Skoda Karoq 2018 Workshop Manual
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Skoda Karoq 2018 Workshop Manual

Skoda Karoq 2018 Workshop Manual

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Service
Workshop Manual
Karoq 2018 ➤
1,5/110 kW TSI EVO Engine
Engine ID
Edition 07.2017
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
DAD
A

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Summary of Contents for Skoda Karoq 2018

  • Page 1 Service Workshop Manual Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine Engine ID Edition 07.2017 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 24 - Mixture preparation - injection...

  • Page 3: Table Of Contents

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Contents 00 - Technical data ........... .
  • Page 4 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Assembly overview - piston and conrod ........
  • Page 5 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Testing oil pressure and oil pressure switch ........167 Removing and installing oil filter housing .
  • Page 6 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Assembly overview - air filter housing ........258 Removing and installing air filter housing .

  • Page 7: Technical Data

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 00 – Technical data Denomination (SRL001109; Edition 07.2017) ⇒ “1.1 Engine number, engine data”, page 1 Engine number, engine data Type plate on upper toothed belt guard The engine code letters and the engine number are located on the type plate, which is affixed to the sticker on the upper toothed belt guard.
  • Page 8 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Engine codes The “engine identification characters” and “serial number” are lo‐ cated on the cylinder block -arrow-. ♦ The engine identification characters are also indicated on the vehicle data sticker and the type plate.
  • Page 9 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Engine codes DADA Fuel - RON min. 95 unleaded Ignition system/fuel injection Motronic MG 1 Firing order 1-3-4-2 Exhaust gas recirculation Balancing shaft module Intake manifold change-over Camshaft control valve, inlet / exhaust...

  • Page 10: Safety Instructions

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 ⇒ “2.2 Safety precautions when working on vehicles with start- stop system”, page 4 ⇒ “2.3 Safety precautions during road tests in which testing and measuring equipment is used”, page 4...

  • Page 11: Safety Precautions When Working On Cooling System

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 There is a risk of injury if testers and measuring instruments are not secured adequately. Increased risk of injury from unsecured testers and measuring instruments must be prevented. Measuring instruments can turn into dangerous projectiles on air‐...

  • Page 12: Repair Instructions

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Repair instructions ⇒ “3.1 Rules of cleanliness”, page 6 ⇒ “3.2 Foreign bodies in the engine”, page 6 ⇒ “3.3 Contact corrosion”, page 6 ⇒ “3.4 Cable routing and securing”, page 6 ⇒...

  • Page 13: Assembly Of Radiators And Condensers

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Activated charcoal filter system lines ♦ Electrical lines To rule out mix ups and ensure the original fitting position, mark the lines before disassembly. Make photos or sketches where necessary.
  • Page 14 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid, cooling fluid and refrigerant, brake fluid, vacuum) and electri‐ cal lines in such a way that the original line guide is re- established.
  • Page 15 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 inal Parts . The use of clamp-type or screw-type clips is not allowed. ♦ A minimum voltage of 11.5 V is required for perfect functioning of the electrical components.

  • Page 16: Removing And Installing Engine

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 10 – Removing and installing engine Removing and installing engine ⇒ “1.1 Removing engine”, page 10 ⇒ “1.2 Disconnecting engine and gearbox”, page 20 ⇒ “1.3 Attach engine attached to engine and gearbox mount”, page 21 ⇒...
  • Page 17 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Cover radiator with radiator protection mat - VAS 531003- . WARNING Fuel under very high pressure creates a risk of injury. ♦ Before opening the injection system high-pressure system, the fuel pressure must be reduced.
  • Page 18 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove the vacuum hose -1- from the brake vacuum pump - V192- -A-. – Remove vacuum hose from the engine mounting. – Remove the heat shield on top of the catalyst ⇒...
  • Page 19 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect the fuel feed line -1- and vent line -2- to the acti‐ vated charcoal filter. – Unscrew retaining clip -2- from hoses from the coolant tank. – Loosen hose clamp -3- and remove coolant hose.
  • Page 20 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen hose clamp -1- and remove coolant hose. – Raise holding clamp -arrow- and disconnect top right coolant hose from charge air cooling circuit radiator. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 21 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Open the cable guide -2- upwards in -direction of arrow-. – Expose electric cables. – Disconnect plug connection -2-. – Remove B+-pole protection -1- and unscrew B+-cable from the starter magnet switch.
  • Page 22 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew nut -arrow-, remove and expose electric cable. For vehicles with manual gearbox – Disconnect connectors -1- and -2-. – Remove shift mechanism from the gearbox ⇒ Rep. gr. 34 ;...
  • Page 23 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Undo screws -1-, -2-, -3- and remove the pendulum support. – Unscrew screws -arrows- and remove heat shield for right cardan shaft, if present. – Unscrew left and right cardan shaft from gearbox ⇒ Chassis, axles, steering;...
  • Page 24 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew nuts -arrows- on right and left steering joint. – Unhook swivel hub from track control arm on left and right. – Swivel suspension strut left towards the outside and support with extension -2024 A /1- , as shown in the illustration.
  • Page 25 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 2 screws – Screw out screws -arrows- on gearbox mount by approxi‐ mately 2 turns. Gearbox mount with 3 screws – Screw out screws -arrows- on gearbox mount by approxi‐...

  • Page 26: Disconnecting Engine And Gearbox

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Screw out engine mount screws -arrows- fully. Gearbox mount with 2 screws – Screw out gearbox mount screws -arrows- fully. Gearbox mount with 3 screws – Screw out gearbox mount screws -arrows- fully.

  • Page 27: Attach Engine Attached To Engine And Gearbox Mount

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Install shackle - 10-222A/12- on gearbox. – Hook additional hook - MP9-200/10 (10-222A/2)- with shackle - 10-222A/12- onto the workshop crane - VAS 6100- . Note Pre-load the workshop crane - VAS 6100- slightly, but do not raise the gearbox.

  • Page 28: Installing Engine

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Secure engine using bolts -arrows- to the engine and gearbox mount - VAS 6095- . Installing engine Special tools and workshop equipment required ♦ Extension - 2024 A /1- of lifting device - MP9-201 (2024A)- ♦...
  • Page 29 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Check the clutch release bearing for wear. Replace release bearing when worn ⇒ Rep. gr. 30 ; Clutch control; Summary of components- Clutch release mechanism . For vehicles with automatic gearbox –...
  • Page 30 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 2 screws – Initially insert screws -arrows- for gearbox 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 31 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 3 screws – 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 32 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Connect the remaining electric cables to the engine and gear‐ box. – Connect coolant hoses. – Install the front left and right wheelhouse liner ⇒ Exterior body work ; Rep. gr. 66 ; Wheelhouse liner; Removing and installing the front wheelhouse liner .

  • Page 33: Tightening Torque

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Tightening torques Note Tightening torques apply only for lightly greased, oiled, ♦ phosphatized or blackened nuts and screws. Other lubricants such as engine and gearbox oil are allowed, ♦...

  • Page 34: Assembly Bracket

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Assembly bracket ⇒ “2.1 Summary of components - assembly mountings”, page 28 ⇒ “2.2 Removing and installing engine mount”, page 30 ⇒ “2.3 Removing and installing gearbox mount”, page 30 ⇒...

  • Page 35: Unless Authorised By Škoda Auto A. S. Škoda Auto A. S. Does Not Guarantee Or Accept Any Liability

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 9 - Pendulum support ❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 32 10 - Screw ❑ Replace after removal ❑ Tightening torque and tightening order ⇒...

  • Page 36: With Respect To The Correctness Of Information In This Document. Copyright By Škoda Auto A. S.� Removing And Installing Engine Mount

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Pendulum support - tightening torque and tightening order Note Screws which have been tightened firmly to a torquing angle must be replaced. – Tighten screws gradually in the given sequence:...
  • Page 37 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . – Remove the engine control unit ⇒ “6.1 Removing and installing engine control unit J623 ”, page –...

  • Page 38: Removing And Installing Pendulum Support

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 3 screws – Unscrew screws -2- and then screws -arrow-. – Remove gearbox mount -1-. Installing Installation is performed in the reverse order; pay attention to the...

  • Page 39: Support The Engine In Its Installed Position

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Support the engine in its installed posi‐ tion Special tools and workshop equipment required ♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)- ♦ Supporting device - MP9–200 (10 - 222 A)- ♦...

  • Page 40: Adjusting The Unit Mounting

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note The figure shows the suspension of the 1.4 TSI engine. The suspension of the 1.5 TSI engine is identical. • Adapter - 10 - 222 A /13- with the inscription L located on the right side of the vehicle.
  • Page 41 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . – Suspend engine into the installation position ⇒ “2.5 Support the engine in its installed position”, page 33 –...

  • Page 42: Check Assembly Bracket Setting

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 2 screws Make sure that the edges of the supporting arm of the gearbox sides -2- and the gearbox support -1- are parallel. • Dimension -x- = -x-.

  • Page 43: Engine Trim Panel

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Engine trim panel ⇒ “3.1 Removing and installing engine trim panel”, page 37 Removing and installing engine trim panel Removing – Remove engine cover -1- upwards from the ball studs in the following order: –...

