Skoda Karoq 2018 Instruction manual

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Workshop Manual
Karoq 2018 ➤
Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine
Engine ID DFG
ADFH ACRG BDBG CDDY ADFFA
Edition 06.2017
Service
Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2017 ŠKODA AUTO a. s. D4B806D83BB

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions for working on vehicles with start-stop system . . . . . . . . . . . . . . . . . . 3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Assembly of radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Attach engine attached to engine and gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.5 Support the engine in its installed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.6 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.7 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Summary of components - sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . . . 37
1.3 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.4 Removing and installing tensioning pulley for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 39
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.6 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.8 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 43
2 Cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.1 Summary of components - cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1 Summary of components - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Replace the needle bearing in the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Karoq 2018 ➤ , Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
Contents i

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4.3 Measure piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.4 Check piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.5 Removing and installing gasket rings for injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.5 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.2 Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.3 Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.4 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.1 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.1 Assembly overview - pan/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.3 Removing and installing the bottom part of the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.4 Removing and installing top part of the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 140
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Summary of components - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 146
3.4 Testing oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.5 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.6 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 149
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.4 Flushing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.1 Summary of components - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.3 Summary of components - coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . 197
Karoq 2018 ➤ , Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
ii Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.6 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.7 Testing the coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.8 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 213
2.9 Removing and installing coolant temperature transmitter G62 . . . . . . . . . . . . . . . . . . . . . . 213
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.1 Summary of components - coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4 Coolers, radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.2 Summary of components - fan shroud and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4.3 Summary of components - radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.5 Removing and installing charge air cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.6 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.7 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
4.8 Removing and installing radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.9 Removing and installing the radiator blind control motor V544 . . . . . . . . . . . . . . . . . . . . . . 256
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1.3 Replacing exhaust gas turbocharger pressure box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
1.4 Removing and installing the exhaust gas turbocharger connection fitting . . . . . . . . . . . . . . 290
2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2.2 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.3 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.4 Installing and removing the air guide pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
2.5 Leak testing the charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.2 Installation location overview - fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.3 Filling/bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.4 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
2.1 Connection diagram - Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
2.2 Checking the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3 Injection units/high pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3.1 Summary of components - injection units (injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3.2 Summary of components - High pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.3 Adjust the correction values for injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3.4 Check injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3.5 Check injection unit return quantity with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3.6 Check injection unit return flow quantity at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3.7 Checking the injection units in open state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3.8 Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.9 Removing and installing high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3.10 Removing and installing high pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Karoq 2018 ➤ , Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
Contents iii

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4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
5.3 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 344
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
6.1 Removing and installing the fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . 347
6.2 Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
6.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
6.4 Removing and installing air flow mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
6.5 Removing and installing differential pressure transmitter G505 . . . . . . . . . . . . . . . . . . . . 357
6.6 Removing and installing pressure sensor for exhaust gas 1 G450 . . . . . . . . . . . . . . . . . . 360
6.7 Removing and installing intake air temperature sender G42 . . . . . . . . . . . . . . . . . . . . . . 361
6.8 Removing and installing charge air temperature sender after charge air cooler G811 . . . . 362
6.9 Removing and installing fuel temperature transmitter G81 . . . . . . . . . . . . . . . . . . . . . . . . 362
6.10 Removing and installing NOx sender control unit GX30 . . . . . . . . . . . . . . . . . . . . . . . . . . 363
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
8 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
9.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
9.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
1.2 Removing and installing pre-exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
1.4 Removing and installing middle silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
1.5 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
1.6 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
1.7 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
1.8 Summary of components - pre-exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
1.9 Align exhaust tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
2 Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2.1 Summary of components - exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
2.3 Removing and installing exhaust gas cleaning module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
2.4 Removing and installing the exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . 414
3 SCR system (Selective Catalytic Reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
3.1 Summary of components - reduction agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
3.2 Summary of components - delivery line for reduction agent . . . . . . . . . . . . . . . . . . . . . . . . 421
3.3 Summary of components - delivery module for reduction agent . . . . . . . . . . . . . . . . . . . . 424
3.4 Removing and installing reduction agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
3.5 Removing and installing the front part of the delivery line for reduction agent . . . . . . . . . . 429
3.6 Removing and installing the delivery module for reduction agent . . . . . . . . . . . . . . . . . . . . 440
3.7 Removing and installing the injection valve for reduction agent N474 . . . . . . . . . . . . . . . . 442
3.8 Removing and installing the control unit for reduction agent heater J891 . . . . . . . . . . . . . . 444
3.9 Summary of components - injection valve for reduction agent . . . . . . . . . . . . . . . . . . . . . . 444
3.10 Removing and installing the rear section of the delivery line for reduction agent . . . . . . . . 446
3.11 Removing and installing the filler tube for reduction agent tank . . . . . . . . . . . . . . . . . . . . . . 449
3.12 Disconnect delivery line for reduction agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
3.13 Adjusting the learnt value for the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
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1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
iv Contents

