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Skoda Fabia II 2007 Workshop Manual
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Skoda Fabia II 2007 Workshop Manual

Skoda Fabia II 2007 Workshop Manual

1.9/77 kw tdi pd engine
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Service
Workshop Manual
Fabia II 2007 ➤ , Fabia II 2009 ➤ ,
Octavia II 2004 ➤ , Octavia II 2010 ➤ ,
Roomster 2006 ➤ , Superb II 2008 ➤
1.9/77 kW TDI PD Engine
Engine ID
Edition 12.2015
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
AXR
BJB
BKC
BLS BSW BXE

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Summary of Contents for Skoda Fabia II 2007

  • Page 1 Service Workshop Manual Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ➤ , Roomster 2006 ➤ , Superb II 2008 ➤ 1.9/77 kW TDI PD Engine BLS BSW BXE Engine ID Edition 12.2015...
  • 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 20 - Fuel supply system 21 - Turbocharging/supercharging...

  • Page 3: Table Of Contents

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Contents 00 - Technical data ........... .
  • Page 4 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Disassembling and assembling pistons and conrods ......
  • Page 5 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing radiator (Octavia II, Superb II) ......222 Removing and installing radiator (Fabia II, Roomster) .
  • Page 6 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing exhaust gas turbocharger (Fabia II, Roomster) ....318 Removing and installing parts of the charge air cooler (Superb II) .
  • Page 7 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Checking mechanical exhaust gas recirculation valve for engine with identification characters AXR, BSW, BJB, BKC, BXE ..........424 Checking the change-over flap of the radiator for exhaust gas recirculation for engine with engine identification characters BKC, BXE (Octavia II, Superb II) .
  • Page 8 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

  • Page 9: Technical Data

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 00 – Technical data Identification (SRL000892; Edition 12.2015) ⇒ “1.1 Engine number”, page 1 ⇒...

  • Page 10: Engine Characteristics (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Engine characteristics (Fabia II, Roomster) Engine identification charac‐ ters Manufactured Fabia II ---- 04.07 ►...

  • Page 11: Safety Instructions

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Safety instructions ⇒ “2.1 Regulations concerning safety precautions when working on the fuel system”, page 3 ⇒...

  • Page 12: Safety Precautions When Working On The Fuel Supply Of The Diesel Direct Injection System

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Safety precautions when working on the fuel supply of the diesel direct injection system If test and measuring devices are required during test drives ob‐...

  • Page 13: Repair Instructions

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Repair instructions ⇒ “3.1 Self-diagnosis”, page 5 ⇒ “3.2 Supplementary instructions and assembly work on vehi‐...

  • Page 14: Regulations Concerning Cleanliness When Working On The Fuel Supply/Fuel Injection System

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Regulations concerning cleanliness when working on the fuel supply/fuel in‐ jection system Carefully observe the following rules for cleanliness when working on the fuel supply/injection system: ♦...

  • Page 15: Handling The Ceramic Glow Plugs

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Caution In case a mechanical damage to the exhaust gas turbocharger is found, for example, damage to the compressor wheel, it is not sufficient to only replace the turbocharger.
  • Page 16 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note The ceramic glow plugs are very fragile due to the used com‐...

  • Page 17: Removing And Installing Engine

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 10 – Removing and installing engine Removing and installing engine ⇒ “1.1 Removing (Octavia II, Superb II)”, page 9 ⇒...

  • Page 18: Drain Coolant

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Lift the engine cover at the sides -arrows 1- and pull out to‐...
  • Page 19 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For the vehicles Octavia II up to 08.05 – Unlatch fuses, remove fuel filter with its connected lines up‐...
  • Page 20 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For Octavia II vehicles as of 08.05 and Superb II vehicles. – Release screw -1- by one turn.
  • Page 21 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Continued for all vehicles – Remove drive shaft to the right ⇒ Chassis; Rep. gr. 40 .
  • Page 22 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Screw on -T10012- engine mount to the cylinder block with fixing nut and bolt. Tighten screw M10 x 25/8.8 to approx.

  • Page 23: Removing (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – ... at gearbox 02E -2-. Note Check whether all hose and line connections between engine, ♦...
  • Page 24 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove charge-air pipe at the top -1- with connecting hose -2- -arrows-.
  • Page 25 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unbolt the pendulum support -arrows-. – Remove holder for electric installation at the bottom from the gearbox.
  • Page 26 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Disconnect the coolant hose -1- from the cylinder head. – Disconnect the fuel intake hose -3- and the fuel return hose -2- from the pipes.

  • Page 27: Securing The Engine To The Assembly Stand

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release the screws which connect the engine mount with the engine support -arrows-.

  • Page 28: Installing (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Attach lifting device -MP9-201 (2024 A)- at engine and at workshop crane (e.g. -VAS 6100- ).
  • Page 29 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For vehicles with manual gearbox 0A4 or 02Q Note Clean the serration on the drive shaft and if the clutch discs ♦...
  • Page 30 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Successively release screws at gearbox 0A4 -arrows- or ... – ... at the gearboxes 02Q or 02E -arrows-.
  • Page 31 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Tighten pendulum support with screws -1 ... 3- at gearbox and at assembly carrier. Use new screws for attaching.
  • Page 32 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Only then re-use drained coolant, if the cylinder head or cyl‐ ♦...

  • Page 33: Installing (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Gearbox mount 0A4 A - 40 Nm + 90° - replace after disassembly B - 60 Nm + 90°...
  • Page 34 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Replace the self-locking nuts and screws when undertaking ♦ assembly work. Replace screws which have been tightened to a torquing angle ♦...
  • Page 35 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Install Bowden cable support -arrows- and insert cable -A- for slave cylinder into the bracket on the gearbox.
  • Page 36 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Screw on screws -arrows- for left steering joint ⇒ Chassis; Rep. gr. 40 .

  • Page 37: Checking And Adjusting The Assembly Bracket (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.5.1 Assembly bracket Tightening torques Engine mount 20 Nm + 90° - replace after disassembly 30 Nm + 90°...
  • Page 38 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.6.1 Checking the assembly bracket Check dimensions on the right hanger for engine/gearbox unit: •...
  • Page 39 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release the screws -arrows- of the assembly bracket at the engine. – Slightly loosen the screws -arrows- of the assembly bracket at the gearbox (less than 1 revolution).

  • Page 40: Checking And Adjusting The Assembly Bracket (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Checking and adjusting the assembly bracket (Octavia II) ⇒ “1.7.1 Checking the assembly bracket”, page 32 ⇒...
  • Page 41 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release the screws -arrows- of the assembly bracket at the engine. – Slightly loosen the screws -2- of the unit mounting at the gear‐...

  • Page 42: Crankshaft Group

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 13 – Crankshaft group Removing and installing a V-ribbed belt and a toothed belt ⇒...
  • Page 43 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Poly V-belt pulley ❑ with vibration damper ❑ Adjust TDC with the vi‐...

  • Page 44: Removing And Installing V-Ribbed Belt (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ❑ do not kink Bolts at bracket for auxiliary units - tightening sequence...
  • Page 45 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For Octavia II vehicles as of 08.05 and Superb II vehicles. – Release screw -1- by one turn.

  • Page 46: Summary Of Components - V-Ribbed Belt (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 On vehicles with air conditioning – First position the ribbed V-belt on the belt pulleys of the crank‐...
  • Page 47 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Screw ❑ Replace after disas‐ sembly ❑ 10 Nm + 90°...
  • Page 48 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.2 Summary of components - Vehicles with air conditioning Note Mark the rotation direction before removing the V-ribbed belt.

  • Page 49: Removing And Installing V-Ribbed Belt (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 14 - V-ribbed belt ❑ removing and installing ⇒ “1.4 Removing and installing V-ribbed belt (Fabia II, Roomster)”, page 41 Fitting sleeve –...
  • Page 50 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Swing the tensioning pulley in -the direction of the arrow- de‐ tension the V-ribbed belt.

  • Page 51: Summary Of Components - Toothed Belt (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Lock tensioning pulley with locking pin - T10060A- . – Remove V-ribbed belt; first from the air conditioning compres‐...
  • Page 52 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Screw ❑ Replace after disas‐ sembly ❑ 10 Nm + 90°...
  • Page 53 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 11 - Camshaft pulley ❑ Mark installation position 12 - 100 Nm ❑ to release and tighten use the counterholder -T10051- 13 - Hub ❑...

