Engine Cusb Cuta Cusa Repair Manual Eng
Engine Cusb Cuta Cusa Repair Manual Eng
Engine Cusb Cuta Cusa Repair Manual Eng
Workshop Manual
Fabia III 2015 ➤
Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine
Engine ID
CUS CUT CUS
B A A
Edition 05.2019
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
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.
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 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
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Assembly of radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview - V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Summary of components - sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . . . 30
1.3 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4 Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . 33
1.5 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.7 Removing and installing belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.8 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
2.1 Summary of components - cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Summary of components - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 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
Contents i
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Assembly overview - pan/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Removing and installing the bottom part of the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing top part of the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 117
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.1 Summary of components - oil filter housing/oil 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 filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 126
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.2 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.4 Flushing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Flushing cooling system, quick start guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Summary of components - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ii Contents
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.3 Replacing exhaust gas turbocharger pressure box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.4 Removing and installing charge air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.5 Checking the charge-air system for leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.6 Leak testing the charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Contents iii
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
iv Contents
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
00 – Technical data
1 Denomination
(SRL001380; Edition 05.2019)
1. Denomination 1
Fabia III 2015 ➤ , Rapid NH 2013 ➤
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”,
page 2
⇒ “2.2 Safety precautions for working on vehicles with start-stop
system”, page 4
⇒ “2.3 Safety precautions during road tests in which testing and
measuring equipment is used”, page 4
⇒ “2.4 Safety precautions when working on cooling system”, page
5
⇒ “2.5 Safety precautions when working on the exhaust system”,
page 5
CAUTION
♦ 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.
CAUTION
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.
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 radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Prevent skin contact with fuel!
♦ Wear fuel-resistant gloves!
NOTICE
♦ Do not remove fuel hoses from the fuel filter.
♦ Do not lever the connection fittings.
♦ This leads to leaks and damage to the fuel filter top part.
♦ Ensure that no diesel fuel gets onto other components in the
engine compartment. If this happens, clean immediately!
NOTICE
♦ 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.
CAUTION
Risk of accident due to the fuel tank weight!
The fuel tank must be empty for removal.
2. Safety instructions 3
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
NOTICE
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 it is necessary to perform the fuel
system filling/bleeding process
⇒ “1.3 Filling/bleeding the fuel system”, page 211 .
♦ If the fuel pump, fuel line or fuel filter have been removed or
replaced, the fuel system filling/bleeding process must be
performed
⇒ “1.3 Filling/bleeding the fuel system”, page 211 .
♦ If the high pressure pump is removed or replaced, the initial
fuel filling of the high pressure pump must be carried out
before the first engine start
⇒ “1.3 Filling/bleeding the fuel system”, page 211 .
♦ If the high pressure system was opened, it must be checked
for tightness
⇒ “1.4 Check the fuel system for tightness”, page 212 .
CAUTION
There is risk of injury from automatic engine starting on vehicles
with start/stop system!
♦ In vehicles with an activated start-stop system (indicated by
a message in the dash panel insert), the engine can start
automatically if necessary.
♦ It is 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).
CAUTION
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.
CAUTION
♦ Wear protective gloves and safety goggles when discon‐
necting the exhaust system!
♦ When disconnecting, use a suction device or provide ade‐
quate ventilation.
2. Safety instructions 5
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 6
⇒ “3.2 Foreign bodies in the engine”, page 6
⇒ “3.3 Contact corrosion”, page 6
⇒ “3.4 Cable routing and securing”, page 6
⇒ “3.5 Assembly of radiators and condensers”, page 7
3. Repair instructions 7
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
NOTICE
When installing a complete new engine and after fitting the high
pressure lines, it is absolutely necessary to tighten the clamping
claws of the injection units to the specified tightening torque
⇒ “3.1 Summary of components - injection units (injectors)”,
page 215 . In order to align the injection units when fitting 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.
NOTICE
Risk of damaging the slave cylinder.
After removing the slave cylinder with connected tube-hose line,
no longer press the clutch pedal.
Note
– Release and pull off connectors -2- and -3- and unlatch brack‐
et -4- and place it on the engine with the solenoid valves.
– Disconnect vacuum line of the brake booster.
– Remove engine control unit - J623- from the holder
⇒ “7 Engine control unit”, page 249 .
– 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 ⇒ “1.3 Draining and filling coolant”, page 131 .
– Release and pull off connector -2- and unscrew screws -1-.
Pull off coolant expansion tank -3- and place on the engine.
– Release retaining clips -1- and -2-, release hose clamp -3- and
disconnect coolant hoses.
CAUTION
Risk of injury through refrigerant!
♦ Do not open the refrigerant circuit of the air conditioning
system.
– 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.
Note
When attaching the engine mount, take note of the gap at the bolt
-T10536/3- . The gap must point towards the oil pan. If necessary,
loosen and turn the bolt.
Note
Use the double ladder to release the screws for the assembly
bracket.
CAUTION
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.
– Attach the gearbox with the clevis - 10-222 A/12- to the work‐
shop crane - VAS 6100- .
– Unscrew the connecting screws -1-, -2-, -5-, -6-, -7-, -8- con‐
necting the gearbox/engine.
– Remove the gearbox from the engine, taking care with the in‐
termediate plate.
– Unscrew screws -1- and -2- and starter from the gearbox.
– Unscrew the connecting screws -1-, -3-, -5-, -6-, -7-, -8-, -9-,
-10- connecting the gearbox/engine.
Note
CAUTION
Use securing pins on the hooks and rig pins to prevent release!
Note
For coordination with the unit centre of gravity, the perforated rails
of the lifting hook must be placed as shown.
CAUTION
There is a 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.A.G 1383 A- .
Note
Work procedure
Note
Note
NOTICE
Risk of damaging control units as a result of overvoltage.
♦ Do not use charger for jump starting!
Note
NOTICE
♦ When installing a complete new engine and after fitting the
high pressure lines, it is absolutely necessary to tighten the
clamping claws of the injection units to the specified tight‐
ening torque
⇒ “3.1 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
Screws/nuts M6 10
M7 15
M8 20
M10 40
M12 65
Note
♦ Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”,
page 21 .
♦ Attach gearbox to engine ⇒ Rep. gr. 34 ; Removing and in‐
stalling gearbox .
2 Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”, page 21
⇒ “2.2 Removing and installing engine mount”, page 22
⇒ “2.3 Removing and installing gearbox mount”, page 23
⇒ “2.4 Removing and installing pendulum support”, page 24
⇒ “2.5 Support the engine in its installed position”, page 25
1 - Screw
❑ Gearbox mount
❑ Replace after disas‐
sembly
❑ 40 Nm + 90°.
2 - Screw
❑ Gearbox mount to body
❑ Replace after disas‐
sembly
❑ 50 Nm + 90°.
3 - Gearbox mount
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling gearbox mount”,
page 23
4 - Gearbox bracket
5 - Screw
❑ Gearbox bracket
❑ ⇒ Gearbox; Rep. gr.
34 ; Assembly bracket
6 - Screw
❑ for pendulum support to
assembly carrier
❑ Replace after disas‐
sembly
❑ 30 Nm + 90°.
7 - Screw
❑ for pendulum support
❑ Replace after disas‐
sembly
❑ 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
❑ Replace after disassembly
❑ 20 Nm + 90°.
2. Assembly bracket 21
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
11 - Double screw
❑ for engine mounting
❑ Replace after disassembly
❑ 30 Nm + 90°.
12 - Screw
❑ for engine mounting
❑ Replace after disassembly
❑ 30 Nm + 90°.
– 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 position
⇒ “2.5 Support the engine in its installed position”,
page 25 .
– Uniformly pre-tension the engine/gearbox unit with spindles,
but do not raise.
Note
♦ Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”, page 21
2. Assembly bracket 23
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
Note
NOTICE
There is a risk of damaging the thread in the gearbox support
by 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 until the bolts securing the
assembly mounting have been tightened to specified torque.
Note
♦ Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”, page 21
♦ Battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing
and installing battery
– Unscrew screws -1- and -2- and remove the pendulum sup‐
port.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
Note
Note
2. Assembly bracket 25
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
1 - MP9-200 (10-222A)
2 - MP9–200/10
3 - MP9–200/18 (10-222A/18)
4 - 10-222A/32
5 - T10540/1
6 - T10540/2
7 - 10–222A/12
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - V-ribbed 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 31
⇒ “1.4 Removing and installing tensioning element for V-ribbed
belt”, page 33
⇒ “1.5 Removing and installing bracket for auxiliary units”,
page 34
⇒ “1.6 Removing and installing engine support”, page 35
⇒ “1.7 Removing and installing belt pulley”, page 37
⇒ “1.8 Replacing crankshaft sealing ring on the belt pulley side”,
page 37
⇒ “1.9 Removing and installing the sealing flange on the belt pul‐
ley side”, page 40
1 - V-ribbed belt
❑ check for wear
❑ before removing, mark
out the rotation direction
with chalk or felt pen
(risk of damage through
reversing the rotation di‐
rection of an already
used belt).
❑ do not kink
❑ Routing of the ribbed V-
belt ⇒ page 32
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling V-ribbed belt”,
page 31
❑ Pay attention to the cor‐
rect position of the V-rib‐
bed belt in the belt pulley
when installing it
2 - Screw
❑ Replace after disas‐
sembly
❑ 10 Nm + 90°.
3 - V-ribbed belt pulley
❑ Removing and installing
⇒ “1.7 Removing and in‐
stalling belt pulley”,
page 37
4 - Mounting bracket
❑ for generator
❑ installed on crankcase
❑ Removing and installing
⇒ “1.5.2 Removing and
installing bracket for alternator”, page 35
5 - Screw
❑ Replace after disassembly
❑ 20 Nm + 180°.
6 - AC generator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator .
7 - Screw
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator .
8 - AC compressor
❑ Do not open refrigerant circuit
❑ 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
⇒ “1.4 Removing and installing tensioning element for V-ribbed belt”, page 33
11 - Screw
❑ 20 Nm + 90°.
1 - Screw
❑ Tightening torque Pos.
-1-
⇒ Item 1 (page 82)
2 - Crankshaft toothed belt
sprocket
❑ there must not be any oil
present on the contact
surface between the
pulley and the crank‐
shaft
❑ can be installed only in
one position
3 - Sealing ring
❑ for crankshaft on the
belt pulley side
❑ Replace sealing ring
⇒ “1.8 Replacing crank‐
shaft sealing ring on the
belt pulley side”,
page 37
4 - Screw
❑ Tightening torque and
tightening order
⇒ Fig. ““Sealing flange
on the belt pulley side -
tightening torque and
tightening order”“ , page
31
5 - Fit pin
❑ Different versions ⇒ ET‐
KA - Electronic Cata‐
logue of Original Parts
6 - Fit pin
❑ Different versions ⇒ ET‐
KA - Electronic Catalogue of Original Parts
7 - Sealing flange on the belt pulley side
❑ Removing and installing
⇒ “1.9 Removing and installing the sealing flange on the belt pulley side”, page 40
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- to -6- crosswise in steps up to 13 Nm
3. -7- to -10- 13 Nm
Note
The repair kit includes the V-ribbed belt, the assembly tool -
T10367- 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. 66 ; Wheelhouse liner; Removing and
installing the front wheelhouse liner .
– Cut through V-ribbed belt.
Installing
Assembly is carried out in the reverse order. When installing, ob‐
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.
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 .
NOTICE
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-tip pen be‐
fore removing the V-ribbed belt so that it can be reinstalled
again.
Note
Note
Note
♦ Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 63
Note
– 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
⇒ “2.3.2 Removing and installing bottom toothed belt guard”,
page 84
– Install top toothed belt guard
⇒ “2.3.1 Removing and installing top toothed belt guard”, page
83 .
Note
– 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:
Note
Note
Work procedure
– Remove top toothed belt guard
⇒ “2.3.1 Removing and installing top toothed belt guard”, page
83 .
– 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 camshaft”,
page 93 .
– Crankshaft arrester - T10490- for crankshaft.
NOTICE
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.
Risk of damage to the toothed belt!
♦ Do not over-tension or kink the toothed belt.
NOTICE
If it is turned back too much, the inner pressure plate loosens -
T10443- from the pressure screw.
The pressure plate must then be pressed onto the pressure
screw once again.
Note
The sealing lip of the gasket ring must not be oiled or greased
additionally.
NOTICE
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.
Note
♦ Toothed belt
⇒ “2.2 Summary of components - toothed belt”, page 82
Note
NOTICE
Risk of blockage of the lubrication system through excess seal‐
ant!
♦ The sealant bead must not be thicker than specified.
Note
Note
♦ Sealing flange
⇒ “1.2 Summary of components - sealing flange on the belt
pulley side”, page 30
1 - Screw
❑ Replace after disas‐
sembly
❑ 60 Nm + 90°.
2 - Flywheel
❑ Removing and installing
⇒ “2.2 Removing and in‐
stalling flywheel”,
page 44
❑ Pre-tension gearing in
the flywheel
⇒ “2.2 Removing and in‐
stalling flywheel”,
page 44
❑ Can only be installed in
one position
3 - Engine speed transmitter -
G28-
❑ Summary of compo‐
nents
⇒ “1.1 Summary of com‐
ponents - Glow plug
system”, page 294
4 - Screw
❑ Tightening torque
⇒ “1.1 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
❑ 2 units
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”, page 45
8 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Sealing flange on the gearbox side - tightening torque and tightening order”“ , page 44
Note
NOTICE
In vehicles with automatic gearbox, the gearing of the gearbox
in the flywheel must be pre-tensioned and secured.