  • Page 44: Crankshaft Group

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 13 – Crankshaft group Cylinder block (pulley end) ⇒ “1.1 Assembly overview - V-ribbed belt drive”, page 38 ⇒ “1.2 Removing and installing V-ribbed belt”, page 41 ⇒ “1.3 Removing and installing tensioning pulley for V-ribbed belt”, page 43...
  • Page 45 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 1 - Screw ❑ Replace after removal ❑ to release and tighten use counterholder - T10475- ❑ 150 Nm + 180° 2 - Vibration damper ❑ with vibration damper ❑...
  • Page 46 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Version of V-ribbed belt pulley with freewheel 1.1.2 Summary of components - V-ribbed belt drive for vehicles with air condi‐ tioning system 1 - V-ribbed belt ❑ check for wear ❑...

  • Page 47: Removing And Installing V-Ribbed Belt

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ lock with locking pin - T10060A- ❑ Removing and installing ⇒ “1.3 Removing and installing tensioning pulley for V-ribbed belt”, page 43 5 - Screw ❑ Replace after removal ❑...
  • Page 48 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Locking pin - T10060A- NOTICE Risk of damage by reversing the direction of rotation of a V- ribbed belt that has already been used. – Mark the direction of rotation with chalk or a felt-tip pen for the re-installation before removing the V-ribbed belt.

  • Page 49: Removing And Installing Tensioning Pulley For V-Ribbed Belt

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Mark the direction of rotation with chalk or a felt-tip pen for the re-installation before removing the V-ribbed belt. – Loosen the V-ribbed belt by turning the tensioning pulley in the -direction of the arrow-.

  • Page 50: Removing And Installing Vibration Damper

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Version 1 – Unscrew screws -arrows- and pull off tensioning pulley -1- for V-ribbed belt. Version 2 – Unscrew screws -arrows- and pull off tensioning pulley -1- for V-ribbed belt.

  • Page 51: Removing And Installing Engine Support

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen screw -arrow- for vibration damper; to do so, use counterholder - T10475- . – Unscrew screw and remove the vibration damper. NOTICE Risk of destruction of the engine.
  • Page 52 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect the fuel feed line -1- and vent line -2- to the acti‐ vated charcoal filter. Note Open closed lines and connections immediately with suitable screen caps. – Disconnect plug connection -1-.
  • Page 53 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew screws -arrows- from bracket of the pre-exhaust pipe. – Remove pendulum support ⇒ “2.4 Removing and installing pendulum support”, page 32 – Suspend engine into the installation position ⇒...

  • Page 54: Replacing Crankshaft Sealing Ring On The Belt Pulley Side

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Gearbox mount with 3 screws – Remove screws -arrows-. Continued for all vehicles – Press engine/gearbox unit slightly to the left and remove en‐ gine support. Installing Installation is performed in the reverse order; pay attention to the following points: –...
  • Page 55 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Pry sealing ring off with the extractor tool -T20143/2- -arrow-. – Clean the contact and sealing surfaces. Note Do not oil new sealing ring. – Push new sealing ring in -direction of the arrow- over the as‐...
  • Page 56 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Pull sealing ring -2- up to the stop using the thrust piece - T10485/1- and the belt pulley screw -1-. – Fit crankshaft toothed belt sprocket onto the crankshaft.

  • Page 57: Cylinder Block On Gearbox Side

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Cylinder block on gearbox side ⇒ “2.1 Summary of components - cylinder block on gearbox side”, page 51 ⇒ “2.2 Removing and installing flywheel”, page 53 ⇒ “2.3 Removing and installing sealing flange on gearbox side”,...
  • Page 58 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 53 12 - Screw ❑ Tightening torque and tightening order ⇒ Fig. ““Sealing flange on the gearbox side - tightening torque and tightening order”“ , page 52 13 - Screw ❑...

  • Page 59: Removing And Installing Flywheel

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Screw plug for “TDC” bore in the cylinder block behind - tightening torque Note Screw -arrow- onto inner sealing ring. ♦ Replace if damaged. ♦ Component Tightening torque Screw for “TDC”-...
  • Page 60 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note After replacing the sealing flange, the new values must be ♦ transferred to the engine control unit. The work sequence must be absolutely observed. ♦ Touch-up assembly device - T10134- with guide pins - T10578- .
  • Page 61 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew screws -arrows- on sealing flange -1-. – Sealing flange and rotor are pressed together with 3 M6x35 mm screws from the crankshaft. – Alternating, screw in three screws -arrows- (max.
  • Page 62 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Assembly tool - T10134- A - Clamping surface B - Hexagon nut C - Assembly housing Locating pin E - Allan screws (2 pieces) F - Guide bolts for petrol engines...
  • Page 63 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 • The locating hole -A- on the rotor -C- must be flush with the marking -B- on the sealing flange. – Place sealing flange with front side facing down on a clean level surface.
  • Page 64 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Press on the sealing flange -1- and sealing lip supporting ring -2- by tightening the 3 knurled screws -H- onto the surface of the assembly tool - T10134- .
  • Page 65 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Screw C - attach assembly tool - T10134- onto crankshaft flange – Push the assembly cup -C- by hand in the -direction of the arrow- until the sealing lip supporting ring -1- rests on the crankshaft flange -2-.
  • Page 66 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Measure distance -a- between crankshaft flange -2- and rotor -1-. • Set value: Dimension -a- = 0.5 mm. If dimension »a« is too small: – Press down rotor ⇒...
  • Page 67 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Tighten nut -B- of the assembly tool - T10134- to 40 Nm. – Check the fitting position of the rotor on the crankshaft again ⇒ page 59 If the dimension »a« is too small again: –...
  • Page 68 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Rework the type plate on the toothed belt guard Note The crankshaft drive has many mechanical and electronic tol‐ ♦ erances. These tolerances are already determined on the factory side ♦...

  • Page 69: Crankshaft

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Crankshaft ⇒ “3.1 Measuring axial play of crankshaft”, page 63 ⇒ “3.2 Replace the needle bearing in the crankshaft”, page 63 ⇒ “3.3 Crankshaft dimensions”, page 64 Measuring axial play of crankshaft Special tools and workshop equipment required ♦...

  • Page 70: Crankshaft Dimensions

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Pulling out the needle bearing – Remove needle bearing -1- with internal extractor -Kukko 21/2- -A- and countersupport -Kukko 22/1- -B- from crankshaft -2-. Fit the internal extractor -Kukko 21/2- behind the needle rim -arrow-.

  • Page 71: Pistons And Conrods

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Pistons and conrods ⇒ “4.1 Assembly overview - piston and conrod”, page 65 ⇒ “4.2 Removing and installing the piston”, page 66 ⇒ “4.3 Separating new connecting rod”, page 67 ⇒...

  • Page 72: Removing And Installing The Piston

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 7 - Piston ❑ Mark the installation position and the assignment to cylinder ⇒ Fig. ““Fitting position of piston and assignment of piston to cylinder”“ , page 66 ❑ Removing and installing ⇒...

  • Page 73: Separating New Connecting Rod

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Drift , e.g. -T10046- ♦ Commercially available piston ring tensioning strap Removing – Remove cylinder head ⇒ “1.3 Removing and installing cylinder head”, page 78 – Removing the oil pan ⇒...

  • Page 74: Removing And Installing Oil Injection Nozzles

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Tension the conrod in a vice equipped with protective alumi‐ nium jaws. Note Only tension the conrod slightly in order to avoid damage. – Tension the conrod below the dotted line.

  • Page 75: Check Piston And Cylinder Bore

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew and remove the pressure relief valves -1- with Torx insert T40 - T10545- . – Remove oil spray nozzles -2-. Installing NOTICE Risk of damaging the oil injection nozzles.

  • Page 76: Check Radial Clearance Of Connecting Rods

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Measure piston ring end gap – Push the piston ring into the bottom cylinder opening at right angles to the cylinder wall from above to about 15 mm from the cylinder edge.

  • Page 77: Position Piston To Tdc

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Clean the connecting rod bearing cap and connecting rod bearing pin. – Place plastigage of the bearing width according to the con‐ necting rod bearing pin or into the bearing shell.
  • Page 78 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Screw in the locating screw - T10340- up to the stop into the cylinder block and tighten. • The head of the fixing screw - T10340- must be in contact with the cylinder block.

  • Page 79: Tightening Torque

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 • Edge -e-, machined surfaces on the intake camshaft, must point upwards. When the edge -e- does not point upwards: – Turn the crankshaft in direction of rotation of engine by 1 turns ⇒...

  • Page 80: Cylinder Head, Valve Gear

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 15 – Cylinder head, valve gear Cylinder head ⇒ “1.1 Summary of components - cylinder head”, page 74 ⇒ “1.2 Summary of components - camshaft housing”, page 76 ⇒ “1.3 Removing and installing cylinder head”, page 78 ⇒...
  • Page 81 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 8 - Cylinder head gasket ❑ replace after removal ⇒ “1.3 Removing and installing cylinder head”, page 78 ❑ Observe fitting position: Part number points to cylinder head. 9 - Screw for camshaft housing ❑...

  • Page 82: Summary Of Components - Camshaft Housing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Summary of components - camshaft housing 1 - O-ring ❑ Check O-ring for dam‐ ❑ O-ring is not available separately; in the event of damage, replace to‐ gether with exhaust cam adjuster .
  • Page 83 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ O-ring is not available separately; in the event of damage, replace together with exhaust camshaft control valve 1 - N318- . 14 - Position sensor for exhaust camshaft - G1003- ❑...