  • Page 54: Removing And Installing Toothed Belt (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Tensioning pulley Additional hole in the eccentric of the tensioning pulley for 6 mm hexagon socket wrench -arrow-.
  • Page 55 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt.
  • Page 56 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -1- and -2- and remove connecting stud. – Unscrew screws -3 ... 6- and remove engine mount console.
  • Page 57 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Lock hub with rig pin -3359- . – Lock the crankshaft toothed belt sprocket with the crankshaft arrester -T10100- .
  • Page 58 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Now turn eccentric of the tensioning pulley clockwise -arrow- as far as the stop and tighten fixing nut -1- by hand.
  • Page 59 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Loosen the fixing nut -1- of the tensioning pulley. – Turn the eccentric of the tensioning pulley with offset screw‐...
  • Page 60 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Check whether: ♦ The crankshaft can be interlocked with the crankshaft arrester -T10100- .

  • Page 61: Summary Of Components - Toothed Belt (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Insert counterholder -T10172- with bolts -T10172/4- as shown and press in -direction of arrow-.
  • Page 62 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Top toothed belt guard ❑ to remove, remove the right charge air pipe ❑...
  • Page 63 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 13 - Guide pulley 14 - Coolant pump ❑ removing and installing ⇒ “1.8 Removing and installing coolant pump”, page 210 15 - Crankshaft - toothed belt sprocket ❑...
  • Page 64 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Tensioning pulley Additional hole -arrow- in the eccentric of the tensioning pulley for 6 mm hexagon socket wrench.

  • Page 65: Removing And Installing Toothed Belt (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Tightening order for engine support I: Engine support bracket for vehicles built between 05.2005 and 05.2007...
  • Page 66 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt.
  • Page 67 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -1- and -2- and remove connecting stud. – Unscrew screws -3 ... 6- and remove engine mount console.
  • Page 68 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Depending on the version, lock the crankshaft toothed belt sprocket with the crankshaft arrester -T10050- or crankshaft arrester -T10100- .
  • Page 69 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Always perform adjusting work on the timing belt only on a cold ♦...
  • Page 70 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Insert counterholder -T10172- with bolts -T10172/4- as shown and press in -direction of arrow-.
  • Page 71 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Rotate crankshaft in direction of rotation of engine until it can be interlocked with the crankshaft arrester -T10050- or crank‐...

  • Page 72: Summary Of Components - Toothed Belt (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Install engine support. Screw un screws -1 ... 3- by hand first, then tighten to 40 Nm + torque a further 90°.
  • Page 73 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Top toothed belt guard 2 - Toothed belt ❑ before removing mark running direction ❑...
  • Page 74 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 15 - Guide pulley 16 - Crankshaft - toothed belt sprocket ❑ Contact surface between crankshaft toothed belt sprocket and crankshaft must be clean and free of grease ❑...

  • Page 75: Removing And Installing Toothed Belt (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.10 Removing and installing toothed belt (Fabia II, Roomster) ⇒ “1.10.1 Removing”, page 67 ⇒...
  • Page 76 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Install supporting device -MP9-200 (10-222A)- and support the engine with spindle -B- in fitting position. Allow spindle -A- to hang loosely.
  • Page 77 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Engines with identification characters BLS • The gear segment -arrow- must point upwards.
  • Page 78 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Loosen the fixing nut -1- of the tensioning pulley. – Carefully turn eccentric of the tensioning pulley in anti-clock‐...

  • Page 79: Test Timing

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Check the correct catch fitting of the tensioning pulley in the hole in the rear timing belt guard -arrow-.
  • Page 80 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note The bolt of the crankshaft arrester -T10050- or -T10100- must ♦ engage in the sealing flange. (Crankshaft arrester should be inserted just ahead of TDC on toothed belt sprocket.)
  • Page 81 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Loosen the screws -arrows- of the camshaft sprocket. – Rotate crankshaft in direction of rotation of engine until the crankshaft can be interlocked with the crankshaft arrester - T10050- or -T10100- .

  • Page 82: Removing And Installing Sealing Flange And Flywheel

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing sealing flange and flywheel ⇒ “2.1 Summary of components (Octavia II, Superb II)”, page 74 ⇒...
  • Page 83 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 6 - Intermediate plate ❑ must be positioned on dowel sleeves ❑ do not damage/bend during assembly work ❑...

  • Page 84: Summary Of Components - (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - (Fabia II, Roomster) 1 - Sealing ring ❑ Replace.

  • Page 85: Replacing Crankshaft Sealing Ring On Belt Pulley Side (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Lock the flywheel – Position the flywheel lock -MP1-504- on the starter ring gear and turn crankshaft until it rests against the distance sleeve - T30010- .
  • Page 86 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Before positioning the gasket ring extractor, screw the central bolt of the toothed belt sprocket into the crankshaft by hand up to the stop.

  • Page 87: Replacing Crankshaft Sealing Ring On Belt Pulley Side (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Press in the gasket ring flush with the central screw for toothed belt sprocket and with pressure bushing of -T10053- .
  • Page 88 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Screw the bolt by hand into the crankshaft as far as the stop.

  • Page 89: Removing And Installing The Sealing Flange On The Belt Pulley Side

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Install crankshaft - toothed belt sprocket and lock with coun‐ terholder - T30004- or counterholder - MP1-310 (3099)- .
  • Page 90 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove crankshaft toothed belt sprocket, to this end lock toothed belt sprocket with counterholder or counterholder for toothed belt sprocket.

  • Page 91: Removing And Installing Sealing Flange On Gearbox Side (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Apply silicone sealant bead -arrow- to the clean sealing sur‐ face of the sealing flange, as shown.
  • Page 92 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Steel straightedge ♦ Screw M6 x 35 (3x) ♦ Screw M7 x 35 (2x)
  • Page 93 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Alternately screw in 3 screws M6x35 -arrows- (max. / 2 turn (180°) per screw) into the threaded holes of the sealing flange -1- and remove the sealing flange together with the sender wheel -2- from the crankshaft -3-.
  • Page 94 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Mounting sealing ring with sender wheel on assembly tool - T10134- – Untwist nut -B- until just before it touches the clamping surface -A- of the threaded spindle.
  • Page 95 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Lay the front side of the sealing flange on a clean and level surface.
  • Page 96 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Attach assembly tool - T10134- with sealing flange to the crank‐ shaft flange and cylinder block •...
  • Page 97 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Press sender wheel onto crankshaft flange using assembly tool - T10134- – Tighten nuts -B- on the assembly tool - T10134- with torque wrench to 35 Nm.

  • Page 98: Removing And Installing Two-Mass Flywheel (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Install engine speed sender - G28- Position -1-. – Installing the oil pan ⇒...
  • Page 99 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Engine mount - MP1-202 (VW 540)- ♦ Bushing - T30010 (VW 540/1B)- ♦...
  • Page 100 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note When removing, ensure that no screw head touches the two- mass flywheel, otherwise the flywheel may be damaged at the following turning of the screw.

  • Page 101: Crankshaft, Piston And Conrod

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Crankshaft, Piston and Conrod ⇒ “3.1 Summary of components - Removing and installing crank‐...

  • Page 102: Summary Of Components - Removing And Installing Crankshaft (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 6 - Bearing shells 1, 2, 4 and 5 ❑ for cylinder block with lubricating groove ❑...

  • Page 103: Summary Of Components - Removing And Installing Crankshaft (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 3.2.1 Replacing the needle bearing for crank‐ shaft (Octavia II, Superb II) Only on vehicles fitted with automatic gearbox.
  • Page 104 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Bearing shells 1, 2, 4 and 5 ❑ for bearing cap without lubricating groove ❑...
  • Page 105 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 11 - Thrust washer ❑ for cylinder block, bearing 3 Checking projection of fit pin from crankshaft Special tools and workshop equipment required ♦...

  • Page 106: Disassembling And Assembling Pistons And Conrods

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Disassembling and assembling pistons and conrods 1 - Piston rings ❑ Offset joint 120°...
  • Page 107 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ❑ Pay attention to version: top bearing shell (towards the piston) must be in long wearing material, distin‐...
  • Page 108 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Inspect piston ring end clearance Special tools and workshop equipment required ♦ Feeler gauges –...