Pre-tensioning is 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 .
Note
Note
♦ Cylinder block
⇒ “2.1 Summary of components - cylinder block on gearbox
side”, page 43
Note
– Turn the crankshaft at the screw for toothed belt pulley until
the crankshaft is positioned on “TDC” as shown in the illustra‐
tion.
– Removing the oil pan
⇒ “1.3 Removing and installing top part of the oil sump”, page
111 .
– Remove engine speed transmitter - G28-
⇒ “1.6 Removing and installing the engine speed transmitter
G28 ”, page 298 .
Note
– Remove the securing clip -arrow- from the new sealing flange
-1-.
Note
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.
• 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- so that the positioning pin -D- engages into the
hole -3- of the rotor -2-.
• Sealing flange must lie straight on the assembly tool.
• Only 2 of the 3 knurled screws -H- can be screwed in at a time!
– Press on the sealing flange -1- and sealing lip supporting ring
-2- by tightening the 2 knurled screws -H- onto the surface of
the assembly tool - T10134- .
Note
This prevents locating pin from slipping out of sender wheel hole.
Attach the assembly tool - T10134- with the sealing flange -1- to
the crankshaft flange:
• The crankshaft flange must be free of grease and oil.
• The engine is at “TDC”.
– Screw nut -B- on until it reaches end of threaded spindle.
– Press the threaded spindle of the assembly tool - T10134- in
-direction of arrow- until 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.
Note
– Slide the guide pin for diesel engines (black knob) -G- into the
crankshaft flange.
Note
The guide bolt for petrol engines (red knob) must not be fitted into
the threaded hole of the crankshaft.
Press rotor onto the crankshaft flange using the assembly tool -
T10134- :
– Tighten nut -B- of the assembly tool - T10134- to 35 Nm.
• After nut is tightened to 35 Nm, a small air gap must still be
present between cylinder block and sealing flange -1-.
Note
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
1 - Drive wheel
❑ for balancing shaft
❑ is not as spare part
2 - Crankshaft
❑ Measure axial play
⇒ “3.4 Measuring axial
play of crankshaft”,
page 55
❑ Checking axial clear‐
ance with Plastigage:
❑ Axial clearance: new
part: 0.03-0.08 mm;
wear limit: 0.17 mm
❑ do not rotate crankshaft
when checking radial
clearance
❑ Crankshaft dimensions
⇒ “3.2 Crankshaft di‐
mensions”, page 54
❑ A needle 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 cyl‐
inder block/bearing cap
must be on top of one
another
5 - Screw
❑ Replace after disassembly
❑ 50 Nm + 90°.
6 - Bearing shell
❑ in cylinder block
❑ with lubricating groove
❑ Replace used
7 - Thrust washers
❑ for bearing 3
3. Crankshaft 53
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
❑ only in cylinder block
❑ moisten with oil
8 - Cylinder block
Note
Condition:
• If the engine and transmission were separated, always replace
the needle bearing -arrow-.
• The leading edges of the internal extractor must not have bro‐
ken out.
Removing
Note
Note
If the needle bearing is driven into too deep it will need replacing
as it is damaged when pulling it out.
3. Crankshaft 55
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
1 - Conrod bolt
❑ Replace after disas‐
sembly
❑ Oil threads and contact
surface
❑ 30 Nm + 90°.
2 - Connecting rod bearing cap
❑ Check fitting position
❑ as 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
⇒ Fig. ““Bearing shell in‐
stallation position”“ ,
page 57
❑ Replace used
❑ check for firm seating
4 - Top bearing shell
❑ Fitting position
⇒ Fig. ““Bearing shell in‐
stallation position”“ ,
page 57
❑ Replace used
❑ check for firm seating
5 - Connecting rod
❑ with a 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 ⇒ “4.2 Removing and installing the piston”, page 58
7 - Circlip
❑ 2 units
❑ Replace after disassembly
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 57
❑ Removing and installing ⇒ “4.2 Removing and installing the piston”, page 58
❑ Check piston and cylinder bore ⇒ “4.4 Check piston and cylinder bore”, page 60
❑ Measure projection in TDC ⇒ “4.3 Measure piston projection in TDC”, page 59
9 - Oil scraper ring
❑ Check ring gap ⇒ Fig. ““Checking piston ring gap”“ , 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
10 - Compression rings
❑ Check ring gap ⇒ Fig. ““Checking piston ring gap”“ , 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
❑ Offset gaps by 120°
NOTICE
Risk of damaging the piston crown!
♦ For re-installation, mark the assignment in colour on the pis‐
ton crown of cylinders that have already been used.
NOTICE
Risk of damaging the oil injection nozzles!
♦ Do not bend oil injection nozzles.
♦ Check oil injection nozzles after reinstalling the pistons.
♦ Replace the oil injection nozzles if they are bent.
Note
Note
Note
Note
Note
Note
1 - Cylinder block
2 - Dowel sleeves for centering
❑ for cylinder head
❑ replace after removing
the cylinder head
3 - Cylinder head gasket
❑ replace after removal
⇒ “1.3 Removing and in‐
stalling cylinder head”,
page 66
❑ Identification of the cyl‐
inder head gasket
⇒ Fig. ““Identification of
the cylinder head gas‐
ket”“ , page 65
❑ Observe part number ⇒
ETKA - Electronic Cata‐
logue of Original Parts
4 - Screw
❑ Replace after disas‐
sembly
❑ 20 Nm + 90°.
5 - Bracket for auxiliary units
❑ for high pressure pump
❑ with lifting eye for en‐
gine
❑ Removing and installing
⇒ “1.5.1 Removing and
installing bracket for
high pressure pump”,
page 34
6 - Screw
❑ Replace after disas‐
sembly
❑ 20 Nm + 90°.
7 - Cylinder head
❑ Removing and installing ⇒ “1.3 Removing and installing cylinder head”, page 66
1. Cylinder head 63
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
❑ Lay removed cylinder head on a foam pad only, otherwise the glow connectors may be damaged
❑ check for distortion ⇒ Fig. ““Checking cylinder head for distortion”“ , page 65
❑ must not be reworked
❑ before installing, check whether both dowel sleeves for centering the cylinder head at the cylinder block
are present
❑ with plug on gearbox side (15 Nm) ⇒ ETKA - Electronic Catalogue of Original Parts
8 - Screw
❑ Replace if damaged.
❑ 15 Nm
9 - Fit pin
❑ for camshaft housing
10 - Screw
❑ Replace after disassembly
❑ pay attention to order for slackening
⇒ Fig. ““Cylinder head - tightening torque and tightening order”“ , page 65
❑ Tightening torque and tightening order
⇒ Fig. ““Cylinder head - tightening torque and tightening order”“ , page 65
11 - Sealing ring
❑ component part of position -12-
12 - Screw
❑ 15 Nm
13 - Mounting bracket
❑ for charge air cooler
❑ with lifting eye for engine
14 - Screw
❑ 20 Nm
15 - O-ring
❑ Replace after disassembly
❑ Moisten with coolant
16 - Screw
❑ Replace after disassembly
❑ 20 Nm + 45°.
17 - Countersupport
❑ for high pressure pump
18 - Coolant temperature transmitter - G62-
❑ Removing and installing
⇒ “2.9 Removing and installing coolant temperature transmitter G62 ”, page 166
19 - Screw
❑ 5 Nm
Note
Note
Note
1. Cylinder head 65
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
1 - Seal
❑ Replace if damaged.
2 - Cylinder head cover
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling cylinder head
cover”, page 73
3 - Differential pressure trans‐
mitter
❑ Pressure sensor 1 for
exhaust gas - G450-
❑ Differential pressure
transmitter - G505-
❑ Removing and installing
⇒ “6 Senders and sen‐
sors”, page 240
4 - Screw
❑ 8 Nm
5 - Hall sender G40
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling Hall sender G40
”, page 298
6 - Screw
❑ 8 Nm
7 - Grommet
❑ in the cylinder head cov‐
er
8 - O-ring
❑ Replace if damaged.
9 - Coolant pipe
❑ Summary of components ⇒ “3.1 Summary of components - coolant pipe”, page 169
10 - Screw
❑ 8 Nm
11 - Hose
❑ for crankcase ventilation
12 - Screw cap
13 - Seal
❑ for cap
14 - Grommet
15 - Screw
❑ 8 Nm
16 - Vacuum line
1. Cylinder head 67
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
– Unscrew screw -2- for oil pipe -1- and cut cable strap -3-.
NOTICE
Risk of oil contamination by coolant and dirt!
♦ You must close the opening for the oil pipe in the oil pan with
screw plugs after removing the oil pipe.
– Unscrew screw -1- and pull own oil pipe -2- to top.
– Remove camshaft housing
⇒ “1.6 Removing and installing camshaft housing”,
page 76 .
– Release retaining clips -1- and disconnect fuels hoses -2- and
-3- from the high pressure pump.
– Use the assembly tool - T10118- to release and pull off the
connector -1-.
– Disconnect connector Pos. -9- ⇒ Item 9 (page 233) and vac‐
uum line Pos. -10- ⇒ Item 10 (page 233) on the intake mani‐
fold.
– Remove exhaust gas cleaning module
⇒ “2.2 Removing and installing exhaust gas cleaning module”,
page 275 .
– Tie off heat shield collar and release and pull off connector
-1-.
– Remove radiator for exhaust gas recirculation -2- downwards.
1. Cylinder head 69
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
Installing
NOTICE
The use of inadmissible abrasives can result in consequential
damage, such as turbocharger damage, connecting rod bearing
damage, etc..
♦ Abrasives (sandpaper, grinding wheels, sanding pads,
sanding fleece, abrasive wool, etc.) cannot be used.
♦ The sealing surface (see photo) must not be raised.
♦ Dark discolouration (see photo) does not need to be re‐
moved.
♦ When removing the seal residue, make sure that no dis‐
solved seal residue enters the open channels from the en‐
gine.
♦ Ensure that adjacent workplaces are clean and that none of
the above mentioned abrasives are used.
– Remove any residual gas from the cylinder head and cylinder
block using a standard scraper with a blade. Sealing surfaces
must not be damaged!
– Remove any dissolved residue with a lint-free cloth.
• Sealing surfaces must not be damaged!
• There must not be any oil or coolant present in the blind holes
for the screws.
• Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
• If a new cylinder head is installed, the contact surfaces be‐
tween roller cam follower and cam slide must be oiled.
• To prevent the silicon layer and the area of the bead from being
damaged, handle the gasket with the utmost care.
• To ensure that no valve is set during starting, turn the crank‐
shaft carefully by at least 2 turns.
• When the cylinder head or the cylinder head gasket is re‐
placed, all the coolant and engine oil must be replaced.
– Make sure that when cleaning the cylinder head and cylinder
block no foreign particles can get into the cylinder or into the
oil and coolant galleries.
– Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.
– Remove the crankshaft arrester - T10490- before fitting on the
cylinder head and turn back the crankshaft in the opposite di‐
rection of rotation of the engine until all the pistons are almost
evenly at “TDC”.
– If there are no dowel sleeves are available for centering the
cylinder block and cylinder head, insert dowel sleeves.
Note
– Fit cylinder head gasket onto the dowel sleeves -A- in cylinder
block with marking facing upwards.
Note
1. Cylinder head 71
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
NOTICE
If a new cylinder head has been fitted, the cooling system must
be flushed and the coolant must be replaced to ensure optimum
protection of the surface
⇒ “1.4 Flushing the cooling system”, page 135 .
Note
Note
♦ Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 63
♦ Exhaust gas turbocharger
⇒ “1.1 Summary of components - exhaust gas turbocharger”,
page 182
1. Cylinder head 73
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
– Unlock and pull off connector -1- for hall sender - G40- and
remove vacuum line -2-.
Note
♦ Renew O-ring.
♦ Replace gasket and screws for cylinder head cover if dam‐
aged or leaking.
Note
1. Cylinder head 75
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
– Screw the gasket ring extractor - T40195- into the gasket ring
-1-.
– Fit extractor - T10133/3- with extractor - T10133/2- onto the
gasket ring extractor and pull carefully towards the top by tap‐
ping it.
Installing
– Press in the new gasket ring for the injection unit using the
driver - 3390- and a short extension -1- from the top up to the
stop.
NOTICE
Risk of contamination of the lubrication system and bearing!
Cover opened engine parts.
CAUTION
Wear protective gloves and goggles when working with gasket
remover and degreasing agent!
Note
NOTICE
Risk of contamination of the camshaft bearings through excess
sealant!
♦ Do not apply thicker sealant beads than indicated.
1. Cylinder head 77
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
– Apply sealant bead -1- onto the clean sealing surfaces of the
cylinder head as shown in the illustration.
• Thickness of sealant beads: 2 mm.
Note
NOTICE
Risk of damaging valves and piston crowns after work on the
valve gear!