  • Page 84: Removing And Installing Cylinder Head

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 28 - O-ring ❑ Check O-ring for damage ❑ O-ring is not available separately; in the event of damage, replace together with inlet camshaft 1 - G1002- . 29 - Screw cap 30 - O-ring ❑...
  • Page 85 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove the roller towing lever and balancing elements ⇒ page 84 – Disconnect plug connection -3-. – Disconnect plugs -1-, -2- and -3-. – Unscrew screw -1- at the engine support.
  • Page 86 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen and remove the screws for the cylinder head in the sequence -1-10- NOTICE Danger of damage to cylinder head and valves. – Remove cylinder head and place it on a clean base (foam).
  • Page 87 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 CAUTION Risk of injury to eyes and skin. Wear safety gloves and safety goggles. – Carefully remove old sealant residue from the cylinder head and cylinder block using a chemical sealant remover.

  • Page 88: Removing And Installing Camshaft Housing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing and installing camshaft hous‐ Note After installing new parts (engine/partial engine, cylinder head, ♦ camshaft housing or exhaust gas turbocharger), the oil pres‐ sure control must be limited to the high pressure level for approx.
  • Page 89 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove connector of wiring harness -1-. The number of connections may vary. – Unscrew screw -2- and expose the wiring loom and lay it to the side. – Pull out oil dipstick -3-.
  • Page 90 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove bracket -1-. – Screw in screws -arrows- , unclip the pipe from the intake manifold ⇒ “4.2 Removing and installing intake manifold”, page 262 If the camshaft housing is to be replaced: –...
  • Page 91 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 • Locating screw - T10340- screwed up to the stop into the cyl‐ inder block and tightened to 30 Nm. • Crankshaft in direction of rotation of engine in contact with the locating screw - T10340- = “TDC”...

  • Page 92: Checking Compression

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Replace gasket ring -4-. – Fit gasket -4- onto dowel pins -2-. – Carefully set the camshaft housing -3- onto the dowel pins -2-. Note Make sure that the camshaft housing does not tilt.
  • Page 93 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Test condition • Engine oil temperature at least 30 C. • Battery voltage at least 12.5 V – Remove fuse for fuel pump control unit from the fuse holder.

  • Page 94: Checking The Combustion Chamber For Tightness

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Check compression pressure with the Compression tester de‐ vice - V.A.G 1763- with adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- ; Operation ⇒ Owner's Manual , –...

  • Page 95: Summary Of Components - V-Ribbed Belt Drive For Vehicles

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Carefully insert a screwdriver into the opening of the ignition plug of the appropriate cylinder, minimum length of shaft 250 mm, in -direction of arrow- so that it touches the piston head.

  • Page 96: Toothed Belt Drive

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Toothed belt drive ⇒ “2.1 Summary of components - toothed belt guard”, page 90 ⇒ “2.2 Summary of components - toothed belt”, page 91 ⇒ “2.3 Assembly overview - Adjustment tool for control times”, page 93 ⇒...

  • Page 97: Summary Of Components - Toothed Belt

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Summary of components - toothed belt 1 - Screw ❑ 7 Nm 2 - Screw cap 3 - O-ring ❑ Replace after removal 4 - Screw ❑ Replace after removal ❑...

  • Page 98: Removing And Installing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ check for wear ❑ Removing and installing ⇒ “2.5 Removing and installing toothed belt”, page 94 ❑ Set the timing ⇒ “2.8 Setting the timing”, page 108 16 - Holder for radial shaft seal ❑...

  • Page 99: Assembly Overview - Adjustment Tool For Control Times

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Assembly overview - Adjustment tool for control times A - Angle sensor - VAS 611 007/1- B - Locking - VAS 611 007/2- C - Clamping ring - VAS 611 007/3- D - Adapter for camshaft hous‐...

  • Page 100: Removing And Installing Toothed Belt

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Expose vacuum hose on the holder -3-. – Remove screws -2-. – Remove top toothed belt guard -1-. Installing Installation is performed in the reverse order; pay attention to the...
  • Page 101 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Mark the direction of rotation with chalk or a felt-tip pen for the re-installation before removing the toothed belt pulley. Bending radius of the toothed belt NOTICE Risk of damage to the toothed belt.
  • Page 102 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Replace screw -4- and loosely insert a new screw ⇒ “3.4.2 Removing and installing camshaft control, outlet side”, page 132 – Take the control valve -3- and loosely screw it in ⇒...
  • Page 103 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Bending radius of the toothed belt NOTICE Risk of damage to the toothed belt. ♦ The bending radius -r- of the toothed belt -2- must not be al‐ lowed to drop below the minimum of 25 mm (approx. half the Ø...
  • Page 104 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Tensioning toothed belt – Rotate the eccentric -2- of the tensioning pulley with the wrench - T10499A- in -direction of arrow- until the adjustment pointer -3- is located approx. 10 mm to the right from the ad‐...

  • Page 105: Pre-Assembly And Assembly Of The Adjustment Tool For Control Times

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Toothed belt drive ⇒ “2.2 Summary of components - toothed belt”, page 91 ♦ Screw plug for bore in the cylinder block ⇒ Fig. ““Screw plug for TDC bore in the cylinder block behind - tightening torque”“...
  • Page 106 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 A - Angle sensor - VAS 611 007/1- B - Locking - VAS 611 007/2- C - Clamping ring - VAS 611 007/3- D - Adapter for camshaft hous‐...
  • Page 107 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Take note when mounting on the position of the locating pins -a-. Adapter for angle encoder - VAS 611 007/5- -E- fits only in one position. – Check whether the brake -b- Is detached. Do not use force.
  • Page 108 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Check shaft can move freely. • The adapter for the angle encoder - VAS 611 007/5- -e- must be easily rotatable. 2.6.2 Electronically teach the adjustment tool - VAS 611 007- and carry out basic set‐...

  • Page 109: Select Function

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Rotate adapter for angle encoder - VAS 611 007/5- -E- for exhaust camshaft. Exhaust camshaft is relearned when »OK« appears. – Rotate adapter for angle encoder - VAS 611 007/5- -E- for intake camshaft.
  • Page 110 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 2.6.3 Install Adjustment tool - VAS 611 007- – Pre-assemble adjustment tool - VAS 611 007- ⇒ page 100 – Electronically teach the adjustment tool - VAS 611 007- and carry out basic settings ⇒...

  • Page 111: Checking Valve Timing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 • The position of the lugs at adapter for angle encoder - VAS 611 007/5- -e- must exactly line up with the groove -arrow- of the adapter for the camshaft - VAS 611 007/6- or the adapter for camshaft - VAS 611 007/7- to match.
  • Page 112 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove the noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation . – Remove the front right wheelhouse liner ⇒ General body re‐...
  • Page 113 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – In this display, check that the brake symbol is »green« -A-. • The symbol should not be »yellow« or »red«. – Unscrew locating screw - T10340- . – Turn the crankshaft in direction of rotation of engine by 2 turns.

  • Page 114: Setting The Timing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Installation is performed in the reverse order; pay attention to the following points: – Screws which have been tightened firmly to a torquing angle must be replaced. – Replace O-rings and seal after disassembly Tightening torques ♦...
  • Page 115 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Check that the piston for cylinder 1 for working on the toothed belt is at “TDC” ⇒ page 72 Note To set the control times, leave the control belt tensioned.
  • Page 116 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – The two camshafts are set to »0.0 °«. – For this purpose, turn the camshafts with the Adapter for angle encoder - VAS 611 007/5- -e-. – Stop camshafts using the Adapters for angle sensors - VAS 611 007/5- -e- with the key in the »0.0 °«position.
  • Page 117 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Release brakes -a- at the adjustment tool - VAS 611 007- on both sides. – In this display, check that the brake symbol is »green« -A-. • The symbol should not be »yellow« or »red«.
  • Page 118 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Read out and note the control times in the display. The figure shows the values as an example. Note The inclination angle is determined individually for each vehi‐...
  • Page 119 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Check if the screws -a- for brakes on adjustment tool - VAS 611 007- are released on both sides. – In this display, check that the brake symbol is »green« -A-.
  • Page 120 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – In this display, check that the brake symbol is »red« -A-. • The symbol should not be »yellow« or »green«. – Unscrew locating screw - T10340- . – Pre-torque intake camshaft adjuster with torque ⇒...

  • Page 121: Test Timing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – In this display, check that the brake symbol is »green« -A-. • The symbol should not be »yellow« or »red«. – Seal phaser -1- and -2- with stopper -A- from the sealing plug set for engine - VAS 6122- as shown.

  • Page 122: Remove The Toothed Belt From The Camshaft

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Tighten outlet camshaft adjuster with final tightening torque ⇒ page 135 Tightening torques ♦ Camshaft control ⇒ “2.2 Summary of components - toothed belt”, page 91 ♦ Screw plug for “TDC” bore ⇒...
  • Page 123 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Bending radius of the toothed belt NOTICE Risk of damage to the toothed belt. ♦ The bending radius -r- of the toothed belt -2- must not be al‐ lowed to drop below the minimum of 25 mm (approx. half the Ø...