  • Page 109: Checking Piston Projection In Tdc

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Inspecting cylinder bore Special tools and workshop equipment required ♦ Internal precision measuring instrument –...

  • Page 110: Separating New Conrod

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Test sequence When fitting new pistons or a partial engine, check the piston pro‐...

  • Page 111: Removing And Installing Drive Chain Sprocket

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Carefully knock against the conrod bearing cap with a plastic hammer in -direction of arrow- in order to loosen it.
  • Page 112 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Slide on the chain sprocket with drive bushing - MP1-316 (30-100)- until the stop on the crankshaft is reached.

  • Page 113: Cylinder Head, Valve Gear

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 15 – Cylinder head, valve gear Removing and installing the cylinder head ⇒ “1.1 Summary of components”, page 105 ⇒...
  • Page 114 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.1.1 Summary of components for engine with engine identification characters BXE, BJB, BKC (Octavia II, Superb II) Note Cylinder heads with cracks between the valve seats may con‐...
  • Page 115 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Screw ❑ mount using locking agent -D 000 600 A2- ❑ 10 Nm 2 - Screw ❑...
  • Page 116 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 10 - Intermediate flange 11 - Sealing sleeve 12 - Screw cap 13 - Gasket ❑...
  • Page 117 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Inspect cylinder head at several points for distortion using a knife-edge straightedge and feeler gauge.
  • Page 118 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Vacuum hose ❑ for connecting piece of tandem pump / brake...
  • Page 119 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Octavia II ⇒ “1.5 Removing and installing cylinder head (Octavia II)”, page 129 15 - Screw ❑...
  • Page 120 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Inspecting the cylinder head for distortion Special tools and workshop equipment required ♦ Feeler gauges ♦...
  • Page 121 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 order of tightening 1.1.3 Summary of components for engine with engine identification characters BSW...
  • Page 122 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Cylinder head cover ❑ Removing and installing ⇒ “1.3 Removing and in‐...
  • Page 123 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 17 - Gasket ❑ replace 18 - Screw ❑ 20 Nm 19 - Ball knob screw ❑...

  • Page 124: Removing And Installing Cylinder Head Cover (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Maximum permitted distortion: 0.1 mm Note It is not permissible to rework the cylinder heads of diesel engines.
  • Page 125 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew connection fitting with mechanical exhaust gas re‐ circulation valve -arrows-. – Remove top toothed belt guard, to do so release retaining clips.

  • Page 126: Removing And Installing Cylinder Head Cover (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Apply on both edges on the sealing surfaces of the bearing cap/cylinder head -arrows- at front ...
  • Page 127 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Protective goggles and gloves ♦ Sealant - D 454 300 A2- – Lift the engine cover at the sides -arrows A- and pull out to‐...
  • Page 128 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release the screws for the cylinder head cover in the se‐ quence -13 ... 1- and remove the cover.

  • Page 129: Removing And Installing Cylinder Head (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For engine with engine code BLS – Tighten the screws for the cylinder head cover in the sequence -1 ...

  • Page 130: Drain Coolant

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove charge air pipes and charge air hoses ⇒ “1.4 Summary of components - air filter (Octavia II, Superb II)”, page 364...
  • Page 131 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -1- and -2- and remove bracket for turbo‐ charger. Note Collect any engine oil which flows out with a cloth.
  • Page 132 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Pull the vacuum hose -arrow- off the brake servo unit. – Remove coolant hose -arrow- at coolant fitting.
  • Page 133 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew screws out of the flange between the radiator for ex‐ haust gas recirculation and the intake manifold --.
  • Page 134 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Follow the specified order for loosening cylinder head bolts. – Slightly raise the cylinder head with lifting device - MP9-201- and workshop crane - VAS 6100- and laterally remove from the engine next to the toothed belt guard.
  • Page 135 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Pay attention to the identification of the cylinder head seal. ♦ Part number = arrow -1- ♦...
  • Page 136 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Position hub onto camshaft. – Tighten screw -1- to 100 Nm, use counterholder -T10051- to hold.

  • Page 137: Removing And Installing Cylinder Head (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Push camshaft sprocket onto the hub. • The tooth segment -arrow- of the camshaft sprocket must be at the top.
  • Page 138 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.5.1 Removing Requirements • Engine temperature should not exceed 35 °C, because the cylinder head could be twisted when slackening the screws.
  • Page 139 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Detach the fuel intake hose -2- and the fuel return hose -1- from the fuel lines.
  • Page 140 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Disconnect plug connection at changeover valve for radiator of exhaust gas recirculation -N345- -arrow-.
  • Page 141 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Disconnect coolant hose -1- at exhaust gas recirculation radi‐ ator. – Remove connection pipe for exhaust gas recirculation radiator...
  • Page 142 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove timing belt tensioning pulley. – Screw out screw -3- and remove Hall sender -G40- from cyl‐...
  • Page 143 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.5.2 Install Note Carefully remove residual sealant from the cylinder head and ♦...
  • Page 144 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Pay attention to the identification of the cylinder head seal. ♦ Part number = arrow -1- ♦...
  • Page 145 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Position hub onto camshaft. – Tighten screw -1- to 100 Nm, use counterholder -T10051- to hold.

  • Page 146: Removing And Installing Cylinder Head (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Push camshaft sprocket onto the hub. • The tooth segment -arrow- of the camshaft sprocket must be at the top.
  • Page 147 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 WARNING Observe measures when disconnecting the battery ⇒ Electri‐ cal System; Rep. gr. 27 .
  • Page 148 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove fuel hoses -1- and -4-. – Detach coolant hose -5-. – Remove central plug connection -2- for pump-nozzle units.
  • Page 149 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Detach vacuum hose -2- from vacuum setting element for charge pressure control.
  • Page 150 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -1-, screw -2- and the hollow screw -3-. – Remove support for exhaust turbocharger with oil return line.
  • Page 151 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Slacken cylinder head bolts in the specified order and un‐ screw. – Raise cylinder head and remove sideways past the toothed belt guard.

  • Page 152: Testing Compression Pressure (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Pay attention to the identification of the cylinder head seal. ♦ Part number = arrow -1- ♦...

  • Page 153: Testing Compression Pressure (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Test conditions • Engine temperature, min. 30 ℃ Test sequence – Remove engine cover.
  • Page 154 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Test sequence – Lift the engine cover at the sides -arrows A- and pull out to‐...

  • Page 155: Repairing Valve Gear

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Repairing Valve Gear ⇒ “2.1 Valve gear - Summary of components”, page 147 ⇒...
  • Page 156 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Cylinder head ❑ reworking valve seats ⇒ “3.1 Reworking valve seats”, page 168 2 - Bearing shell ❑...

  • Page 157: Checking The Axial Play Of The Camshaft

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Superb II ⇒ “2.4 Removing and installing camshaft (Superb II)”, page 152 Octavia II ⇒...

  • Page 158: Replacing Camshaft Gasket Ring

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Test sequence – Perform measurement with the bucket tappets removed and the first and last bearing cap fitted.
  • Page 159 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Loosen fixing bolt of the hub -1- approx. 2 turns, to do so use the counterholder -T10051- .

  • Page 160: Removing And Installing Camshaft (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Press in the gasket ring with the thrust piece of the insertion tool -MP1-214 (10-203)- and the screw M12 x 65 up to the stop.
  • Page 161 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove toothed belt ⇒ “1.5 Summary of components - toothed belt (Superb II)”, page 43 –...
  • Page 162 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 • Interlock the crankshaft toothed belt sprocket with the crank‐ shaft arrester -T10100- at TDC for cylinder 1.

  • Page 163: Removing And Installing Camshaft (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Install and tighten bearing caps -1-, -3- and -5-. • Bearing cap -5- must fit flush with the outer edge of the cylinder head as this may otherwise cause leaks on the tandem pump.
  • Page 164 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove toothed belt ⇒ “1.7 Summary of components - toothed belt (Octavia II)”, page 53 –...
  • Page 165 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 • Depending on the version, interlock the crankshaft toothed belt sprocket with the crankshaft arrester -T10050- or crank‐...
  • Page 166 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Apply sealant -D 454 300 A2- thinly and uniformly to the outer bearing caps onto the surfaces -1-.