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4 Exhaust temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
4.1 Summary of components - exhaust temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . 455
4.2 Removing and installing the exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . 459
4.3 Removing and installing the exhaust gas temperature sender 2 G448 . . . . . . . . . . . . . . . . 462
4.4 Removing and installing the exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . 464
4.5 Removing and installing the exhaust gas temperature sender 4 G648 . . . . . . . . . . . . . . . . 465
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
5.1 Summary of components - Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
5.2 Summary of components - exhaust gas recirculation 1 GX5 . . . . . . . . . . . . . . . . . . . . . . 473
5.3 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 473
5.4 Removing and installing exhaust gas recirculation valve 1 GX5 . . . . . . . . . . . . . . . . . . . . 481
5.5 Removing and installing exhaust gas recirculation valve 2 GX6 . . . . . . . . . . . . . . . . . . . . 482
5.6 Removing and installing temperature sensor for exhaust gas recirculation G98 . . . . . . . . 483
5.7 Test air-tightness of the radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 485
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
1.1 Summary of components - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
1.2 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 490
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
1.5 Removing and installing the engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . 491
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1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
Contents v

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vi Contents

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00 – Technical data
1 Identification
(SRL001096; Edition 06.2017)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data
♦ The engine number (“engine identification characters” and
“serial number”) is located in the front at the engine/gearbox
joint -arrow-.
♦ In addition, a sticker with the “engine identification characters”
and “serial number” is attached to top toothed belt guard.
♦ Starting with the letter “C”, new four digit engine codes have
been introduced.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched on the cylinder block including
the serial number.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine control unit.
Note
♦ The 4-digit engine identification characters are on the identifi‐
cation plate (country version), the vehicle data sticker and on
the engine control unit.
♦ See ⇒ Maintenance ; Booklet Kodiaq or ⇒ Maintenance ;
Booklet Karoq for the installation locations for identification
plate (country version) and vehicle data sticker.
Kodiaq
Engine codes DFGA DFHA DBGC CRGB
Manufac‐
tured
10.2016 ► 10.2016 ► 01.2017 ► 04.2017 ►
Emission
standards
conforming
to
EU6 plus EU6 plus EU5 plus EU3/EU4
Displace‐
ment l 1.968 1.968 1.968 1.968
Output kW at rpm 110/3500 - 4000 140/3500 - 4000 110/3500 … 4000 130/3600 … 4000
Torque Nm at rpm 340/1750 … 3000 400/1750 … 3250 340/1750 … 3500 380/1750 … 3500
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Cylinder/
valves per
cylinder
4/4 4/4 4/4 4/4
Compres‐
sion ratio
16.2 15.5 16.2 16.2
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
SCR catalytic converter yes yes no no
Exhaust gas recircula‐
tion with radiator yes yes yes yes
Karoq 2018 ➤ , Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
1. Identification 1

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Engine codes DFGA DFHA DBGC CRGB
Turbocharging yes yes yes yes
Charge air cooler yes yes yes yes
Particle filter with cata‐
lyser yes yes yes yes
Balancing shafts yes yes yes yes
Karoq
Engine codes DDYA DFFA
Manufactured 07.2017 ► 07.2017 ►
Emission standards
conforming to
EU6 plus EU6 plus
Displacement l 1.598 1.968
Output kW at rpm 85/3250 - 4000 110/3500 - 4000
Torque Nm at rpm 250/1500 … 3200 340/1750 … 3000
Bore ∅ mm 79.5 81.0
Stroke mm 80.5 95.5
Cylinder/valves per
cylinder
4/4 4/4
Compression ratio 16.2 16.2
Firing order 1-3-4-2 1-3-4-2
SCR catalytic converter no yes
Exhaust gas recirculation with radiator yes yes
Turbocharging yes yes
Charge air cooler yes yes
Particle filter with catalyser yes yes
Balancing shafts no no
Karoq 2018 ➤ , Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
2 Rep. gr.00 - Technical data