  • Page 124: Valve Gear

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Valve gear ⇒ “3.1 Assembly overview - valve gear”, page 118 ⇒ “3.2 Removing and installing bracket for radial shaft seal”, page ⇒ “3.3 Removing and installing gasket ring for camshaft”, page 122 ⇒...
  • Page 125 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 6 - Valve spring plate ❑ Removing and installing ⇒ “3.8 Removing and installing valve stem seals”, page 138 7 - Valve spring ❑ Fitting position ⇒ Fig. ““Fitting position of the valve spring”“ , page 119 ❑...

  • Page 126: Removing And Installing Bracket For Radial Shaft Seal

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing and installing bracket for ra‐ dial shaft seal Special tools and workshop equipment required ♦ Centring mandrel - T10576- ♦ Torx Bit T30 - T10584- ♦ Insertion tool - T10572- ♦...
  • Page 127 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Lightly oil centring mandrel - T10576- -A- around the entire circumference -4-. Note Also lightly oil the area of the holder for the radial shaft seal ring into which the centring pin engages.

  • Page 128: Removing And Installing Gasket Ring For Camshaft

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Place holder -2- with centring - T10576- -A- into the camshaft housing -3-. – Set 4.2 Nm on the torque wrench - V.A.G 1783- . – Tighten mounting screws -arrows- with Working tool - T10572- and Torx Bit 30 - T10584- .
  • Page 129 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Place centring mandrel - T10576- -A-, from the side of Valve 1 for camshaft adjustment - N205- , into the holder -2-. The centring mandrel - T10576- -A- reaches its position when the shoulder is completely at the holder -2- -arrow-.
  • Page 130 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Place a new sealing ring -1- on the holder -2-. Fitting position: • The closed side -d- of the gasket points outwards. Apply sealing ring – Shoulder -e- of the mounter - T10582- -C- must be inserted between the sealing ring -1- and centring mandrel - T10576- -A-.
  • Page 131 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push sealing ring -1- over the receiver tube -T10478/3- onto the guide bushing -T10478/2- . Fitting position: • Closed side of sealing ring points to the receiver tube.
  • Page 132 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Tighten nuts -D- until the thrust piece - T10478/1A- -C- is fitted on the camshaft housing -1-. – Check whether the sealing ring with thrust piece - T10478/1A- -C- is correctly pressed into the camshaft housing.
  • Page 133 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push sealing ring -1- over the receiver tube -T10478/3- onto the guide bushing -T10478/2- . • Installation position: Closed side of sealing ring points to the receiver tube.
  • Page 134 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Carefully fit extractor hook - T20143/2- -A- between camshaft -1- and seal -2-. – Support the extractor hook - T20143/2- -A- in the area of the -arrow- on the camshaft housing -3-.

  • Page 135: Removing And Installing Camshaft Control

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Screw in screw - T10579/4- -D- in the direction of the -arrow- until the thrust piece - T10579/3- -E- is on the camshaft hous‐ ing -3-. – Remove assembly device - T10579- .
  • Page 136 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Remove inlet camshaft control – Expose hoses on bracket -2- and place to one side. – Disconnect plug connection -1-. – Unlock catches using a screwdriver -arrow- and lay coolant expansion tank to the side.
  • Page 137 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Place holder - T10575- -B- over the full surface of the camshaft adjuster -1-. – Secure camshaft adjuster »clockwise« with holder - T10575- -B- and backstop - T10172A- -A- in this position.
  • Page 138 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Tighten inlet camshaft adjuster with final tightening torque. – Tighten control valve -2- for camshaft adjuster in 2 stages with final tightening torque. Level Control valve for intake Tightening torque...
  • Page 139 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Insert support - T10554- The row spacings -1- and -2- of the holder - T10554- are arranged unevenly. They are equal to the hole spacings in the camshaft control.
  • Page 140 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Place holder - T10554- on camshaft adjuster -1- as shown in the figure. The bolts of the holder - T10554- are not evenly spaced. The distances are equal to the hole spacings in the camshaft control.

  • Page 141: Removing And Installing Cam Adjuster

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Pre-torque outlet camshaft adjuster with tightening torque . – Hold the camshaft control with the holder - T10554- and coun‐ terholder - T10172A- . – Pre-tighten screws -1- with torque wrench.
  • Page 142 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Cam adjuster for cylinder 3 – Remove the air guide pipe between the charge air cooler and the exhaust turbocharger ⇒ “2.4.1 Removing and installing the air guide pipe between the charge air cooler and the exhaust gas turbocharger”, page...

  • Page 143: Removing And Installing Camshaft Control Valve 1 N205

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing and installing camshaft con‐ trol valve 1 - N205- Removing – Disconnect plug connection -2-. NOTICE Risk of damage to the toothed belt due to leaking engine oil.

  • Page 144: Removing And Installing Valve Stem Seals

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing and installing valve stem seals ⇒ “3.8.1 Removing and installing valve stem seal with cylinder head installed”, page 138 ⇒ “3.8.2 Removing and installing valve stem seal with cylinder head removed”, page 143...
  • Page 145 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove the coolant line -1- from the exhaust gas turbocharger -2-. – Unscrew screws -arrows- and remove coolant line. – Assignment of the roller towing levers -1-, Compensating ele‐...
  • Page 146 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 A - Guide plate - VAS 5161A/ B - Knurled screws - VAS 5161/12- C - Drift - VAS 5161/3A- D - Support fork - VAS 5161/5- E - Grid part - VAS 5161/6-...
  • Page 147 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Inlet side – In guide plate - VAS 5161A/40- -A- screw in support fork - VAS 5161/5- -D- with grid part - VAS 5161/6- -e-. – In the guide plate - VAS 5161A/40- -A- place the mounting cartridge - VAS 5161A/32-1- -F- complete with the pushed on shell - VAS 5161A/40-1- -G-.
  • Page 148 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Use valve shaft pliers - VAS 6770- to pull off valve stem seal. Installing Installation is performed in the reverse order; pay attention to the following points: NOTICE Risk of damage to valve stem seals during installation.
  • Page 149 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Install the valve cones – Rescrew guide plate - VAS 5161A/40- -A- to the cylinder head with screws - VAS 5161/12- -B-. – Place mounting cartridge - VAS 5161A/32-1- -F- with shell - VAS 5161A/40-1- -G- into the guide plate.

  • Page 150: Remove Cylinder Head

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 A - Clip - VAS 6419- B - Adjustment link - VAS 6419/2- C - Adjustment link - VAS 6419/1- a - Lever for moving the air cushion b - Air cushion c - Button »on«...
  • Page 151 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Affix cylinder head cylinder head tensioning device - VAS 6419- – Insert the cylinder head tensioning device - VAS 6419- into the engine and gearbox jack - VAS 6095- .
  • Page 152 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 A - Guide plate - VAS 5161A/ B - Knurled screws - VAS 5161/12- C - Drift - VAS 5161/3A- D - Support fork - VAS 5161/5- E - Grid part - VAS 5161/6-...
  • Page 153 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – In guide plate - VAS 5161A/40- -A- screw in support fork - VAS 5161/5- -D- with grid part - VAS 5161/6- -e-. Note In addition, select for this purpose a suitable area for screwing in the guide plate - VAS 5161A/40- -A-.
  • Page 154 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Install the valve stem seal – Lightly oil sealing lip of the valve stem seal -8-. – Install valve stem seal ⇒ Fig. ““Mounting valve stem seal”“ , page 119 –...

  • Page 155: Install Cylinder Head

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Install the valve cones – Rescrew guide plate - VAS 5161A/40- -A- to the cylinder head -1- with screws - VAS 5161/12- -B-. – Place mounting cartridge - VAS 5161A/32-1- -F- with shell - VAS 5161A/40-1- -G- into the guide plate.

  • Page 156: Inlet And Exhaust Valves

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Inlet and exhaust valves ⇒ “4.1 inspecting valve guides”, page 150 ⇒ “4.2 Testing valves”, page 150 ⇒ “4.3 Valve dimensions”, page 150 inspecting valve guides Special tools and workshop equipment required ♦...

  • Page 157: Lubrication

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 17 – Lubrication Sump, oil pump ⇒ “1.1 Assembly overview - pan/oil pump”, page 151 ⇒ “1.2 Engine oil”, page 155 ⇒ “1.3 Removing and installing oil pan”, page 155 ⇒...
  • Page 158 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 1 - Oil pan ❑ Removing and installing ⇒ “1.3 Removing and in‐ stalling oil pan”, page 155 2 - Screw ❑ Replace after removal ❑ Tightening sequence ⇒ Fig. ““Oil sump - tight‐...

  • Page 159: Removing And Installing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ Check for damage and replace if necessary 15 - Sealing ring 16 - Dowel pin 17 - Oil filter ❑ pay attention to the notes ⇒ page 151 ❑...
  • Page 160 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Oil sump - tightening torque and tightening order – Tighten screws gradually in the given sequence: Level Screws Tightening torque/torquing angle -1 … 19- Tighten by hand as far as the stop -1 …...