  • Page 167: Removing And Installing Camshaft (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing camshaft (Fa‐ bia II, Roomster) Special tools and workshop equipment required ♦...
  • Page 168 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.6.2 Install Install in the reverse order of removal. When doing this, note the...
  • Page 169 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Apply sealant -D 454 300 A2- thinly and uniformly to the outer bearing caps onto the surfaces -1-.

  • Page 170: Testing Hydraulic Bucket Tappets

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Testing hydraulic bucket tappets Special tools and workshop equipment required ♦ Feeler gauges ♦...

  • Page 171: Replacing The Valve Stem Seals On The Installed Cylinder Head

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Determine the play between the cams and the bucket tappet: – Press down the bucket tappet using a wooden or plastic wedge.
  • Page 172 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Octavia II ⇒ “2.5 Removing and installing camshaft (Octavia II)”, page 155 ♦...
  • Page 173 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Screw adapter - VAS 5161/11- into the threaded hole of the glow plug by hand.
  • Page 174 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note If the valve collets were removed from the assembly cartridge, first of all they must be inserted into the insertion device - VAS 5161/18- .
  • Page 175 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Insert the assembly cartridge - VAS 5161/15- again into the guide bushing - VAS 5161/16- .

  • Page 176: Inlet And Exhaust Valves

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Inlet and exhaust valves ⇒ “3.1 Reworking valve seats”, page 168 ⇒ “3.2 Inspect valve guides”, page 171 ⇒...
  • Page 177 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Measure distance -a- between the end of the valve stem and the upper face of the cylinder head with a depth gauge.
  • Page 178 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Mill valve seats with NAC milling cutter – Place cylinder head on a felt base and secure to prevent it from turning.

  • Page 179: Inspect Valve Guides

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Grind in valves with fine grinding paste to achieve a perfect contact pattern between the valve and valve seat --.

  • Page 180: Lubrication

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 17 – Lubrication Removing and installing parts of the lubrication system ⇒ “1.1 Lubrication system - Summary of components”, page 172 ⇒...
  • Page 181 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Screw ❑ 15 Nm 2 - Nut ❑ 15 Nm 3 - Support ❑...
  • Page 182 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 17 - O-ring ❑ Replace after disassembly 18 - Oil pump ❑ with pressure relief valve 1.2 MPa (12 bar) ❑...

  • Page 183: Summary Of Components - Oil Filter Bracket (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - oil filter bracket (Octavia II, Superb II) 1 - Screw plug ❑...
  • Page 184 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 12 - Oil filter element ❑ pull off from screw cap Pos. 10 ❑...

  • Page 185: Summary Of Components - Oil Filter Bracket (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - oil filter bracket (Fabia II, Roomster) 1 - Screw plug ❑...

  • Page 186: Removing And Installing Oil Pan (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ❑ Observe the mounting sequence: – Screw on the union nuts first of all by hand.
  • Page 187 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew the bolts of oil pan/gearbox --. – Loosen bolts -1...20- crosswise and release.

  • Page 188: Removing And Installing Oil Pan (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Fit on oil pan immediately and tighten the bolts as follows: – First of all pre-tighten screws -1…20- crosswise to 5 Nm.
  • Page 189 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew the bolts of oil pan/gearbox --. – Loosen bolts -1 ... 20- crosswise and release.

  • Page 190: Removing And Installing Oil Pump

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Fit on oil pan immediately and tighten the bolts as follows: – First of all tighten screws -1 ... 20- crosswise to 5 Nm.

  • Page 191: Testing Oil Pressure And Oil Pressure Switch

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Testing oil pressure and oil pressure switch Special tools and workshop equipment required ♦...

  • Page 192: Start Engine

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Screw oil pressure switch tester (e.g. -V.A.G 1342- ) onto the oil pressure switch bore.

  • Page 193: Cooling

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 19 – Cooling Cooling system ⇒ “1.1 Connection diagram for coolant hoses (Superb II)”, page 185 ⇒...
  • Page 194 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Radiator ❑ removing and installing ⇒ “2.3 Removing and in‐ stalling radiator (Octa‐...
  • Page 195 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Radiator ❑ removing and installing ⇒ “2.3 Removing and in‐ stalling radiator (Octa‐...

  • Page 196: Removing And Installing

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.1.2 Summary of components for engine with identification characters BLS 1 - Expansion tank ❑...

  • Page 197: Connection Diagram For Coolant Hoses (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Connection diagram for coolant hoses (Octavia II) ⇒ “1.2.1 Engine with identification characters BJB”, page 189 ⇒...
  • Page 198 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.2.2 Engine with identification characters BKC, BXE For vehicles without auxiliary heating. 1 - Radiator ❑...
  • Page 199 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 9 - Radiator flap for exhaust gas recirculation 10 - ATF radiator ❑ for models with an automatic gearbox ❑...
  • Page 200 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 7 - Intake manifold 8 - Radiator for exhaust gas recirculation ❑ fill with fresh coolant after replacing ⇒...

  • Page 201: Connection Diagram For Coolant Hoses (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ant (Octavia II, Superb II)”, page 205 5 - Cylinder head/cylinder block ❑ fill with fresh coolant after replacing ⇒...
  • Page 202 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.1 Engine with identification characters AXR, BSW 1 - Radiator ❑ fill with fresh coolant af‐...

  • Page 203: Parts Of The Cooling System On Engine Side (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.2 Engine with identification characters BLS 1 - Expansion tank ❑ with cap ❑...
  • Page 204 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.4.1 Summary of components for engine with identification characters AXR, 1 - Screw ❑...
  • Page 205 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 17 - Coolant pipe 18 - to compensation bottle (bottom) ❑ connection diagram for coolant hoses ⇒...

  • Page 206: Parts Of Cooling System On Engine Side (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 9 - Coolant temperature sender - G62- ❑ checking ⇒ Vehicle diagnostic tester.
  • Page 207 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.5.1 Summary of components for engine with identification characters BJB 1 - to the compensation bottle above ❑...
  • Page 208 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Octavia II ⇒ “1.2 Connection diagram for coolant hoses (Octavia II)”, page 189 Superb II ⇒...
  • Page 209 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.5.2 Summary of components for engine with identification characters BKC, BXE 1 - Radiator for exhaust gas re‐...
  • Page 210 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Octavia II ⇒ “1.2 Connection diagram for coolant hoses (Octavia II)”, page 189 Superb II ⇒...
  • Page 211 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Superb II ⇒ “1.1 Connection diagram for coolant hoses (Superb II)”, page 185 24 - Top coolant pipe ❑...
  • Page 212 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 10 - from heat exchanger ❑ Return-flow line ❑ Connection diagram for coolant hoses: Octavia II ⇒...

  • Page 213: Drain And Fill Coolant (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Octavia II ⇒ “1.2 Connection diagram for coolant hoses (Octavia II)”, page 189 Superb II ⇒...

  • Page 214: Replace O-Rings

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For engine with identification characters BXE, BJB, BKC – Remove the coolant hose from the radiator; to do so pull the retaining clip -arrow-.
  • Page 215 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For engine with engine code BLS – Connect coolant hose at bottom of radiator -arrow-.

  • Page 216: Draining And Filling Coolant (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Check coolant level when the expansion reservoir is closed. • When engine is at operating temperature the coolant level must be at the “max”...
  • Page 217 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – In addition, remove the front coolant hose at the bottom of the engine oil cooler -arrow- and allow remaining coolant to drain.

  • Page 218: Removing And Installing Coolant Pump

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing coolant pump Removing – Draining coolant: ♦ Fabia II, Roomster ⇒...

  • Page 219: Removing And Installing Coolant Regulator (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew fixing bolts -1- of the coolant pump and remove the coolant pump -2-.

  • Page 220: Drain Coolant

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 WARNING Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully.

  • Page 221: Removing And Installing Coolant Regulator (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Turn the coolant thermostat -2- approx. 90° clockwise -arrow- and remove it from the connection fitting.

  • Page 222: Checking The Coolant System For Leaktightness

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove coolant hose from connection fittings -2-. – Unscrew bolts -1- attaching connection and remove connec‐...
  • Page 223 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Test sequence WARNING Hot steam may escape when the coolant expansion reservoir is opened. Wear safety goggles and safety clothing, in order to avoid eye injuries and scalding.
  • Page 224 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Open the cap of the coolant expansion tank. – Screw adapter - V.A.G 1274/8- into the coolant expansion bottle.

