin, which 's inserted into a hole in the crankshaft = page 47 Assembly tool - T10134- A- Clamping surface B-Nut C- Assembly housing D- Locating pin E- Allan screws (2 pieces) F - Guide pin for petrol engines (red knob) c- GE Guide pin for diesel engines (black knob) H-Knurled screws (3 pieces) | Inner part Mount sealing flange with rotor on assembly tool - 110134- = Untwist nut-B- untiljust before it touches the clamping surface -A. of the threaded spindle. 710134 2. Cylinder back on goatbaxsids 47@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 - Clamp assembly tool - T10134- on clamping surface -A- of the threaded spindle in a vice -1~. = Press assembly housing -C- downwards until it lies on hexa- gon nut -B-. — Screw nut onto threaded spindle unti inner part of assembly tool and assembly housing are at same height, — Remove the securing clip -arrow- from the new sealing flange Ae (F] me Do not remove the rotor from the sealing flange or turn it +The locating hole -A- on the rotor -C- must be flush with the marking -B- on the sealing flange, — Place sealing flange with front side facing down on a clean level surface. ~ Press down sealing lip supporting ring -1- in direction of arrows, unti it rests on the level surface. ] 4B op or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa + The upper edge of the sealing lip supporting ring -1- and front edge of the sealing flange -2- must align -arrows-. Lay the sealing flange -1- with the front side on the assembly tool - T10134- $0 that the positioning pin -D- engages into the hole -3- of the rotor -2.. + Sealing flange must lie straight on the assembly tool: + Only 2of the 3 knurled screws -H- can be screwed in at a time! TH0134 Press on the sealing flange -1- and sealing lip supporting rin -2- by tightening the 2 knurled screws -H- onto the surface of the assembly tool - 710134- (B) note This prevents locating pin from slioping out of sender whee! hole. - When installing the sealing flange, ensure that the sender ‘wheel remains fixed in the assembly device. Attach the assembly tool - T10134- with the sealing flange -1- to the crankshaft flange: +The cranksheff flange must be free of grease and cil + The engine is at "TDC" — Screw nut -B- on until it reaches end of threaded spindle. — Press the threaded spindle of the assembly tool - 740134. in -direction of arrow- unti the nut -B- rests against the assembly cup -C- = Align flat side of assembly housing to the cylinder block sealing surface on the oil sump side. 2. Cylinder back on goatbarsids 49@® rosie 2015 ~, Ronen 2019 ~ sxooa_1.4/55; 66, 77 kW TDI CR Engine - Edition 05.2019 ~ Secure the assembly tool - T10134- and the sealing flange ~1- with Allan screws -E- to the crankshaft flange -2. T0134 ff Note ‘Screw in Allan screws -E- into the crankshaft flange by approx. five thread turns. =. Slide the guide pin for diesel engines (black knob) -G- into the crankshaft flange. — Screwin two M6x35 mm screws -2- by about 3 tums for sealing flange guide -1- into the cylinder block Secure assembly tool - T10134- to crankshaft flange — Push the assembly cup -C- by hand in the - , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa Checking transmitter whee! installation position on crankshaft Screw nut -B- on until it reaches end of threaded spindle. Unscrew both bolts -2- from the cylinder block, = Pull the guide bolt for diesel engines (black knob) -G- out of the crankshaft flange. = Remove knurled screws -He from the sealing lange -1-. = Unscrew the Allan screws -E- from the crankshaft flange. = Remove assembly tool - 710134 = Remove sealing lip eupport ring cE) ~ Mount depth gauge - VAS 6082- onto the crankshaft lange VAS 6082 = Measure distance - te between crankshaft flange -2- and rotor + Set value: dimension -a- = 0.5 mm If dimension »a« is too smal: =. Press down rotor = page 51 If dimension vac is achieved: = Complete the remaining installation > page 52 Re-pressing transmitter wheel = Secure the assembly too! - T10134- and with Allan screws -E- to the crankshaft flange. Make sure the positioning pin of the assembly tool - 110134- en- gages in the bore of the rotor. = Tighten the two Allan screws -E- hand-tight. = Press the assembly tool - 110134- against the sealing flange “t= by hand, — Screw nut-B- onto threaded spindle by hand unt it lies against the assembly housing - T10134- Slide the guide pin for diesel