Skoda Karoq 2018 Workshop Manual
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Skoda Karoq 2018 Workshop Manual

1.6/85; 2.0/110; 130; 140 kw tdi cr engine
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Service
Workshop Manual
Karoq 2018 ➤
Kodiaq 2017 ➤
1.6/85; 2.0/110; 130; 140 kW TDI CR engine
Engine ID
Edition 06.2017
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.�
Service Department. Technical Information
DFG
DFH
CRG
A
A
B
DBG
DDY
DFFA
C
A

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Summary of Contents for Skoda Karoq 2018

  • Page 1 Service Workshop Manual Karoq 2018 ➤ Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine DFFA Engine ID Edition 06.2017 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.
  • Page 2 Service List of Workshop Manual Repair Groups R e p a i r G r o u p 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...

  • Page 3: Table Of Contents

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Contents 00 - Technical data ........... .
  • Page 4 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Measure piston projection in TDC ..........
  • Page 5 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing electric coolant pump ........198 Removing and installing coolant pump .
  • Page 6 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing air filter housing ........336 Intake manifold .
  • Page 7 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Exhaust temperature regulation ..........455 Summary of components - exhaust temperature regulation .
  • Page 8 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.

  • Page 9: Technical Data

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 00 – Technical data Identification (SRL001096; Edition 06.2017) ⇒ “1.1 Engine number, engine data”, page 1 Engine number, engine data ♦ The engine number (“engine identification characters” and “serial number”) is located in the front at the engine/gearbox...
  • Page 10 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Engine codes DFGA DFHA DBGC CRGB Turbocharging Charge air cooler Particle filter with cata‐ lyser Balancing shafts Karoq Engine codes DDYA DFFA Manufactured 07.2017 ►...

  • Page 11: Safety Instructions

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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...

  • Page 12: Safety Precautions During Road Tests In Which Testing And Measuring Equipment Is Used

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.
  • Page 13 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.

  • Page 14: Repair Instructions

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Repair instructions ⇒ “3.1 Rules of cleanliness”, page 6 ⇒ “3.2 Foreign bodies in the engine”, page 6 ⇒ “3.3 Contact corrosion”, page 6 ⇒...

  • Page 15: Cable Routing And Securing

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.

  • Page 16: Removing And Installing Engine

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 10 – Removing and installing engine Removing and installing engine ⇒ “1.1 Removing engine”, page 8 ⇒ “1.2 Attach engine attached to engine and gearbox mount”, page 17 ⇒...
  • Page 17 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – 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.
  • Page 18 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unlock catch -arrow-, remove vacuum hose -1-. – Disconnect lines for the injection valve for reduction agent - N474- on the top toothed belt guard ⇒...
  • Page 19 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – 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.
  • Page 20 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.
  • Page 21 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with dual clutch gearbox – Release and pull off electrical plug connection for the dual clutch gearbox mechatronics - J743- ⇒ Rep. gr. 34 ; Mecha‐...
  • Page 22 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove air conditioner compressor with attached refrigerant lines from the engine ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing and installing air con‐...
  • Page 23 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Raise holding clamp -arrow-, remove top left coolant hose from radiator. – Raise holding clamp -arrow-, remove top right coolant hose from charge air cooling circuit radiator.
  • Page 24 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with double gearbox screwed connection – Screw out screws -arrows- on gearbox mount by approxi‐ mately 2 turns. Continued for all vehicles –...

  • Page 25: Attach Engine Attached To Engine And Gearbox Mount

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with double gearbox screwed connection – Screw out gearbox mount screws -arrows- fully. NOTICE Risk of damaging vacuum lines or electric cables and the engine compartment.

  • Page 26: Installing Engine

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Secure engine to the engine and gearbox support - MP1-202- or the -VW 540- on the engine and gearbox support - VAS 6095- .
  • Page 27 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Work procedure Note After removal, replace screws which have been tightened to a ♦ torquing angle. Replace self-locking nuts and screws as well as sealing rings, ♦...
  • Page 28 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Initially insert screws -arrows- for engine mount by hand as far as the stop. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 29 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Initially insert screws -arrows- for gearbox mount by hand as far as the stop. Note The screws must not be permanently tightened until the assembly bracket is adjusted ⇒...
  • Page 30 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Karoq – Install lock carrier from the service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Move to service position and reset .

  • Page 31: Assembly Bracket

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Assembly bracket ⇒ “2.1 Assembly overview - assembly mountings”, page 23 ⇒ “2.2 Removing and installing engine mount”, page 24 ⇒ “2.3 Removing and installing gearbox mount”, page 25 ⇒...

  • Page 32: Removing And Installing Engine Mount

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 10 - Screw ❑ Replace after disassembly ❑ Tightening torque and tightening order ⇒ page 28 11 - Screw ❑ Replace after disassembly ❑...

  • Page 33: Removing And Installing Gearbox Mount

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -arrows- and remove engine mount -1-. Installing Installation is performed in the reverse order, while paying atten‐ tion to the following:...
  • Page 34 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screw -1-, unclip upwards -arrows- and push slightly to the side. – Unscrews nuts -arrow- and remove earth cable. – Support the engine and gearbox in installed position ⇒...

  • Page 35: Removing And Installing Pendulum Support

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with triple gearbox screwed connection – Unscrew screws -2-, then remove screws -arrows- and re‐ move the gearbox mount -1-. Installing Installation is performed in the reverse order, while paying atten‐...

  • Page 36: Support The Engine In Its Installed Position

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release screws -1, 2, 3- and remove pendulum support. Installing Installation is performed in the reverse order, while paying atten‐ tion to the following: Note Threaded inserts (e.g.
  • Page 37 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Adapter - MP9-200/3 (10-222A/3)- ♦ Hook - MP9-200/10 (10-222A/10)- ♦ Coupling - T40091/3- ♦ Carrier part - T40091/1- ♦ Spindle - T40093/3- ♦...
  • Page 38 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit the supporting device - MP9-200 (10-222 A)- together with the other elements, as shown. A - Adapter - MP9-200/3 (10-222A/3)-...

  • Page 39: Adjusting The Unit Mounting

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect vacuum hoses on the air guide pipe -arrows-. – Loosen clamps -3- and -4- and remove air guide hose. – Fit the supporting device - MP9-200 (10-222 A)- together with the other elements, as shown.
  • Page 40 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew nut -3- and expose earth cable. – Unscrew screws -arrows- for gearbox mount one after another and replace (if not already done during engine installation).

  • Page 41: Check Assembly Bracket Setting

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with triple gearbox screwed connection – Make sure that on the gearbox side the edges of the support‐ ing arm and gearbox support are parallel.

  • Page 42: Engine Trim Panel

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Engine trim panel ⇒ “3.1 Removing and installing engine trim panel”, page 34 Removing and installing engine trim panel Removing NOTICE When removing and installing the engine cover, where appli‐...

  • Page 43: Crankshaft Group

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 13 – Crankshaft group Cylinder block (pulley end) ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page 35 ⇒ “1.2 Summary of components - sealing flange on the belt pulley side”, page 37...
  • Page 44 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 4 - Tensioning device for V-ribbed belt ❑ Removing and installing ⇒ “1.4 Removing and installing tensioning pulley for V-ribbed belt”, page 39 5 - Screw ❑...

  • Page 45: Summary Of Components - Sealing Flange On The Belt Pulley Side

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Bracket for auxiliary units - tightening torque and tightening order Note After removal, replace screws which have been tightened to a torquing angle.

  • Page 46: Removing And Installing V-Ribbed Belt

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ⇒ Item 1 (page 95) Sealing flange on the belt pulley side - tightening torque and tight‐ ening order – Tighten screws in steps in the given sequence:...

  • Page 47: Removing And Installing Tensioning Pulley For V-Ribbed Belt

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Hold the tensioning element with the ring spanner and pull out the locking pin - T10060 A- . – Release pressure on tensioning device.

  • Page 48: Removing And Installing Bracket For Auxiliary Units

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installing Installation is performed in the reverse order, while paying atten‐ tion to the following: Note After removal, replace screws which have been tightened to a torquing angle.

  • Page 49: Removing And Installing Engine Support

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Expose bracket -1- with fuel hoses. – Remove screws -arrows-. – Release screw -arrows-, remove damper wheel. – Release the screws in the order -6...1-.
  • Page 50 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove top toothed belt guard ⇒ “2.3 Removing and installing toothed belt guard”, page 96 Kodiaq – Use the spindle - 10-222A/11- to raise/lower the engine until the applicable screw is accessible on the engine support bracket.

  • Page 51: Removing And Installing The Sealing Flange On The Belt Pulley Side

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Engine support bracket - tightening torque and tightening order Note After removal, replace screws which have been tightened to a torquing angle.
  • Page 52 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove crankshaft - toothed belt sprocket, to this end lock toothed belt sprocket with counterholder - T30004 (3415)- or counterholder - MP 1-310 (3099)- .
  • Page 53 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note The sealant bead must not be thicker than 3 mm otherwise ♦ excess sealant may get into the oil pan and clog the strainer in the oil suction pipe.

  • Page 54: Cylinder Block On Gearbox Side

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Cylinder block on gearbox side ⇒ “2.1 Summary of components - cylinder block on gearbox side”, page 46 ⇒ “2.2 Removing and installing flywheel”, page 47 ⇒...

  • Page 55: Removing And Installing Flywheel

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installing intermediate plate Version 1 – Hook intermediate plate -1- onto the sealing flange -2- arrow -B-. – Slide the intermediate plate onto the dowel sleeves arrows Version 2 –...

  • Page 56: Removing And Installing Sealing Flange On Gearbox Side

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing • Gearbox removed. NOTICE Risk of destruction of the flywheel. ♦ Do not unscrew screws -B- using a pneumatic power wrench or impact wrench - unscrew by hand.
  • Page 57 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note For clearer illustration, the following work sequences are shown with the engine removed. – Remove intermediate plate -1- from the dowel sleeves arrows -A-.
  • Page 58 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note The sealing flange with PTFE sealing ring is provided with ♦ sealing lip supporting ring -2-. This support ring serves as a fitting sleeve and must not be removed prior to installation.
  • Page 59 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove the securing clip -arrow- from the new sealing flange -1-. Note Do not twist rotor or take it out of the sealing flange.
  • Page 60 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Screw in the knurled screws -H- on the sealing flange -1-. – Press the sealing flange -1- and sealing lip supporting ring -2- by tightening onto the surface of the assembly tool - T10134- .
  • Page 61 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Attach the assembly tool - T10134- with the sealing flange -1- to the crankshaft flange • The crankshaft flange must be free of grease and oil.
  • Page 62 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Press sender wheel onto crankshaft flange using assembly tool - T10134- – Tighten nut -B- of the assembly device - T10134- to 35 Nm.
  • Page 63 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Re-pressing sender wheel – Attach the assembly tool - T10134- to the crankshaft flange. – Make sure the positioning pin of the assembly tool - T10134- engages in the bore of the rotor.
  • Page 64 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Press out sealing flange with rotor • Gearbox removed. – Remove the flywheel ⇒ “2.2 Removing and installing flywheel”, page 47 – Remove intermediate plate -1- from the dowel sleeves arrows -A-.
  • Page 65 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Press in sealing flange with rotor Note The sealing flange with PTFE sealing ring is provided with ♦ sealing lip supporting ring -2-. This support ring serves as a fitting sleeve and must not be removed prior to installation.
  • Page 66 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Place sealing flange with front side facing down on a clean level surface. Note Do not twist rotor or take it out of the sealing flange.
  • Page 67 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Attach the assembly tool - T50010- with the sealing flange -1- to the crankshaft flange: • The crankshaft flange must be free of grease and oil.
  • Page 68 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Press sender wheel onto crankshaft flange using assembly tool - T50010- – Tighten nut -B- of the assembly tool - T50010- to 35 Nm.
  • Page 69 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Re-pressing sender wheel – Attach the assembly tool - T50010- to the crankshaft flange. – Make sure the positioning pin of the assembly tool - T50010- engages in the bore of the rotor.