  • Page 225: Radiator And Radiator Fan

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Radiator and radiator fan ⇒ “2.1 Parts of cooling system on body side (Octavia II, Superb II)”, page 217...

  • Page 226: Test Pressure

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Top coolant hose ❑ To connection fitting at cylinder head 2 - O-ring ❑...
  • Page 227 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.1.2 Summary of components for engine with identification characters BLS WARNING Hot steam or hot coolant may escape when the compensation bottle is opened.

  • Page 228: Parts Of Cooling System On Body Side (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 7 - Screw ❑ 5 Nm 8 - O-ring ❑ replace if damaged 9 - Bottom coolant hose ❑...
  • Page 229 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Radiator ❑ removing and installing ⇒ “2.4 Removing and in‐ stalling radiator (Fabia II, Roomster)”,...

  • Page 230: Removing And Installing Radiator (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ off: 84 … 91 ℃ 2. Stage ♦ on: 99 … 105 ℃...

  • Page 231: Removing And Installing Radiator (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove left charge air hose, to do so pull the retaining clips -arrows-.
  • Page 232 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Collect drained coolant in a clean container for proper disposal or reuse.

  • Page 233: Removing And Installing Fan Shroud For Radiator Fan V7 And V177 (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release the bolts securing the condenser -arrows-. – Remove screw for bracket of condenser wire at the bottom from radiator.

  • Page 234: Tightening Torques

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unplug connector -1-. – Screw out screws -arrows- and take out fan shroud down‐...

  • Page 235: Fuel Supply System

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 20 – Fuel supply system Removing and installing parts of the fuel supply system ⇒...

  • Page 236: Summary Of Components - Fuel Tank With Attached Parts (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - fuel tank with attached parts (Superb II) Note Fuel lines are secured with quick-release couplings.

  • Page 237: Removing And Installing

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 delivery unit (with fuel gauge sender -G- ) and the flange with fuel gauge sender 2 -G169- ”“ , page 230 ❑...

  • Page 238: Summary Of Components - Fuel Tank With Attached Parts (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Fitting position of the flange of the fuel delivery unit (with fuel gauge sender -G- ) and the flange with fuel gauge sender 2 -...

  • Page 239: (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 (Octavia II)”, page 247 12 - to fuel filter 13 - Nut ❑ 20 Nm 14 - Sealing ring ❑...
  • Page 240 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Fitting position of the flange of the fuel delivery unit with fuel gauge...
  • Page 241 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Return-flow line ❑ from fuel cooler ❑ clipped in place on fuel tank ❑...
  • Page 242 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 delivery unit (with fuel gauge sender -G- ) and the flange with fuel gauge sender 2 -G169- ”“ , page 235 ❑...

  • Page 243: Summary Of Components - Fuel Tank With Attached Parts (Fabia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Fitting position of the flange of the fuel delivery unit (with fuel gauge sender -G- ) and the flange with fuel gauge sender 2 - G169- The markings on the flanges -arrows- must be aligned with mark‐...
  • Page 244 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 10 - Tensioning strap 11 - Fuel cooler ❑ removing and installing ⇒ “1.12 Removing and installing fuel cooler (Fabia II, Roomster)”, page 248 12 - Nut ❑...

  • Page 245: Summary Of Components - Fuel Tank With Attached Parts (Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Installation position of flange of fuel pump The marking on the flange must be aligned with marking on the fuel tank -arrows-.
  • Page 246 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Fuel tank ❑ when removing support, for example with the en‐...
  • Page 247 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 7 - Overflow hose 8 - O-ring ❑ Replace after disassembly 9 - Gravity valve ❑...

  • Page 248: Summary Of Components - Fuel Filter (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Fitting position of the flange of the fuel delivery unit/the sender for the fuel gauge display The marking on the flange must be aligned with marking on the fuel tank -arrows-.

  • Page 249: Summary Of Components - Fuel Filter (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Return-flow hose ❑ to fuel cooler ❑ blue/blue marking 2 - Screw ❑...
  • Page 250 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.7.1 Fuel filter type one and two Note Before disconnecting the fuel hoses, mark assignment to the sup‐...
  • Page 251 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 13 - Fuel filter - bottom part ❑ mounted up to 08.2005 ❑ with integrated preheating valve 14 - Support ❑...

  • Page 252: Summary Of Components - Fuel Filter (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - fuel filter (Fabia II, Roomster) The fuel flow direction is indicated with arrows on the hoses and on the fuel filter.

  • Page 253: Extract Fuel From The Fuel Tank

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing fuel filter – Remove the preheating valve with the fuel hoses fitted (pull out retaining clip).
  • Page 254 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note For vehicles with auxiliary heating, the plug connection for the dosing pump -V54- must also be separated.

  • Page 255: Removing And Installing Fuel Cooler (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.10 Removing and installing fuel cooler (Su‐ perb II) Note The fuel cooler is located at the return-flow line to the fuel tank.

  • Page 256: Removing And Installing Fuel Cooler (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew fixing nuts for fuel cooler -arrows- and remove fuel cooler. Install The installation occurs in reverse order: Tighten fixing nuts for the fuel cooler to 18 Nm.
  • Page 257 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing Note Safety precautions when working on the fuel supply system ♦ ⇒ “2.1 Regulations concerning safety precautions when work‐...
  • Page 258 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew screws -1- for filler neck on the body. – Unclip the electrical cable from the bracket -2- at the top and bottom of the filler neck.

  • Page 259: Removing And Installing The Fuel Tank (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Check fitting position of the earth lead -1-. • The plug -1- on the metal plate ring -2- must be placed on firmly.

  • Page 260: Removing And Installing Fuel Tank For Vehicles With Four-Wheel Drive (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove the rear right wheelhouse liner ⇒ Body Work; Rep. gr. 66 .
  • Page 261 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Removing rear seat bench ⇒ Body Work; Rep. gr. 72 . – Remove the cover from the fuel delivery unit and the fuel gauge sender 2 -G169- .

  • Page 262: Removing And Installing Fuel Tank (Fabia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Clip on cable from four-wheel drive control unit -J492- at the fuel tank -arrows-.

  • Page 263: Removing And Installing The Fuel Tank (Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew bolts on filler neck -arrows-. – Detach fuel return-flow line (blue) from the fuel delivery unit -16- ⇒...
  • Page 264 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 • The fuel tank must be empty for weight reasons when remov‐ ing it, if necessary suction the fuel out of the fuel tank ⇒...

  • Page 265: Separating Quick Couplings

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew tensioning strap and fixing screw -arrows-. – Pull the filler neck out of the rubber bowl and swivel the fuel tank downwards.
  • Page 266 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Variant 1 Note When the push-fit coupling is fitted with a plastic circlip, leave it inserted when removing and installing the quick release.
  • Page 267 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Variant 2 Push-on coupling with pull-release mechanism -arrow- – Press the quick coupling -1- in direction of arrow -A-.
  • Page 268 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Variant 5 Quick coupling with release buttons -arrows- on right and left. – Press release buttons -arrows- and detach quick coupling.

  • Page 269: Fuel Delivery Unit, Fuel Gauge Sender

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Fuel delivery unit, fuel gauge sender ⇒ “2.1 Testing the fuel pump (Octavia II, Superb II)”, page 261 ⇒...
  • Page 270 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Continuing searching for faults using a multimeter e.g. - V.A.G 1715- ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

  • Page 271: Testing Fuel Pump (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Compare the fuel rate with the specified value. Note The amount of the fuel pumped is dependent on the voltage.
  • Page 272 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Switch on ignition. The fuel pump must be heard to start run‐...

  • Page 273: Removing And Installing Fuel Delivery Unit (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Compare the amount of the fuel pumped to the specified value (the amount of the fuel pumped is dependent on the voltage at the fuel delivery unit).
  • Page 274 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Open lock ring with the wrench - T30101- . – Slightly raise the closing flange and check if the spring -2- is still fastened on the flange -1-.
  • Page 275 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Separate through the opening of the fuel tank the fuel line -1- to the suction jet pump, to do so press the release button.

  • Page 276: Removing And Installing Fuel Delivery Unit (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Pay attention that the electrical cables -1- and the fuel feed line -3- are routed according to the illustration and the float arm -2- is not blocked.
  • Page 277 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove the cover from the fuel delivery unit. Note For vehicles with auxiliary heating, the plug connection for the dosing pump - V54- must be disconnected additionally.