  • Page 161: Engine Oil

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Oil drain plug with replaceable gasket ring (all next oil change service) – Unscrew oil drain plug -2- and dispose of used sealing ring -3-. – Install new oil drain plug -2- with new captive gasket ring -1-.
  • Page 162 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect plug connection -1- on the control valve for the air conditioning system compressor - N280- . – Release screws -arrows- for AC compressor. NOTICE Risk of damaging AC compressor, refrigerant lines and hoses.
  • Page 163 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Carefully lever the oil pan at the recess -arrow- from the cyl‐ inder block. – Remove the oil pan from the cylinder block. – Unscrew the remaining two screws.

  • Page 164: Removing And Installing Oil Pump

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Plug -2- Into the holes and push in. Note Do not damage the plug. ♦ Do not press the plug with a pointed tool or with sharp-edged ♦...
  • Page 165 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove gasket -1- from dowel pins -arrows-. Installing – Fit new gasket -1- onto dowel pins -arrows-. – Check the oil pump for smooth operation, pushing the bearing -arrows- with a finger.

  • Page 166: Removing And Installing Oil Level And Oil Temperature Sender G266

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing and installing oil level and oil temperature sender - G266- Removing – Remove the noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation .

  • Page 167: Engine Oil Cooler

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Engine oil cooler ⇒ “2.1 Summary of components - engine oil cooler”, page 161 ⇒ “2.2 Removing and installing engine oil cooler”, page 161 Summary of components - engine oil cooler 1 - Engine oil cooler ❑...
  • Page 168 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen coolant pipe ⇒ “3.1 Summary of components - coolant pipe”, page 200 – Unscrew bolts -arrows- and remove engine oil cooler -1-. Installing Installation is performed in the reverse order; pay attention to the following points: –...

  • Page 169: With Respect To The Correctness Of Information In This Document. Copyright By Škoda Auto A. S.� Crankcase Ventilation

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Crankcase ventilation ⇒ “3.1 Summary of components - crankcase ventilation”, page 163 ⇒ “3.2 Removing and installing oil separator”, page 164 Summary of components - crankcase ventilation 1 - Oil separator below ❑...

  • Page 170: Removing And Installing Oil Separator

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Oil separator below - tightening torque and tightening order – Tighten the bolts in the sequence -1- through -9-to 9 Nm. Oil separator above- tightening torque and tightening order –...
  • Page 171 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 3.2.2 Removing and installing oil separator – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 37 – Remove the air guide pipe between the charge air cooler and the exhaust turbocharger ⇒...

  • Page 172: Oil Filter, Oil Pressure Switch

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Oil filter, oil pressure switch ⇒ “4.1 Summary of components - oil pressure switch/oil pressure control”, page 166 ⇒ “4.2 Testing oil pressure and oil pressure switch”, page 167 ⇒...

  • Page 173: Testing Oil Pressure And Oil Pressure Switch

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Testing oil pressure and oil pressure switch Note Oil Pressure Sensor - G10- Is installed on the engine. ♦ The oil pressure sender - G10- can be diagnosed. ♦...

  • Page 174: Removing And Installing Oil Pressure Sender G10

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect plug connection -2-. – Collect any engine oil which flows out with a cloth. – Remove screw -3- and remove oil pressure control valve - N428- -1-.

  • Page 175: Tightening Torques

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect connectors -1- and -3-. – Remove and move clear the electric wiring loom -arrow-. – Collect any engine oil which flows out with a cloth. – With the Extension No 24 - T40284- unscrew the oil pressure sensor - G10- -2-.

  • Page 176: Cooling

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 19 – Cooling Cooling system, coolant ⇒ “1.1 Connection diagram - coolant hoses”, page 170 ⇒ “1.2 Check cooling system for leaks”, page 171 ⇒ “1.3 Draining and filling coolant”, page 174...

  • Page 177: Additional Equipment

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 6 - Integrated exhaust manifold 7 - Heat exchanger for heating 8 - Coolant pump ❑ with Module for engine temperature control - GX33- 9 - Coolant radiator ❑ Summary of components ⇒...
  • Page 178 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Cover the cap -arrow- of the coolant expansion tank with a cloth and open carefully. – Position the cooling system testing device - V.A.G 1274- with adapter - V.A.G 1274/8 - on the coolant expansion reservoir.
  • Page 179 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note To ensure that the leaktightness test can be carried out correctly, first carry out the test (self-test) of the cooling system testing de‐ vice - V.A.G 1274 B- .

  • Page 180: Draining And Filling Coolant

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Fit the cooling system testing device - V.A.G 1274 B- with adapter -V.A.G 1274/8- onto the coolant expansion tank. – Build up a pressure of approximately 0.15 MPa (1.5 bar) using hand pump on cooling system testing device - V.A.G 1274 B- .
  • Page 181 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note The drained coolant must not be re-used. ♦ Collect and dispose of drained coolant in a clean container. ♦ Observe the disposal instructions. Draining CAUTION Risk of injury due to hot steams.
  • Page 182 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Raise holding clamp -arrow-, remove coolant hose from charge-air cooling circuit radiator, allow remaining coolant to drain. Filling up The drained coolant must not be re-used. Select the appropriate coolant additive from the ⇒ ETKA - Elec‐...
  • Page 183 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Open the valve -B-, while doing so turn the lever in the direction of flow. • A vacuum pump is created in the cooling system by the vac‐...
  • Page 184 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Inspecting coolant level • If the engine is cold the coolant level must be between the “Min” and “Max” markings. • When the engine is at operating temperature, the coolant level may be at or above the “Max”...

  • Page 185: Coolant Pump, Regulation Of Cooling System

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Coolant pump, regulation of cooling system ⇒ “2.1 Summary of components - coolant pump/thermostat”, page ⇒ “2.2 Summary of components - electric coolant pump”, page 181 ⇒ “2.3 Summary of components - coolant temperature transmit‐...
  • Page 186 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 1 - Toothed belt ❑ For coolant pump ❑ Replace after removal 2 - Pulley ❑ For coolant pump drive ❑ Removing and installing ⇒ “2.6 Removing and in‐...

  • Page 187: Summary Of Components - Electric Coolant Pump

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Summary of components - electric coolant pump 1 - Charge air cooler pump - V188- ❑ With holder ❑ Removing and installing ⇒ “2.4 Removing and in‐ stalling electric coolant pump”, page 182...

  • Page 188: Summary Of Components - Coolant Temperature Transmitter

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Summary of components - coolant temperature transmitter 1 - O-ring ❑ Replace after removal 2 - Coolant temperature send‐ er at radiator outlet - G83- ❑ Removing and installing ⇒...

  • Page 189: Removing And Installing Coolant Pump

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing CAUTION Risk of injury due to hot steams. Wear safety goggles, safety gloves and safety clothing. When the engine is warm, the cooling system is under overpres‐ sure.
  • Page 190 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Cooling system charge unit - VAS 6096- ♦ Adapter for cooling system tester - V.A.G 1274/8- Removing – Drain coolant ⇒ “1.3 Draining and filling coolant”, page 174 –...
  • Page 191 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen holding clips for cable harness -b- belt guard -3- of the coolant pump. – Release screws-arrows- and remove toothed belt protector -3-. – Remove connector -c- from the module for engine tempera‐...

  • Page 192: Removing And Installing Toothed Belt Pulley For Coolant Pump

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 • The pins -a- on the coolant pump must enter the openings -b- on the cylinder head. Note Thanks to the centring pins of the coolant pump, the toothed belt is tensioned automatically.
  • Page 193 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 • Drilling on the toothed belt wheel for driving the coolant pump -3- and the bore on the camshaft housing -4- must be in one axis. – Rotate crankshaft in engine direction until the holes are in one axis.
  • Page 194 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Screw in the screw - T10479/4- -a- by hand in the crankshaft up to the stop. – Position the extractor - T10221A- -3- on the toothed belt pulley -4-, as shown.

  • Page 195: Removing And Installing Coolant Temperature Transmitter G62

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Position the toothed belt -1- on camshaft -2- so that the shoul‐ der on the toothed belt wheel is in an axis with the edge of the milled surface on the camshaft -arrows-.

  • Page 196: Removing And Installing Coolant Temperature Sender At Radiator Outlet G83

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Briefly open the cap -arrow- for the coolant expansion reser‐ voir to release residual pressure in the coolant system, then close again until it clicks into place. – Place a cloth below to absorb leaking coolant.

  • Page 197: Removing And Installing Coolant Temperature Sender At Engine Outlet G82

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Briefly open the cap -arrow- for the coolant expansion reservoir to release residual pressure in the coolant system, then close again until it clicks into place. – Remove the noise insulation ⇒ General body repairs, exterior;...

  • Page 198: Removing And Installing Element For Engine Temperature Control Gx33

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect plug connection -4-. – Unscrew screw -arrow- and pull out coolant temperature send‐ er at the engine outlet - G82- -2-. Installing Installation is performed in the reverse order; pay attention to the following points: –...
  • Page 199 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Release holder -a- for cable harness and place it laterally. – Remove fuel line -b- from the holders -1- at the intake manifold and place it laterally. – Unscrew fixing screw for coolant pipe -c- from the charge air cooler -2- and place the tube laterally.
  • Page 200 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew screw -arrow- for Module for engine temperature control - GX33- -3-. – Pull the cable harness forward. – Remove Module for engine temperature control - GX33- -3- in -arrow- from the shaft -f- for coolant pump.