♦ Because hydraulic compensation elements must be set, the
engine must not be started until approximately 30 minutes
after camshaft installation.
♦ To ensure that no valve is set during starting, turn the crank‐
shaft carefully by at least 2 turns.
Note
♦ Camshaft housing
⇒ Fig. ““Camshaft housing - tightening torque and tightening
order”“ , page 97
♦ Charge-air system
⇒ “2.1 Summary of components - charge air system”,
page 195
Note
1. Cylinder head 79
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
Note
1 - Screw
❑ 5 Nm
2 - Pipes
❑ to differential pressure
transmitter - G505-
3 - Top toothed belt guard
❑ Removing and installing
⇒ “2.3.1 Removing and
installing top toothed
belt guard”, page 83
4 - Screw
❑ with collar
❑ inserted in the bottom
toothed belt guard such
that it cannot be lost
❑ 12 Nm
5 - Bottom toothed belt guard
❑ Removing and installing
⇒ “2.3.2 Removing and
installing bottom tooth‐
ed belt guard”,
page 84
6 - Screw
❑ with collar
❑ inserted in the bottom
toothed belt guard such
that it cannot be lost
❑ 12 Nm
7 - Rear toothed belt guard
8 - Screw
❑ 20 Nm
1 - Screw
❑ Replace after disas‐
sembly
❑ Release and tighten us‐
ing counterholder -
T30004 (3415)-
❑ Do not additionally oil
threads and collar
❑ Further rotation can be
done across several
stages, e.g. 90° + 45°
❑ 180 Nm + 135°.
2 - Crankshaft toothed belt
sprocket
❑ there must not be any oil
present on the contact
surface between the
pulley and the crank‐
shaft
❑ can be installed only in
one position
3 - Nut
❑ Replace after disas‐
sembly
❑ 20 Nm + 45°.
4 - Tensioning pulley
5 - Pin screw
❑ Replace if damaged.
❑ 15 Nm
6 - Toothed belt
❑ mark the direction of ro‐
tation with chalk or a felt- Volkswagen Technical Site: https://vwts.ru
tip pen before removing
❑ check for wear
❑ removing ⇒ “2.4 Removing and installing toothed belt”, page 85
❑ install (set the timing) ⇒ page 88
7 - Screw
❑ to loosen and tighten, use counterholder - T10172- or -T10172A- with adapters -T10172/11-
❑ Do not additionally oil threads and collar
❑ 100 Nm
8 - Locating screw
❑ 9 Nm
9 - Camshaft toothed belt pulley
❑ There must not be any oil present on the contact surface between the toothed belt pulley and the camshaft
10 - Camshaft driver
❑ Removing and installing ⇒ “1.6 Removing and installing camshaft housing”, page 76
11 - High pressure pump
❑ Summary of components ⇒ “8.1 Summary of components - high pressure pump”, page 253
12 - Hub
❑ for high pressure pump
❑ Summary of components ⇒ “8.1 Summary of components - high pressure pump”, page 253
❑ There must not be any oil present between the lock hub and the toothed belt pulley
13 - Guide pulley
14 - Screw
❑ 23 Nm
15 - Toothed belt pulley high pressure pump
❑ Summary of components ⇒ “8.1 Summary of components - high pressure pump”, page 253
❑ There must not be any oil present between the lock hub and the toothed belt pulley
16 - Nut
❑ Do not additionally oil threads and collar
❑ Tightening torque Pos. -2- ⇒ Item 2 (page 253)
17 - O-ring
❑ Replace after disassembly
❑ Moisten with coolant
18 - Screw
❑ Tightening torque Pos. -5- ⇒ Item 5 (page 157)
19 - Coolant pump
❑ Removing and installing ⇒ “2.5 Removing and installing coolant pump”, page 162
Note
– Loosen clamp -1-, disconnect fuel line and place to the side.
– Unscrew screws -1- and -2- and remove the top toothed belt
guard upwards.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
Tightening torques - summaries of components
Note
♦ Toothed belt
⇒ “2.2 Summary of components - toothed belt”, page 82
– Release and pull off connector -6- and unscrew screws -1-.
– Unscrew nuts -1- and push coolant pipe -2- to the side.
Note
♦ Toothed belt
⇒ “2.2 Summary of components - toothed belt”, page 82
♦ Coolant pipes
⇒ “3.1 Summary of components - coolant pipe”, page 169
NOTICE
Risk of damage to the engine as a result of the toothed belt
pulley jumping.
♦ Only rotate the crankshaft in the direction of rotation of the
engine!
– Turn the crankshaft at the screw for toothed belt pulley until
the camshaft toothed belt pulley is positioned on “TDC”.
– Lock hub of the high pressure pump using the rig pin -
T10492- ; to do so, insert the rig pin into fork -2- of the hub and
into the bore behind it -1- in the auxiliary units bracket.
NOTICE
Risk of engine damage!
♦ The rig pin - T10492- must not be used as a counterholder
for loosening the screw for the camshaft toothed belt pulley.
– Remove rig pin and partially undo the screws for the camshaft
sprocket. Before removing fully, peg back the rig pin.
– Loosen nut -arrow- for high pressure pump toothed belt pulley
by approximately 90°, use counterholder - T10051- to do so.
– Then turn the eccentric of the tensioning pulley with the offset
screwdriver - T10264- clockwise -arrow- up to the stop and
tighten nut -1- by hand.
NOTICE
Risk of damage through reversing the rotation direction of an
already used toothed belt!
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the toothed belt pulley.
– First remove the toothed belt from the coolant pump and then
from the remaining toothed belt gears.
Installing (set the timing)
Note
NOTICE
Risk of damage to valves and piston crowns!
♦ When rotating the camshaft, the crankshaft must not be
positioned at “TDC” with any one piston.
Requirements:
• Tensioning pulley locked with rig tool - T10265- and fixed with
nut -1- up to right stop.
• The hub of the camshaft is locked with the rig pin - T10492- .
• Screw loosely inserted.
• It must still be possible to just turn the camshaft toothed belt
pulley, however it must not tilt.
• Fixing screw -1- of the driver loosened by one half turn, posi‐
tioned in the centre position in the elongated hole.
– Turn the camshaft toothed belt pulley and high pressure pump
toothed belt pulley in their elongated holes clockwise as far as
the stop.
– Fit the toothed belt in the following order:
1- Crankshaft toothed belt sprocket
2- Tensioning pulley
3- Camshaft toothed belt pulley
4- Toothed belt pulley high pressure pump
5- Coolant pump toothed belt pulley
– Loosen nut -1- for tensioning pulley and remove rig tool -
T10265- .
Note
NOTICE
The locking screw must not rest at the bottom stop of the elon‐
gated hole after the camshaft sprocket is tightened!
NOTICE
♦ The high pressure pump toothed belt pulley can only be
twisted to a limited extent.
♦ It is therefore crucial to check that the toothed belt gear does
not lie against the »stop« of the twisting range after tighten‐
ing.
– Make sure that the marking on the toothed belt gear is not flush
with the rig pin. You may need to correct the position of the
toothed belt gear of the high pressure pump by one tooth
clockwise and fit the toothed belt back into position.
– Remove the rig pin - T10492- and crankshaft arrester -
T10490- and test the timing ⇒ page 91 .
Test timing:
NOTICE
Risk of damage to the engine as a result of the toothed belt
pulley jumping.
♦ Only rotate the crankshaft in the direction of rotation of the
engine!
– Turn the crankshaft at the screw for timing belt gear 2 turns in
the direction of running of the engine until the crankshaft is
positioned shortly before “TDC”.
NOTICE
Adjustment error as a result of inaccurate “TDC” setting!
♦ If it has been rotated above “TDC”: Rotate crankshaft again
by 2 turns until it is again positioned shortly before “TDC”.
♦ Then lock the crankshaft from the direction of rotation using
the crankshaft arrester - T10490-
The hub of the camshaft must be locked with the rig pin - T10492- .
• The locking point of the hub of the high pressure pump is al‐
ways difficult to find again. A slight difference -arrow- does not
influence the engine running.
Note
NOTICE
Risk of engine damage!
♦ The locking pin - T10492- must not be used for loosening or
tightening the screw under any circumstances.
Note
Secure all hose connection with spring-type clips that comply with
the series design ⇒ ETKA - Electronic Catalogue of Original
Parts .
Note
♦ Toothed belt
⇒ “2.2 Summary of components - toothed belt”, page 82
♦ Toothed belt guard
⇒ “2.1 Summary of components - toothed belt guard”,
page 81
NOTICE
Risk of destruction as a result of the toothed belt pulley jumping!
♦ Only rotate the crankshaft in the direction of rotation of the
engine!
– Turn the crankshaft at the screw for toothed belt pulley until
the camshaft toothed belt pulley is positioned on “TDC”.
– Lock hub of the high pressure pump using the rig pin -
T10492- ; to do so, insert the rig pin into fork -2- of the hub and
into the bore behind it -1- in the auxiliary units bracket.
NOTICE
Risk of engine damage!
♦ The rig pin - T10492- must not be used as a counterholder
for loosening the screw for the camshaft toothed belt pulley.
– Remove rig pin - T10492- and loosen screw -1- for camshaft
toothed belt pulley; to do so, use counterholder - T10172- with
adapters -T10172/11- .
– Loosen nut -arrow- for high pressure pump toothed belt pulley
by approximately 90°, use counterholder - T10051- to do so.
– Then turn the eccentric of the tensioning pulley with the offset
screwdriver - T10264- clockwise -arrow- up to the stop and
tighten nut -1- by hand.
– Unscrew screw of the toothed belt pulley and remove the
toothed belt with the toothed belt pulley.
Install (set the timing) ⇒ page 88 .
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 96
⇒ “3.2 Removing and installing gasket ring for camshaft”,
page 97
⇒ “3.3 Checking hydraulic balancing elements”, page 99
⇒ “3.4 Removing and installing valve stem seals”, page 99
1 - Screw cap
❑ Replace after disas‐
sembly
❑ Removing: In cases
where there is a built-in
camshaft housing, in‐
sert a punch at the side
of the cover and lever
out
❑ Installing: Drive in flush
without sealant with a
suitable thrust piece,
e.g. driver - 3390-
2 - Camshaft sealing ring
❑ replace after removal
⇒ “3.2 Removing and in‐
stalling gasket ring for
camshaft”, page 97
3 - Camshaft housing
❑ with integrated cam‐
shaft
❑ Removing and installing
⇒ “1.6 Removing and in‐
stalling camshaft hous‐
ing”, page 76
4 - Screw
❑ Sequence for loosening
⇒ “1.6 Removing and in‐
stalling camshaft hous‐
ing”, page 76
❑ Tightening torque and
tightening order
⇒ Fig. ““Camshaft hous‐
ing - tightening torque
and tightening order”“ ,
page 97
5 - Locking clip
❑ for hydraulic balancing element
6 - Hydraulic balancing element
❑ Check ⇒ “3.3 Checking hydraulic balancing elements”, page 99
❑ mark the fitting position for re-installation
❑ oil the contact surfaces before installing
7 - Fit pin
❑ for camshaft housing
8 - Cylinder head
❑ the valve seats must not be reworked because of the narrow tolerances
9 - Valve
❑ do not rework, only grinding in is permissible
❑ mark the fitting position for re-installation
❑ Check ⇒ “4.2 Testing valves”, page 106
❑ Valve dimensions ⇒ “4.3 Valve dimensions”, page 107
❑ inspecting valve guides ⇒ “4.1 inspecting valve guides”, page 106
10 - Valve stem gasket
❑ replace after removal ⇒ “3.4 Removing and installing valve stem seals”, page 99
11 - Valve spring
12 - Valve spring plate
13 - Valve collets
14 - Roller rocker finger
❑ Removing and installing ⇒ “1.6 Removing and installing camshaft housing”, page 76
❑ mark the fitting position for re-installation
❑ inspect roller bearings for smooth operation
❑ oil the contact surfaces before installing
3. Valve gear 97
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
NOTICE
♦ If it is turned back too much, the inner pressure plate loosens
-T10443- from the pressure screw.
♦ The pressure plate must then be pressed onto the pressure
screw once again.
Note
The sealing lip of the gasket ring must not be oiled or greased
additionally.
Note
Note
3. Valve gear 99
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
Removing
– Remove all glow plugs
⇒ “1.2 Removing and installing glow plugs”, page 295 .
– Remove camshaft housing
⇒ “1.6 Removing and installing camshaft housing”, page 76 .
– Assignment of the roller towing levers -1-, hydraulic compen‐
sating elements -4- and valves -3- for reintegration.
– Remove the roller rocker arms together with the hydraulic bal‐
ancing elements and lay aside on a clean surface.
– Bring piston of the relevant cylinder to “top dead centre”.
Note
Note
Note
– Pull off valve stem seal with the valve steam seal extractor -
MP 1-230 (3364)- .
Installing
NOTICE
Risk of damage to valve stem seals during installation!
– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve -A-.
– Repeat the procedure for each valve.
Installation is carried out in the reverse order. When installing,
note the following:
– Insert the valve spring and the valve spring retainer.
– Align the downholder for valve spring - MP 1-229 (3362)- with
the valve.
– Press the pressure piece - 3362/1- with the spindle to the pre‐
viously determined degree.