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2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.2 Safety precautions for working on vehicles with start-stop
system”, page 3
⇒ “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
4
⇒ “2.5 Safety precautions when working on the SCR system”,
page 4
2.1 Safety precautions when working on
fuel supply system
Leaking fuel creates a fire hazard
When the battery is connected, the door contact switch activates
the fuel pump when the driver door is opened. Escaping fuel can
ignite and cause a fire.
– Interrupt the supply voltage to the fuel pump before opening
the fuel system.
Risk of injury caused by fuel which is under high pressure.
The fuel system is under pressure. There is a risk of injury from
ejected fuel.
Before opening the fuel system:
– Wear safety goggles.
– Wear protective gloves.
– Relieve the pressure: place clean cloths around the connec‐
tion point and carefully open the connecting point.
Malfunctions caused by air in the fuel supply
After working on the fuel tank or the fuel delivery unit, the dosing
pump takes in air and conveys the air to the auxiliary heating. The
auxiliary heating may malfunction as a result of air in the fuel sup‐
ply to the auxiliary heating.
– Fill the new fuel extraction pipe with fuel.
2.2 Safety precautions for working on vehi‐
cles with start-stop system
Risk of injury due to automatic engine start.
The engine may start up unexpectedly on vehicles with activated
start-stop system. A message in the dash panel insert indicates
whether the start-stop system is activated.
– Deactivate start/stop system: switch off the ignition.
Karoq 2018 ➤ , Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
2. Safety instructions 3

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2.3 Safety precautions during road tests in
which testing and measuring equipment
is used
There is a risk of injury from unsecured testing and measuring
instruments.
If the front passenger airbag is inflated in an accident, testing and
measurement equipment that is insufficiently secured can be‐
come a dangerous projectile.
– Secure testers and measuring instruments on the rear seat
using a seat belt.
Or
– Have a second person operates the testing and measurement
equipment on the rear seat.
2.4 Safety precautions when working on
cooling system
Risk of scalding from hot coolant
When the engine is warm, the cooling system is under overpres‐
sure. Danger of scalding due to hot steam and hot coolant.
– Wear protective gloves.
– Wear safety goggles.
– Dissipate pressure: cover the cap of the coolant expansion
reservoir with a cloth and open carefully.
2.5 Safety precautions when working on the
SCR system
Risk of injury caused by the reduction agent
Reduction agent can irritate eyes and skin and can also damage
the respiratory system and poison users.
– Wear safety goggles.
– Wear protective gloves.
– Wear protective work clothing.
– Make sure the area is ventilated with fresh air. Switch on the
extraction system in closed spaces.
Risk of damage caused by the reduction agent
If reduction agent is gets on trim or body parts, it can crystallise
after a while and damage the surface.
– Prevent reduction agent from getting on trim or body parts.
– If it comes into contact with any surface, immediately remove
the reduction agent with water and a cloth.
Risk of injury caused by the reduction agent
Reduction agent can irritate eyes and skin and can also damage
the respiratory system and poison users.
– Wear safety goggles.
– Wear protective gloves.
– Wear protective work clothing.
– Make sure the area is ventilated with fresh air. Switch on the
extraction system in closed spaces.
Karoq 2018 ➤ , Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
4 Rep. gr.00 - Technical data