  • Page 201: Testing The Coolant Pump

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Module for motor temperature control - GX33- is guided to the coolant pump via the opening -3- and the knurled pin -4-. Observe the mounting sequence. – If necessary, insert the coolant pump shaft into the mounting position ⇒...
  • Page 202 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Affix Testing tool - T10577- to the coolant pump – Position Dial - T10577/2- on the pin -4-. – Screw on Dial - T10577/2- in the two holes -arrows- at the coolant pump -1-.
  • Page 203 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 When positioning, the normal arrow marking must show»O« -1- for the marking on the testing tool - T10577/1- . If the arrow does not match the mark, the coolant pump must be placed in the installation position ⇒...
  • Page 204 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Testing the coolant pump • The testing tool - T10577/1- -B- is connected to the coolant pump -1- ⇒ page 196 – Bring cooling pump to installation position ⇒ page 197 •...
  • Page 205 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Thereby rotate the marking arrow -a- to both end stops in the direction of the arrow -b-. • When the end stops are reached and exceeded, the overload protection must be activated.

  • Page 206: Coolant Pipes

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Coolant pipes ⇒ “3.1 Summary of components - coolant pipe”, page 200 ⇒ “3.2 Removing and installing coolant pipes”, page 201 Summary of components - coolant pipe 1 - Coolant hose ❑...

  • Page 207: Connection Diagram

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 14 - Clamp 15 - Screw ❑ 8 Nm 16 - Coolant tube top left ❑ Removing and installing ⇒ “3.2.2 Removing and installing the upper left coolant pipe”, page 203 ❑...
  • Page 208 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Cover the cap -arrow- of the coolant expansion tank with a cloth and open carefully. – Loosen lower hose clamp -arrow- and remove coolant hose -c-. – Release screw -d- at bracket for coolant pipe.
  • Page 209 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 3.2.2 Removing and installing the upper left coolant pipe Special tools and workshop equipment required ♦ Hose binding claw - VAS 6362- ♦ Catch pan , e.g. -VAS 6208- Removing –...
  • Page 210 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew fixing screw -b- for coolant pipe -1- from the charge air cooler -2-. – Release clamp -arrow- For coolant hose -4-. – Detach coolant hose from the charge air cooler -1-.
  • Page 211 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Cover the cap -arrow- of the coolant expansion tank with a cloth and open carefully. – Remove fuel line -b- from the holders -1- at the intake manifold and place it laterally.
  • Page 212 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing CAUTION Risk of injury due to hot steams. Wear safety goggles, safety gloves and safety clothing. When the engine is warm, the cooling system is under overpres‐ sure.

  • Page 213: Coolers, Radiator, Radiator Fan

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Coolers, radiator, radiator fan ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 207 ⇒ “4.2 Summary of components - fan shroud and radiator fan”, page 209 ⇒ “4.3 Removing and installing radiator”, page 209 ⇒...
  • Page 214 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ Screw tightening torque for top radiator bearing, 5 Nm. 11 - Charge air cooling circuit radiator ❑ Removing and installing ⇒ “4.3 Removing and installing radiator”, page 209 12 - Condenser ❑...

  • Page 215: Summary Of Components - Fan Shroud And Radiator Fan

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Summary of components - fan shroud and radiator fan 1 - Screw ❑ 5 Nm 2 - Fan shroud ❑ Removing and installing ⇒ “4.4 Removing and in‐ stalling fan shroud”,...
  • Page 216 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing – Drain coolant ⇒ “1.3 Draining and filling coolant”, page 174 – Removing fan shroud ⇒ “4.4 Removing and installing fan shroud”, page 212 – Remove the front bumper ⇒ General body repairs, exterior;...
  • Page 217 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note If the fuse latches break, you will not need to replace the top ra‐ diator bearing -1- . The fuse is replaced by a special screw -3- ⇒...

  • Page 218: Removing And Installing Fan Shroud

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Press left and right radiator locking lugs simultaneously -arrow- and remove coolant radiator from the charge air cool‐ ing circuit radiator. Installing Installation is performed in the reverse order; pay attention to the...

  • Page 219: Remove Screws

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove screws -3-. – Release catch - 2 -. – Slide the cover -1- forwards and out of the brackets -arrows-. – Remove cover -1-. – Slacken the coolant hose -2- and lay aside.

  • Page 220: Removing And Installing Radiator Fan V7

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect connector -1- for radiator fan. To do this, detach screw clamp backwards in direction of arrow -A- and press release tab. – Press locking lugs for fan shroud left and right simultaneously arrow -B- and remove fan shroud downwards from the radia‐...

  • Page 221: Turbocharging/Supercharging

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 21 – Turbocharging/supercharging Exhaust gas turbocharger ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 215 ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 218 ⇒ “1.4 Removing and installing element for load pressure control GX34 ”, page 223...

  • Page 222: Unless Authorised By Škoda Auto A. S. Škoda Auto A. S. Does Not Guarantee Or Accept Any Liability

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ⇒ “1.4 Removing and installing element for load pressure control GX34 ”, page 223 8 - Screw ❑ Replace after removal ❑ 8 Nm + 90° 9 - O-ring ❑...
  • Page 223 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 1.1.2 Assembly overview - Piping on the exhaust gas turbocharger 1 - Exhaust gas turbocharger ❑ Removing and installing ⇒ “1.2 Removing and in‐ stalling exhaust gas tur‐ bocharger”, page 218 2 - O-ring ❑...

  • Page 224: Removing And Installing Exhaust Gas Turbocharger

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing and installing exhaust gas turbocharger Special tools and workshop equipment required ♦ Screw plug set for engine , e.g. -VAS 6122- ♦ Hose binding claw - VAS 6362- ♦...
  • Page 225 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push release button -b- on hose for crankcase ventilation -1- and remove the hose. – Unscrew screw -a- and remove the hose -1- from the exhaust gas turbocharger -2-.
  • Page 226 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Assignment of installation for screw clamp -2- between ex‐ haust gas turbocharger and catalytic converter ⇒ “2.2 Removing and installing catalytic converter”, page 300 – Loosen and remove screw clamp -2-.
  • Page 227 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove seal -6- using removal tool - T10498- -A-. – Remove seal -7- using removal tool - T10498- -A-. – Replace gaskets, gasket rings, fixing nuts and O-rings.

  • Page 228: Removing And Installing The Exhaust Gas Turbocharger Connection Fitting

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push screwdriver -2- into the recess -arrow- of the exhaust gas turbocharger and lever out the sealing ring -1-. – Replace screw clamp between exhaust gas turbocharger and catalytic converter item -9- ⇒...

  • Page 229: Removing And Installing Element For Load Pressure Control Gx34

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew screws (non-detachable) -arrows- and remove con‐ nection fittings -1-. Installing Installation is performed in the reverse order; pay attention to the following points: Secure all hose connections with hose clamps which comply with the series design ⇒...
  • Page 230 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew screws -arrows- and remove heat shield for right cardan shaft, if present. – Remove connection fitting on exhaust gas turbocharger ⇒ “1.3 Removing and installing the exhaust gas turbocharger connection fitting”, page 222...

  • Page 231: Charge-Air System

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Charge-air system ⇒ “2.1 Summary of components - charge air system”, page 225 ⇒ “2.2 Removing and installing charge air cooler”, page 227 ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 228 ⇒...
  • Page 232 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 7 - Sealing ring ❑ Replace after removal ❑ moisten with engine oil 8 - Throttle valve control unit - GX3- ❑ comprises: Throttle valve control unit - J338-...

  • Page 233: Removing And Installing Charge Air Cooler

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Mounting overview - charge pressure sender - GX26- 1 - Charge pressure sender - GX26- ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 228 2 - Screw, 3 Nm...

  • Page 234: Removing And Installing Charge Pressure Sender Gx26

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove plug -a- also pull out-arrow- slightly. – Release electrical wiring harness -1- from the charge air cooler -2- -arrow-. – Secure charge air cooler -2- upon loosening the fastening screw -b- to prevent it from falling down.
  • Page 235 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing – Remove the throttle valve control unit - GX3- ⇒ “4.3 Removing and installing the throttle valve control unit GX3 ”, page 265 – Remove plug -a- also pull out-arrow- slightly.

  • Page 236: Installing And Removing The Air Guide Pipe

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Installing and removing the air guide pipe ⇒ “2.4.1 Removing and installing the air guide pipe between the charge air cooler and the exhaust gas turbocharger”, page 230 ⇒ “2.4.2 Removing and installing the air guide pipe between the charge air cooler and the suction pipe”, page 232...
  • Page 237 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unlock mounting bracket -a- at the ends of the two sides -2- in direction of -arrow-. – Remove mounting bracket -a- in -direction of arrow-. – Unhook mounting bracket -a- from the lock -2-.
  • Page 238 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Replace mounting bracket -a- before installation. – Press the air guide pipe up to the stop on the exhaust gas turbocharger. – Press the air guide pipe up to the stop on the charge air cooler.
  • Page 239 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Release catches -a- and remove plug -1-. Note Intake manifold sender - GX9- -2- does not need to be removed – Unscrew mounting screws -c- between holders -3- and throttle valve control unit - GX3- .