  • Page 278: Removing And Installing Fuel Tank For Vehicles With Four-Wheel Drive (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note Insert new dry gasket ring into the opening of the fuel tank.
  • Page 279 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note For vehicles with auxiliary heating, the plug connection for the ♦ dosing pump - V54- must be disconnected additionally.
  • Page 280 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Disconnect the plug, the black feed line -1- and the blue return- flow line -2- from the flange.
  • Page 281 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Separate through the opening of the fuel tank the fuel line -1- to the suction jet pump, to do so press the release button.

  • Page 282: Removing And Installing Fuel Delivery Unit (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 • The spring -2- must be fastened to the retaining lugs -1- of the closing flange.
  • Page 283 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Conditions • The fuel tank must not be more than / 3 full.

  • Page 284: Removing And Installing The Sender For Fuel Gauge Display G (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew union nut with wrench -MP1-227- . – Pull the fuel delivery unit and the gasket ring out of the opening of the fuel tank.

  • Page 285: Removing And Installing The Transmitter For Fuel Gauge Display G (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unlatch and disconnect the plug connection of the lines -1- (brown), -2- (blue) and -3- (black).
  • Page 286 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unlatch and disconnect the plugs of the electrical cables -1- (brown), -2- (blue) and -3- (black).

  • Page 287: Removing And Installing The Sender For Fuel Gauge Display G (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unlatch and disconnect the plugs of the electrical cables -1- (brown), -2- (blue) and -3- (black).
  • Page 288 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note If necessary drain the fuel tank ♦ ⇒ “1.9 Extract fuel from the fuel tank”, page 245 Safety precautions when working on the fuel supply system ♦...
  • Page 289 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Fit the suction jet pump in the fuel tank onto the fuel gauge transmitter 2 - G169- and push it in until the securing tabs -arrows- latch into position.

  • Page 290: Removing And Installing Suction Spray Pump (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.11 Removing and installing suction spray pump (Octavia II, Superb II) Note The fuel tank consists of a left and right chamber. In order to ♦...
  • Page 291 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Conditions • Ignition is switched off and ignition key is withdrawn. Removing Note Safety precautions when working on the fuel supply system ♦...

  • Page 292: Inspecting A Tandem Pump

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Separate vacuum line -1- for brake servo unit from tandem pump -4-.
  • Page 293 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 • Unit injectors O.K. • Fuel filter and fuel line must not be blocked.
  • Page 294 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Connect pressure gauge -VAS 5187- as shown. – Start engine and run in idle.

  • Page 295: Open Valve

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew pressure control valve -2- fully and close the valves -3- and -4-.

  • Page 296: Accelerator Control

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Accelerator control ⇒ “3.1 Summary of components - accelerator pedal module (Oc‐ tavia II, Superb II)”, page 288 ⇒...

  • Page 297: Summary Of Components - Accelerator Pedal Module (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - accelerator pedal module (Fabia II, Roomster) 1 - Bearing bracket ❑...
  • Page 298 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Insert release tool -T10238- (on vehicles with right-hand drive, release tool -T10240- ) in the corresponding openings up to the stop.
  • Page 299 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Fit on connector 1K0 973 706 – Push the socket housing -B- down in -direction of arrow- until the housing can be heard to lock in place.

  • Page 300: Turbocharging/Supercharging

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 21 – Turbocharging/supercharging Charge-air system with exhaust gas turbocharger - Part 1 ⇒ “1.1 Connection diagram for vacuum hoses (Superb II)”, page 292 ⇒...
  • Page 301 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Vacuum reservoir 2 - Mechanical exhaust gas re‐ circulation valve 3 - To vacuum setting element...
  • Page 302 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.1.2 Engine with identification characters Note Regulations concerning cleanliness when working on the ex‐...

  • Page 303: Connection Diagram For Vacuum Hoses (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Connection diagram for vacuum hoses (Octavia II) ⇒ “1.2.1 Engine with identification characters BJB”, page 295 ⇒...
  • Page 304 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 7 - Tandem pump 8 - Bleeder hose ❑ to air filter Connection diagram for valve block...
  • Page 305 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Vacuum reservoir 2 - Mechanical exhaust gas re‐ circulation valve 3 - To vacuum setting element...
  • Page 306 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Connection diagram for vacuum sockets Note The side for the hose connection is shown in the fig.

  • Page 307: Connection Diagram For Coolant Hoses (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Exhaust gas turbocharger 2 - Charge air cooler 3 - Air intake hose...
  • Page 308 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.1 Engine with identification characters AXR, BSW Note Regulations concerning cleanliness when working on the ex‐...
  • Page 309 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.2 Engine with identification characters Note Regulations concerning cleanliness when working on the ex‐...

  • Page 310: Inspect Vacuum Setting Element And Tension Rods For Charge Pressure Control

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Inspect vacuum setting element and tension rods for charge pressure control (Octavia II, Superb II) Note Regulations concerning cleanliness when working on the ex‐...
  • Page 311 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Connect hand vacuum pump and turbocharger tester with auxiliary hoses as shown. Fit test hose onto the connection fitting -I- and put the band switch of the unit into the position -I- (absolute pressure).

  • Page 312: Charge-Air System With Exhaust Gas Turbocharger - Part 2

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Charge-air system with exhaust gas turbocharger - Part 2 ⇒ “2.1 Summary of components - exhaust gas turbocharger (Oc‐...
  • Page 313 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Gasket ❑ Replace after disas‐ sembly 2 - to changeover valve of ra‐...
  • Page 314 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 16 - Connection fittings ❑ 40 Nm 17 - Screw ❑ 17 Nm 18 - Screw ❑...
  • Page 315 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 8 - Vacuum hose 9 - Gasket ❑ Replace after disassembly ❑ Check fitting position...
  • Page 316 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.1.3 Summary of components for engine with identification characters BJB 1 - Nut ❑...

  • Page 317: Summary Of Components - Exhaust Gas Turbocharger (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 16 - Connection fittings ❑ 40 Nm 17 - Screw ❑ 17 Nm 18 - Nut ❑...
  • Page 318 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.2.1 Summary of components for engine with identification characters AXR, 1 - Intake manifold 2 - Inlet connection ❑...
  • Page 319 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 21 - Exhaust gas turbocharger ❑ Can only be replaced complete with exhaust manifold ❑...
  • Page 320 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.2.2 Summary of components for engine with identification characters BLS 1 - Screw ❑...

  • Page 321: Removing And Installing Exhaust Gas Turbocharger (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 16 - Screw ❑ 15 Nm 17 - O-ring ❑ Replace after disassembly 18 - Hollow screw ❑...
  • Page 322 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing – Lift the engine cover at the sides -arrows 1- and pull out to‐...
  • Page 323 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew oil feed line at exhaust turbocharger and at exhaust manifold -arrows- and lay it to one side.
  • Page 324 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Pliers for spring strap clamps Caution In case of mechanical damage to the exhaust gas turbocharg‐...
  • Page 325 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove exhaust gas temperature sender 1 - G235- ( temper‐ ature sender upstream turbocharger - G507- ) -arrow- using socket insert SW 17 from the set of tools - T10395- .

  • Page 326: Removing And Installing Exhaust Gas Turbocharger (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew nuts -arrows- and remove exhaust manifold with ex‐ haust turbocharger downwards.
  • Page 327 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Caution In case of mechanical damage to the exhaust gas turbocharg‐ er, e.g. damage of the compressor wheel, it is not sufficient to only replace the exhaust gas turbocharger.
  • Page 328 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove screw -3- and disconnect connecting hose -2- on the charge-air cooler -right arrow-.
  • Page 329 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew the oil return line -3- from the cylinder block. – Release screws -1- and -2- and remove the support for turbo‐...
  • Page 330 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Pliers for spring strap clamps Caution In case of mechanical damage to the exhaust gas turbocharg‐...
  • Page 331 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -1-, screw -2- and hollow screw -3-. – Remove left heat shield at exhaust manifold -arrows-.

  • Page 332: Removing And Installing Parts Of The Charge Air Cooler (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew nuts -arrows- and remove exhaust manifold with ex‐ haust turbocharger downwards.
  • Page 333 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Screw ❑ 8 Nm 2 - Support ❑ Check fitting position 3 - Charge air cooler ❑...