  • Page 70: Crankshaft

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Crankshaft ⇒ “3.1 Summary of components - crankshaft”, page 62 ⇒ “3.2 Replace the needle bearing in the crankshaft”, page 63 Summary of components - crankshaft...

  • Page 71: Replace The Needle Bearing In The Crankshaft

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ Different versions of needle bearing; assignment ⇒ ETKA - Electronic Catalogue of Original Parts ❑ Axial play when new: 0.07-0.17 mm Wear limit: 0,37 mm ❑...
  • Page 72 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Drive in the needle bearing using the centring pin - T30029 (3176)- . Assembly depth: dimension -a- = 2.0 mm. Note If the needle bearing is driven in too deep accidentally, it will need replacing as it is damaged when pulled out.

  • Page 73: Pistons And Conrods

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Pistons and conrods ⇒ “4.1 Assembly overview - piston and conrod”, page 65 ⇒ “4.2 Removing and installing the piston”, page 67 ⇒...
  • Page 74 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ Installation position: markings -A- towards belt pulley side 5 - Circlip ❑ Replace after disassembly 6 - Piston pin ❑ Removing and installing ⇒...

  • Page 75: Removing And Installing The Piston

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Fitting position of the bearing shells in the conrods – Insert bearing shells centrally in the conrod and conrod bear‐ ing cap.
  • Page 76 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Commercially available piston ring tensioning strap Removing • Engine secured to engine and gearbox mount ⇒ “1.2 Attach engine attached to engine and gearbox mount”, page 17 –...

  • Page 77: Measure Piston Projection In Tdc

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Measure piston projection in TDC Note When installation a new piston or engine part, you must check ♦ the piston protrusion in the “TDC”.
  • Page 78 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Using an external micrometer, measure 75-100 mm at approx. 15mm from the lower edge of skirt and 90° to the piston pin axis.
  • Page 79 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Measure piston ring vertical gap – Clean before inspecting the annular groove of the piston. Piston ring Wear limit 1st compression ring 0.06 …...

  • Page 80: Cylinder Head, Valve Gear

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 15 – Cylinder head, valve gear Cylinder head ⇒ “1.1 Summary of components - cylinder head”, page 72 ⇒ “1.2 Assembly overview - cylinder head cover”, page 75 ⇒...
  • Page 81 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 4 - Fit pin ❑ for camshaft housing 5 - Screw ❑ Replace after disassembly ❑ Sequence for loosening ⇒ page 82 ❑...
  • Page 82 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Screw plug on the cylinder head Note There is a screw plug with sealing ring on the cylinder head ♦ on the gearbox side (not shown).

  • Page 83: Assembly Overview - Cylinder Head Cover

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Cylinder head - tightening torque and tightening order Note Screws which have been tightened firmly to a torquing angle must be replaced.

  • Page 84: Removing And Installing Cylinder Head

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 12 - Fuel return-flow line 13 - O-ring ❑ Replace after disassembly 14 - Injection unit ❑ Observe rules for cleanliness ⇒ “3.1 Rules of cleanliness”, page 6 ❑...
  • Page 85 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing Note Fit all heat protection sleeves on again in the same place when ♦ installing. Cable straps should be fastened again in the same place when ♦...
  • Page 86 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with front-wheel drive and with exhaust gas cleaner – Press heat protection sleeve to the side, disconnect electrical plug connection -5-.
  • Page 87 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles fitted with auxiliary heating – Remove coolant pipes on the front wall ⇒ Auxiliary heating; Rep. gr. 82 ; Coolant circuit with auxiliary heating .
  • Page 88 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Continued for all vehicles – Disconnect and expose electrical connectors. 1 - Charge air temperature transmitter after charge air cooler - G811-...
  • Page 89 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect the electrical plug connection -2- on the coolant temperature sender - G62- . – Loosen hose clamp -1-, remove coolant hose.
  • Page 90 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release the cylinder head bolts in the order -1…10-. Note A 2nd mechanic is required for removing the cylinder head. – Swivel the cylinder head to the left out of the rear toothed belt guard and simultaneously remove the tensioning pulley.
  • Page 91 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note Cylinder heads for TDI engines must not be reworked. ♦ After removal, replace screws which have been tightened to a ♦...
  • Page 92 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Place cylinder head gasket on the dowel sleeves -arrows- in the cylinder block. • Installation position of cylinder head seal: Identification “top”...
  • Page 93 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Turn the crankshaft in the direction of rotation of the engine until the stud -arrow- of the crankshaft arrester -T10490- en‐...

  • Page 94: Removing And Installing Cylinder Head Cover

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note The function to increase oil pressure does not always have to ♦ be available on the engine control unit. In this case, the oil pressure is not increased.

  • Page 95: Removing And Installing Gasket Rings For Injection Units

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Slacken the screws for the cylinder head cover in the se‐ quence -7 … 1- and release them. – Remove cylinder head cover.

  • Page 96: Removing And Installing Camshaft Housing

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Press in the new sealing ring for the injection unit using the driver - 3390- and short extension -1- from above up to the stop.
  • Page 97 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Expose electric cables -1, 3-. – Unscrew screws -arrows- and push coolant pipe -2- to the left side. – Unscrew screw -1- using socket insert XZN 10 - T10501- , loosen screw -2-.
  • Page 98 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen screws for camshaft housing in the sequence -18-1- – Unscrew the screws and carefully loosen the camshaft hous‐ ing and remove from the bonding.
  • Page 99 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Apply sealant bead -arrow- onto the clean sealing surfaces of the camshaft housing as shown. • Thickness of sealant bead: 2 mm.

  • Page 100: Checking Compression

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 261 ♦ ⇒ “2.1 Summary of components - exhaust gas cleaning”, page ♦...
  • Page 101 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Screw in adapter - V.A.G 1763/8- in place of the respective glow plugs and connect the compression tester - V.A.G 1763- .

  • Page 102: Toothed Belt Drive

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Toothed belt drive ⇒ “2.1 Summary of components - toothed belt guard”, page 94 ⇒ “2.2 Summary of components - toothed belt”, page 95 ⇒...

  • Page 103: Summary Of Components - Toothed Belt

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - toothed belt 1 - Screw ❑ Replace after disas‐ sembly ❑ Release and tighten us‐ ing counterholder - T30004 (3415)- ❑...

  • Page 104: Removing And Installing Toothed Belt Guard

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 13 - Camshaft driver ❑ Removing and installing ⇒ “1.6 Removing and installing camshaft housing”, page 88 14 - Screw ❑ 20 Nm...
  • Page 105 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with SCR system – Release electrical plug connector from injection valve for re‐ duction agent - N474- -5- and pull off.
  • Page 106 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove bracket for coolant hose -2- from engine. – Unscrew bolt -3- to do so. – Place coolant expansion tank to one side.
  • Page 107 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.3.2 Removing and installing bottom toothed belt guard Removing Note To simplify the production process in manufacturing plants, ♦ the bottom toothed belt guard is fitted with a guide, which rea‐...

  • Page 108: Removing And Installing Toothed Belt

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove screws -arrows-. – Remove bottom toothed belt guard -1-. Installing Installation is performed in the reverse order, while paying atten‐...
  • Page 109 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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! –...
  • Page 110 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Before unscrewing completely, insert the rig pin again. – Lock hub of the high-pressure pump with locking pin - T10492- -3-.
  • Page 111 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Then turn the eccentric of the tensioning pulley with the offset screwdriver - T10264- clockwise -arrow- up to the stop. – Tighten nut -1- by hand.
  • Page 112 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 • The hub of the camshaft is locked with the rig pin for diesel injection pump - 3359- . • Screw loosely inserted.
  • Page 113 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Turn the camshaft toothed belt pulley and high pressure pump toothed belt pulley within their range of rotation clockwise as far as the stop.
  • Page 114 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Turn the eccentric of the tensioning pulley carefully with the offset screwdriver - T10264- or offset screwdriver SW8 - T10409- clockwise -arrow- until the pointer -2- is in the centre of gap in the base plate.
  • Page 115 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Position the crankshaft arrester -T10490- on the crankshaft toothed belt sprocket again. – Turn the crankshaft in the direction of rotation of the engine until the stud -arrow- of the crankshaft arrester engages during this rotary movement in the sealing flange.
  • Page 116 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 • The tensioning pulley pointer -2- must be positioned in the centre between the pegs -1- and -3- of the base plate.

  • Page 117: Remove The Toothed Belt From The Camshaft

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – If it is now possible to lock the camshaft hub, tighten screw -1- for camshaft pulley to the end position using counterholder - T10172- or -T10172A- with adapters -T10172/11- Pos.
  • Page 118 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing – Remove top toothed belt guard ⇒ “2.3 Removing and installing toothed belt guard”, page 96 – Remove vibration damper ⇒ “1.5 Removing and installing vibration damper”, page 39 NOTICE Risk of destruction as a result of the toothed belt pulley jumping.
  • Page 119 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Lock hub of the high-pressure pump with locking pin -T10492- -3-. – To do so, insert the rig pin into the fork -2- of the hub and the bore behind it -1- on the bracket for auxiliary units.

  • Page 120: Valve Gear

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Valve gear ⇒ “3.1 Assembly overview - valve gear”, page 112 ⇒ “3.2 Removing and installing gasket ring for camshaft”, page 114 ⇒...
  • Page 121 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 7 - Screw ❑ Replace after disassembly ❑ Sequence for loosening ⇒ page 90 ❑ Tightening torque and tightening order ⇒ page 114 8 - Sealing ring ❑...

  • Page 122: Removing And Installing Gasket Ring For Camshaft

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 25 - Valve stem gasket ❑ replace after removal ⇒ “3.4 Removing and installing valve stem seals”, page 116 26 - Valve spring...

  • Page 123: Checking Hydraulic Balancing Elements

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Carefully turn back set screw -arrow- of the extractor -T10443- until a slight resistances noticeable. – Place extractor - T10443- straight, as shown in the illustration, and lock by tightening the set screw -A-.

  • Page 124: Removing And Installing Valve Stem Seals

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Special tools and workshop equipment required ♦ Feeler gauge Work procedure – Start engine and allow to run until the radiator fan has cut in once.
  • Page 125 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Work procedure – Remove all glow plugs ⇒ “1.2 Removing and installing glow plugs”, page 488 – Remove camshaft housing ⇒ “1.6 Removing and installing camshaft housing”, page 88 –...
  • Page 126 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Insert the impact drift -VAS 5161/3A- into the guide plate and knock off the tightly fitted valve collets using a plastic hammer.
  • Page 127 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 NOTICE Risk of damage when installing the valve stem seals. ♦ Fit the plastic bushing -A-, which is attached to the new valve stem seals -B-, onto the valve stem.
  • Page 128 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Cylinder head tensioning device - VAS 6419- Work procedure Condition: • Intake manifold removed ⇒ “5.1 Assembly overview - intake manifold”, page 339 •...
  • Page 129 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Continued for all cylinders – Insert the impact drift -VAS 5161/3A- into the guide plate and knock off the tightly fitted valve collets using a plastic hammer.
  • Page 130 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 If the valve collets were removed from the assembly cartridge, first of all they must be inserted into the insertion device - VAS 5161/18- .