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Risk of damage caused by the reduction agent
If reduction agent is gets on trim or body parts, it can crystallise
after a while and damage the surface.
– Prevent reduction agent from getting on trim or body parts.
– If it comes into contact with any surface, immediately remove
the reduction agent with water and a cloth.
Please note the following when removing and installing compo‐
nents on the SCR system
♦ The reduction agent tank must be empty when working on the
SCR system. Consult the work instructions for when the re‐
duction agent tank must be emptied. Empty the reducing agent
tank ⇒ Maintenance ; Booklet Kodiaq or. ⇒ Maintenance ;
Booklet Karoq ,
Automatic back-suction of reduction agent
• After the ignition is turned off, the reduction agent is sucked
back out from the dosage line to the injection valve for reduc‐
tion agent - N474- back into the reduction agent tank.
• Before working in this area, you need to wait for the back-suc‐
tion to be completed. This may take up to 10 minutes after
turning off the ignition.
• The battery can also not be disconnected until this back-suc‐
tion has completed, i.e. 10 minutes after the ignition was
turned off ⇒ Electrical system; Rep. gr. 27 ; Battery; discon‐
necting and connecting the battery .
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1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
2. Safety instructions 5

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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 7
⇒ “3.5 Assembly of radiators and condensers”, page 7
3.1 Rules of cleanliness
Even slight contamination can lead to defects. Therefore, when
working on the fuel supply system, on the injection system and
on the turbocharger, observe the following rules for cleanliness.
♦ Clean connection points and their environment thoroughly with
engine or brake cleaner thoroughly before loosening. Dry the
cleaned areas thoroughly.
♦ Close open lines and connections with clean plugs, e.g. from
the plug set for engine - VAS 6122- .
♦ Place removed parts on a clean surface and cover. Use lint-
free cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes).
♦ When the system is open, do not use compressed air. Avoid
moving the vehicle.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
3.2 Foreign bodies in the engine
To prevent foreign bodies entering the system, all open connec‐
tions on the engine must be closed during assembly work. Use
suitable plugs, e.g. from the screw plug set for engine - VAS
6122- .
Note
Please note the following instructions in the event of mechanical
damage to the exhaust gas turbocharger
⇒ “1.2 Removing and installing exhaust gas turbocharger”,
page 268 .
3.3 Contact corrosion
The use of unsuitable connection elements causes contact cor‐
rosion (screws, nuts, washers, etc.).
This is why only connection elements with a special surface coat‐
ings are fitted.
Therefore, the rubber or plastic parts and the adhesives are made
from electrically non-conductive materials.
If there is a question mark about the suitability of parts, use new
parts ⇒ ETKA - Electronic Catalogue of Original Parts .
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6 Rep. gr.00 - Technical data

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Please note the following
♦ Use original spare parts, which are tested and compatible with
aluminium.
♦ Only use Volkswagen accessories.
♦ Any damage resulting from contact corrosion is not covered
by the terms of the warranty.
3.4 Cable routing and securing
Risk of damage to cables
Cables may be damaged by moving or hot components.
– Lay cables in the original cable guide.
– Ensure that there is adequate clearance from all moving or hot
components.
3.5 Assembly of radiators and condensers
The radiator, condenser and charge air cooler may have minor
indentations on the fins, even if assembled correctly. This is not
a case of damage. Radiators, condensers and charge air coolers
do not have to be replaced because of these indentations.
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3. Repair instructions 7

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10 – Removing and installing engine
1 Removing and installing engine
⇒ “1.1 Removing engine”, page 8
⇒ “1.2 Attach engine attached to engine and gearbox mount”,
page 17
⇒ “1.3 Installing engine”, page 18
1.1 Removing engine
NOTICE
When installing a new stripped engine and after fitting the high
pressure lines, you must tighten the clamping claws of the in‐
jection units to the specified torque
⇒ “3.1 Summary of components - injection units (injectors)”,
page 316 . 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 fail to do so, the engine may
be damaged.
Special tools and workshop equipment required
♦ Disassembly tool for door panel - MP8-602/1-
♦ Engine/gearbox jack - V.A.G 1383 A- or engine/gearbox jack
- VAS 6931-
♦ Screw plug set for engine - VAS 6122-
♦ Catch pan , e.g. -VAS 6208-
♦ Hose binding claw - VAS 6362-
♦ Locking pin - T10060 A-
♦ Engine support -T10497- or -T10497A- with pin -T10497/1-
♦ Radiator protection mat - VAS 531003-
♦ Protective goggles
♦ Protective gloves
♦ Commercially available double ladder
Work procedure
Note
♦ The engine is removed downwards together with the gearbox.
♦ Fit all cable straps on again in the same place when installing.
♦ Fit all heat protection sleeves on again in the same place when
installing.
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8 Rep. gr.10 - Removing and installing engine