Note
Do not twist the spindle too much, otherwise the valve cone
pieces cannot be used correctly.
– Mount the rolling tower levers -1- together with the hydraulic
compensating element -4-.
Ensure that all the roller arms are correctly positioned on the valve
stem ends and are clipped in place on the relevant hydraulic bal‐
ancing elements.
– Install camshaft housing
⇒ “1.6 Removing and installing camshaft housing”, page 76 .
– Install glow plugs
⇒ “1.2 Removing and installing glow plugs”, page 295 .
– Insert the cylinder head tensioning device - VAS 6419- into the
engine and gearbox jack - VAS 6095- .
– Tension the cylinder head in the cylinder head tensioning de‐
vice, as shown in the illustration.
– Connect cylinder head tensioning device to compressed air.
– Push the air cushion with the lever -arrow- under the appro‐
priate combustion chamber.
– Allow just enough air to flow into the air bag so that it applied
to the valve disc.
Note
Note
– Pull off valve stem seal with the valve steam seal extractor -
MP 1-230 (3364)- .
Installing
NOTICE
Risk of damage to valve stem seals during installation!
– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve -A-.
– Repeat the procedure for each valve.
Installation is carried out in the reverse order. When installing,
note the following:
– Insert the valve spring and the valve spring retainer.
– Align the downholder for valve spring - MP 1-229 (3362)- with
the valve.
– Press the pressure piece - 3362/1- with the spindle to the pre‐
viously determined degree.
Note
Do not twist the spindle too much, otherwise the valve cone
pieces cannot be used correctly.
– Mount the rolling tower levers -1- together with the hydraulic
compensating element -4-.
Ensure that all the roller arms are correctly positioned on the valve
stem ends and are clipped in place on the relevant hydraulic bal‐
ancing elements.
– Install cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 66 .
Note
– Secure dial gauge to the cylinder head using the universal dial
gauge bracket - MP 3-447 (VW 387)- .
Note
If the valves are replaced when carrying out repair work, use new
valves for the measurement.
– Insert valve into valve guide. End of valve stem must be flush
with guide.
• Valve rock: maximum 1.0 mm
Note
Note
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - pan/oil pump”, page 108
⇒ “1.2 Removing and installing the bottom part of the oil sump”,
page 110
⇒ “1.3 Removing and installing top part of the oil sump”,
page 111
⇒ “1.4 Removing and installing oil pump”, page 114
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 117
1 - Nut
❑ 10 Nm
2 - Oil level and oil temperature
transmitter - G266-
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling oil level and oil
temperature sender
G266 ”, page 117
3 - Oil drain plug
❑ Replace after disas‐
sembly
❑ 30 Nm
4 - Sealing ring
❑ component part of posi‐
tion -3-
5 - Bottom part of oil sump
❑ Removing and installing
⇒ “1.2 Removing and in‐
stalling the bottom part
of the oil sump”,
page 110
6 - Seal
❑ Replace after disas‐
sembly
7 - Fit pin
❑ Different versions ⇒ ET‐
KA - Electronic Cata‐
logue of Original Parts
8 - Top part of the oil sump
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling top part of the oil
sump”, page 111
9 - Screw
❑ 8 Nm
10 - Oil suction pipe
11 - Sealing ring
12 - Screw
❑ 8 Nm
13 - Cover
14 - Oil pump
Note
15 - Fitting sleeve
16 - Cylinder block
17 - O-ring
❑ component part of position -18-
18 - Oil pressure control valve - N428-
❑ Removing and installing
⇒ “3.5 Removing and installing valve for oil pressure control N428 ”, page 126
19 - Screw
❑ 8 Nm
20 - Screw
❑ 8 Nm
21 - Oil pipe
22 - Seal
❑ Different versions ⇒ ETKA - Electronic Catalogue of Original Parts
23 - Screw
❑ 8 Nm
24 - O-ring
❑ Replace after disassembly
25 - Screw
❑ 16 Nm + 135°.
26 - Fit pin
❑ Different versions ⇒ ETKA - Electronic Catalogue of Original Parts
27 - Screw
❑ 13 Nm
28 - Screw
❑ 10 Nm
29 - Sealing ring
❑ Replace after disassembly
– Release connector -4- and pull off, loosen clips -5- and dis‐
connect electrical line.
– Unscrew screws -1-, loosen clips -2- and remove noise insu‐
lation -3- for oil pan.
– Drain engine oil:
♦ ⇒ Maintenance ; Booklet Fabia III
♦ ⇒ Maintenance ; Booklet Rapid NH
Note
Note
– Release nuts -1- and screw -3- and remove bracket -2-.
– Unscrew screw -2- for oil pipe -1- and cut cable strap -3- on
top and at bottom.
– Remove oil sump bottom part
⇒ “1.2 Removing and installing the bottom part of the oil sump”,
page 110 .
– Unscrew screw -1- and pull own oil pipe -2- to top.
– Remove V-ribbed belt
⇒ “1.3 Removing and installing V-ribbed belt”, page 31 .
– Unscrew screws -2- and remove sump top part -1- from bond‐
ing. If necessary, undo the top part of the oil sump by applying
slight blows with a rubber-headed hammer.
Installing
CAUTION
Wear protective gloves and goggles when working with gasket
remover and degreasing agent!
Note
NOTICE
There is risk of blockage of the lubrication system through ex‐
cess sealant.
♦ Do not apply thicker sealant strips than indicated.
When the sealing flange on the belt pulley side was not replaced
Note
The bottom surface of the sealing flange on the belt pulley side
has a displacement of approx. 1 mm to the bottom cylinder block
surface after removing the old silicone seal, which must be com‐
pensated for by applying the required sealant on the correspond‐
ing area of the oil pan sealing surface.
– Apply sealant bead onto the clean sealing surfaces of the oil
sump, as shown in the illustration.
• Sump top part must be in contact with the intermediate plate
so that it is lined up with the gearbox flange.
Note
♦ When installing the oil pan with the engine removed you must
ensure that the oil sump is flush with the cylinder block at the
flywheel side.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
Note
Note
– Secure drive wheel of the oil pump with rig pin - 3359- .
NOTICE
♦ During installation, the backlash between crankshaft sprock‐
et and drive wheel for the new oil pump must be set.
♦ The wheel for the new oil pump has a smooth paint covering
which wears off after a short running time, and thus auto‐
matically sets the backlash.
– Lock oil pump in the bore in the drive wheel -1- using the rig
pin - 3359- .
– Position oil pump -3- and initially screw in screws -2- and -4-
by hand as far as the stop.
– Insert balancing shaft module in -direction of arrow- and tight‐
en screws -2- and -4- hand-tight.
– Check that the marks on the gear wheels of the balancing shaft
-1- and the crankshaft -2- are opposite each other.
– Screw in the remaining screws and tighten by hand.
Note
– Release connector -4- and pull off, loosen clips -5- and dis‐
connect electrical line.
– Unscrew screws -1-, loosen clips -2- and remove noise insu‐
lation -3- for oil pan.
– Drain engine oil:
♦ ⇒ Maintenance ; Booklet Fabia III
♦ ⇒ Maintenance ; Booklet Rapid NH
Note
Note
Note
The engine oil cooler must not be disconnected from the oil filter
housing In the event of a defect, the engine oil cooler with the oil
filter housing must be replaced
⇒ “3.4 Removing and installing oil filter housing”, page 123 .
9 - Seal
❑ Replace after disassembly
– Release connector -1- and pull off and remove locking clips
-2-.
Note
Note
Note
Note
Because of the clutch guard speed, not all of the oil pressure
control steps can be set when the vehicle is stationary. For this
reason, the oil pressure must be tested with the vehicle diagnosis
tester.
Note
You must close the opening for the oil pipe in the oil pan with
screw plugs after removing. Otherwise, coolant would flow into
the oil.
– Unscrew screw -1- for oil pipe -2- on the oil pan.
– Release and pull off connector -1-, unscrew nut -2- and cut
cable strap -3-.
Note
Note
– Install AC compressor
⇒ “1.1 Assembly overview - V-ribbed belt drive”, page 28 .
– Install the V-ribbed belt
⇒ “1.3 Removing and installing V-ribbed belt”, page 31 .
– Install the front right wheelhouse liner⇒ Exterior body work;
Rep. gr. 66 ; Wheelhouse liner; Removing and installing the
front wheelhouse liner .
– Top up coolant ⇒ page 132 .
Tightening torques - summaries of components
Note
Note
– Release and pull off connector -1-, unscrew screw -2- and re‐
move the valve for oil pressure control - N428- -3-.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
Note
Note
19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 128
⇒ “1.2 Check cooling system for leaks”, page 129
⇒ “1.3 Draining and filling coolant”, page 131
⇒ “1.4 Flushing the cooling system”, page 135
⇒ “1.5 Flushing cooling system, quick start guide”, page 155
Note
CAUTION
Hot steam may escape when the expansion reservoir is
opened!
♦ Cover the cap with a cloth and open carefully.
CAUTION
Risk of scalding!
♦ Before the cooling system testing device -V.A.G 1274 B- is
separated from the connecting hose or the connecting piece
-V.A.G 1274 B/1- , the existing pressure must absolutely be
released.
♦ For this step, press the pressure relief valve on the cooling
system testing device -V.A.G 1274 B- and hold it pressed
until the pressure gauge indicates the value »0«.
• The pressure must not drop below 0.02 MPa (0.2 bar) after 10
minutes.
If the pressure falls below 0.02 MPa (0.2 bar):
– Search position of the leak and repair fault.
Note
– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Build up overpressure using the hand pump on the tester.
Blue filler cap:
♦ The pressure relief valve should open at a pressure of 0.14 to
0.16 MPa (1.4 to 1.6 bar).
Black filler cap:
♦ The pressure relief valve should open at a pressure of 0.16 to
0.18 MPa (1.6 to 1.8 bar).
If the pressure relief valve opens too early or too late:
– Renew cap.
♦ Refractometer
♦ Protective goggles
♦ Protective gloves
Note
Draining
CAUTION
Danger of scalding due to hot steam and hot coolant.
♦ When the engine is warm the cooling system is under pres‐
sure.
♦ Reduce pressure by covering the cap of the coolant expan‐
sion reservoir with a cloth and opening it carefully.
NOTICE
Risk of engine damage if the cooling system is not filled/bled
adequately!
♦ You must bleed the cooling system with the ⇒ Vehicle diag‐
nostic tester after filling.
Note
– Close the valves -A- and -B-, while doing so turn the lever at
right angles to the direction of flow.
– Connect hose -4- to compressed air.
• Pressure: 0.6 - 1.0 MPa (6 - 10 bar)
– Open the valve -B-, while doing so turn the lever in the direction
of flow.
• Vacuum is generated in the cooling system by the suction
spray pump.
• The display instrument pointer must move into the green area.
– In addition, briefly open the valve -A- by turning the lever in the
direction of flow, so that the hose of the coolant expansion
bottle is -VAS 6096- filled with coolant.
– Close the valve -A- again.
– Leave the valve -B- open a further 2 minutes.
• A vacuum pump is created in the cooling system by the vac‐
uum pump; the display instrument pointer must remain in the
green area.
– Close the valve -B-.
• If the display instrument pointer remains in the green area the
vacuum in the cooling system is sufficient for subsequent fill‐
ing.
Note
Note
Note
Note
Note
Do not fit the valve block to the test adapter - VAS 691 005/5- yet.
The filler hose should be bled first.
Connecting the coolant flushing and charge unit - VAS 531 007-
– Open cap -arrow- for coolant expansion tank.
– Screw the test adapter -2- ( -VAS 691 005/5- ) onto the coolant
expansion reservoir -1-.
– Fit the valve block -1- onto the test adapter -2-.
– Connect the ejector -2- from the -VAS 6096- to the quick cou‐
pling -B- on the valve block -1-.
Note
♦ If the vacuum drops, check the cooling system for leak points.
♦ The generated vacuum depends on the pressure in the compressed air system.
– Connect the bleeder hose -2- for the coolant expansion res‐
ervoir to the flushing hose -1-.
– Close the connection fitting on the coolant expansion reservoir
with a plug -3-. Secure the plug with hose clamp.
– Close shut-off tap -B-.
– Remove engine cover.
The cooling system is sub-divided into the following coolant cir‐
cuits:
♦ Cylinder block and cylinder head
♦ Heat exchanger for heating
♦ Coolant radiator
♦ Charge air cooler and charge air cooling circuit radiator
Note
1. Flushing the cylinder block and cylinder head with distilled wa‐
ter
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps distilled water.
– Check the inspection glass: as soon as the coolant changes
colour, close the shut-off tap -A-.
• Required quantity of distilled water: approx. 2 litres
3. Flush radiator with distilled water
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps distilled water.
– Check the inspection glass: as soon as the coolant changes
colour, close the shut-off tap -A-.
• Required quantity of distilled water: approx. 2 litres
4. Flushing the charge air cooler and charge air cooling circuit
radiator with distilled water
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps distilled water.
– Check the inspection glass: as soon as the coolant changes
colour, close the shut-off tap -A-.
• Required quantity of distilled water: approx. 2 litres
Repeat flushing steps 1-4 times, but always only pump approx. 1
litre of distilled water ⇒ page 142 . Then flush the cooling system
with coolant.