  • Page 131: Inlet And Exhaust Valves

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Inlet and exhaust valves ⇒ “4.1 inspecting valve guides”, page 123 ⇒ “4.2 Testing valves”, page 123 ⇒ “4.3 Valve dimensions”, page 124...

  • Page 132: Valve Dimensions

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Valve dimensions Note Inlet and exhaust valves must not be reworked. Only lapping-in is permitted. For 1.6 l engines Dimension Inlet valve Exhaust valve ∅...

  • Page 133: Lubrication

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 17 – Lubrication Sump, oil pump ⇒ “1.1 Assembly overview - pan/oil pump”, page 125 ⇒ “1.2 Removing and installing oil pan”, page 130 ⇒...
  • Page 134 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Screw ❑ self-locking ❑ Replace after disas‐ sembly ❑ 8 Nm 2 - Oil level and oil temperature sender - G266- ❑...
  • Page 135 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 14 - Fitting sleeve 15 - Cylinder block 16 - O-ring ❑ Replace after disassembly 17 - Oil pressure control valve - N428- ❑...
  • Page 136 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ ⇒ Maintenance ; Booklet Karoq 1 - Oil pressure control valve - N428- ❑ Removing and installing ⇒ “3.6 Removing and installing valve for oil pressure control N428 ”,...
  • Page 137 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 16 - Screw ❑ Top part of oil sump ❑ tightening order and tightening torque ⇒ page 130 17 - Oil pump ❑...

  • Page 138: Removing And Installing Oil Pan

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Oil sump top part - tightening torque and tightening order Note 3 bolts -9- to -11- are coated with special sealing point; note ♦...
  • Page 139 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Silicone sealant ⇒ ETKA - Electronic Catalogue of Original Parts ♦ Sealant remover Gasket Stripper (stock code GST, stock item No. R 34402), manufacturer Retech s.r.o.
  • Page 140 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note Pay attention to the use by date on sealant. – Cut off nozzle tube at the front marking (∅ of nozzle approx.

  • Page 141: Removing And Installing The Bottom Part Of The Oil Sump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Apply sealant bead onto the clean sealing surfaces of the oil sump, as shown in the illustration. ♦ Thickness of sealant bead: 2 ... 3 mm.
  • Page 142 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing – Remove the noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation .
  • Page 143 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen and remove screws -1- to -20-. – Screw in the screw for the oil sump bottom part by 3 turn for the welded-on nut -arrow-.

  • Page 144: Removing And Installing Top Part Of The Oil Sump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Cut off nozzle tube at the front marking (∅ of nozzle approx. 2 mm). NOTICE Risk of blockage of the lubrication system through excess seal‐...
  • Page 145 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Cleaning and degreasing agent , e.g. -D 009 401 04- ♦ Protective goggles and gloves Removing – Remove oil sump bottom part ⇒...
  • Page 146 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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 ♦...

  • Page 147: Removing And Installing Oil Pump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 The sealing flange on the belt pulley side has been replaced – Apply a silicone sealant bead -2- evenly onto the clean sealing surface of the oil sump top part -1- as shown in the illustration.

  • Page 148: Removing And Installing Oil Level And Oil Temperature Sender G266

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with two-part oil sump – Remove sump top part ⇒ “1.4 Removing and installing top part of the oil sump”, page...
  • Page 149 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ ⇒ Maintenance ; Booklet Kodiaq ♦ ⇒ Maintenance ; Booklet Karoq – Disconnect electrical connector -arrow- on the oil level and temperature sender - G266- and pull off.
  • Page 150 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ ⇒ Maintenance ; Booklet Karoq – Remove noise insulation of oil sump ⇒ page 130 – Unlock and disconnect electrical plug connection -3- on the oil level and oil temperature sender - G266- .

  • Page 151: Engine Oil Cooler

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Engine oil cooler 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 ⇒...

  • Page 152: Oil Filter, Oil Pressure Switch

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Oil filter, oil pressure switch ⇒ “3.1 Summary of components - oil filter housing/oil pressure switch”, page 144 ⇒ “3.2 Removing and installing oil pressure switch F1 ”, page 145 ⇒...

  • Page 153: Removing And Installing Oil Pressure Switch F1

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 8 - Screw ❑ Replace after disassembly ❑ Tightening torque and tightening order ⇒ page 145 9 - Oil filter housing with engine oil cooler ❑...

  • Page 154: Removing And Installing Oil Pressure Switch For Reduced Oil Pressure F378

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit radiator protection mat - VAS 531003- to vehicle, as shown. – Disconnect plug connection -arrow-. – Place a cloth below to absorb leaking engine oil.

  • Page 155: Testing Oil Pressure

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect plug connection -arrow-. Note Place a cloth below to absorb leaking engine oil. – Unscrew oil pressure switch for reduced oil pressure - F378- .
  • Page 156 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit radiator protection mat - VAS 531003- to vehicle, as shown. – Remove the front left coolant pipe ⇒ “3.2.3 Removing and installing the front left coolant pipe”, page 220 –...

  • Page 157: Removing And Installing Valve For Oil Pressure Control N428

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect electrical plug connection -arrow- at the oil pres‐ sure switch for reduced oil pressure - F378- . – Place a cloth below to absorb leaking engine oil.
  • Page 158 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect electrical plug connection -1-. Note Place a cloth below to absorb leaking engine oil. – Unscrew screws -2- and remove oil pressure control valve - N428- .

  • Page 159: Cooling

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 19 – Cooling Cooling system, coolant ⇒ “1.1 Connection diagram - coolant hoses”, page 151 ⇒ “1.2 Check cooling system for leaks”, page 161 ⇒...
  • Page 160 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Charge air cooling circuit radiator ❑ Summary of compo‐ nents ⇒ “4.1 Assembly over‐ view - radiator/radiator fan”, page 230 ❑...
  • Page 161 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 11 - Heat exchanger for heating 12 - Radiator for exhaust gas recirculation ❑ Summary of components ⇒ “5.1 Summary of components - Exhaust gas recirculation”, page 468 ❑...
  • Page 162 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1.1.2 Connection diagram - coolant hoses, Karoq Note Blue = large coolant circuit. ♦ Red = small coolant circuit. ♦ Violet = coolant circuit for charge air cooler.
  • Page 163 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ The fitting position is not defined, therefore the coolant hose must not be unclipped with the hose clamp (Risk of damage!)
  • Page 164 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 10 - Heat exchanger for heating ❑ After replacing, also replace coolant 11 - Radiator for exhaust gas recirculation ❑ After replacing, also replace coolant ❑...
  • Page 165 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Charge air cooling circuit radiator ❑ After replacing, also re‐ place coolant 2 - Charge air cooler ❑ After replacing, also re‐...
  • Page 166 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 17 - Non-return valve 18 - Coolant connector 19 - Coolant regulator 20 - Engine oil cooler 21 - Choke ❑ integrated into the coolant hose, not visible from the outside ❑...
  • Page 167 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1.1.4 Connection diagram - coolant hoses, vehicles with 2.0 l engine and water- cooled exhaust gas turbocharger Note Red = big coolant circuit.
  • Page 168 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ Removing and installing ⇒ “5.3 Removing and installing radiator for exhaust gas recirculation”, page 473 ❑ Check for leaks ⇒ “5.7 Test air-tightness of the radiator for exhaust gas recirculation”, page 485 8 - Exhaust gas turbocharger ❑...

  • Page 169: Check Cooling System For Leaks

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ ⇒ Auxiliary heating; Rep. gr. 82 ; Fitting location overview - auxiliary heating Check cooling system for leaks Special tools and workshop equipment required ♦...

  • Page 170: Draining And Filling Coolant

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Open cap -arrow- for coolant expansion tank. – Fit the cooling system testing device - V.A.G 1274 B- with adapter -V.A.G 1274/8- onto the coolant expansion tank.
  • Page 171 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Draining Note The drained coolant must not be re-used. ♦ Observe the disposal instructions. ♦ CAUTION The cooling system remains pressurised while the engine is warm! Danger of scalding due to hot steam and hot coolant.
  • Page 172 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Raise holding clip -2- and remove bottom right coolant hose from charge air circuit radiator. – Drain coolant. – Raise the retaining clip -arrow- and remove the bottom left coolant hose from the radiator.
  • Page 173 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release vacuum hose -arrow-. – Remove bottom coolant hose to heating backup pump - V488- . – Drain coolant. Filling up After replacing the components ♦...
  • Page 174 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Screw the adapter for cooling system testing device - V.A.G 1274/8- into the coolant expansion reservoir -1-. – Fit cooling system charge unit - VAS 6096- to the adapter - V.A.G 1274/8- .

  • Page 175: Flushing The Cooling System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fill up coolant to “Max” marking. Note Hose connections and air guide pipes and hoses must be free of oil and grease before being installed.
  • Page 176 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Coolant radiator ♦ Charge air cooling circuit radiator ♦ Intake manifold with charge air cooler When flushing, the coolant is replaced by the new coolant. This ensure that the surfaces of the new components are properly protected.
  • Page 177 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Container with distilled wa‐ ❑ fill with at least 20 litres of distilled water 2 - Coolant reservoir ❑ fill with at least 20 litres of coolant ❑...
  • Page 178 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Empty containers »3« and »4«. – Connect the battery charger. – Remove valve block from the quick coupling on the trolley with the device.
  • Page 179 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Screw the test adapter -2- ( -VAS 691 005/5- ) onto the coolant expansion reservoir -1-. – Disconnect the discharge hose -arrow- from the quick coupling -B- on the valve block.
  • Page 180 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Guide the bleeder hose -8- for ejector into a container. – Connect the vacuum hose -6- to the suction spray pump -7-.
  • Page 181 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 • The pump -VAS 531 007- must be switched on. – »Slowly« open the shut-off tap -A- to avoid coolant foaming. •...
  • Page 182 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – 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-.
  • Page 183 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 A non-return valve -1- is installed in the bleeder hose of the charge air cooler. The hose can therefore only be closed at the point shown.
  • Page 184 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Close the bleeder hoses with hose clamps at the points indi‐ cated. – Open the shut-off tap -A- on the valve block. The motor now pumps distilled water.
  • Page 185 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.
  • Page 186 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.
  • Page 187 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Repeat flushing steps 1-4 times, but always only pump approx. 1 litre of distilled water ⇒ page 174 . Then flush the cooling system with coolant.
  • Page 188 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Check the inspection glass: if you can see the coolant coming out in the inspection glass, close the shut-off tap -A-.
  • Page 189 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Close the bleeder hoses with hose clamps at the points indi‐ cated. – Open the shut-off tap -A- on the valve block. The motor now pumps coolant.
  • Page 190 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Close the bleeder hoses with hose clamps at the points indi‐ cated. – Open the shut-off tap -A- on the valve block. The motor now pumps coolant.
  • Page 191 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Disconnect the coolant flushing and charge unit - VAS 531 007- : – Open the shut-off tap -B- and leave open to dissipate the pres‐...
  • Page 192 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note Use the adapter for extraction, Pos. -14-, to extract coolant ⇒ Item 14 (page 169) – Disconnect the intake hose -5- from the container -2-.
  • Page 193 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Connect vehicle diagnosis tester . – Switch on the ignition and select the following on the vehicle diagnosis tester : ♦...
  • Page 194 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 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.