engines (black knob) -G- into the crankshaft flange. = Screw the knurled screws -H- to the flange -1~. = Screw 2 screws M6x35 -2- to guide the sealing flange into the cylinder block, 2. Oylindor block on gearbox side 51® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 ~ Tighten nut -B- of the assembly tool - T10134- to 40 Nm. — Check the fitting position of the rotor on the crankshaft again = page 54 Ifthe dimension »a« is too small again: ~ Tighten nut -B- of the assembly tool - T10134- to 45 Nm, = Check the fitting position of the rotor on the crankshaft again = page 51 Installing Installation is carried out in the reverse order. When installing, ‘observe the following: Tighten screws for sealing flange crosswise. Installing the oll pan 2"1'3 Removing end installing top part ofthe ol sump". page am Install intermediate plate Install the flywheel = '2.2 Removing and installing fiywhee!’, page 44 Tightening torques - summaries of components (Fn Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal. # Sealing flange on the gearbox side ='2.4 Summary of components - cylinder block on gearbox side", page 43. # Engine speed sender - G28- = "1.1 Summary of components - Glow plug system’, page 204 52 Rep or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 3 Crankshaft ='3.1 Summary of components - crankshaft’, page 53 "3.2 Crankshaft dimensions”, page 54 3.3 Replace the needle bearing in the crankshaft’, page 54 3.4 Measuring axial play of crankshaft’, page 55 34 Summary of components - crankshaft 1 - Drive wheel for balancing shaft Is not as spare part 2- Crankshaft Meesure axial play = "3.4 Measuring axial play of crenkshaff’ page 55 Checking axial clear- ance with Plastigage: 2 Axial clearance: new part: 0.03-0.08 mm; wear limit: 0.17 mm do net rotate crankshaft When checking radial clearance Crankshaft dimensions Cr ft 2 Aneedle bearing is in- stalled in vehicles with automatic gearbox 3- Bearing shell in bearing cap without lubricating groove Replace used 4 Bearing caps Bearing cap 1: belt pul ley side retaining lugs of the bearing shells of the cy inder block/bearing cap must be on top of one another 5- Screw 2 Replace after disassembly 2 50. Nm + 90° 6 - Bearing shell 2 incylinder block with lubricating groove Replace used 7 = Thrust washers for bearing 3 3.Cranksnat 5S® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edi 1D only in cylinder block moisten with oil 8 - Cylinder block 3.2 Crankshaft dimensions (Grinding di- | Crankshaft bearing | Rod bearing journal- mension joural-2 mm mm [Basic dimen-| 4.00 -0.022 47.80 -0.022 sion 0.042 0.042 3.3 Replace the needle bearing in the crank- shaft Special tools and workshop equipment required * Interior extractor 16-18 mm , 6.9, -Kukko 21/2- or VAS 251 # Countersupport , 6.9. -Kukko 22/1- or -VAS 251 621- # Centering mandrel -T30029 (3176)- (Bre (Only on vehicles fitted with automatic gearbox. Condition: + Ifthe engine ang transmission were separated, always replace the needle bearing -arrow-. + The leading edges of the internal extractor must not have bro- ken out. Removing — Altach interior extractor to the needle bearing edge -arrow- = Pull out the needle bearing -1- with internal extractor -A @.9, -Kukko 21/2- or -VAS 251 635- and countersupport - Kukko 22/1- or -VAS 251 621- from the crankshaft -2. Installing (B) noe The marked side of the needle bearing should be legible when in iis installed conaition. — Clean the bearing in the crankshaft and apply @ thin coat of lubricating grease. 54 op or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa Drive the needle bearing with the centring mandrel - T3029 (3176)- into the crankshaft. Assembly depth: dimension -a- = 0 mm. (B) Note if the needle bearing is driven into too deep it will need replacing as itis damaged when pulling it out. 3.4 Measuring axial play of crankshaft Special tools and workshop equipment required © Universal dial gauge bracket - MP3-447 (VW'387)- © Dial gauge e.g. -VAS 6079- Work procedure: Screw on the dial gauge with universal dial gauge bracket - MP3.447 (VW 387)- to the cylinder block and set against the wall of the crankshaft. Push off the crankshaft off the dial gauge and set the dial gauge to = Press the crankshaft by hand against the dial gauge and read off the value. Axial clearance + New part: 0.07-0.17 mm + Wear limit: 0,37 mm b= VAS 6070 3.Cranksnat 5S® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edi 