Flushing the cooling system with coolant
– Connect suction hose -A- to container -2- with distilled water.
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps coolant.
– Check the inspection glass: if you can see the coolant coming
out in the inspection glass, close the shut-off tap -A-.
• Required quantity of coolant: approx. 2-3 litres
2. Flushing the heat exchanger for heating with coolant
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps coolant.
– Check the inspection glass: if you can see the coolant coming
out in the inspection glass, close the shut-off tap -A-.
• Required quantity of coolant: approx. 2 litres
3. Flush the radiator with coolant
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps coolant.
– Check the inspection glass: if you can see the coolant coming
out in the inspection glass, close the shut-off tap -A-.
• Required quantity of coolant: approx. 2 litres
4. Flushing the charge air cooler and charge air cooling circuit
radiator with coolant
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps coolant.
– Check the inspection glass: if you can see the coolant coming
out in the inspection glass, close the shut-off tap -A-.
• Required quantity of coolant: approx. 2 litres
Repeat flushing steps 1-4 times, but always only pump approx. 1
litre of coolant ⇒ page 147 . The flushing procedure is then fin‐
ished.
– Switch off the pump after flushing.
– Remove all hose clamps.
Disconnect the coolant flushing and charge unit - VAS 531 007- :
– Open the shut-off tap -B- and leave open to dissipate the pres‐
sure in the cooling system.
– Remove the plug -3- from the coolant expansion reservoir and
re-connect the bleeder hose -2-.
– Close the flushing hose -1- with a plug.
– Remove the valve block -1- and the test adapter -2-.
Extracting coolant
Note
Use the adapter for extraction, Pos. -14-, to extract coolant ⇒ Item 14 (page 137) .
Note
Cleaning the coolant flushing and charge unit - VAS 531 007-
Note
♦ If the coolant stays in the inspection glass for a long time, it may discolour. The inspection glass must
therefore be flushed with distilled water after each flushing.
♦ If the inspection glass is discoloured, clear it with a nylon brush.
♦ Use the adapter for cleaning, Pos. -13-, to flush ⇒ Item 13 (page 137) .
Note
The Quick Start Guide lists the main steps in the workflow. These
can be printed and scraped during the workflow. A detailed work‐
flow is listed here
⇒ “1.4 Flushing the cooling system”, page 135 .
Locking points
8 - Screw
❑ 8 Nm
9 - O-ring
❑ Replace after disassembly
❑ Moisten with coolant
10 - Screw
❑ 20 Nm
11 - Coolant regulator housing
12 - Coolant regulator
❑ Removing and installing ⇒ “2.7 Testing the coolant regulator”, page 165
13 - O-ring
❑ check for damage
❑ Moisten with coolant
14 - Connection fitting
15 - Screw
❑ 8 Nm
16 - O-ring
❑ Replace after disassembly
❑ Moisten with coolant
17 - Retaining clip
❑ check for firm seating
18 - Screw
❑ 20 Nm
1 - Coolant hose
❑ Connection diagram
⇒ “1.1 Connection dia‐
gram - coolant hoses”,
page 128
2 - Fixing clamp
3 - Heating backup pump -
V488-
❑ Removing and installing
⇒ “2.4.1 Removing and
installing the heating
backup pump V488 ”,
page 160
4 - Fixing clamp
5 - Coolant hose
❑ Connection diagram
⇒ “1.1 Connection dia‐
gram - coolant hoses”,
page 128
6 - Mounting bracket
❑ Heating backup pump -
V488-
7 - Screw
❑ 8 Nm
8 - Grommet
9 - Screw
❑ 8 Nm
10 - Coolant hose
❑ Connection diagram
⇒ “1.1 Connection dia‐
gram - coolant hoses”,
page 128
11 - Fixing clamp
12 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 128
13 - Fixing clamp
14 - Charge air cooler pump - V188-
❑ Removing and installing ⇒ “2.4.2 Removing and installing charge air cooler pump V188 ”, page 161
15 - Screw
❑ 8 Nm
16 - Mounting bracket
❑ Charge air cooler pump - V188-
17 - Grommet
18 - Screw
❑ 8 Nm
1 - O-ring
❑ Replace after disas‐
sembly
❑ Moisten with coolant
2 - Coolant temperature trans‐
mitter - G62-
❑ Removing and installing
⇒ “2.9 Removing and in‐
stalling coolant temper‐
ature transmitter G62 ”,
page 166
3 - Screw
❑ 8 Nm
Note
Note
Secure all hose connection with spring-type clips that comply with
the series design ⇒ ETKA - Electronic Catalogue of Original
Parts .
Note
Note
– Release and pull off connector -1-, loosen clamps -2- and dis‐
connect coolant hoses.
– Unscrew screw -3- and remove charge air cooler pump - V188-
-4-.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
Note
Secure all hose connection with spring-type clips that comply with
the series design ⇒ ETKA - Electronic Catalogue of Original
Parts .
Note
♦ Coolant pump
⇒ “2.2 Summary of components - electric coolant pump”, page
159
♦ Engine cover ⇒ General body repairs, exterior ; Rep. gr. 66 ;
Noise insulation; Summary of components- noise insulation .
– Release and pull off connector -1- for coolant valve for cylinder
head - N489- with the assembly tool - T10118- .
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page 131 .
– Remove bottom toothed belt guard
⇒ “2.3 Removing and installing toothed belt guard”, page 83 .
– Remove the toothed belt from the camshaft
⇒ “2.5 Remove the toothed belt from the camshaft”,
page 93 .
NOTICE
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.
Risk of damage to the toothed belt!
♦ Do not over-tension or kink the toothed belt.
Note
Note
♦ Coolant pump
⇒ “2.2 Summary of components - electric coolant pump”, page
159
Note
Note
♦ Coolant pump
⇒ “2.1 Summary of components - coolant pump/thermostat”,
page 157
♦ Air filter housing
⇒ “4.1 Assembly overview - air filter housing”, page 230
Note
Note
♦ Coolant pump
⇒ “2.1 Summary of components - coolant pump/thermostat”,
page 157
– Release nuts -1- and screw -3- and remove bracket -2-.
– Use the assembly tool - T10118- to release and pull off the
connector -1- and unscrew screws -2-.
– Pull out coolant temperature sender - G62- to the front.
Note
Use a wire to pull out any O-ring or distance ring that has re‐
mained stuck inside the cylinder head.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
Note
♦ Replace O-rings.
♦ Replace distance ring if it is damaged.
Note
3 Coolant pipes
⇒ “3.1 Summary of components - coolant pipe”, page 169
⇒ “3.2 Removing and installing coolant pipes”, page 170
Note
The arrows on the coolant pipes and the coolant hose ends must
stand opposite to each other.
– Unscrew screw -1- and pull own oil pipe -2- to top.
Note
♦ Replace O-rings.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ ETKA - Electronic Catalogue of Orig‐
inal Parts .
Note
– Release clamps -2-, push coolant hoses to the side and un‐
screw nuts -1-.
– Release clamps -arrows-, disconnect hoses and remove right
coolant pipes.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
Note
Secure all hose connections with hose clamps which comply with
the series design ⇒ ETKA - Electronic Catalogue of Original
Parts .
Note
♦ Coolant pipes
⇒ “3.1 Summary of components - coolant pipe”, page 169
♦ Wheelhouse liner ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheelhouse liner; removing and installing front wheel‐
house liner
Note
The arrows on the coolant pipes and the coolant hose ends must
stand opposite to each other.
1 - Radiator mounting
❑ Radiator clips in bottom
front part of the vehicle
2 - Cooler for charge air circuit
❑ Removing and installing
⇒ “4.3 Removing and in‐
stalling radiator”,
page 175
3 - Coolant temperature trans‐
mitter - G83-
❑ not fitted
❑ closed with plugs
4 - O-ring
❑ Replace if damaged.
5 - Screw
❑ 5 Nm
❑ 2 units
6 - Radiator mounting
❑ Top
7 - Radiator
❑ Removing and installing
⇒ “4.3 Removing and in‐
stalling radiator”,
page 175
❑ After replacing, also re‐
place coolant
8 - Coolant hose
❑ Connection diagram
⇒ “1.1 Connection dia‐
gram - coolant hoses”,
page 128
9 - expansion reservoir
❑ Check for leaks ⇒ “1.2 Check cooling system for leaks”, page 129
10 - Screw cap
❑ Check for leaks ⇒ “1.2 Check cooling system for leaks”, page 129
11 - Screw
❑ 2 Nm
❑ 2 units
12 - Connector
13 - Fan shroud with radiator fan - V7-
❑ Summary of components ⇒ “4.2 Summary of components - fan shroud and radiator fan”, page 175
❑ Removing and installing ⇒ “4.4 Removing and installing fan shroud”, page 178
14 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 128
Note
The coolant radiator and charge air cooling circuit radiator are
removed together.
Note
♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
♦ Coolant radiator
⇒ “4 Coolers, radiator, radiator fan”, page 173
Removing
– Remove the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Summary of components -
noise insulation .
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page 131 .
– Remove air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
– Release cover -1- and take off.
CAUTION
Risk of injury through refrigerant!
♦ Do not open the refrigerant circuit of the air conditioning
system.
NOTICE
Risk of damaging the condenser, the refrigerant lines and ho‐
ses!
♦ Do not over-tension or buckle refrigerant lines and hoses.
NOTICE
To prevent damage to the charge air cooler, the separation of
the charge air cooler from the radiator must be carried out by 2
mechanics.
– Slide the charge air cooler -1- off in direction of arrow -A-, at
the same time slide it in direction of arrow -B-, and unhook it
from the lock on the right -arrow- of the radiator -2-.
– Secure charge air cooler -1- against falling down.
– Remove radiator.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
– Insert the charge air cooler -2- into the right support.
– Lock the charge air cooler -2- to the supports of the radiator
-1-.
– Check for firm seating by pulling in the opposite direction.
Note
Replace O-rings.
NOTICE
If a new radiator has been fitted, the cooling system must be
flushed and the coolant must be replaced to ensure optimum
protection of the surface
⇒ “1.4 Flushing the cooling system”, page 135 .
Note
♦ Radiator
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 173
Removing
– Remove air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
– Unlock the catches of the fan shroud with the radiator fan -
V7- , e.g. using a screwdriver.
Note
♦ Fan shroud
⇒ “4.2 Summary of components - fan shroud and radiator fan”,
page 175
Removing
Note
All cable straps should be fastened again in the same place when
installing.
– Carefully lift the fan ring on the rear side of the cover, e.g. using
a screwdriver.
– Remove fan ring.
Note
♦ Radiator
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 173
♦ Fan shroud
⇒ “4.2 Summary of components - fan shroud and radiator fan”,
page 175
21 – Turbocharging/supercharging
1 Exhaust gas turbocharger
⇒ “1.1 Summary of components - exhaust gas turbocharger”,
page 182
⇒ “1.2 Removing and installing exhaust gas turbocharger”,
page 183
⇒ “1.3 Replacing exhaust gas turbocharger pressure box”,
page 187
1 - Pulsation dampener
2 - Screw
❑ 8 Nm
3 - O-ring
❑ Replace after disas‐
sembly
4 - Exhaust gas turbocharger
❑ Removing and installing
⇒ “1.2 Removing and in‐
stalling exhaust gas tur‐
bocharger”, page 183
5 - Exhaust gas temperature
transmitter 1 - G235-
❑ Summary of compo‐
nents
⇒ Item 1 (page 258)
6 - Seal
❑ Replace after disas‐
sembly
7 - Nut
❑ Replace after disas‐
sembly
❑ Tightening torque and
tightening order
⇒ Fig. ““Exhaust gas tur‐
bocharger - tightening
torque and tightening
order”“ , page 183
8 - Seal
❑ Replace after disas‐
sembly
9 - Screw
❑ 14 Nm
10 - Oil return-flow line
11 - Seal
❑ Replace after disassembly
12 - Screw
❑ Replace after disassembly
❑ 8 Nm + 45°.
13 - Compression rings
❑ Replace after disassembly
14 - Hollow screw
❑ 27 Nm
15 - Oil feed line
16 - Screw
❑ 10 Nm
17 - Screw
❑ 10 Nm
18 - Heat shield
19 - Hollow screw
❑ Replace after disassembly
❑ 16 Nm
Removing
– Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 6 .
– Remove engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Remove air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page 131 .
– If present, release connector -3- and pull off.
– Press release buttons on the hose -1- for crankcase ventilation
and remove from cylinder head.
– Release retaining clip -2- and remove air guide.
– Remove charge air cooler
⇒ “2.2.1 Removing and installing charge air cooler”,
page 196 .
– Release and pull off connector -1- for position sender for
charge pressure regulator - G581- and pull off hose -2-.
– Release clamp -3- and disconnect coolant hose.
– Unscrew screws -3- and remove air guide hose with pulsation
damper -2-.
– Remove exhaust gas cleaning module
⇒ “2.2 Removing and installing exhaust gas cleaning module”,
page 275 .
– Tie off heat shield collar and release and pull off connector
-1-.
– Remove radiator for exhaust gas recirculation -2- downwards.
– Unscrew screws -2-, screw off nuts -3- and remove exhaust
gas recirculation -1-.