  • Page 195: Coolant Pump, Regulation Of Cooling System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Coolant pump, regulation of cooling system ⇒ “2.1 Summary of components - coolant pump/thermostat”, page ⇒ “2.2 Summary of components - electric coolant pump”, page 191 ⇒...
  • Page 196 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - O-rings ❑ Replace after disas‐ sembly ❑ Moisten with coolant 2 - Connection fitting 3 - O-ring ❑ Replace after disas‐...
  • Page 197 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 17 - Coolant regulator housing 18 - O-ring ❑ Replace after disassembly ❑ Moisten with coolant 19 - Coolant regulator ❑ Removing and installing ⇒...
  • Page 198 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 12 - Connection fitting 13 - Retaining clip ❑ check for firm seating 14 - O-ring ❑ Replace after disassembly ❑ Moisten with coolant 15 - Screw ❑...

  • Page 199: Summary Of Components - Electric Coolant Pump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - electric cool‐ ant pump ⇒ “2.2.1 Summary of components - charge air cooler pump V188 and heating backup pump V488 , variant 1”, page 191 ⇒...
  • Page 200 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.2.2 Summary of components - charge air cooler pump - V188- , variant 2 1 - Retaining clip 2 - Screw ❑ 23 Nm...
  • Page 201 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.2.3 Summary of components - heating backup pump - V488- , variant 2 1 - Screw ❑ 1.5 Nm 2 - Bushing 3 - Rubber bearing ❑...
  • Page 202 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.2.4 Summary of components - charge air cooler pump - V188- , variant 3 1 - Screw ❑ 40 Nm 2 - Mounting bracket ❑...
  • Page 203 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.2.5 Summary of components - heating backup pump - V488- , variant 3 1 - Screw ❑ 40 Nm 2 - Mounting bracket...
  • Page 204 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.2.6 Summary of components - charge air cooler pump - V188- , variant 4 1 - Screw ❑ 1.5 Nm 2 - Bushing 3 - Rubber bearing ❑...

  • Page 205: Summary Of Components - Coolant Temperature Transmitter

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - coolant temperature transmitter 1 - Coolant temperature send‐ er - G62- ❑ Removing and installing ⇒ “2.9 Removing and in‐...

  • Page 206: Removing And Installing Electric Coolant Pump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing electric coolant pump ⇒ “2.4.1 Removing and installing charge air cooler pump V188 , variants 1 and 2”, page 198 ⇒...
  • Page 207 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with charge air cooler pump - V188- variant 2 – Disconnect electrical plug connection -3-. – Place a cloth below to absorb leaking coolant.
  • Page 208 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 If the heating backup pump - V488- has to be removed – Disconnect electrical plug connection -3-. – Place a cloth below to absorb leaking coolant.
  • Page 209 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Disassembly tool for door panel - MP8-602/1- If the charge air cooler pump - V188- has to be removed from the mounting bracket for reasons of space ⇒...
  • Page 210 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 If the charge air cooler pump - V188- has to be removed – Place catch pan - VAS 6208- underneath. – Release and disconnect electrical plug connection -3-.
  • Page 211 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Catch pan , e.g. -VAS 6208- If the heating backup pump - V488- has to be removed ⇒ page 203 If the heating backup pump - V488- has to be removed from the engine because of lack of space ⇒...
  • Page 212 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Expose wiring loom. – Release and disconnect electrical plug connection -6-. – Unscrew bolt -2-. – Lay heating backup pump - V488- -5- to the side.
  • Page 213 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 If the heating backup pump - V488- has to be removed – Disconnect electrical plug connection -arrow- on the oil level and temperature sender - G266- and pull off.
  • Page 214 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Expose wiring loom. – Release and disconnect electrical plug connection -6-. – Unscrew bolt -2-. – Lay heating backup pump - V488- -5- to the side.
  • Page 215 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 If the charge air cooler pump - V188- has to be removed from the engine for reasons of space – Release and disconnect electrical plug connection -3-.

  • Page 216: Removing And Installing Coolant Pump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 If the heating backup pump - V488- has to be removed from the support – Loosen hose clamps -arrows-, remove coolant hoses.

  • Page 217: Removing And Installing Coolant Regulator

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing – Drain coolant ⇒ “1.3 Draining and filling coolant”, page 162 – Remove the toothed belt from the camshaft ⇒ “2.5 Remove the toothed belt from the camshaft”, page 109 –...
  • Page 218 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit radiator protection mat - VAS 531003- to vehicle, as shown. – Unlock lock arrow -B-. – Turn and pull off connection fittings -1- in arrow direction -A-.
  • Page 219 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit radiator protection mat - VAS 531003- to vehicle, as shown. – Remove front coolant connection fitting ⇒ “3.2.8 Removing and installing front coolant connection fit‐...

  • Page 220: Testing The Coolant Regulator

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove screws -arrows-. – Remove connection fitting -1-. – Remove thermostat. Installing Installation is performed in the reverse order, while paying atten‐...

  • Page 221: Removing And Installing Coolant Valve For Cylinder Head N489

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing coolant valve for cylinder head - N489- Removing – Remove top toothed belt guard ⇒ “2.3 Removing and installing toothed belt guard”, page 96 –...
  • Page 222 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Expose electric wiring loom -1-. – Release nut -4- and screws -2, 3-. – Push coolant pipes slightly to the left.

  • Page 223: Coolant Pipes

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Coolant pipes ⇒ “3.1 Summary of components - coolant pipe”, page 215 ⇒ “3.2 Removing and installing coolant pipes”, page 216 Summary of components - coolant pipe Note The arrows on the coolant pipes and the coolant hose ends must stand opposite to each other.

  • Page 224: Removing And Installing Coolant Pipes

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 16 - Screw ❑ 10 Nm 17 - Front coolant pipes ❑ Removing and installing ⇒ “3.2.1 Removing and installing the front top coolant pipes”, page 216 18 - Screw ❑...
  • Page 225 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Detach coolant hose -2-. – Unlock catches -arrows-, remove air guide pipe upper part -1-. – Remove screws -arrows-. – Unclip and remove bottom part -1- of air guide.
  • Page 226 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -2-. Note The number of connected coolant hoses is different, depending on build version. – Loosen hose clamps -arrows-, remove coolant hoses.
  • Page 227 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -arrows- and place bracket -1- with electric wiring harness to the side. – Remove the throttle valve control unit - J338- ⇒...
  • Page 228 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 3.2.3 Removing and installing the front left coolant pipe Special tools and workshop equipment required ♦ Hose binding claw - VAS 6362- Removing –...
  • Page 229 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Version 2 – Remove air filter housing ⇒ “4.2 Removing and installing air filter housing”, page 336 – Raise holding clamp -1-, remove coolant connection fittings.
  • Page 230 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles without gear oil cooler – Expose electric wiring loom -1-. – Release nut -4- and screws -2, 3-. – Loosen hose clamps -arrows-, remove coolant hoses.
  • Page 231 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 3.2.5 Removing and installing the rear coolant pipe Special tools and workshop equipment required ♦ Catch pan , e.g. -VAS 6208- ♦ Hose binding claw - VAS 6340- ♦...
  • Page 232 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen hose clamp-4-, remove coolant hose, allow coolant to drain. – Loosen hose clamps -1-, remove coolant hoses. – Release nut -3- and screw -2-, remove rear coolant pipe.
  • Page 233 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and pull off the electrical plug connections at the front wall ⇒ “1.2.6 Installation location overview - electrical plug con‐...
  • Page 234 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles fitted with auxiliary heating – Unscrew nuts -arrows- and push the coolant pipes slightly to the side. Continued for all vehicles –...
  • Page 235 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen hose clamp -1-, remove coolant hose. – Unscrew double screw -2- and screw -3-, remove rear right coolant pipe. Installing Installation is performed in the reverse order, while paying atten‐...
  • Page 236 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing: – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 34 – Remove connection fitting on exhaust gas turbocharger ⇒...
  • Page 237 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit radiator protection mat - VAS 531003- to vehicle, as shown. – Open clamps -arrows-. – Disconnect coolant hoses. – Unlock retaining clip in -direction of arrow- and pull off the connection fitting -1-.

  • Page 238: Coolers, Radiator, Radiator Fan

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Coolers, radiator, radiator fan ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 230 ⇒ “4.2 Summary of components - fan shroud and radiator fan”, page 234 ⇒...
  • Page 239 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Coolant radiator ❑ Removing and installing ⇒ “4.4 Removing and in‐ stalling radiator”, page 238 ❑ After replacing, also re‐...
  • Page 240 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 15 - Coolant hose ❑ to remove, raise the holding clamps ❑ Connect ⇒ page 233 4.1.2 Summary of components - radiator/radiator fan, Karoq...
  • Page 241 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 13 - Coolant hose ❑ to remove, raise the holding clamps ❑ Connect ⇒ page 233 14 - O-ring ❑ Replace after disassembly ❑...

  • Page 242: Summary Of Components - Fan Shroud And Radiator Fan

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - fan shroud and radiator fan ⇒ “4.2.1 Summary of components - fan shroud and radiator fan, fan shroud with two radiator fans”, page 234 ⇒...
  • Page 243 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 4.2.2 Summary of components - fan shroud and radiator fan, vehicles with one radiator fan 1 - Screw ❑ 5 Nm 2 - Fan shroud ❑...

  • Page 244: Summary Of Components - Radiator Blind

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - radiator blind ⇒ “4.3.1 Summary of components - radiator blind”, page 236 ⇒ “4.3.2 Summary of components - component parts of the radi‐...
  • Page 245 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 12 - Front seal Installing the wire on the radiator blind – Wiring loom -2- for the control motor for radiator blind - V544- is attached in the retaining tab in the frame of the radiator blind -1- -arrows-.

  • Page 246: Removing And Installing Radiator

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Arrangement of the lamellas 1 - Flap 1 le = flap 1 on the left 2 - Flap 1 ri = flap 1 on the right Šipka - Control flap...
  • Page 247 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Push the screwdriver out of the engine compartment in direc‐ tion of arrow -B- between the catch arrow -A- and the catch mechanism.
  • Page 248 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Catch pan for workshop cranes - VAS 6208- Removing – Drain coolant ⇒ “1.3 Draining and filling coolant”, page 162 – Remove air filter housing ⇒...
  • Page 249 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Push the screwdriver out of the engine compartment in direc‐ tion of arrow -B- between the catch arrow -A- and the catch mechanism.

  • Page 250: Removing And Installing Charge Air Cooling Circuit

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing charge air cool‐ ing circuit ⇒ “4.5.1 Removing and installing charge air cooling circuit radia‐ tor, Kodiaq”, page 242 ⇒...
  • Page 251 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unlock catches -4- for air guide -arrows-. – Press top air guide -3- and bottom air guide -5- off lock carrier.
  • Page 252 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Lever out the charge air cooling circuit radiator -1- at the bot‐ tom from the radiator mountings -arrows-. – Remove both radiators.
  • Page 253 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit the radiator mountings -1- on right and left onto the radiator. Please note the fitting position -arrow- while doing this.
  • Page 254 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Raise holding clamp -arrow-, remove top left coolant hose from radiator. – Raise holding clamp -arrow-, remove top right coolant hose from charge air cooling circuit radiator.
  • Page 255 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Press the catches -1- on both sides in -direction of arrow A- and unlock them. – Pull condenser -3- upwards in direction of arrow -B- and un‐...
  • Page 256 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – The radiators must lock together. Check the catches by pulling in the opposite direction. – Insert the radiator package -1- downwards into the radiator bearing -arrows-.
  • Page 257 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Top radiator bearing fitting position – Fit the top radiator mountings -1- on right and left onto the radiator. Please note the fitting position -arrow- while doing this.