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– Open cap -arrow- for coolant expansion tank.
CAUTION
The cooling system remains pressurised while the engine is
warm!
Danger of scalding due to hot steam and hot coolant.
Reduce excess pressure by covering the cap of the coolant ex‐
pansion tank with a cloth and opening it carefully.
– Remove engine cover
⇒ “3.1 Removing and installing engine trim panel”,
page 34 .
– Remove air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 336 .
– Remove NOx sender control unit - GX30- on battery tray
⇒ page 364 .
– Remove battery tray -1- ⇒ Electrical system; Rep. gr. 27 ;
Battery; Removing and installing battery tray .
– Detach the connection fitting from the exhaust gas turbocharg‐
er
⇒ “1.4 Removing and installing the exhaust gas turbocharger
connection fitting”, page 290 .
– Unlock and disconnect connector -2- from charge pressure
control solenoid valve - N75- -1-.
– Unscrew the nuts -arrows-.
– Place the charge pressure control solenoid valve - N75- -1-
with vacuum lines on the engine.
– Release and pull off the plug connections at the front wall
⇒ page 311 .
– Move clear the electric cables at the front wall.
– Remove the vacuum hose -2- from the vacuum unit for charge
pressure control.
– Disconnect the vacuum hose -1- at the T-piece.
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1. Removing and installing engine 9

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Unlock catch -arrow-, remove vacuum hose -1-.
– Disconnect lines for the injection valve for reduction agent -
N474- on the top toothed belt guard
⇒ “2.3.1 Removing and installing top toothed belt guard”, page
96 .
– Disconnect delivery line for reduction agent at the injection
valve for reduction agent - N474-
⇒ “3.12 Disconnect delivery line for reduction agent”,
page 452 .
– Remove injection valve for reduction agent - N474- on exhaust
gas cleaning module and place on the engine with connected
cables
⇒ “3.7 Removing and installing the injection valve for reduction
agent N474 ”, page 442 .
– Open quick couplings -A- and -B- of the fuel lines and discon‐
nect fuel lines. Separate quick couplings ⇒ Rep. gr. 20 ; Quick
couplings; separating quick couplings .
Kodiaq
Karoq
– Press the fixing -2- and pull out in the direction of -arrow- in
order to remove the support of the fuel pipes from the com‐
pensating tank.
– Pull out fixing from the support -arrow- and the fuel delivery
line -1-.
Continued for all vehicles
– Screw off the fuel filter and place it on the engine with attached
fuel hoses ⇒ Rep. gr. 20 ; Fuel filter; Summary of components
- fuel filter .
– Disconnect electrical plug connection -1-.
– Remove bracket -2- with fuel hoses.
– Remove coolant hoses, opening the mounting brackets to do
so.
– Unlock catches using a screwdriver -arrow-, lay coolant ex‐
pansion tank to the side.
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1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017
10 Rep. gr.10 - Removing and installing engine

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– Disconnect the plug connection -2- at the engine control unit
- J623- ⇒ “7 Engine control unit”, page 366 .
– Remove electrical plug connections -3- and -4- from the holder
and then release and pull off them.
– Expose electric cables.
– Unlock catches -arrows-, remove cover-1- for engine com‐
partment E-box.
– Unlock catch with a screwdriver -arrow-, pull cover -1- for E-
box engine compartment upwards.
– Unscrew nut -arrow-, remove and expose electric cable.
– Remove the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Summary of components -
noise insulation .
– For the following clip unclipping procedure, use the removal
tool for door panel - MP8-602/1- .
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1. Removing and installing engine 11

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Vehicles fitted with a manual gearbox
– Release and disconnect electrical plug connection -2-.
– Press back B+-pole protection -1- and unscrew B+-cable from
the starter magnet switch.
– Unscrew nut -3- and remove earth cable.
– Unlock and pull off electrical plug connections -1- and -2- at
front left on the gearbox.
– Remove breather from slave cylinder ⇒ Rep. gr. 30 ; Clutch
mechanism; Removing and installing the breather .
– Remove shift mechanism from the gearbox ⇒ Rep. gr. 34 ;
Shift mechanism; removing and installing shift mechanism .
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12 Rep. gr.10 - Removing and installing engine