  • Page 240: Checking The Charge-Air System For Leaktightness

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove the air guide pipe -2- from the throttle valve control unit - GX3- and the intake manifold -4- in -the direction of the arrow-. Installing Installation is performed in the reverse order; pay attention to the following points: –...
  • Page 241 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Detach vent line -3-. To do so, press the locks. – Close open connections of vent line using suitable plugs from the screw plug set for engine - VAS 6122- .

  • Page 242: Leak Testing The Charge Air Cooler

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Prepare tester for charge air system - V.A.G 1687- as follows: – Unscrew pressure control valve -2- fully and close the valves -3- and -4-. • The rotary switch must be pulled to the top in order to rotate the pressure control valve -2-.
  • Page 243 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Test condition • The coolant temperature must be at least 40 °C. Connect turbocharger tester - V.A.G 1397A- – Screw the test adapter - VAS 691 005/5- onto the coolant ex‐...
  • Page 244 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Detach vent line -3-. To do so, press the locks. – Close open connections of vent line using suitable plugs from the screw plug set for engine - VAS 6122- .
  • Page 245 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Prepare tester for charge air system - V.A.G 1687- as follows: – Unscrew pressure control valve -2- fully and close the valves -3- and -4-. • The rotary switch must be pulled to the top in order to rotate the pressure control valve -2-.

  • Page 246: Replace O-Rings

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Clean Y distributor - VAS 691 005/1- Note After completing the leakage test, the Y distributor - VAS 691 005/1- must be cleaned when necessary to remove any moisture that has got in.

  • Page 247: Mixture Preparation - Injection

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 24 – Mixture preparation - injection Injection system ⇒ “1.1 Installation location overview - fuel injection system”, page Installation location overview - fuel injection system 1 - Lambda probe 1 in front of the catalytic converter - GX10- ❑...
  • Page 248 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 6 - Module for air mass measurement - GX35- ❑ not fitted to all engines ❑ comprises: ♦ Air mass meter - G70- ♦ Temperature sensor in the air mass meter - G1005- ❑...
  • Page 249 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Contact assignment at bulkhead plenum chamber 1 - Lambda probe 1 in front of the catalytic converter - GX10- 2 - Lambda probe 1 after catalytic converter - GX7-...
  • Page 250 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 6 - Exhaust cam adjuster for cylinder 2 - N587- ❑ Summary of components ⇒ “1.2 Summary of components - camshaft housing”, page 76 ❑ Removing and installing ⇒ “3.5 Removing and installing cam adjuster”, page 135 7 - Ignition coil 3 with power output stage - N291- ❑...
  • Page 251 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ Removing and installing ⇒ “5.1 Removing and installing intake manifold pressure sender GX9 ”, page 268 Installation overview: engine from front 1 - Knock sensor 1 - G61- ❑...
  • Page 252 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 7 - Module for engine temperature control - GX33- ❑ comprises: ♦ Position sensor for engine temperature control - G1004- ♦ Actuator for engine temperature control - N493- ❑ Summary of components ⇒...
  • Page 253 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 3 - Lambda probe 1 after catalytic converter - GX7- ❑ comprises: ♦ Lambda probe downstream of catalytic converter - G130- ♦ Lambda probe heater 1 downstream of catalytic converter - Z29- ❑...

  • Page 254: Injection Valves

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Injection valves ⇒ “2.1 Summary of components - fuel distributor with injectors”, page 248 ⇒ “2.2 Removing and installing the fuel distributor”, page 249 ⇒ “2.3 Removing and installing injectors”, page 250 ⇒...

  • Page 255: Removing And Installing The Fuel Distributor

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 11 - High pressure tube ❑ Removing and installing ⇒ “7.3 Removing and installing high pressure pipe”, page 280 ❑ Replace after removal ❑ Connections must not be damaged ❑...

  • Page 256: Removing And Installing Injectors

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect the plug connections -arrows-. – Release the screws -1- and disconnect the fuel distributor from the high pressure injection valves. Note When removing the fuel distributor, the injection valves can be withdrawn from the cylinder head.
  • Page 257 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 A - Pressure element - T10581/3- B - Extractor - T10581/4- C - Removal tool - T10133/16A- D - Screw from the Removal tool - T10133/16A- E - Baseplate - T10581/1-...
  • Page 258 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Remove injection valves on cylinder head. – Disconnect plug -3- at the impact sleeve -1-. – Sealing ring and spacer rings -2- must be carefully removed with Removal tool - T10498- .
  • Page 259 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Insert extractor - T10581/4- -B- into the groove at the injec‐ tor-1- . – Slide in Removal tool - T10133/16A- -C- over the puller - T10581/4- -B-. – Screw in screws -D- for Removal tool - T10133/16A- in the puller - T10581/4- -B-.
  • Page 260 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Disassembling the injector Injector Sealing ring Spacer ring (white) Spacer ring (red) Combustion chamber sealing ring Support ring Replace distance rings and gasket rings. Replace seal ring -2- and spacer rings -3- and -4- after removal.
  • Page 261 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push mounting sleeve - T10581/6- -H- on mounting cone - T10581/5- -G- up to the combustion chamber sealing ring -5-. – Slide combustion chamber sealing ring -5- with mounting sleeve - T10581/6- -H- on to the sealing ring groove ⇒...

  • Page 262: Clean Injectors

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Press the injection valve -1- by hand up to the stop into the hole of the cylinder head. Pay attention to the correct seating and fitting position of the in‐...
  • Page 263 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Clean – Remove injectors ⇒ “2.3 Removing and installing injectors”, page 250 – Remove the combustion chamber sealing ring ⇒ page 254 – Insert injectors -1- into the feeder plate for injection units - VAS 6418/1- -2-.

  • Page 264: Air Filter

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Air filter ⇒ “3.1 Assembly overview - air filter housing”, page 258 ⇒ “3.2 Removing and installing air filter housing”, page 259 Assembly overview - air filter housing 1 - Clamp...

  • Page 265: Removing And Installing Air Filter Housing

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 13 - Water drain hose ❑ clean 14 - Air deflector 15 - Cover ❑ for air guide 16 - Screw ❑ 2 Nm 17 - Screw ❑ captive ❑...
  • Page 266 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove the air filter housing -2- in -the direction of the arrow- from the air guidance -c-. Installing Installation is performed in the reverse order; pay attention to the...

  • Page 267: Intake Manifold

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Intake manifold ⇒ “4.1 Assembly overview - intake manifold”, page 261 ⇒ “4.2 Removing and installing intake manifold”, page 262 ⇒ “4.3 Removing and installing the throttle valve control unit GX3 ”, page 265...

  • Page 268: Removing And Installing Intake Manifold

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 12 - Screw ❑ 7 Nm 13 - Air guide pipe between the charge air cooler and the suction pipe. ❑ Removing and installing ⇒ “2.4.2 Removing and installing the air guide pipe between the charge air cooler and the suction pipe”,...
  • Page 269 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Detach vacuum hose -arrow- from intake manifold -1-. – Unlock the locks -e- and remove the vacuum line. – To do so, press the locks in the -direction of arrow-.
  • Page 270 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew screws -a- from intake manifold -1-. – Release coolant pipe -2- in the points -b-. – Place coolant tube, hoses and electrical cables sideways. – Remove the air guide pipe between the charge air cooler and the suction pipe ⇒...

  • Page 271: Removing And Installing The Throttle Valve Control Unit Gx3

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push out Intake manifold from the receptacles -a- and -b-. – Remove intake manifold. Installing Installation is performed in the reverse order; pay attention to the following points: –...

  • Page 272: Cleaning Throttle Valve Control Unit Gx3

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing – Remove the air guide pipe between the charge air cooler and the suction pipe ⇒ “2.4.2 Removing and installing the air guide pipe between the charge air cooler and the suction pipe”, page 232 –...
  • Page 273 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Open throttle valve by hand and lock in open position using wood or a plastic wedge -arrow-. CAUTION Danger when working with easily inflammable liquids. Wear safety goggles and safety clothing.

  • Page 274: Senders And Sensors

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Senders and sensors ⇒ “5.1 Removing and installing intake manifold pressure sender GX9 ”, page 268 ⇒ “5.2 Removing and installing fuel pressure sender G247 ”, page ⇒ “5.3 Check fuel pressure sender G247 ”, page 270 ⇒...

  • Page 275: Removing And Installing Fuel Pressure Sender G247

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Turn intake manifold sender - GX9- -2- about 45 ° in -direction of the arrow-. – Remove intake manifold sender - GX9- -2- from the air guide tube -3- in -the direction of the arrow-.

  • Page 276: Check Fuel Pressure Sender G247

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Pull off connector -1- using assembly tool - T10118- . – Unscrew screws from the coolant pipe -1-. – Place a cloth below to absorb any fuel. – Unscrew the fuel pressure sender - G247- -2- with the socket insert SW 27 - T40218- .
  • Page 277 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Release the screw plug -2- and screw the fuel pressure sender - G247- into the tester -VAS 6394/1- . – Connect the pressure line -1- of the tester onto the adapter - VAS 6394/3- .
  • Page 278 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Switch on the tester -VAS 6394/1- , for this step, briefly press the button -A-. Note If the button -A- is pressed for 2 seconds, the illumination is ♦...

  • Page 279: Removing And Installing Pressure Sensor For Exhaust Gas 1 G450

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove fuel feed line -1-. – Collect the fuel which flows out with a cloth. – Connect pressure gauge - VAS 6550- to fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .

  • Page 280: Removing And Installing Valve For Air Mass Meter Gx35

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect plug connection -2-. – Exhaust gas temperature sender 1 - G450- -1- using extension SW 24 - T40284- . Installing Installation is performed in the reverse order; pay attention to the following points: –...

  • Page 281: Engine Control Unit

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Engine control unit ⇒ “6.1 Removing and installing engine control unit J623 ”, page 275 Removing and installing engine control unit - J623- ⇒ “6.1.1 Removing and installing engine control unit J623 without protective housing”, page 275...
  • Page 282 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Remove the shear screws -arrows- as follows to remove the pro‐ tective housing -1-: – Make a slot for a screwdriver in the head of shear screw -1- with a miniature grinder -2-.
  • Page 283 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Continued for slackened screws – Unscrew shear screw -1- with a screwdriver -2-. – Remove protective housing -1-. NOTICE Risk of engine control unit destruction. If the engine control unit touches the plus pole of the battery, this will destroy it.

  • Page 284: High Pressure Pump

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 High pressure pump ⇒ “7.1 Summary of components - high pressure pump”, page 278 ⇒ “7.2 Removing and installing the high pressure pump”, page 279 ⇒ “7.3 Removing and installing high pressure pipe”, page 280...

  • Page 285: Removing And Installing The High Pressure Pump

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Level Screws M8 Tightening torque/torque angle Tighten by hand as far as the stop Tighten by 1 turn alternately until the flange of the high pressure pump is at...

  • Page 286: Removing And Installing High Pressure Pipe

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Installation roller tappet • Lug -A- of the tappet -3- must be in groove -B- in the camshaft housing -4-. • When setting the position correctly, the contour must be -C- visible! •...
  • Page 287 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew union nuts -arrows-. – Remove fastening screw on holder -1- and remove the high pressure pipe. Installing Installation is performed in the reverse order; pay attention to the following points: •...

  • Page 288: Lambda Probe

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Lambda probe ⇒ “8.1 Summary of components - lambda probe”, page 282 ⇒ “8.2 Removing and installing Lambda probe”, page 282 Summary of components - lambda probe Note New lambda probes are coated with assembly paste. This paste must not come into contact with the slots ♦...
  • Page 289 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Lambda probe 1 in front of catalytic converter - GX10- comprises: ♦ Lambda probe - G39- . ♦ Lambda probe heater - Z19- . Lambda probe 1 after catalytic converter - GX7- comprises: ♦...
  • Page 290 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Unscrew respective lambda probe using a spanner from the lambda probe ring spanner set - 3337- . Lambda probe 1 after catalytic converter - GX7- Lambda probe 1 in front of the catalytic converter - GX10- Installing Installation is performed in the reverse order;...

  • Page 291: Exhaust System

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 26 – Exhaust system Exhaust pipes/silencers ⇒ “1.1 Assembly overview - silencers”, page 285 ⇒ “1.2 Removing and installing silencers”, page 289 ⇒ “1.3 Separating exhaust pipes/silencers”, page 294 ⇒...
  • Page 292 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 3 - Retaining strap ❑ replace if damaged ❑ Observe part number ⇒ ETKA - Electronic Catalogue of Original Parts 4 - Mounting bracket ❑ Observe part number ⇒ ETKA - Electronic Catalogue of Original Parts 5 - Screw ❑...
  • Page 293 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Difference between clamping sleeves ♦ Clamping sleeve -A-: 95 mm long. ♦ Clamping sleeve -B-: 88 mm long. Installation dimension for vehicles with marking on the exhaust pipe 1 - Clamping sleeve...
  • Page 294 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 1 - Screw ❑ 20 Nm 2 - Mounting bracket ❑ Observe part number ⇒ ETKA - Electronic Cata‐ logue of Original Parts 3 - Retaining strap ❑ replace if damaged ❑...

  • Page 295: Removing And Installing Silencers

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Installation position of rear clamp – Install clamping sleeve in the position shown. • Bolted connections to the left. • The bolted connection -arrow- must not protrude under the bottom edge of the clamping sleeve.
  • Page 296 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Body saw e.g. -V.A.G 1523/A- ♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931- ♦ Protective goggles Note for first version the unit, replace individually when carrying out ♦...
  • Page 297 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Remove the separate middle damper – Separate the middle damper -2- from the front damper-1- and the rear damper-4- In the area of the -arrow- ⇒ “1.3 Separating exhaust pipes/silencers”, page 294 –...
  • Page 298 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note for first version the unit, replace individually when carrying out ♦ repairs. A separating point has been provided in the connecting pipe ♦ to remove parts of the exhaust system separately.
  • Page 299 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Secure the exhaust pipe -1- with tensioning strap -2- to the propshaft. – Detach retaining loop -2-. – Remove front damper -3-. Remove the separate exhaust gas rear damper –...

  • Page 300: Separating Exhaust Pipes/Silencers

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen the screws -arrows- of the clamping sleeve -1- and slide the sleeve backwards. – Secure the exhaust pipe -1- with tensioning strap -2- to the propshaft. – Remove the electrical plug connections -6- at the exhaust flap control unit - J883- .

  • Page 301: Align Exhaust System Free Of Stress

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 CAUTION Risk of injury from ejected swarf. Wear safety goggles and safety clothing. – Cut through exhaust pipe at separation point -arrow- at right angle with body saw - V.A.G 1523A- or chain pipe cutter - VAS 6254- .

  • Page 302: Inspecting The Exhaust System For Leaks

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push the exhaust system so far forward in the direction of travel until the retaining strap is pre-tensioned -a- = 5mm. – Tighten front clamping sleeve screw connections evenly ⇒...

  • Page 303: Cleansing Exhaust Emissions

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Cleansing exhaust emissions ⇒ “2.1 Summary of components - exhaust gas cleaning”, page 297 ⇒ “2.2 Removing and installing catalytic converter”, page 300 ⇒ “2.3 Removing and installing the exhaust flap control unit J883 ”, page 303...
  • Page 304 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ❑ 20 Nm 7 - Pre-exhaust pipe with catalytic converter ❑ do not twist decoupling element more than 10° - risk of damage ❑ Do not load decoupler with tensile stress ❑...
  • Page 305 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Difference between clamping sleeves ♦ Clamping sleeve -A-: 95 mm long. ♦ Clamping sleeve -B-: 88 mm long. Installation dimension for vehicles with marking on the exhaust pipe Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

  • Page 306: Removing And Installing Catalytic Converter

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Installing catalytic converter - tightening torque and tightening or‐ – Position catalytic converter on exhaust gas turbocharger, loosely tighten clamp -arrow- – Loosely screw in screws -3-, • It must still be pos‐...
  • Page 307 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Release screws -arrows- of the holder. – Remove tunnel bridge -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
  • Page 308 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Loosen the clamping sleeve -arrow- and slide it backwards. For vehicles with four-wheel drive – Unscrew propshaft -1- from the angle gear ⇒ Rep. gr. 39 ; Components for angle gears; Removing and installing angle gear .

  • Page 309: With Respect To The Correctness Of Information In This Document. Copyright By Škoda Auto A. S.� Removing And Installing The Exhaust Flap Control Unit J883

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Push screwdriver -2- into the recess -arrow- of the exhaust gas turbocharger and lever out the sealing ring -1-. Installing Installation is performed in the reverse order; pay attention to the...

  • Page 310: Ignition System

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 28 – Ignition system Ignition system ⇒ “1.1 Assembly overview - ignition system”, page 304 ⇒ “1.2 Removing and installing ignition coils with output stage”, page 305 ⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page 308 ⇒...

  • Page 311: Removing And Installing Ignition Coils With Output Stage

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 ♦ Ignition coil 1 with power output stage - N70- ♦ Ignition coil 2 with power output stage - N127- ♦ Ignition coil 3 with power output stage - N291- ♦...
  • Page 312 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Note The ignition coils are easier to remove when the engine is ♦ warm. Using grease makes removal easier. Ignition coil with power stage and spark plug connector are ♦...
  • Page 313 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Remove ignition coil with extractor -T10530- in -direction of arrow- out of the camshaft housing. Installing Installation is performed in the reverse order; pay attention to the following points: Note Spark plugs are to be removed from the ignition coil by hand.

  • Page 314: Removing And Installing Knock Sensor 1 G61

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 Removing and installing knock sensor 1 - G61- Removing – Remove the noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Summary of components - noise insulation .

  • Page 315: Removing And Installing Position Transmitter For Exhaust Camshaft G1003

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect the plug -3- on the position sender for inlet cam‐ shaft - G1002- -1-. – Remove screw -2-. Note If engine oil touches the sealing ring for the coolant pump, it may be damaged chemically.

  • Page 316: Removing And Installing The Engine Speed Sender G28

    Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Disconnect plug connection -2-. – Unscrew screw -arrow- and remove position sensor for ex‐ haust camshaft - G1003- -1-. Installing Installation is performed in the reverse order; pay attention to the following points: –...
  • Page 317 Karoq 2018 ➤ 1,5/110 kW TSI EVO Engine - Edition 07.2017 – Separate the plug connection -4- for the engine speed sensor - G28- -1-. – Remove sealing plug -3- , thread these out from the engine speed sensor - G28- -1- .

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