  • Page 258: Removing And Installing Fan Shroud

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with screwed-on radiator bearing on top – Clamp the radiator bearing at the top on the lock carrier with a pinched catch. Screws -2- ⇒ ETKA (electronic parts cata‐...
  • Page 259 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Detach coolant hose -2-. – Unlock catches -arrows-, remove air guide pipe upper part -1-. – Release screw left and right -arrow-.
  • Page 260 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect plug connection -1- on the fan shroud. – To do so, slide the securing mechanism in direction of arrow -A- and then release the plug.
  • Page 261 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release screw left and right -arrow-. – Unclip and remove bottom part -1- of air guide. CAUTION There is risk of injury from radiator fans starting up automati‐...

  • Page 262: Removing And Installing Radiator Fan V7

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing radiator fan - ⇒ “4.7.1 Removing and installing radiator fan V7 ”, page 254 ⇒ “4.7.2 Removing and installing the radiator fan, vehicles with two fan motors”, page 254...

  • Page 263: Removing And Installing Radiator Blind

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Radiator fan - V7- – Release and disconnect electrical plug connection -6-. – Unclip electrical plug connection -7- from the fan shroud -3-.

  • Page 264: Removing And Installing The Radiator Blind Control Motor V544

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect external temperature sensor connector -2-. – Disconnect plug connection -1- of the cooling shutter. – Unscrew screws -4-. – Remove the cooling shutter -3- in - direction of arrow -.
  • Page 265 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen the seal -2- out of the retaining tabs -arrows- at top and bottom. – Remove the seal -2- from the radiator blind -1-.
  • Page 266 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Pry the flaps -2- on the right side out of the frame -1-. – Mark the fitting position of the connecting bridge -1-.
  • Page 267 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Position and lock the flaps -1- to -8- as shown. – Slide in and lock the control flap -6-. – When installing, note the fitting position of the plug -arrows-.
  • Page 268 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Reconnect connector -2-. – Secure the wiring loom in the retaining tabs -arrows-. – Place the seal -2- on the frame of the radiator blind -1-.

  • Page 269: Turbocharging/Supercharging

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 21 – Turbocharging/supercharging Exhaust gas turbocharger ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 261 ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 268 ⇒...
  • Page 270 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Hollow screw ❑ 30 Nm 2 - Oil feed line ❑ check continuity ❑ Fill the exhaust turbo‐ charger with engine oil...
  • Page 271 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 20 - Nut ❑ Replace after disassembly ❑ Tightening torque and tightening order ⇒ page 263 21 - Mounting bracket ❑ for exhaust gas cleaning module 22 - Screw ❑...
  • Page 272 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1.1.2 Summary of components - exhaust gas turbocharger with cooling 1 - Screw ❑ 15 Nm 2 - Heat shield 3 - Screw ❑...
  • Page 273 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 16 - Screw ❑ 10 Nm 17 - Ribbed bolt ❑ 14 Nm 18 - Sealing rings ❑ Replace after disassembly 19 - Hollow screw ❑...
  • Page 274 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Exhaust gas turbocharger - tightening torque and tightening order – Tighten screws in steps in the specified sequence: Stage Bolts Specified torque...
  • Page 275 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 11 - Mounting bracket ❑ for radiator for exhaust gas recirculation ❑ Tightening torque and tightening order ⇒ page 472 12 - Screw ❑...

  • Page 276: Removing And Installing Exhaust Gas Turbocharger

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Exhaust gas turbocharger - tightening torque and tightening order – Tighten bolts step by step in the given sequence: Stage Specified torque -Arrows- tighten from inside to outside cross‐...
  • Page 277 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 NOTICE Risk of malfunctions caused by soiling. ♦ ⇒ “3.1 Rules of cleanliness”, page 6 – Remove right drive shaft ⇒ Running gear, axles, steering;...
  • Page 278 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove coolant pipe -1- from turbocharger and engine. – To do so, unscrew screws -arrows-. – Release and pull off connector -3-.
  • Page 279 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen screw -1- and remove screw clamp. Vehicles with front-wheel drive – Unscrew screws -arrows-, push exhaust gas cleaning module and exhaust gas recirculation cooler backwards.
  • Page 280 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -arrows- and remove heat shield -1-. – Remove the vacuum hose -2- from the vacuum unit for charge pressure control.
  • Page 281 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – When installing the coolant pipe -1-, ensure that the guide -2- is seated correctly in the holder. – Check electrical connections and proper routing ⇒ Electrical System;...
  • Page 282 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ ⇒ “4.1 Assembly overview - air filter housing”, page 335 ♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 75 1.2.2...
  • Page 283 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – For vehicles with auxiliary heating, remove coolant pipes from front wall ⇒ Auxiliary heating; Rep. gr. 82 ; Coolant circuit with auxiliary heating .
  • Page 284 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – 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.
  • Page 285 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Open clip -arrow- and pull the coolant hose -1- off the coolant pipe -2-. Vehicles with four-wheel drive – Remove radiator for exhaust gas recirculation ⇒...
  • Page 286 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release nut -2- and remove union nut -4-. – Unscrew screws -3, 5-, remove oil return-flow line. – Unscrew screws -1-4- and remove bracket for diesel particle filter.
  • Page 287 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – When installing the coolant pipe -1-, ensure that the guide -2- is seated correctly in the holder. – Electrical connections and proper routing ⇒ Electrical System;...
  • Page 288 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 75 1.2.3 Removing and installing exhaust gas turbocharger, vehicles with particle filter...
  • Page 289 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Electrical plug connection for exhaust gas temperature trans‐ mitter 1 - G235- – Remove catalytic converter or particle filter ⇒ “2.2 Removing and installing catalytic converter”, page 405 –...
  • Page 290 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove the vacuum hose -2- from the vacuum unit for charge pressure control. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 291 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew nuts -arrows- and remove the exhaust gas turbo‐ charger with exhaust manifold -1- from the cylinder head and take out at top.

  • Page 292: Replacing Exhaust Gas Turbocharger Pressure Box

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note The function to increase oil pressure does not always have to ♦ be available on the engine control unit. In this case, the oil pressure is not increased.
  • Page 293 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Version 1 – Disconnect the electrical plug connection -3- on the position sender for charge pressure regulator - G581- . – Remove the vacuum hose -2- from the vacuum unit for charge pressure control.
  • Page 294 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Version 1 – Hook the control rod into the adjuster lever. – Position pressure box and screw in screws -1- by hand up to the stop.
  • Page 295 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – 3Put the sliding ring -1- of the hand vacuum pump - VAS 6213- in position -A- for “vacuum” – Connect the hand vacuum pump - VAS 6213- to the pressure box -arrow-.
  • Page 296 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Version 2 – Slide the pressure box in the -direction of arrow- until a voltage of 0.75 ± 0.02 V is displayed on the ⇒ Vehicle diagnostic tester.
  • Page 297 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1.3.2 Replacing exhaust gas turbocharger pressure box, version 3 Note Before removing the pressure box for the exhaust gas turbo‐ charger, check whether the repair set is available ⇒ ETKA - Electronic Catalogue of Original Parts .

  • Page 298: Removing And Installing The Exhaust Gas Turbocharger Connection Fitting

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Use new screws and a new circlip from the repair kit! – Hook the control rod into the adjuster lever. – Install the circlip -4-.
  • Page 299 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove hose -4- for the crankcase ventilation and air guide hose -1-. – To do so, press the release. – Disconnect vacuum hoses on the air guide pipe -arrows-.

  • Page 300: Charge-Air System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Charge-air system ⇒ “2.1 Summary of components - charge air system”, page 292 ⇒ “2.2 Removing and installing charge pressure sender G31 ”, page 294 ⇒...
  • Page 301 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 13 - Charge air temperature transmitter after charge air cooler - G811- ❑ Removing and installing ⇒ “6.7 Removing and installing intake air temperature sender G42 ”, page 361 ❑...

  • Page 302: Removing And Installing Charge Pressure Sender G31

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing charge pres‐ sure sender - G31- Removing – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 34 –...
  • Page 303 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Detach vent pipe for crankcase ventilation -arrow-. – Close connection fitting with a plug -1- from the screw plug set for engine . Secure the plug with a hose clamp -2-.

  • Page 304: Installing And Removing The Air Guide Pipe

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Prepare tester for charge air system - V.A.G 1687- as follows: – Pull the pressure control valve -2- upwards and unscrews completely, then close valves -3- and -4-.
  • Page 305 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – 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 –...

  • Page 306: Leak Testing The Charge Air Cooler

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Leak testing the charge air cooler Note The charge air cooler generates a pressure of 0.05 MPa (0.5 bar) on the air side. The pressure in this case is measured in the cool‐...
  • Page 307 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Detach vent pipe for crankcase ventilation -arrow-. – Close connection fitting with a plug -1- from the screw plug set for engine . Secure the plug with a hose clamp -2-.
  • Page 308 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Read off the turbocharger tester - V.A.G 1397A- • Observe the turbocharger tester for approx. 5 minutes. • The pressure displayed on the turbocharger tester must not exceed 0.0025 MPa (0.025 bar)!

  • Page 309: Mixture Preparation - Injection

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 23 – Mixture preparation - injection Injection system ⇒ “1.1 Schematic overview - fuel system”, page 301 ⇒ “1.2 Installation location overview - fuel injection system”, page ⇒...
  • Page 310 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ⇒ “3.10 Removing and installing high pressure reservoir (rail)”, page 331 5 - Control valve for fuel pressure - N276- ❑ Summary of components ⇒...

  • Page 311: Installation Location Overview - Fuel Injection System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation location overview - fuel in‐ jection system ⇒ “1.2.1 Installation location overview - engine compartment”, page 303 ⇒ “1.2.3 Installation overview - engine from front”, page 308 ⇒...
  • Page 312 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 8 - Air mass meter - G70- ❑ Fitting location ⇒ page 311 ❑ Summary of components ⇒ “4.1 Assembly overview - air filter housing”, page 335 9 - Engine control unit - J623- ❑...
  • Page 313 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Accelerator pedal module - GX2- The accelerator pedal module - GX2- consists of: ♦ Accelerator pedal position sender - G79- ♦ Accelerator pedal position sender 2 - G185-...
  • Page 314 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Differential pressure trans‐ mitter - G505- ❑ its use depends on ex‐ haust gas standard ❑ Observe part number ⇒...
  • Page 315 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 6 - Injection valve for cylinder 4 - N33- ❑ ⇒ “3.1 Summary of components - injection units (injectors)”, page 316 ❑...
  • Page 316 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1.2.3 Installation overview - engine from front 1 - Oil pressure control valve - N428- ❑ Removing and installing ⇒ “3.6 Removing and installing valve for oil pressure control N428 ”,...
  • Page 317 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1.2.4 Installation location overview - engine from rear, vehicles without SCR sys‐ 1 - Oil level and oil temperature sender - G266- ❑...
  • Page 318 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation location of electrical connector for lambda probe 1 af‐ ter catalytic converter - GX7- • Behind the left centre underfloor trim panel -arrow- 1.2.5...
  • Page 319 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 6 - Lambda probe 1 upstream of catalytic converter - GX10- Consists of lambda probe - G39- and heating for lambda probe - Z19- ❑...

  • Page 320: Filling/Bleeding The Fuel System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Version 2 1 - Solenoid valve for charge pressure control - N75- 2 - Exhaust gas temperature sender 4 - G648- 3 - Exhaust gas temperature sender 3 - G495-...

  • Page 321: Check The Fuel System For Tightness

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Check the fuel system for tightness – Let the engine run at idling speed for a few minutes. Do not accelerate and then switch off the engine again. (The fuel sys‐...

  • Page 322: Vacuum System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vacuum system ⇒ “2.1 Connection diagram - Vacuum system”, page 314 ⇒ “2.2 Checking the vacuum system”, page 315 Connection diagram - Vacuum system 1 - Vacuum line ❑...