– Screw off nuts -2- and remove exhaust gas turbocharger -1-
downwards.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
Note
Note
Note
Note
– Remove vacuum hose -3- pull off the plug -2- from Position
transmitter for boost pressure plate - G581- .
– Remove screws -arrows-.
Note
When removing and installing the circlip, keep the force exerted
on the lever hoist to a minimum. Pushing the circlip e.g. with a
large screwdriver can damage the exhaust gas turbocharger.
– Turn the vacuum unit -1- and circlip -4- and remove them so
that the exhaust gas turbocharger is not damaged.
– Unhook the control rod from the adjuster lever and remove the
pressure box with position sender for charge pressure regu‐
lator - G581- .
Installing
– Screw counter nut and end piece onto the control rod of the
pressure can from the repair kit.
– For the first adjustment, compare the pressure box from the
repair kit with the original pressure box.
– Adjust the position of the end piece from the repair kit to the
thread length of the end piece of the original pressure box.
– Hook the vacuum unit -1- with tail on adjusting lever of the
exhaust gas turbocharger. Position the pressure box and
screw in the screws -arrows- by hand up to the stop.
– Attach the plug -2- on the position sender for charge pressure
regulator - G581- .
– Tighten screws -arrows- to 10 Nm.
– Start engine. Connect vehicle diagnostic tester .
– Querying and erasing event memory of engine control unit
⇒ Vehicle diagnostic tester.
– To perform basic adjustments:
♦ Systems capable of diagnostics
♦ 01 - Engine electronics, functions
♦ 01 - Basic setting
♦ Adaptation of the exhaust gas turbocharger
Check the voltage value
– Check raw voltage. In addition, use the Vehicle diagnostic
tester .
– The voltage value in the:
♦ Self-diagnosis
– 3Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
in position -A- for “vacuum”.
NOTICE
Risk of damage to the pressure box from excessive vacuum!
♦ Under no circumstances may a vacuum greater than 0.08
MPa (800 mbar) be generated.
– Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
into position -B- to ensure the pressure box is vented until the
pressure reaches the ambient pressure.
Voltage value o.k.
Note
When removing and installing the circlip, keep the force exerted
on the lever hoist to a minimum. Pushing the circlip e.g. with a
large screwdriver can damage the exhaust gas turbocharger.
– Hook the vacuum unit -1- on the adjusting lever of the turbo‐
charger. Position the pressure box and screw in the screws
-arrows- by hand up to the stop.
– Check voltage ⇒ page 189 .
Voltage not OK.
– Repeat the process ⇒ page 190 .
Voltage value o.k.
– Tighten the screws of the pressure box ⇒ page 191 .
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Start engine. Connect vehicle diagnostic tester .
– Querying and erasing event memory of engine control unit
⇒ Vehicle diagnostic tester.
Tightening torques - summaries of components
screws Tightening torque
Screws -arrows- 10 Nm
Note
Note
When removing and installing the circlip, keep the force exerted
on the lever hoist to a minimum. Pushing the circlip e.g. with a
large screwdriver can damage the exhaust gas turbocharger.
– Hook in the control rod at the adjuster lever, attach the pres‐
sure box, and turn in the screws -3- as far as they can go by
hand.
Note
When removing and installing the circlip, keep the force exerted
on the lever hoist to a minimum. Pushing the circlip e.g. with a
large screwdriver can damage the exhaust gas turbocharger.
– 3Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
in position -A- for “vacuum”.
NOTICE
Risk of damage to the pressure box from excessive vacuum!
♦ Under no circumstances may a vacuum greater than 0.08
MPa (800 mbar) be generated.
– Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
into position -B- to ensure the pressure box is vented until the
pressure reaches the ambient pressure.
Voltage value o.k.:
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Start engine. Connect vehicle diagnostic tester .
– Querying and erasing event memory of engine control unit
⇒ Vehicle diagnostic tester.
Voltage not OK:
– Release screws -1-.
– Adjust the voltage value ⇒ page 193 .
– Coat the screws with sealing varnish from the repair kit.
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Start engine. Connect vehicle diagnostic tester .
– Querying and erasing event memory of engine control unit
⇒ Vehicle diagnostic tester.
Tightening torques
screws Tightening torque
Screws -1- 10 Nm
2 Charge-air system
⇒ “2.1 Summary of components - charge air system”, page 195
⇒ “2.2 Removing and installing charge air cooler”, page 196
⇒ “2.3 Removing and installing charge pressure sender G31 ”,
page 199
⇒ “2.4 Removing and installing charge air temperature sender”,
page 200
⇒ “2.5 Checking the charge-air system for leak-tightness”,
page 201
⇒ “2.6 Leak testing the charge air cooler”, page 203
11 - Hose clamp
12 - Screw
❑ 8 Nm
13 - Throttle valve control unit - J338-
❑ Removing and installing ⇒ “5.3 Removing and installing the throttle valve control unit J338 ”, page 238
14 - Mounting bracket
❑ Throttle valve control unit - J338-
15 - Double screw
❑ 20 Nm
16 - Screw
❑ 20 Nm
17 - O-ring
❑ Different versions ⇒ ETKA - Electronic Catalogue of Original Parts
18 - Air guide pipe
19 - O-ring
❑ Different versions ⇒ ETKA - Electronic Catalogue of Original Parts
20 - Charge air temperature transmitter after charge air cooler - G811-
❑ 22 Nm
21 - O-ring
❑ Different versions ⇒ ETKA - Electronic Catalogue of Original Parts
– Unscrew screws -2- and then screws -3-, -4-, -5-, detach and
remove charge air cooler -1-.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
NOTICE
If a new charge air cooler has been fitted, the cooling system
must be flushed and the coolant must be replaced to ensure
optimum protection of the surfaces
⇒ “1.4 Flushing the cooling system”, page 135 .
Note
♦ Charge-air system
⇒ “2.1 Summary of components - charge air system”,
page 195
– Disconnect vacuum lines -1- and -2- and unscrew screw -3-.
– Release screw -4-. Release vacuum line and remove bracket
for charge air cooler.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Install radiator for exhaust gas recirculation (high pressure)
⇒ “4.2.1 Removing and installing radiator for high pressure
exhaust gas recirculation”, page 288 .
– Top up coolant ⇒ page 132 .
Tightening torques - summaries of components
Note
♦ Charge-air system
⇒ “2.1 Summary of components - charge air system”,
page 195
Note
Note
♦ Charge-air system
⇒ “2.1 Summary of components - charge air system”,
page 195
– Release and pull off connector -1- and screw out charge air
temperature sender after charge air cooler - G811- -2-.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
Tightening torques - summaries of components
Note
♦ Charge-air system
⇒ “2.1 Summary of components - charge air system”,
page 195
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
Note
NOTICE
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 0.05 MPa (0.5 bar).
– Listen to, touch or use commercially available leak search
spray or the ultrasonic measuring device e. g. -V.A.G 1842- to
check the charge-air system with exhaust gas turbocharger for
leak points.
Note
Note
The charge air cooler generates a pressure of 0.05 MPa (0.5 bar)
on the suction side. The pressure in this case is measured in the
cooling system.
Conditions
• The coolant temperature must be at least 40 °C.
Connect turbocharger tester - V.A.G 1397A-
– Screw the adapter - VAS 691 005/5- onto the coolant expan‐
sion reservoir.
– Mount Y distributor - VAS 691 005/1- onto the adapter - VAS
691 005/5- .
– Connect valve -1- of connection »C« and open valve -2- of
connection »A«.
– Connect hose of the connection »A« Y distributor to connec‐
tion »II« of the turbocharger tester - V.A.G 1397A- .
– Put turbocharger tester - V.A.G 1397A- in switch position
»II« (measuring relative pressure) and switch on. The »II«
must be visible.
Connect tester for charge air systems - V.A.G 1687-
– Remove engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
Note
NOTICE
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 0.05 MPa (0.5 bar).
Note
A small amount of air escapes via the valves into the engine. For
this reason no pressure test is possible.
Note
Note
– Insert washer jet -D- into the hose connection -A- of the Y dis‐
tributor.
– Position test adapter - VAS 691 005/5- on the hose at con‐
nection -B-.
– Connect pressure hose to connection -C-.
– Open the shut-off tap and blow air through the hose for approx.
15 seconds.
Note
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
❑ Summary of compo‐
nents ⇒ Fuel system;
Rep. gr. 20 ; Fuel tank;
Summary of compo‐
nents - Fuel tank
2 - Injection units
❑ Summary of compo‐
nents
⇒ “3.1 Summary of com‐
ponents - injection units
(injectors)”, page 215
3 - High-pressure accumulator
(fuel distributor)
❑ with fuel pressure send‐
er - G247-
❑ with fuel pressure regu‐
lating valve - N276-
❑ Summary of compo‐
nents
⇒ “3.2 Summary of com‐
ponents - High pressure
reservoir (fuel distribu‐
tor)”, page 217
4 - High pressure pump
❑ with fuel dosage valve -
N290-
❑ Summary of compo‐
nents
⇒ “8.1 Summary of com‐
ponents - high pressure
pump”, page 253
Note
If air is still present in the fuel system the engine may enter dry-
running operation during the test drive. Switch off engine and
delete the event memory. Then proceed with the test drive.
2 Vacuum system
⇒ “2.1 Connection diagram - Vacuum system”, page 213
⇒ “2.2 Inspect the vacuum system”, page 213
1 - Vacuum unit
❑ for charge pressure
control
❑ at exhaust gas turbo‐
charger
2 - Air deflector
3 - Solenoid valve for charge
pressure control - N75-
♦ a - Vacuum supply
♦ b - To intake manifold
♦ c- To the vacuum unit for
charge pressure control
♦ d - To hose of the vent line
4 - Changeover valve for intake
manifold flap - N239-
♦ a - Vacuum supply
♦ b - To intake manifold
♦ c- To the vacuum unit for
charge pressure control
♦ d - To hose of the vent line
5 - Non-return valve
❑ Check fitting position
6 - Intake manifold flap
7 - Cylinder block
8 - Cylinder head cover
❑ with vacuum unit
11 - Screw
❑ 8 Nm
Note
Each injection unit has a small amount of return. If this return flow
quantity is relatively great (in relation to the return flow quantity of
the other injection units), this injection unit is probably defective.
Note
♦ Pay attention to cleanliness, no dirt must get into the fuel sys‐
tem!
♦ Check cylinders one after another.
Note
– Take hold of the lowest recess -arrow- and carefully unlock the
centre part -1- of the return-flow connections in
-direction of arrow-.
– Pull off return-flow line connections on injection unit by pulling
release buttons -2- upwards with removal tool - T10236-
-arrows-.
Note
– Place the hose lines of the return flow meter -VAS 6684- on
the return connections.
– Start engine and run in idle for a few minutes.
Speed Measured time Quantity per VAS 6684
injection unit scale
(max.)
Idle speed 4 minutes 25 ml between the
2nd and 3rd
line from the
top
2500 rpm 2 minutes 35 ml Measuring
glass is full
– When the engine is at operating temperature while the engine
is idling there must be only minimal difference in the return flow
quantity of all 3 return-flow lines (example -1-).
NOTICE
Risk of damaging the injection units!
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 6 .
Note
♦ Pay attention to cleanliness, no dirt must get into the fuel sys‐
tem!
♦ Check cylinders one after another.
Note
– Take hold of the lowest recess -arrow- and carefully unlock the
centre part -1- of the return-flow connections in
-direction of arrow-.
– Pull off return-flow line connections on injection unit by pulling
release buttons -2- upwards with removal tool - T10236-
-arrows-.
Clean and blow out adapter C7 of the return flow quantity meas‐
uring device - VAS 6684- .
NOTICE
Risk of damaging the injection units!
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 6 .
– Unscrew screws -1- and push down the coolant pipe -2- to the
rear.
– release and pull off connector -3- of the injection unit that is to
be removed.
Note
– Take hold of the lowest recess -arrow- and carefully unlock the
centre part -1- of the return-flow connections in
-direction of arrow-.
– Pull off return-flow line connections on injection unit by pulling
release buttons -2- upwards with removal tool - T10236-
-arrows-.
Note
NOTICE
Risk of damage to injection unit sealing surfaces!
♦ To remove the soot particles on the sealing surface of the
injection unit, clean the injection unit shaft in the cylinder
head with cleaning set - VAS 6811- or with a cloth soaked in
engine oil.
– Replace the sealing ring for the injection unit, using the as‐
sembly sleeve - T10377- .
Continued for used and new injection units
– Coat all O-rings with assembly oil, engine oil or diesel fuel be‐
fore installation.
– Install the injection units.
– First tighten the union nuts of the high pressure lines hand-
tight. Check that seating is free of tension.
– After replacement of one or more injection units the correction
values for the new injection units must be written to the engine
control unit ⇒ Vehicle diagnostic tester.
– Filling and bleeding the fuel system
⇒ “1.3 Filling/bleeding the fuel system”, page 211 .
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
Tightening torques - summaries of components
Note
♦ Injection units
⇒ “3.1 Summary of components - injection units (injectors)”,
page 215
NOTICE
Risk of damaging the injection units!
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 6 .
– Release nuts -1- and screw -3- and remove bracket -2-.