  • Page 334: Removing And Installing Parts Of The Charge Air Cooler (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.5.2 Summary of components for engine with identification characters BLS Note Before testing or repairing, check all hoses and lines for tight connection and leaktightness.
  • Page 335 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ⇒ “2.6.2 Summary of components for engine with identification characters BLS”, page 328 2.6.1...

  • Page 336: Removing And Installing Parts Of The Charge Air Cooler (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.6.2 Summary of components for engine with identification characters BLS Note Before testing or repairing, check all hoses and lines for tight connection and leaktightness.

  • Page 337: Crankcase Ventilation

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ⇒ “2.7.2 Summary of components for engine with identification characters BLS”, page 330 2.7.1...

  • Page 338: Removing And Installing Charge Air Cooler (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.7.2 Summary of components for engine with identification characters BLS Note Before testing or repairing, check all hoses and lines for tight ♦...
  • Page 339 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing – Remove coolant radiator ⇒ “2.3 Removing and installing radiator (Octavia II, Superb II)”, page 222 –...

  • Page 340: Removing And Installing Charge Air Cooler (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing charge air cool‐ er (Octavia II) Special tools and workshop equipment required ♦...

  • Page 341: Removing And Installing Charge Air Cooler (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Press off the charge air cooler from the lock carrier with the assistance of a 2nd mechanic so that the fixing screw -1- for the coolant lines on the radiator is accessible.

  • Page 342: Hose Connections

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove the connecting hose -1- from the charge-air cooler -3-. – Release screws -2- and remove charge-air cooler -3-.

  • Page 343: Checking The Charge-Air System For Leaktightness

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Move the locking clip in the position “unlocked” -1-. – Insert the charge air hose up to the stop into the coupling.
  • Page 344 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Test sequence – Remove the intake hose -1- from the air filter. – Fit adapter -1687/10- into the intake hose -1- and secure with a clamp.

  • Page 345: Replacing And Adjusting The Vacuum Setting Element For Exhaust Gas Turbocharger On Engines With Identification Characters Bls (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Connect tester for charge air system - V.A.G 1687- to adapter -1687/10- .
  • Page 346 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing – Remove cover and bulkhead plenum chamber ⇒ Body Work; Rep. gr. 66 .
  • Page 347 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Mark the opposite position of the pressure box of the vacuum setting element and the control rod in the released position, as shown, in different colours.
  • Page 348 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Put the sliding ring -1- of the hand vacuum pump - VAS 6213- in position -A- for vacuum.
  • Page 349 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Slowly unscrew the counternut -B- of the control rod by hand until it makes contact with the adjusting lever, do not turn fur‐...

  • Page 350: Replacing And Adjusting The Vacuum Setting Element For Exhaust Gas Turbocharger On Engines With Identification Characters Bjb (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Press the lock washer on the control rod by hand and turn it 90°...
  • Page 351 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing – Lift the engine cover at the sides -arrows 1- and pull out to‐...
  • Page 352 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Mark the opposite position of the pressure box of the vacuum setting element and the control rod in the released position, as shown, in different colours.
  • Page 353 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Put the sliding ring -1- of the hand vacuum pump - VAS 6213- in position -A- for vacuum.
  • Page 354 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Slowly unscrew the counternut -B- of the control rod by hand until it makes contact with the adjusting lever, do not turn fur‐...
  • Page 355 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Position the feeler gauge of 0.05 mm, as shown in the figure, between the adjusting lever and the adjusting screw.

  • Page 356: Mixture Preparation - Injection

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 23 – Mixture preparation - injection Repairing Diesel Direct Injection sys‐ ⇒ “1.1 Overview of installation locations (Octavia II, Superb II)”, page 348 ⇒...
  • Page 357 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 A - Diesel direct injection sys‐ tem relay - J322- ❑ on the additional relay...
  • Page 358 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2 - Inlet connection ❑ with mechanical exhaust gas recirculation valve ❑ with an intake manifold flap 3 - Engine control unit - J248- ❑...
  • Page 359 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.1.2 Summary of components for engine with identification characters BXE, BKC The components A through H are not represented in the overview figure.
  • Page 360 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 5 - Unit injectors -N240- , -N241- , -N242- and -N243- ❑ under cylinder head cover ❑...
  • Page 361 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.1.3 Summary of components for engine with identification characters BLS The components A through G are not represented in the overview figure.
  • Page 362 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 6 - Exhaust gas temperature sender 2 - G448- ( Temperature sender upstream particle filter - G506- ) ❑...

  • Page 363: Overview Of Installation Locations (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - plug on the front wall Solenoid valve for charge pressure control - N75-...
  • Page 364 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 A - Diesel direct injection sys‐ tem relay - J322- ❑ on relay carrier ⇒...

  • Page 365: Summary Of Components

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2 - Mechanical exhaust gas recirculation valve and intake manifold flap motor - V157-...
  • Page 366 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.2.2 Summary of components for engine with identification characters BLS The components A through H are not represented in the overview figure.
  • Page 367 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 footwell”“ , page 359 G - Brake light switch - F- and brake pedal switch - F47- ❑...

  • Page 368: Intake Manifold - Summary Of Components

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Relay carrier 7 - Low heat output relay - J359- 8 - High heat output relay - J360-...
  • Page 369 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Intake manifold 2 - O-ring ❑ Replace after disas‐ sembly 3 - Inlet connection ❑...
  • Page 370 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.2 Summary of components for engine with identification characters BXE, BKC, AXR, BSW...
  • Page 371 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.3 Summary of components for engine with identification characters BLS Note The actuation of the exhaust gas recirculation system is performed by the engine control unit -J248- for the ♦...

  • Page 372: Summary Of Components - Air Filter (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - air filter (Octavia II, Superb II) 1 - Air intake hose ❑...
  • Page 373 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.5.1 Summary of components for engine with identification characters AXR, 1 - Air intake hose ❑...
  • Page 374 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.5.2 Summary of components for engine with identification characters BLS 1 - Air mass meter - G70- ❑...

  • Page 375: Removing And Installing Air Filter (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing air filter (Fabia II, Roomster) Removing – Loosen spring strap clamp -1- on the air guide hose and re‐...

  • Page 376: Removing And Installing O-Rings For Unit Injector

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Screw ❑ Replace after disas‐ sembly ❑ 20 Nm + 90°...
  • Page 377 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Assembly device - T10056- Removing – Lever off the O-rings from the grooves of the unit injector with extreme care.

  • Page 378: Removing And Installing The Unit Injector

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Insert the assembly sleeve -T10056/3- on the unit injector up to the stop.
  • Page 379 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Set the camshaft in such a way that the cam for Cylinder 2 points in -direction of arrow-.
  • Page 380 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note The O-rings must not be twisted. – Oil the O-rings and place the unit injector with the greatest of care into the cylinder head.

  • Page 381: Removing And Installing Engine Speed Sender G28 (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Place a dial gauge on the adjusting screw of the unit injector.
  • Page 382 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew the fixing screw -2- for the engine speed sender - G28- -1-.

  • Page 383: Engine Control Unit

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Engine control unit ⇒ “2.1 Removing and installing engine control unit (Superb II)”, page 375 ⇒...

  • Page 384: Removing And Installing Engine Control Unit (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Cut with body saw a slot for the cross-head screwdriver in the heads of the pull-off screws -3 and 4-.
  • Page 385 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing – When replacing the engine control unit, in the “guided fault finding” the diagnostic field “replace engine control unit” must be selected ⇒...

  • Page 386: Removing And Installing Engine Control Unit J623 (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unlock retaining bracket -2-. – Push out engine control unit with plugs in -direction of arrow-.
  • Page 387 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note It must be sawed twice with the body saw, so that the slot is wide enough, in order to be able to unscrew the screws with a suitable screwdriver.

  • Page 388: Exhaust System

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 26 – Exhaust system Removing and installing parts of the exhaust system ⇒ “1.1 Summary of components - exhaust system (Superb II)”, page 380 ⇒...
  • Page 389 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Pre-exhaust pipe ❑ with catalytic converter ❑ protect against shocks and blows ❑...
  • Page 390 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.1.2 Summary of components for engine with identification characters BLS 1 - Exhaust gas pressure sen‐...