  • Page 323: Checking The Vacuum System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation location of the pressure line • Screw arrow -A-, 8 Nm • Bracket, arrow -B- To remove, take off intake manifold ⇒...

  • Page 324: Injection Units/High Pressure Reservoir (Rail)

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Injection units/high pressure reser‐ voir (rail) ⇒ “3.1 Summary of components - injection units (injectors)”, page ⇒ “3.2 Summary of components - High pressure reservoir (rail)”, page 318 ⇒...
  • Page 325 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Sealing ring ❑ in the cylinder head cov‐ ❑ replace after removal ⇒ “1.5 Removing and in‐ stalling gasket rings for injection units”, page 87...

  • Page 326: Summary Of Components - High Pressure Reservoir (Rail)

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation position of the clamping claw, variant 1 • One clamping claw has 2 injection units. • The thickening -arrow- of the clamping claw points down‐...
  • Page 327 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Fuel pressure sender - G247- ❑ Removing and installing ⇒ “6.3 Removing and in‐ stalling fuel pressure sender G247 ”, page 354 ❑...

  • Page 328: Adjust The Correction Values For Injection Units

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Adjust the correction values for injection units ♦ The “injector quantity adjustment (IQA)” function is used to correct the injection rate for each cylinder of a Common Rail system individually throughout the characteristic range.
  • Page 329 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect hose connection -2- at the fuel return-flow line. NOTICE Avoid risk of malfunctions caused by contamination. ♦ ⇒ “3.1 Rules of cleanliness”, page 6 –...
  • Page 330 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Pinch of coolant hose -arrow- using a hose clamp of up to 25 mm - MP7-602 (3094)- . – Remove noise insulation.

  • Page 331: Check Injection Unit Return Flow Quantity At Starter Speed

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Check injection unit return flow quantity at starter speed Note If the engine will not start the return flow quantity of the injection units can also be tested at starter speed.

  • Page 332: Checking The Injection Units In Open State

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Connecting the return line, variant 2 – Pull off return-flow line connections on injection unit by pulling release buttons upwards -arrows-. Continued for all vehicles –...
  • Page 333 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Work procedure – Delete event memory entry with Vehicle diagnosis tester . – Remove engine cover ⇒ “3 Engine trim panel”, page 34 NOTICE Avoid risk of malfunctions caused by contamination.

  • Page 334: Removing And Installing The Injection Units

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Connect the clean, blown-through adapter to the return-flow connection of the injection unit to be tested. – A vacuum of -500 mbar is built up using the hand vacuum pump - VAS 6213- .
  • Page 335 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Connecting the return line, variant 2 – Pull off return-flow line connections on injection unit by pulling release buttons upwards -arrows-. Continued for all vehicles –...
  • Page 336 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew bolt -1-. – Position extractor - T10055- with the extractor - T10415- as shown in the illustration and pull out upwards.

  • Page 337: Removing And Installing High Pressure Lines

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Replace the gasket ring for the injection unit. Use the assem‐ bly sleeve - T10377- for this purpose. Continued for used and new injection units –...
  • Page 338 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew union nuts -arrows- and remove high pressure line. NOTICE Avoid risk of malfunctions caused by contamination. ♦ ⇒ “3.1 Rules of cleanliness”, page 6 3.9.2...

  • Page 339: Removing And Installing High Pressure Reservoir (Rail)

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Use the torque wrench - V.A.G 1331- with tool insert SW 17 - V.A.G 1331/6- or socket wrench insert - T40055- to tighten the high pressure lines.
  • Page 340 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and pull off electrical plug connection -2- from control valve for fuel pressure - N276- . – Release and pull off electrical plug connection -arrow- from fuel pressure sender - G247- .
  • Page 341 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Open heat protection sleeve -1-. – Release and pull off electrical connectors -3- and -6-. – If present, release and pull off electrical plug connections -4- and -5-.
  • Page 342 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Expose fuel return-flow hose -1-. – Open holding clamps -arrows-, unclip and remove cable duct -2-. – Disconnect electrical plug connections:...

  • Page 343: Air Filter

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Air filter ⇒ “4.1 Assembly overview - air filter housing”, page 335 ⇒ “4.2 Removing and installing air filter housing”, page 336...

  • Page 344: Removing And Installing Air Filter Housing

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 17 - Insert ❑ for air filter lower part 18 - Air filter bottom part ❑ remove mechanical contaminations 19 - Rubber bearing 20 - O-ring ❑...
  • Page 345 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Detach coolant hose -2-. – Unlock catches -arrows-, remove air guide pipe upper part -1-. – Disconnect the plug connection -2- at the air mass meter - G70- .
  • Page 346 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – When attaching the air guide hose to the air filter housing, pay attention to the installation markings -arrows-. – Position air filter housing on battery tray and push in until there is an audible click.

  • Page 347: Intake Manifold

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Intake manifold ⇒ “5.1 Assembly overview - intake manifold”, page 339 ⇒ “5.2 Removing and installing intake manifold”, page 341 ⇒ “5.3 Removing and installing the throttle valve control unit J338 ”, page 344...
  • Page 348 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 14 - Gasket ❑ Replace after disassembly 15 - Connection fitting ❑ Throttle valve control unit - J338- 16 - Intake air temperature sender - G42- ❑...

  • Page 349: Removing And Installing Intake Manifold

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Intake manifold with charge air cooler - tightening torque and tightening order – Tighten screws in steps: Stag Bolts Specified torque -1- to -10-...
  • Page 350 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove air guide pipe ⇒ “2.4 Installing and removing the air guide pipe”, page 296 – Disconnect electrical plug connection -4-.
  • Page 351 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release screw -1- of guide pipe for oil dipstick. – Unscrew nuts -5- and remove the mounting bracket -6- from the double screw -4-.

  • Page 352: Removing And Installing The Throttle Valve Control Unit J338

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Tighten screws 1-10 to tightening torque and in tightening or‐ der. Installation is carried out in the reverse order. When installing,...
  • Page 353 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove screws -arrows-. – Unclip and remove the air guide pipe bottom -1-. – Remove air guide pipe ⇒ “2.4 Installing and removing the air guide pipe”, page 296 –...
  • Page 354 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect electrical plug connections: – Unlock and remove plugs -2- and -3-. – Loosen hose clamp -4-, remove air guide hose.

  • Page 355: Senders And Sensors

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Senders and sensors ⇒ “6.1 Removing and installing the fuel pressure regulating valve N276 ”, page 347 ⇒ “6.2 Check fuel pressure regulating valve N276 ”, page 353 ⇒...
  • Page 356 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Version 2 – Removing and installing, Variant 2 ⇒ “6.1.3 Removing and installing the fuel pressure regulating valve N276 , Variant 2”, page 351 6.1.2...
  • Page 357 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and pull off connector -1- from charge air temperature transmitter after charge air cooler - G811- . – Release and pull off electrical plug connection -3- for the cool‐...
  • Page 358 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove cover about the injection units. – Release and pull off electrical plug connections -arrows- at the glow plugs. – Disconnect electrical plug connections at the glow plugs.
  • Page 359 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect electrical plug connection -2-. – Loosen union nuts -1- - to do so, counterhold hex on the high pressure reservoir. The unscrew the nuts by hand.
  • Page 360 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and disconnect electrical plug connection -2-. – Remove high pressure reservoir (rail) ⇒ “3.10 Removing and installing high pressure reservoir (rail)”, page 331 –...

  • Page 361: Check Fuel Pressure Regulating Valve N276

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Align the fuel pressure regulating valve - N276- -1- with suit‐ able workshop equipment. – Turn the valve so that the electrical plug can be fitted to the connection -2- without tension.

  • Page 362: Removing And Installing Fuel Pressure Sender G247

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Connect the auxiliary hose -3- to the return-flow connection of the high pressure reservoir -2-. 1) Test with engine running – Start engine and run in idle.

  • Page 363: Removing And Installing Air Flow Mass Meter G70

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect plug connection -arrow-. – Unscrew the fuel pressure sender - G247- with socket insert size 27 - T40218- . – Suction the dirt out of the hole of the high pressure reservoir (thread and sealing surface).
  • Page 364 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew bolt -1-. – Turn the air mass meter - G70- Pos. -2- in direction of arrow -B- and remove. Installing It is essential that the following work instructions are performed to ensure that the air mass meter - G70- functions correctly.

  • Page 365: Removing And Installing Differential Pressure Transmitter G505

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing differential pressure transmitter - G505- ⇒ “6.5.1 Removing and installing differential pressure transmitter G505 , variant 1”, page 357 ⇒...
  • Page 366 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 If the differential pressure transmitter - G505- and pressure sen‐ sor 1 for exhaust gas - G450- have to be removed from the cylinder head cover –...
  • Page 367 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 6.5.2 Removing and installing differential pressure transmitter - G505- , variant 2 If the differential pressure transmitter - G505- has to be removed ⇒...

  • Page 368: Removing And Installing Pressure Sensor For Exhaust Gas 1 G450

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Open heat protection sleeve -4-. – Release and disconnect electrical plug connection -3-. – Unclip and move clear the electric wiring loom -5-.

  • Page 369: Removing And Installing Intake Air Temperature Sender G42

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Open heat protection sleeve -1-. – Disconnect electrical plug connection -8-. – Unscrew screw -2- and press the differential pressure trans‐...

  • Page 370: Removing And Installing Charge Air Temperature Sender After Charge Air Cooler G811

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and disconnect the applicable electrical plug connec‐ tion -2-. – Unscrew intake air temperature sender - G42- . Installing Installation is performed in the reverse order, while paying atten‐...

  • Page 371: Removing And Installing Nox Sender Control Unit Gx30

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and disconnect electrical plug connection -1-. CAUTION The fuel line is under pressure! There is a risk of injury to the eyes and skin when in contact with fuel.
  • Page 372 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing NOx sender - G295- on exhaust gas cleaning module ⇒ page 364 Remove NOx sender control unit - J583- and the wiring loom for space reasons ⇒...
  • Page 373 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and pull off the electrical plug connection -2-. – Unclip NOx sender control unit - J583- -1- -arrows-. – Remove NOx sender control unit - J583- .

  • Page 374: Engine Control Unit

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Engine control unit ⇒ “7.1 Removing and installing engine control unit J623 ”, page 366 Removing and installing engine control unit - J623- ⇒...
  • Page 375 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installing Installation is performed in the reverse order, while paying atten‐ tion to the following: – Insert the engine control unit - J623- with the bottom edge at the front into the mounting bracket arrow -A- and lock at the upper edge.
  • Page 376 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Note The threads of the shear screws are equipped with locking agent. To unscrew the screws the threads must therefore be heated us‐...
  • Page 377 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unlock catch -arrow-, remove engine control unit -1-. – Unlock plug connections for engine control unit - J623- and pull off.

  • Page 378: High Pressure Pump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 High pressure pump ⇒ “8.1 Summary of components - high pressure pump”, page 370 ⇒ “8.2 Removing and installing the high pressure pump”,...

  • Page 379: Removing And Installing The High Pressure Pump

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ follow all instructions for installation of high pressure lines ⇒ “3.9.2 Installing high pressure line”, page 330 Removing and installing the high pres‐...
  • Page 380 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Detach plastic hoses -2-. – Disconnect electrical plug connection -1-. – Remove screws -arrows-. – Carefully remove the high pressure pump.
  • Page 381 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Turn nuts -arrow- to the thread of the high pressure pump shaft. – Place counterholder - T10051- -A- on toothed belt pulley and tighten nut -arrow- hand-tight.