4 Pistons and conrods ="4.1 Assembly overview - piston and conrod’, page 56 = ‘4.2 Removing and installing the piston’, page 58 +» "4.3 Measure piston projection in TDC”, page 59 "4.4 Check piston and cylinder bore", page 60 ‘4.5 Separating new connecting rod’, page 62 44 Assembly overview - piston and conrod 4 = Conrod bolt Replace after disas- sembly 1 Oilthreads and contact surface 30Nm +90", 2-Connecting rod bearing cap Check fiting position Os a result of the con- necting rods separated in the cracking process, the cover fits only in one position and only to the relevant connecting rod Mark assignment to cyl inder 3 Bottom bearing shell Fitting position stallation position™ ~ page 57 Replace used check for firm seating 4 Top bearing shell Fitting position = Fig. “Bearing shellin- Stallation position page 57 Replace used 1D check for firm seating 5 - Connecting rod with @ split bearing cap Renew as set only. Mark assignment to cylinder separate new conrod = “4.5 Separating new connecting rod’, page 62 Axial play wear limit: 0.37 mm 6 - Piston pin Removing and installing > “4, 7 - Cirelip O 2units Replace after disassembly oooog 56 op or-13- Crankshaft groupFebia Ill 2015 > , Rapid NH 2013 > ® 4.4/55; 66:77 kW TDIGR Engine - Edition 05.2019 soa 8 - Piston with combustion chamber replace the piston if there is any sign of crack formation Mark the installation position and the assignment to cylinder = page S7 Removing and installing = “4.2 Removing and installing the piston’, page 58 Check piston and cylinder bore = “4.4 Check piston and cylinder bore’, nage 60 Measure projection in TDC = “4.3 Measure piston projection in TDC”. page 59 9- Oil scraper ring Check ring gep = Fig. “Checking piston ring ge” . page 61 Check end clearance = Fig. ““Checking ring-to-groove clearance” . page 62 Use piston ring pliers for removing and installing Label "TOP" or manufacturer's mark must point upwards towards the piston crown Install edge offset by 120° to piston ring 410 - Compression rings Check ring gap = Fig. “Checking piston ring gap". page 61 Check end clearance = Fig. ““Checking ring-lo-groove clearance” . page 62 Use piston ring pliers for removing and installing Label “TOP” or manufacturer's mark must point upwards towards the piston crown, Offset gaps by 120° ouoooguunKnKon oouoog Installation position and assignment of piston/cylinder DEEZ Risk of damaging the piston crown! ¢ Forre-installation, mark the assignment in colour on the pis- ton crown of cylinders that have already been used, + Arrow on piston crown faces towards the belt pulley side sarrow. Bearing shell installation position = Insert bearing shells in the connecting rod and in the connect- ing rod bearing cap centred. + Dimension -a- = 2.5 mm, 4. Pistons and conrods 57® Fabia Ill 2015 > , Rapid NH 2013 > sxooa_1.4/55; 66: 77 kW TDI CR Engine - Edition 05.2019 Oil spray nozzle and pressure relief valve (depending on design) 1 - Screw with pressure relief valve, 24 Nm 2 - Oil spray jat (piston cooling) + Fitting position: align guide edge of the oil spray nozzle to the cylinder block surface Risk of damaging the oil injection nozzles! Do not bend cil injection nozzles. @ Check oll injection nozzles after reinstalling the pistons. ¢ Replace the oil injection nozzles if they are bent. 42 Removing and installing the piston ‘Special tools and workshop equipment required @ =Mandrel - VW 222 A- Piston ring pliers Removing + Engine secured to engine and gearbox mount = "1.3 Attach engine attached to engine and gearbox mount”, page 16 — Remove cylinder head = "1,3 Removing and installing cylinder head”, page 66 — Remove oil pump = "1.4 Removing and installing oll pump", page 114 -. Forre-installation, mark assignment of the conrod bearing cap to the cylinder and to the conrod. Remove conrod bearing cap, Pull out the piston with conrod upwards. Note If the piston pin is cificult to remove, heat piston to 60 °C. Remove the circlip from the bore of the piston pin. = Remove piston pin with mandrel - VW 222 A- Installing The installation occurs in reverse order. However, pay attention to the following: (a) Note Replace screws which have been tightened firmly to a torque an- gle. = Oilthe contact surfaces of the bearing shells. = Install piston with a commercially available piston ring ten- sloning strap. Fitting position 58 op. or-13- crankshaft group