– Clean fuel line and line end with cold cleaner and blow dry with
compressed air.
NOTICE
Risk of damaging the injection units!
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 6 .
Note
♦ Clean fuel line and line end with cold cleaner before removal,
and blow dry with compressed air.
♦ Pay attention to the cylinder specific marking when re-using
the high pressure lines.
♦ The high pressure lines can be re-used after the following
tests:
♦ Check the sealing cone of the respective high pressure line for
deformations and cracks.
♦ The line borings must not be deformed, constricted or dam‐
aged.
♦ Corroded lines must no longer be used.
NOTICE
Risk of damaging the injection units!
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 6 .
Risk of line break because of high pressure line being under
tension!
♦ Slacken the fuel distributor and the clamping claws for im‐
proved and stress-free positioning of the injection lines.
♦ If necessary, move the fuel distributor slightly and turn the
corresponding injection unit slightly. The lines must be never
bent or twisted.
– Suction off dirt from the sealing cone at the fuel distributor.
– Moisten thread of the nut with clean engine oil.
– Hand-tighten union nuts, ensure that the fit is tension-free.
Note
♦ Injection units
⇒ “3.1 Summary of components - injection units (injectors)”,
page 215
♦ High pressure reservoir
⇒ “3.2 Summary of components - High pressure reservoir (fuel
distributor)”, page 217
NOTICE
Risk of damaging the injection units!
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 6 .
– Release fuel hoses and unscrew pin screw -1- and screw -3-
for the fuel return-flow line -2-.
Note
– Take hold of the lowest recess -arrow- and carefully unlock the
centre part -1- of the return-flow connections in
-direction of arrow-.
– Pull off return-flow line connections on injection unit by pulling
release buttons -2- upwards with removal tool - T10236-
-arrows-.
Note
♦ Injection units
⇒ “3.1 Summary of components - injection units (injectors)”,
page 215
♦ High pressure reservoir
⇒ “3.2 Summary of components - High pressure reservoir (fuel
distributor)”, page 217
4 Air filter
⇒ “4.1 Assembly overview - air filter housing”, page 230
⇒ “4.2 Removing and installing air filter housing”, page 231
1 - Air deflector
❑ on the air filter lower part
2 - Air guide lower part
❑ on the lock support
3 - air guide pipe top
❑ on the lock support
4 - Cover
❑ for air guide
5 - Screw
❑ 2 Nm
6 - Air filter top part
❑ remove mechanical
contaminations
7 - Air mass meter - G70-
Removing and installing
⇒ “6.4 Removing and installing
air flow mass meter G70 ”,
page 243
8 - Hose clamp
9 - Hose clamp
10 - intake hose
11 - Screw
❑ 2 Nm
12 - O-ring
❑ Replace if damaged.
13 - Air filter element
❑ Pay attention to change Volkswagen Technical Site: https://vwts.ru
intervals:
♦ ⇒ Maintenance ; Booklet Fabia III
♦ ⇒ Maintenance ; Booklet Rapid NH
14 - Air filter bottom part
❑ remove mechanical contaminations
15 - O-ring
❑ Replace if damaged.
16 - Drain pipe
❑ with valve
❑ clean
17 - Screw
❑ 5 Nm
18 - Rubber bearing
19 - Mounting bracket
20 - Nut
❑ 20 Nm
21 - Nut
❑ 10 Nm
22 - Screw
❑ 8 Nm
Note
Note
– Release and pull off drain pipe -2- from air filter housing -1-.
– Clean connection and air filter lower part and hose to remove
dirt and leaves.
– Observe the assembly markings -arrow- when placing the in‐
take hose on the air filter housing.
– Place air filter housing onto the support and push in until there
is an audible click.
– Press air filter down again and check by pulling that the air
filter is fully engaged.
Tightening torques - summaries of components
Note
5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 233
⇒ “5.2 Removing and installing intake manifold”, page 233
⇒ “5.3 Removing and installing the throttle valve control unit J338
”, page 238
1 - Screw
❑ 20 Nm
2 - Bushing
3 - Screw
❑ 20 Nm
4 - Intake manifold
❑ with an intake manifold
flap and active intake
manifold position send‐
er - G513- .
❑ Removing and installing
⇒ “5.2 Removing and in‐
stalling intake manifold”,
page 233
5 - Connector
❑ Charge pressure send‐
er - G31-
6 - Charge pressure transmit‐
ter - G31-
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling charge pressure
sender G31 ”, page 199
7 - Screw
❑ 8 Nm
8 - Seal
❑ Replace after disas‐
sembly
9 - Connector
❑ Active intake manifold
position sender - G513-
10 - Vacuum line
❑ for intake manifold flap
❑ ⇒ “2.1 Connection diagram - Vacuum system”, page 213
11 - Screw clamp
12 - Air deflector
Removing
– Remove engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Remove air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
– Release cover -1- and take off.
– Cut cable strap -arrow-. Release and pull off all connectors
visible in the illustration.
– Pull the electric harness -1- up slightly.
– Remove the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Summary of components -
noise insulation .
– Unscrew screw -2- for oil pipe on the intake manifold and pull
out the oil pipe -1- upwards.
– Unscrew screws -1- and -4- and remove throttle valve control
unit - J338- -3-.
– Remove the high pressure line between the high pressure
pump and the high pressure reservoir (fuel distributor)
⇒ “3.6.1 Removing the high pressure line between the high
pressure pump and the high pressure reservoir (fuel distribu‐
tor)”, page 224 .
Note
– Tighten the screws -1- crosswise from the inside outwards and
connect the vacuum line -3-.
– Tighten screw -4- with adapter piece - T10535- .
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
– Install high pressure lines
⇒ “3.6.3 Installing high pressure line”, page 225 .
– Install air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
Tightening torques - summaries of components
Note
♦ Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 233
Note
Note
♦ Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 233
Note
Note
– Loosen hose clamp -1-, remove fuel return-flow hose from the
fuel distributor.
– Close the return-flow line connection with a blind plug.
– Connect the auxiliary hose on the return line of the fuel dis‐
tributor.
– Hold this hose line in a suitable vessel in order to measure the
return flow quantity.
1) Test with engine running
– Start engine and run in idle.
• Specified value of minimum return flow quantity in 30 seconds:
0 ml
• A drop-leakage is permissible.
If the specified value is not reached, the fuel pressure regulating
valve - N276- is defective.
2) Test with engine running
If the condition under point 1) is fulfilled, increase the engine
speed to ≥ 2000 rpm.
• Set value of the return flow quantity: 0 ml.
• A drop-leakage is permissible.
If the specified value is not reached, the fuel pressure regulating
valve - N276- is defective.
3) The engine will no longer start
Perform the test at starter speed.
• Set value of the return flow quantity: 0 ml
• A drop-leakage is permissible
If the specified value is not reached, the fuel pressure regulating
valve - N276- is defective.
– Replace fuel pressure regulating valve - N276-
⇒ “6.1 Removing and installing the fuel pressure regulating
valve N276 ”, page 240 .
Note
– Suction the dirt out of the fuel distributor hole (thread and con‐
tact surface). To do so do not use any mechanical tools.
– Close the fuel distributor hole immediately with a suitable
screw plug in order to prevent dirt from penetrating.
Installing
Note
♦ Look out for damage to the sealing surfaces (biting edge seal)
and the thread of the new fuel pressure sender - G247- . It is
possible to use the fuel pressure sender - G247- again.
♦ Also check the sealing surface in the hole of the fuel distributor.
♦ Coat the threaded insert and deformable sealing lip of the fuel
pressure sender - G247- with diesel fuel.
Note
– Unscrew screws -1- and turn and pull off air mass meter - G70-
-2-.
Installing
It is essential that the following work instructions be performed to
ensure perfect functioning of the air mass meter - G70- :
Note
– Check air mass meter as well as air guide hose (on the side
of the fresh air) for salt residues, dirt and leaves.
– Check suction channel up to air filter insert for dirt. if you find
it is dirty, remove salt residues, dirt and leaves from the air filter
housing (top and bottom section) (clean by washing or using
a vacuum as required).
– Insert and turn the air mass meter - G70- -2- to install it. Screw
in bolts -1-.
– Install air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– After replacement of the Air flow sensor , the Vehicle diag‐
nostic tester was connect ⇒ Vehicle diagnostic tester,
– Switch on the ignition and select:
♦ 0001 - Engine electronics, functions
♦ 0001 - Reset engine control learnt values
♦ Reset after replacing the air mass meter
Tightening torques - summaries of components
Note
Note
Removing
– Remove engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Loosen clamps -arrow- and disconnect hoses of the lines for
differential pressure sender.
– Tie off heat shield collar.
– Unscrew screw -1-, and release and pull off connectors -2- and
-3-
NOTICE
Risk destroying the differential pressure sender - G505- !
♦ Disconnect hose carefully and straight from the connection
fitting (the connection fitting very easily breaks off the differ‐
ential pressure sender - G505- ).
Note
Note
♦ Lambda probe
⇒ “9.1 Summary of components - lambda probe”, page 258
♦ Toothed belt guard
⇒ “2.1 Summary of components - toothed belt guard”,
page 81
– Unscrew screws -1- and release and pull off connectors -2-
and -3-
NOTICE
Risk of destruction of the pressure sensor as a result of the
connection fitting breaking!
♦ Pull hoses off carefully and straight from the connection fit‐
ting.
Note
Note
♦ Lambda probe
⇒ “9.1 Summary of components - lambda probe”, page 258
♦ Toothed belt guard
⇒ “2.1 Summary of components - toothed belt guard”,
page 81
Note
NOTICE
Risk of engine control unit destruction!
♦ The engine control unit must not touch the positive pole of
the battery
Note
Note
CAUTION
Risk of burns due to the hot air blower!
♦ Only warm up the shear screws with a hot air blower.
♦ By warming the shear screws, the cover plate and parts in
its vicinity are heated up strongly too. Where necessary,
protect these parts by a piece of sheet covering.
NOTICE
Risk of engine control unit destruction!
♦ The engine control unit must not touch the positive pole of
the battery
1 - Screw
❑ Replace after disas‐
sembly
❑ 20 Nm + 180°
2 - Nut
❑ to release and tighten
use counterholder -
T10051-
❑ 95 Nm
3 - Toothed belt gear on the
high pressure pump
4 - Hub
❑ to remove, use extractor
-T10489-
5 - Screw
❑ Replace after disas‐
sembly
❑ 20 Nm + 45°
6 - Bracket for auxiliary units
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling bracket for aux‐
iliary units”, page 34
7 - Fuel intake hoses
8 - Fuel return-flow hoses
9 - Hose clamp
10 - Connector
❑ Fuel dosage valve -
N290-
11 - High pressure line
❑ between the high pressure reservoir (fuel distributor) and high pressure pump
❑ removing
⇒ “3.6.1 Removing the high pressure line between the high pressure pump and the high pressure res‐
ervoir (fuel distributor)”, page 224
❑ follow all instructions for installation of high pressure lines
⇒ “3.6.3 Installing high pressure line”, page 225
12 - Screw
❑ 20 Nm + 45°
13 - Screw
❑ 20 Nm + 45°
14 - Support
❑ between the high pressure pump and the cylinder head
NOTICE
Risk of damage to the high pressure pump through running dry.
♦ If the high pressure pump is removed or replaced, the fuel
system must be filled/bled before the engine is started for
the first time
⇒ “1.3 Filling/bleeding the fuel system”, page 211 .
– Release and pull off connector -1- and loosen clamp -2-.
– Unscrew screws -4- and -5- and remove air deflector with ex‐
haust gas recirculation pipe -3-.
– Removing the high pressure line between the high pressure
pump and the high pressure reservoir (fuel distributor)
⇒ “3.6.1 Removing the high pressure line between the high
pressure pump and the high pressure reservoir (fuel distribu‐
tor)”, page 224 .
– Remove the toothed belt from the camshaft
⇒ “2.5 Remove the toothed belt from the camshaft”,
page 93 .
– Release retaining clips -1- and disconnect fuels hoses -2- and
-3- from the high pressure pump.
– To do so, insert the rig pin -T10492- into fork -2- of the hub
and into the bore behind it -1- in the auxiliary units bracket.
NOTICE
Risk of damage to the high pressure pump through running dry.
♦ If the high pressure pump is removed or replaced, the fuel
system must be filled/bled before the engine is started for
the first time.
Note
9 Lambda probe
⇒ “9.1 Summary of components - lambda probe”, page 258
⇒ “9.2 Removing and installing Lambda probe”, page 259
NOTICE
♦ New lambda probes are coated with an assembly paste; the
paste is not allowed to reach to slots on the body of the
probe.
♦ For a re-used lambda probe, only coat the thread with hot
bolt paste .
♦ This paste must not come into contact with the slots of the
lambda probe body.
♦ The electrical wiring of the lambda probe must be attached
to the same position when installing. This prevents the lamb‐
da probe cable from coming into contact with the exhaust
pipe.
Note
♦ Lambda probe
⇒ “9.1 Summary of components - lambda probe”, page 258
– Release and pull off connector -1- and undo line of lambda
probe.
NOTICE
♦ New lambda probes are coated with an assembly paste; the
paste is not allowed to reach to slots on the body of the
probe.