  • Page 382: Lambda Probe

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Lambda probe ⇒ “9.1 Summary of components - lambda probe”, page 374 ⇒ “9.2 Removing and installing Lambda probe”, page 377 Summary of components - lambda probe ⇒...
  • Page 383 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ Removing and installing ⇒ “6.5 Removing and installing differential pressure transmitter G505 ”, page 357 7 - Mounting bracket ❑ Holder version depends on the vehicle ❑...
  • Page 384 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 9.1.2 Summary of components - lambda probe, vehicles with SCR system 1 - Exhaust gas temperature sender 4 - G648- ❑ Removing and installing ⇒...

  • Page 385: Removing And Installing Lambda Probe

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ Removing and installing ⇒ “6.5 Removing and installing differential pressure transmitter G505 ”, page 357 10 - Screw ❑ 8 Nm 11 - Exhaust gas temperature sender 3 - G495- ❑...
  • Page 386 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew lambda probe 1 in front of the catalytic converter - GX10- -3-. Installing Installation is performed in the reverse order, while paying atten‐...
  • Page 387 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove centre left underfloor trim panel ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Underfloor trim panel; Removing and installing underfloor trim panels .
  • Page 388 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Continued for all vehicles – Unscrew lambda probe after catalytic converter - GX7- -arrow- with a tool from the ring spanner set for lambda probe - 3337- .

  • Page 389: Exhaust System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 26 – Exhaust system Exhaust pipes/silencers ⇒ “1.1 Assembly overview - silencers”, page 381 ⇒ “1.2 Removing and installing pre-exhaust pipe”, page 390 ⇒...
  • Page 390 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Clamping sleeve ❑ Fitting position ⇒ page 382 ❑ Tightening torque ⇒ page 383 ❑ Tighten screwed con‐ nections uniformly 2 - Silencer ❑...
  • Page 391 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation position of clamping sleeve, vehicles with 2.0 l/140 kW engine – Install clamping sleeve in the position shown. • Angle -α- = approximately 50°.
  • Page 392 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Screw ❑ 20 Nm 2 - Mounting bracket ❑ Replace if damaged. 3 - Exhaust pipe ❑ Removing and installing ⇒...
  • Page 393 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ Removing and installing ⇒ “1.5 Removing and installing silencers”, page 393 ❑ Installation dimension for vehicles with marking on the exhaust pipe ⇒...
  • Page 394 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1.1.3 Summary of components - Sound damper, 2.0 l engine, vehicles with front drive, Karoq For first equipment building unit with rear silencer, replace indi‐...
  • Page 395 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 12 - Retaining strap ❑ Replace if damaged. 13 - Screw ❑ 20 Nm 14 - Rear silencer ❑ Installing the exhaust system without tension ⇒...
  • Page 396 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation dimension for vehicles with marking on the exhaust pipe 1 - Clamping sleeve 2 - Exhaust pipe a - Installation dimension...
  • Page 397 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 9 - Clamping sleeve ❑ The exhaust system must be aligned free of stress before tightening ⇒ “1.6 Align exhaust system free of stress”, page 396 ❑...

  • Page 398: Removing And Installing Pre-Exhaust Pipe

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Fitting position of screw clamp for pre-exhaust pipe Clamping sleeve fitting position, vehicles with four-wheel drive – Install clamping sleeve in the angle position shown.

  • Page 399: Separating Exhaust Pipes/Silencers

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with front-wheel drive – Remove the front tunnel bridge ⇒ General body repairs, ex‐ terior; Rep. gr. 66 ; Underfloor trim panel; Installation location overview - Underfloor trim panels .

  • Page 400: Removing And Installing Middle Silencer

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ The separating point is marked on the circumference of the exhaust gas pipe. ♦ The separation point is in the area of the rear axle.

  • Page 401: Removing And Installing Silencers

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with clamping sleeve – Remove screw -1-. – Release clamps -arrows-. – Remove central pipe -2-. Installing Installation is performed in the reverse order, while paying atten‐...
  • Page 402 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Slacken clamping sleeve -1-. – Support the silencer with the engine and gearbox jack . – Unscrew the brackets -3- for the silencer.
  • Page 403 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with no clamping sleeve – Cut the exhaust pipe at a right angle along the split cut ⇒ “1.3 Separating exhaust pipes/silencers”, page 391 CAUTION Risk of accident from weight of the rear silencer.

  • Page 404: Align Exhaust System Free Of Stress

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing – Loosen and move the clamping sleeve -3-. – Position engine and gearbox jack - VAS 6931- under the sound damper.

  • Page 405: Inspecting The Exhaust System For Leaks

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Push the rear silencer so far forward until the pre-tensioning on the retaining strap on the exhaust pipe is -a- = 5 mm.
  • Page 406 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Screw clamp ❑ Replace after disas‐ sembly ❑ Fitting position ⇒ page 399 ❑ 7 Nm ❑ For assignment, see ⇒...
  • Page 407 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation position of gasket between exhaust gas cleaning mod‐ ule and pre-exhaust pipe • The square tab of the gasket -arrow- must be in the groove of the particle filter.

  • Page 408: Align Exhaust Tailpipes

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation dimension for vehicles with marking on the exhaust pipe 1 - Clamping sleeve 2 - Exhaust pipe a - Installation dimension...

  • Page 409: Cleansing Exhaust Emissions

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Cleansing exhaust emissions ⇒ “2.1 Summary of components - exhaust gas cleaning”, page 401 ⇒ “2.2 Removing and installing catalytic converter”, page 405 ⇒...
  • Page 410 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.1.2 Summary of components - exhaust gas cleaning, vehicles with exhaust gas cleaning module 1 - Exhaust pipe ❑ Removing and installing ⇒...
  • Page 411 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 13 - Exhaust gas turbocharger ❑ Removing and installing ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 268 14 - Gasket ❑...
  • Page 412 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 2.1.3 Summary of components - exhaust gas cleaning, vehicles with particle filter or with catalytic converter Note Depending on the country-specific exhaust limit values, an unregulated particle filter (article reduction system) or a catalytic converter is installed in this engine.

  • Page 413: Removing And Installing Catalytic Converter

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing catalytic con‐ verter Note Depending on the country-specific exhaust limit values, an un‐ regulated particle filter (article reduction system) or a catalytic converter is installed in this engine.
  • Page 414 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – If installed, unscrew the screws -arrows- of the coolant line and pull the coolant line forwards slightly. – Unscrew screws -1- and -3-, open and remove the clamp -2-.

  • Page 415: Removing And Installing Exhaust Gas Cleaning Module

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing exhaust gas cleaning module Note The exhaust gas cleaning module is attached to the engine with 4 balancing elements among other items. These balancing ele‐...
  • Page 416 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with SCR system – Remove NOx sender control unit - GX30- ⇒ “6.10 Removing and installing NOx sender control unit GX30 ”, page 363...
  • Page 417 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and pull off the plug connection -1- for oil level and temperature sender - G266- . – Remove heating backup pump - V488- from engine and push to one side ⇒...
  • Page 418 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Fit engine support bracket - T10533- , as shown in the illus‐ tration. – The engine support bracket - T10533/2- is fitted to the flat screw connection point on the engine support bracket - T10533/1- .
  • Page 419 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Open clamp -1- and position it on the flared opening of the exhaust gas cleaning module. – Unscrew the remaining screws in the order -4-2-.
  • Page 420 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Slide balancing element onto the firing pin. – Insert balancing element into the centring sleeve. – Bend the retaining straps back by striking the ball stud lightly using the palm of your hand.
  • Page 421 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew balancing element (left-hand thread) -1- on the cyl‐ inder head using socket insert SW 8 - 3247- in -arrow direction- as far as the stop, then rotate a further 90°.

  • Page 422: Removing And Installing The Exhaust Flap Control Unit J883

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Connect hoses, fit hose clamps -1-. – Mark the installation position and assignment of the hoses to the pipes. – Tighten screw -3-, Pos. -4- ⇒...
  • Page 423 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect electrical plug connection -1-. – Unscrew screws -arrows- and remove exhaust flap control unit - J883- . Installing – 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-.

  • Page 424: Scr System (Selective Catalytic Reduction)

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 SCR system (Selective Catalytic Re‐ duction) ⇒ “3.1 Summary of components - reduction agent tank”, page 416 ⇒ “3.2 Summary of components - delivery line for reduction agent”, page 421...
  • Page 425 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Reduction agent tank ❑ with: ♦ Feed unit ♦ Temperature sender for re‐ duction agent - G685- ♦ Reduction agent tank send‐...
  • Page 426 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Mounting bracket ❑ at fuel tank filler tube 2 - Sealing grommet ❑ between body and wheelhouse 3 - Screw cap 4 - Screw ❑...
  • Page 427 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 3.1.2 Summary of components - reducing agent tank, Karoq Summary of components - reduction agent tank from above ⇒ page 420 Summary of components - reduction agent tank from below...
  • Page 428 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ❑ with heating for reduction agent line (heating circuit 2) - Z104- ❑ Removing and installing ⇒ “3.10 Removing and installing the rear section of the delivery line for reduction agent”, page 446...

  • Page 429: Summary Of Components - Delivery Line For Reduction Agent

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - delivery line for reduction agent ⇒ “3.2.1 Summary of components - delivery line for reduction agent, Kodiaq”, page 421 ⇒...
  • Page 430 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 7 - Line for reduction agent ❑ from separation point on the underbody to injection valve for reduction agent - N474- ❑ with heating for reduction agent line (heating circuit 2) - Z104- ❑...
  • Page 431 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 5 - Protection plate ❑ At the bottom, on the right side in the fuel tank area ❑ Disconnect the connector ⇒ “3.12 Disconnect delivery line for reduction agent”, page 452 6 - Screw clamp ❑...

  • Page 432: Summary Of Components - Delivery Module For Reduction Agent

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - delivery module for reduction agent 1 - Delivery module for reduc‐ tion agent ❑ Removing and installing ⇒ “3.6 Removing and in‐...
  • Page 433 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing CAUTION Leaking reduction agent represents danger. ♦ Note the safety precautions for handling reduction agent ⇒ “2.5 Safety precautions when working on the SCR sys‐...
  • Page 434 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unlock and disconnect connectors -1- and -3-. – Release and pull off reduction agent line -2-. Disconnect re‐ duction agent line ⇒...
  • Page 435 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -arrows- of the reduction agent tank -1-. – Carefully lower the reduction agent tank and thread it out as you do so.
  • Page 436 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove cover -1- on the reduction agent tank -2-. – To do so, unscrew the nuts -arrows-. – Unclip all lines -arrows- of the reducing agent tank -1-.

  • Page 437: Removing And Installing The Front Part Of The Delivery Line For Reduction Agent

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen screws -arrows- of the reduction agent tank -1-. – Carefully lower the reduction agent tank and thread it out as you do so.
  • Page 438 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles fitted with auxiliary heating – Unhook dosing pump - V54- from fuel tank ⇒ Auxiliary heating; Rep. gr. 82 ; Fuel system; Removing and installing the dosing pump - V54- .
  • Page 439 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove fuel hoses -1- and -2-. Separate quick couplings ⇒ Rep. gr. 20 ; Quick couplings; separating quick couplings . CAUTION...
  • Page 440 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unclip shielding -1- from pin screws of the body -arrows-. – Unlock expanding rivet arrow -A- and unclip the shielding. – If present, loosen the clip -4- for the fuel line of the auxiliary heating -3- on the body.
  • Page 441 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation position of the lines at the shielding Line guide for the delivery line for reduction agent Brackets for the lines in bottom section of the separation...
  • Page 442 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation position of the fuel lines at the underfloor 2 - Fuel return-flow line 3 - fuel feed line 4 - Fuel line for auxiliary heating –...
  • Page 443 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Retract the delivery line for reducing agent -2- from the mount‐ ing bracket -arrow-. – Disconnect the fuel lines -1- and -2- on the underbody. Open quick couplings ⇒...
  • Page 444 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unclip the reducing agent line from the fixings, arrows -B-. – Disconnect delivery line for reduction agent -2- at the injection valve for reduction agent - N474- .
  • Page 445 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Raise the bracket at the bottom of the cover arrow -A- and pull out sideways, arrow -B-. Vehicles fitted with auxiliary heating –...
  • Page 446 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – If installed, unclip the delivery line for reduction agent -1- from the holding clamp -2- for the lines. Installing – Remove feedthrough aid from the old lines.
  • Page 447 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation position of the lines at the shielding Line guide for the delivery line for reduction agent Brackets for the lines in bottom section of the separation...