  • Page 391: Summary Of Components - Exhaust System (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 11 - Front tunnel bridge 12 - Retaining strap ❑ replace if damaged ❑...
  • Page 392 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.2.1 Summary of components for engine with identification characters BJB, BKC, BXE on vehicles with front-wheel drive...
  • Page 393 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 13 - Nut ❑ 23 Nm 14 - Front tunnel bridge 15 - Rear silencer ❑...
  • Page 394 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ❑ 45 Nm 9 - Identification ❑ for clamping sleeve 10 - to the central silencer 11 - Nut ❑...
  • Page 395 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.2.3 Summary of components for engine with identification characters BKC, BXE on vehicles with four-wheel drive 1 - Pre-exhaust pipe ❑...
  • Page 396 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 13 - Gasket ❑ Replace after disassembly ❑ Check fitting position 1.2.4 Summary of components for engine with identification characters BLS on vehicles with four-wheel drive 1 - Exhaust gas pressure sen‐...

  • Page 397: Summary Of Components - Exhaust System (Fabia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 11 - Screw ❑ 23 Nm 12 - Front tunnel bridge 13 - Retaining strap ❑...
  • Page 398 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.1 Summary of components for engine with identification characters BSW 1 - Gasket ❑...
  • Page 399 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1.3.2 Summary of components for engine with identification characters BLS Pre-exhaust pipe with diesel particle filter 1 - Exhaust gas pressure sen‐...
  • Page 400 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 17 - Support ❑ bolted to the cylinder block 18 - Screw ❑ 25 Nm 19 - Support ❑...

  • Page 401: Summary Of Components - Exhaust System (Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Summary of components - exhaust sys‐ tem (Roomster) ⇒ “1.4.1 Summary of components for engine with identification characters AXR, BSW”, page 393...
  • Page 402 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ❑ Align exhaust system free of stress ⇒ “1.13 Fitting exhaust system free of stress (Fabia II, Roomster)”, page 410...
  • Page 403 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 14 - Gasket ❑ Replace after disassembly ❑ Check fitting position 15 - Fixing clamp ❑...

  • Page 404: Removing And Installing Pre-Exhaust Pipe With Diesel Particle Filter (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Retaining strap ❑ replace if damaged 2 - Nut ❑ 20 Nm 3 - Rear silencer ❑...
  • Page 405 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release fuel hoses and coolant hoses at right air guide pipe. – Remove right air guide pipe.
  • Page 406 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew exhaust gas temperature sender 3 - G495- ( tem‐ perature sender downstream particle filter - G527- ) -1- from exhaust pipe downstream diesel particle filter.

  • Page 407: Removing And Installing Pre-Exhaust Pipe With Diesel Particle Filter (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew hanger of exhaust system -arrows-. – Slacken trim panels for the underfloor ⇒ Body Work; Rep. gr.
  • Page 408 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release fuel hoses and coolant hoses at right air guide pipe. – Remove right air guide pipe.
  • Page 409 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unscrew lambda probe -3-. – Remove exhaust gas temperature sender 2 - G448- ( temper‐...
  • Page 410 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -1…3- and remove pendulum support. – Release screws -arrows- at holder for diesel particle filter.

  • Page 411: Removing And Installing Pre-Exhaust Pipe For Vehicles With Four-Wheel Drive (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note The decoupling element in the pre-exhaust pipe should not be ♦ bent by more than 10° - risk of damage.

  • Page 412: Removing And Installing Pre-Exhaust Pipe With Diesel Particle Filter (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Note The decoupling element in the pre-exhaust pipe should not be ♦ bent by more than 10° - risk of damage.
  • Page 413 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing – Lift the engine cover at the sides -arrows A- and pull out to‐...

  • Page 414: Replacing Middle And Rear Silencer (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -arrows- at holder for diesel particle filter. – Slacken nuts of clamping sleeve.

  • Page 415: Replacing Middle And Rear Silencer (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Work procedure WARNING Wear safety goggles. – Separate exhaust pipe at the separation point -arrow 2- with body saw -V.A.G 1523 A- at right angle.

  • Page 416: Fitting Exhaust System Free Of Stress (Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Separate exhaust pipe at the separation point -arrow 1- with body saw (e.g. -V.A.G 1523 A- ) at a right angle.

  • Page 417: Aligning Exhaust System Free Of Stress (Octavia Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Push the clamping sleeve -1- to the dimension -a- = 5 mm in front of the marking at the pre-exhaust pipe -2-.

  • Page 418: Fitting Exhaust System Free Of Stress (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Continued for all vehicles – Install clamping sleeve in such a way that the ends of the screws do not protrude beyond the bottom edge of the clamp‐...

  • Page 419: Inspecting The Exhaust System For Leaktightness

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 For vehicles Fabia II – Push the rear silencer so far forward until the initial load -a- = 2 ...°5 mm is achieved between hanger/middle silencer and...

  • Page 420: Exhaust Gas Recirculation System

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Exhaust gas recirculation system ⇒ “2.1 Summary of components - cooling for exhaust gas recir‐...
  • Page 421 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 1 - Screw ❑ 22 Nm 2 - Intake manifold ❑ with mechanical ex‐...
  • Page 422 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.1.2 Summary of components for engine with identification characters BLS Note The actuation of the exhaust gas recirculation system is performed by the engine control unit -J248- for the EGR valve -N18- with EGR potentiometer -G212- and EGR control motor -V338- .

  • Page 423: Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ❑ Connection diagram ⇒ “1.1.2 Engine with identification characters BLS”, page 294 2.1.3...
  • Page 424 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.2.1 Summary of components for engine with identification characters AXR, Note The exhaust gas recirculation system is operated by the engine control unit -J623- via the EGR valve -N18- integrated into the valve block to the mechanical exhaust gas recirculation valve.
  • Page 425 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 2.2.2 Summary of components for engine with identification characters BLS Note The actuation of the exhaust gas recirculation system is performed by the engine control unit -J623- for the EGR valve -N18- with EGR potentiometer -G212- and EGR control motor -V338- .

  • Page 426: Removing And Installing Radiator For Exhaust Gas Recirculation For Engine With Engine Identification Characters Bkc, Bxe (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 Removing and installing radiator for ex‐ haust gas recirculation for engine with engine identification characters BKC,...
  • Page 427 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Unplug connector -2- from air mass meter - G70- . – Remove air filter -4-.
  • Page 428 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Disconnect vacuum lines -2- and -3-. – Remove vacuum line from tandem pump -arrow-.

  • Page 429: Removing And Installing Radiator For Exhaust Gas Recirculation For Engine With Engine Identification Characters Bls (Octavia Ii, Superb Ii)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Release screws -arrows-. – Release screws -arrows- and remove radiator for exhaust gas recirculation with exhaust gas recirculation valve.

  • Page 430: Removing And Installing Radiator For Exhaust Gas Recirculation (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Detach coolant hoses from radiator for exhaust gas recircula‐ tion. – Unscrew connection pipe for exhaust gas recirculation radiator -arrows-.
  • Page 431 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Pliers for spring strap clamps Removing For engine with engine code AXR, BSW –...

  • Page 432: Checking Mechanical Exhaust Gas Recirculation Valve For Engine With Identification Characters Axr, Bsw, Bjb, Bkc, Bxe

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ ⇒ Maintenance ; Booklet Roomster . Checking mechanical exhaust gas recir‐ culation valve for engine with identifica‐...

  • Page 433: Removing And Installing Exhaust Gas Recirculation Valve N18 For Engine With Identification Characters Bls (Fabia Ii, Roomster)

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Detach vacuum hose from vacuum setting element -1- of change-over flap of radiator for exhaust gas recirculation.
  • Page 434 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Remove charge-air pipe at the top -1- with connecting hose -2- -arrows-.

  • Page 435: Glow Plug System

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 28 – Glow plug system Glow Plug System ⇒ “1.1 Removing and installing metal glow plugs”, page 427 ⇒...

  • Page 436: Checking Metal Glow Plugs

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Switch off ignition. – Remove engine cover. – Unplug connector of the glow plugs -arrows-.

  • Page 437: Inspecting Ceramic Glow Plugs

    Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 ♦ Handheld multimeter - V.A.G 1526 B- Test conditions • Ignition off. Test sequence –...
  • Page 438 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ... 1.9/77 kW TDI PD Engine - Edition 12.2015 – Check electrical wiring and plug connections for glow plugs. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.

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Fabia ii 2009Octavia ii 2004Octavia ii 2010Roomster 2006Superb ii 2008