♦ For a re-used lambda probe, only coat the thread with hot
bolt paste .
♦ This paste must not come into contact with the slots of the
lambda probe body.
♦ The electrical wiring of the lambda probe must be attached
to the same position when installing. This prevents the lamb‐
da probe cable from coming into contact with the exhaust
pipe.
Note
♦ Lambda probe
⇒ “9.1 Summary of components - lambda probe”, page 258
♦ Underwear ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underfloor trim panel; Summary of components - Floor rein‐
forcement panels
♦ Engine cover ⇒ General body repairs, exterior ; Rep. gr. 66 ;
Noise insulation; Summary of components- noise insulation .
26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Assembly overview - silencers”, page 263
⇒ “1.2 Separating exhaust pipes/silencers”, page 265
⇒ “1.3 Removing and installing pre-exhaust pipe”, page 266
⇒ “1.4 Removing and installing middle silencer”, page 267
⇒ “1.5 Removing and installing rear silencer”, page 268
⇒ “1.6 Align exhaust system free of stress”, page 270
⇒ “1.7 Inspecting the exhaust system for leaks”, page 271
⇒ “1.8 Installation position of clamping sleeve”, page 271
1 - Clamping sleeve
❑ Tightening torque
⇒ “1.8 Installation posi‐
tion of clamping sleeve”,
page 271
2 - Tunnel bridge
❑ Check fitting position
3 - Nut
❑ 20 Nm
4 - Retaining strap
❑ Replace if damaged.
5 - Hanger
❑ Replace if damaged.
6 - screws
❑ 23 Nm
7 - Separation point
8 - Silencer
1 - Separation point
❑ for first equipment rear
part of exhaust system
one building unit with
middle part of exhaust
system
❑ Replace individually
when carrying out re‐
pairs
❑ Position clamping
sleeve on the marking
when installing
⇒ “1.4 Removing and in‐
stalling middle silencer”,
page 267
❑ Installing the exhaust
system without tension
⇒ “1.6 Align exhaust
system free of stress”,
page 270
2 - Retaining strap
❑ Replace if damaged.
3 - Middle and rear part of the
exhaust system
4 - Screw
❑ 23 Nm
5 - Nut
❑ 20 Nm
6 - Tunnel bridge
7 - Clamping sleeve
❑ 23 Nm
Work procedure
– Separate exhaust pipe at the separation point -arrow 2- with
chain pipe cutter (e.g. -VAS 6254- ) at a right angle.
– When installing clamping sleeve -4-, centre it on the side
markings -1- and -3-.
– Unscrew screws -2- of the clamping sleeve -1- and slide the
clamping sleeve backwards.
– Release and pull off connectors -6- of the exhaust flap control
unit - J883- .
– Slacken screw clamp -4-.
– Pull front exhaust pipe -3- off the retaining strap -5- and re‐
move.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
Note
Replace gasket.
– Set up the front exhaust pipe so that the dimension -a- is the
same on left and right.
– Align exhaust system free of stress
⇒ “1.6 Align exhaust system free of stress”, page 270 .
Tightening torques - summaries of components
Note
♦ Screw clamp: 8 Nm
♦ Installation position of clamping sleeve
⇒ “1.8 Installation position of clamping sleeve”, page 271
♦ Engine cover ⇒ General body repairs, exterior ; Rep. gr. 66 ;
Noise insulation; Summary of components- noise insulation .
Removing
Note
CAUTION
To avoid injury from metal shavings, wear eye protection and
protective clothing!
Note
Note
Removing
Separation point without clamping sleeve
– Separate exhaust pipe at the separation point -arrow 2- with
chain pipe cutter (right-angled).
Separation point with clamping sleeve
Note
CAUTION
Risk of accident from weight of the rear silencer!
♦ A second mechanic is required to remove the rear silencer.
– Unhook retaining strap for the rear silencer on the rear axle
⇒ “1.1.2 Summary of components- silencer, Rapid NH”, page
265 .
– Unscrew screws of the retaining strap for the rear silencer
⇒ “1.1.2 Summary of components- silencer, Rapid NH”, page
265 .
– Remove the rear silencer.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Align the mounting brackets for the rear silencer. Align so that
the mountings for the retaining straps are parallel.
– Tighten screws for retaining strap.
– Align exhaust system free of stress
⇒ “1.6 Align exhaust system free of stress”, page 270 .
Tightening torques - summaries of components
♦ Silencer
⇒ “1.1.2 Summary of components- silencer, Rapid NH”, page
265 .
Note
Note
Tightening torque
Component Tightening torque
Clamping sleeve 23 Nm
10 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
11 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
12 - Screw
❑ 9 Nm
13 - Nut
❑ 10 Nm
14 - Measurement pipe
❑ to differential pressure transmitter - G505-
❑ Union nut tightening torque 45 Nm
15 - Measurement pipe
❑ for exhaust gas pressure sensor 1 - G450-
❑ Union nut tightening torque 45 Nm
16 - Screw
❑ 9 Nm
17 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
18 - Mounting bracket
❑ for exhaust gas cleaning module
19 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
20 - Mounting bracket
❑ for exhaust gas cleaning module
21 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
22 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
23 - Screw clamp
❑ Replace after disassembly
❑ 8 Nm
24 - Seal
❑ Replace after disassembly
25 - Exhaust pipe
❑ Removing and installing ⇒ “1.3 Removing and installing pre-exhaust pipe”, page 266
❑ Installing the exhaust system without tension ⇒ “1.6 Align exhaust system free of stress”, page 270
26 - Exhaust gas cleaning module
❑ Particle filter with catalyser
❑ Removing and installing ⇒ “2.2 Removing and installing exhaust gas cleaning module”, page 275
27 - Seal
❑ Replace after disassembly
28 - Screw clamp
❑ Replace after disassembly
❑ 8 Nm
29 - Screw clamp
❑ Replace after disassembly
❑ Tightening torque and tightening order
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
30 - Seal
❑ Replace after disassembly
– Release and pull off connector -1- and undo line of lambda
probe.
– Release and pull off connectors -1-, -2- and -3- and loosen
line.
– Release retaining clip -1- and pull coolant hose off the radiator
for exhaust gas recirculation.
– Release hose clamp -2-, unscrew screws -4- and remove ex‐
haust gas recirculation -1-.
– Release clamp -3- and pull coolant hose off the bulkhead ple‐
num chamber.
– Unscrew screw -1- with socket insert XZN - T10385- and re‐
lease clamp -3-.
– Remove radiator for exhaust gas recirculation -2- from ex‐
haust gas cleaning module.
Note
– Mount new exhaust flap control unit . When doing so, ensure
that the driver of the control unit -1- engages into the tab of the
exhaust flap -2-.
– Insert new securing bolts and screw on new nuts.
– Tighten the top bolts first, then the bottom bolt. Tightening tor‐
que: 10 Nm.
– Remove protective cap for the electrical plug connection and
connect connector -1-. Secure the heat shield collar.
– After replacing the exhaust flap control unit - J883- , the learnt
values must be changed in the engine control unit.
– Connect diagnostic unit ⇒ Vehicle diagnostic tester.
– Switch on the ignition and select:
♦ 0001 - Basic setting
♦ Adaption of the exhaust flap
Tightening torques - summaries of components
Note
NOTICE
♦ Wear safety gloves and safety goggles!
♦ Fit all cable straps on again in the same place when instal‐
ling.
♦ When removing, the electric cable must be not cut off, since
doing so would mean that fault diagnosis would no longer be
possible.
Note
Note
NOTICE
♦ Wear safety gloves and safety goggles!
♦ Fit all cable straps on again in the same place when instal‐
ling.
♦ When removing, the electric cable must be not cut off, since
doing so would mean that fault diagnosis would no longer be
possible.
NOTICE
Malfunction caused by loose exhaust gas temperature trans‐
mitter.
♦ The threads of the exhaust gas temperature transmitter -
G235- and -G495- are coated.
♦ It must NOT be coated additionally with hot bolt paste and
must be tightened to the specified tightening torque.
Note
Note
1 - Screw clamp
❑ Replace after disas‐
sembly
❑ 8 Nm
2 - Exhaust gas circulation
❑ for air guide
3 - Mounting bracket
4 - Screw
❑ 9 Nm
5 - Screw
❑ 20 Nm
6 - Mounting bracket
❑ for charge air cooler and
refrigerant hoses
7 - Ball stud
❑ for engine cover
❑ 4 Nm
8 - Exhaust gas recirculation
valve 1 - GX5-
consists of:
♦ Exhaust gas recirculation
control motor - V338-
♦ Exhaust gas recirculation
potentiometer - G212-
9 - Seal
❑ Replace after disas‐
sembly
10 - Exhaust gas circulation
❑ from exhaust manifold
11 - Screw
❑ 9 Nm
12 - Nut
❑ 20 Nm
13 - Screw
❑ 20 Nm
14 - Screw
❑ 9 Nm
15 - Mounting bracket
16 - Screw
❑ 20 Nm
17 - Seal
❑ Replace after disassembly
18 - Screw
❑ 20 Nm
– Release hose clamp -1-, unscrew screw -3- and remove ex‐
haust gas recirculation -2-.
– Unscrew screws -1- to -4- and remove radiator for exhaust gas
recirculation -5-.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Install charge air cooler
⇒ “2.2 Removing and installing charge air cooler”, page 196 .
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery .
– Install air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
Tightening torques - summaries of components
Note
Removing
– Remove exhaust gas recirculation valve 2 - GX6-
⇒ “4.4 Removing and installing exhaust gas recirculation valve
2 GX6 ”, page 291 .
Vehicles fitted with a manual gearbox
– Remove shift cable with cable support from gearbox and place
laterally ⇒ Rep. gr. 34 ; Shift operation; Removing and in‐
stalling selector mechanism .
Vehicles with automatic gearbox
– Remove selector cable with cable support from gearbox and
place sideways ⇒ Rep. gr. 34 ; Shift operation; Removing and
installing selector mechanism .
Continued for all vehicles
– Unlock latch -arrow-, loosen coolant hose holder, if present.
– Just loosen screw -1-, remove screw -2- with plug insert XZN
- T10385- .
Note
Note
Note
♦ Tool - T10533-
♦ XZN socket - T10385-
Exhaust gas recirculation valve 2 - GX6-
consists of:
♦ Control engine 2 for exhaust gas recirculation - V339-
♦ Exhaust gas recirculation potentiometer 2 - G466-
Removing
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page 131 .
– Remove pre-exhaust pipe
⇒ “1.3 Removing and installing pre-exhaust pipe”, page 266 .
– If present, remove heat shield for underbody.
– Remove pendulum support
⇒ “2.4 Removing and installing pendulum support”, page 24 .
– Unscrew screws -1- for steering gear.
Note
Rotate the spindle so that parts on the fan shroud are not dam‐
aged.
– Release retaining clip -1- and release clamp -2-. Detach cool‐
ant hoses from radiator for exhaust gas recirculation.
– Release hose clamp -2-, unscrew screws -4- and remove ex‐
haust gas recirculation -1-.
– Release and pull off connector -1- and unscrew screws -2-.
– Remove exhaust gas recirculation valve 2 - GX6- -3- down‐
wards.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
Note
Note
1 - Glow plug
♦ Glow plug 1 - Q10-
♦ Glow plug 2 - Q11- with
combustion chamber pres‐
sure sender for cylinder 2 -
G678-
♦ Glow plug 3 - Q12-
❑ Glow plug variants
⇒ Fig. ““Glow plug var‐
iants”“ , page 295
❑ Removing and installing
⇒ “1.2 Removing and in‐
stalling glow plugs”,
page 295
❑ Glow plugs without
combustion chamber
pressure transmitter
17 Nm
❑ Glow plugs with com‐
bustion chamber pres‐
sure transmitter 12 Nm
2 - Electrical plug connection
❑ for glow plugs
3 - O-ring
❑ no spare parts, in case
of damage replace to‐
gether with Hall sender -
G40-
4 - Hall transmitter - G40-
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling Hall sender G40
”, page 298
5 - Screw
❑ 4.5 Nm
6 - Rotor
❑ Engine speed sender - G28-
NOTICE
Risk of damaging support sleeves.
♦ Only press pliers - 3314- for disconnecting glow plug con‐
nectors together so that they grip the support sleeve collar
securely without damaging it.
– Position pliers - 3314- using the pliers groove arrow -A- on the
support sleeve collar arrow -B-, as shown.
– Carefully disconnect the plug from the glow plugs.
– Clean glow plugs in the cylinder head (no dirt must fall into the
cylinder).
NOTICE
Wear protective gloves and protective goggles when working
with grease remover!
Note
Note
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Place the glow plug connectors -1- back onto the glow plugs
-arrows-.
Note
Note
– Unlock locks -arrow- and pull out the automatic glow period
control unit - J179- -1- upwards.
Installing
The installation occurs in reverse order.
– Release and pull off connector -1- and unscrew screw -2-.
– Remove knock sensor 1 - G61- -3-.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Install the engine cover
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Install air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
♦ Tightening torque: 20 Nm
Note
Note
– Insert the engine speed sender - G28- so that the lug -3- en‐
gages in the guide on the sealing flange -4-.
– Tighten screw -2- and insert plug -1-.
Tightening torques - summaries of components
Note