  • Page 448: Removing And Installing The Delivery Module For Reduction Agent

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing the delivery module for reduction agent Special tools and workshop equipment required ♦ Torque wrench - VAS 6854- Removing CAUTION Risk of skin irritation from the reduction agent.
  • Page 449 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Clean the area around the delivery module -5-. – Remove screws -arrows-. – Carefully pry the delivery module -5- out of the recess -4- with a slotted screwdriver.

  • Page 450: Removing And Installing The Injection Valve For Reduction Agent N474

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 order Labelling of screws on the Position of the screw Specified torque supply unit tight‐ ening Screw at medium distance from seal...
  • Page 451 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unclip, release and pull out the connector -3-. – Expose electric wiring harness. – Release and pull off reduction agent line -2- ⇒...

  • Page 452: Removing And Installing The Control Unit For Reduction Agent Heater J891

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing and installing the control unit for reduction agent heater - J891- ⇒ “3.8.1 Removing and installing reduction agent heating control unit J891 , Kodiaq”, page 444 ⇒...
  • Page 453 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Injection valve for reduction agent - N474- ❑ Removing and installing ⇒ “3.7 Removing and in‐ stalling the injection valve for reduction agent N474 ”, page 442...

  • Page 454: Removing And Installing The Rear Section Of The Delivery Line For Reduction Agent

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Variants of the screw clamps Screw clamp, one-piece O-ring Screw, 5 Nm Clamp, two-piece with eye Clamp, two-piece with hook Screw, 8 Nm Lock washer 3.10...
  • Page 455 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect plug connection for the reduction agent line ⇒ “3.12 Disconnect delivery line for reduction agent”, page 452 – To capture escaping reduction agent, place a clean cloth un‐...
  • Page 456 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unclip, release and remove the plug -arrow- for the heating for reducing agent line - Z104- . – Unclip the delivery line for reducing agent from the mounting bracket -2 and 3- on the connection point.

  • Page 457: Removing And Installing The Filler Tube For Reduction Agent Tank

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 3.11 Removing and installing the filler tube for reduction agent tank ⇒ “3.11.1 Removing and installing the filler tube for reduction agent tank, Kodiaq”, page 449 ⇒...
  • Page 458 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove vent line -3- and filler tube -2- from the reduction agent tank -1-. – To do so press the release tabs -arrows-.
  • Page 459 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Open the tank flap and clean the area around the screw cap. – Clean area around fuel filler neck. – Unscrew screw caps -1- and -2-.

  • Page 460: Disconnect Delivery Line For Reduction Agent

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Make sure that the sealing grommet -1- is correctly seated on the body -2- and the filler tubes -arrows-. Specified torques ♦...
  • Page 461 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Lock Note Note the different designs of the securing clip. ♦ Assignment is based on the type of quick coupling. ♦ The guide lug -arrow- is the distinguishing feature.

  • Page 462: Adjusting The Learnt Value For The Scr System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Disconnect delivery line for reduction agent, Variant 3 – Clean the area around the lock with water. – Slide the plug connection in the opposite direction to the pull‐...

  • Page 463: Exhaust Temperature Regulation

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Exhaust temperature regulation ⇒ “4.1 Summary of components - exhaust temperature regula‐ tion”, page 455 ⇒ “4.2 Removing and installing the exhaust gas temperature sender 1 G235 ”, page 459...
  • Page 464 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Lambda probe 1 after cata‐ lytic converter - GX7- ❑ consists of: lambda probe downstream of catalytic converter - G130- and heater for lambda probe 1 down‐...
  • Page 465 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 9 - Screw ❑ Tightening torque Pos. -9- ⇒ Item 9 (page 375) 10 - Exhaust gas temperature sender 3 - G495- ❑...
  • Page 466 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 4.1.2 Summary of components - exhaust temperature regulation, vehicles with SCR system Note Malfunction caused by loose exhaust gas temperature sender ♦...

  • Page 467: Removing And Installing The Exhaust Gas Temperature Sender 1 G235

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 7 - Exhaust gas pressure sensor 1 - G450- ❑ Depending on vehicle ❑ Removing and installing ⇒ “6.6 Removing and installing pressure sensor for exhaust gas 1 G450 ”, page 360 8 - Screw ❑...
  • Page 468 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing Note Fit all cable straps on again in the same place when installing. ♦ When removing, the electric cable must be not cut off, since ♦...
  • Page 469 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Fitting position of the exhaust gas temperature sender -G235- : • Angled shank -1- downwards horizontally. – Check electrical connections and proper routing ⇒ Electrical System;...

  • Page 470: Removing And Installing The Exhaust Gas Temperature Sender 2 G448

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Release and disconnect electrical plug connection -1-. – Remove electrical connector -2- from the mounting bracket. – Expose wiring loom. – Unscrew exhaust gas temperature sender 1 - G235- -3-.
  • Page 471 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 34 – Remove NOx sender control unit - GX30- on exhaust gas cleaning module ⇒...

  • Page 472: Removing And Installing The Exhaust Gas Temperature Sender 3 G495

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Observe the fitting position of exhaust temperature sender. – The exhaust gas temperature sender must be installed as shown. a - 90°...

  • Page 473: Removing And Installing The Exhaust Gas Temperature Sender 4 G648

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with SCR system Vehicles with no SCR system Installing Installation is performed in the reverse order, while paying atten‐ tion to the following:...
  • Page 474 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing Note Fit all cable straps on again in the same place when installing. ♦ When removing, the electric cable must be not cut off, since ♦...
  • Page 475 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew exhaust gas temperature sender 4 - G648- -1-. Installing Installation is performed in the reverse order, while paying atten‐ tion to the following: –...

  • Page 476: Exhaust Gas Recirculation

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Exhaust gas recirculation ⇒ “5.1 Summary of components - Exhaust gas recirculation”, page 468 ⇒ “5.2 Summary of components - exhaust gas recirculation 1 GX5 ”, page 473...
  • Page 477 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Radiator for exhaust gas re‐ circulation ❑ Removing and installing ⇒ “5.3 Removing and in‐ stalling radiator for ex‐ haust gas recirculation”, page 473 ❑...
  • Page 478 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Installation position of air guide hose at radiator for exhaust gas recirculation Installation position of screw clamp for radiator for exhaust gas recirculation •...
  • Page 479 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 1 - Gasket ❑ Replace after disas‐ sembly 2 - Connecting pipe ❑ to exhaust manifold 3 - Nut ❑ Replace after disas‐...
  • Page 480 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 16 - Screw ❑ Observe tightening sequence ⇒ page 472 17 - Radiator for exhaust gas recirculation ❑ Removing and installing ⇒ “5.3.3 Removing and installing the radiator for exhaust gas recirculation, vehicles with particle filter or with catalytic converter”, page 479...

  • Page 481: Summary Of Components - Exhaust Gas Recirculation 1 Gx5

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Summary of components - exhaust gas recirculation 1 - GX5- 1 - Coolant hose 2 - Spring strap clamp 3 - Exhaust gas recirculation...
  • Page 482 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing – 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 –...
  • Page 483 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Turn radiator for exhaust gas recirculation counter to the -direction of arrow-. – The hose -3- of the exhaust gas turbocharger -2- is pulled off as you do so.
  • Page 484 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Position radiator -1- for exhaust gas recirculation on the ex‐ haust gas cleaning module with gasket and screw clamp. – Turn radiator for exhaust gas recirculation -direction of arrow- and simultaneously fit hose -3- onto the exhaust gas turbocharger -2-.
  • Page 485 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Vehicles with SCR system – Release the lock -3- and control unit for NOx encoders - J583- -1- in -arrow- from the holder.
  • Page 486 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -arrows- and remove heat shield -1-. Vehicles with dual clutch gearbox 0GC – Remove pendulum support ⇒ “2.4 Removing and installing pendulum support”, page 27 –...
  • Page 487 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Attach hose -2- to radiator -1- for exhaust gas recirculation. • Installation position: the label “EGR side” -arrow- points to the exhaust gas recirculation radiator.
  • Page 488 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 ♦ Socket - T10347- ♦ Socket insert XZN 10 - T10501- ♦ Set of tools - T10395 A- ♦ Supplemental tool set - T10395/8-/10- ♦...

  • Page 489: Removing And Installing Exhaust Gas Recirculation Valve 1 Gx5

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -1- with socket insert XZN 10 - T10501- . – Unscrew mounting bracket of the vacuum line -2-. – Detach the vacuum hose from radiator for exhaust gas recir‐...

  • Page 490: Removing And Installing Exhaust Gas Recirculation Valve 2 Gx6

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Disconnect electrical plug connection -3-. – Clamp off coolant hoses with hose clamp up to 25 mm diam‐ eter - MP7-602 (3094)- .

  • Page 491: Removing And Installing Temperature Sensor For Exhaust Gas Recirculation G98

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Loosen hose clamps -1, 2- and detach exhaust gas recircula‐ tion hose. – Press heat protection sleeve to the side, disconnect electrical plug connection -3-.
  • Page 492 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 34 – Detach the connection fitting from the exhaust gas turbocharg‐...

  • Page 493: Test Air-Tightness Of The Radiator For Exhaust Gas Recirculation

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 Removing Note Fit all cable straps on again in the same place when installing. ♦ When removing, the electric cable must not be cut off, since ♦...
  • Page 494 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Connect the ⇒ Vehicle diagnostic tester to the vehicle and check function: ♦ Cooling system leak-tightness Note The specified path may vary slightly, depending on vehicle, en‐...

  • Page 495: Glow Plug System

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 28 – Glow plug system Glow plug system ⇒ “1.1 Summary of components - Glow plug system”, page 487 ⇒ “1.2 Removing and installing glow plugs”, page 488 ⇒...

  • Page 496: Removing And Installing Glow Plugs

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 7 - Rotor ❑ For engine speed sender - G28- . ❑ Removing and installing ⇒ “2.1 Summary of components - cylinder block on gearbox side”, page 46 8 - engine speed sender - G28- ❑...
  • Page 497 Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Position pliers - 3314- using the pliers groove arrow -A- on the support sleeve collar arrow -B-, as shown. – Carefully remove the glow plug connectors from the glow plugs.

  • Page 498: Removing And Installing Automatic Glow Period Control Unit J179

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Place the glow plug connectors -1- back onto the glow plugs -arrows-. Note Make sure the glow plug connectors fit tightly.

  • Page 499: Removing And Installing The Engine Speed Sender G28

    Karoq 2018 ➤ , Kodiaq 2017 ➤ 1.6/85; 2.0/110; 130; 140 kW TDI CR engine - Edition 06.2017 – Unscrew screws -arrows- and push the fuel lines forward slightly. – Disconnect electrical plug connection -2-. – Unscrew screw -1- and disconnect Hall sender - G40- .

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Kodiaq 2017

Table of Contents