Cfwa 1 2 Tdi CR Engine Repair English

Service
Workshop Manual
Fabia II 2007 ➤
1,2/55 kW TDI CR Engine
Engine ID
CFW
A
Edition 02.10
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankgear
15 - Cylinder Head, Valve Gear
17 - Lubrication
19 - Cooling
20 - Fuel Supply
21 - Turbocharging
23 - Fuel Formation, Injection
26 - Exhaust System
28 - Glow Plug System
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Fabia II 2007 ➤
1,2/55 kW TDI CR Engine - Edition 02.10
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Regulations concerning safety precautions when working on the fuel system . . . . . . . . . . 3
1.4 Regulations concerning cleanliness when working on the fuel supply/fuel injection system
........................................................................ 4
1.5 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 5
1.6 Fuel hoses in the engine compartment - removing and replacing . . . . . . . . . . . . . . . . . . . . 6
1.7 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1 V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3 Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Removing and installing crankshaft-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Timing belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1 Cylinder block - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Balancing shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Balancing shaft module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Removing and installing balancing shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1 Sealing flanges and flywheel - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 50
5.3 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.4 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1 Crankshaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.2 Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
Fabia II 2007 ➤
15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 Cylinder head cover - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Removing and installing the gasket rings for the injection units in the cylinder head cover
........................................................................ 70
1.4 Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.6 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.7 Removing and installing the vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.8 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.1 Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.2 Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.4 Measuring the axial play of the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.5 Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.6 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.7 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.8 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Parts of the lubrication system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Oil filter holder and engine oil cooler - Summary of components . . . . . . . . . . . . . . . . . . . . 98
1.3 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.4 Removing and installing the oil filter holder with the engine oil cooler . . . . . . . . . . . . . . . . 103
1.5 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.6 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.7 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.2 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.3 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2 Coolant lines, coolant temperature sender, coolant pumps and coolant regulator . . . . . . 117
2.1 Coolant pipes, coolant temperature sender and coolant recirculation pump 2 - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Coolant pump and 4/2 way valve with coolant regulator - Summary of components . . . . . . 119
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.4 Removing and installing 4/2 way valve with coolant regulator . . . . . . . . . . . . . . . . . . . . . . 120
3 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.1 Radiator with radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.2 Fan shroud with radiator fan V7 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 125
3.3 Removing and installing fan shroud with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.1 Behaviour in case of misfuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.2 Fuel tank with component parts - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 132
1.3 Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.4 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.5 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ii Contents
Fabia II 2007 ➤
1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

1.7 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 140
1.8 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.1 Testing the voltage supply of the fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.2 Test feed pressure of fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.3 Checking the fuel flow rate of the fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.4 Checking the power consumption of the fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
21 - Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.2 Oil feed line and oil return-flow line for exhaust gas turbocharger - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.3 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.4 Installing exhaust temperature sender 1 G235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.1 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.2 Hose connections with screw clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.4 Removing and installing left charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.5 Removing and installing right charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.6 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.7 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.8 Inspect the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1 Diesel direct injection system - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2 Fuel system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.2 Fuel system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.3 Injection unit with clamping claw - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 177
3 Removing and installing, testing fuel formation, components . . . . . . . . . . . . . . . . . . . . . . 179
3.1 Filling and bleeding the high pressure pump and the fuel system . . . . . . . . . . . . . . . . . . . . 179
3.2 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.3 Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.4 Removing and installing the fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . 183
3.5 Installing the high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3.6 Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.7 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.8 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.9 Removing and installing the fuel high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4 Intake manifold and air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.1 Intake manifold with component parts - Summary of components . . . . . . . . . . . . . . . . . . . . 198
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.4 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Contents iii
Fabia II 2007 ➤
1.1 Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5 standard (left-hand
drive) - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.2 Installing the exhaust gas temperature sender 3 G495 for vehicles according to EU 5 standard
(left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
(left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.4 Removing and installing the differential pressure sender G505 for vehicles according to EU
5 standard (left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.5 Removing and installing the pre-exhaust pipe for vehicles according to EU 5 standard (left-
hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.6 Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5 standard (right-hand
drive) - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
(right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
(right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.9 Removing and installing the differential pressure sender G505 for vehicles according to EU
5 standard (right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.10 Removing and installing the pre-exhaust pipe for vehicles according to EU 5 standard (right-
hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.11 Rear part of the exhaust system for vehicles according to EU 5 standard - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.12 Exhaust pipe with oxidation catalytic converter for vehicles according to EU-4/BS4 standard
- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.13 Removing and installing the pre-exhaust pipe for vehicles according to EU-4/BS-4 standard
(right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.14 Replacing the middle and rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . 226
1.15 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.16 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.1 Parts of exhaust gas recirculation - Summary of components . . . . . . . . . . . . . . . . . . . . . . 228
2.2 Checking change-over flap for radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . 229
2.3 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 230
28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
iv Contents
Fabia II 2007 ➤
00 – Technical data
1 Technical data
1.1 Engine number

The engine number (“engine identification character” and “serial
number”) is located in the front at the engine/gearbox joint
-arrow-.
In addition, a sticker with the “engine identification characters”
and “serial number” is affixed to the timing belt guard.
The engine code is also indicated on the vehicle data sticker.
♦ The engine identification characters have four digits starting
with the letter “C”.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched on the cylinder block including
the serial number.
♦ The 4th digit refers to the output and torque of the engine. It
depends upon the engine control unit.
1.2 Engine characteristics

Engine identification character CFWA CFWA
Manufactured 04.10 ? 08.10 ?
Exhaust limit values conforming to EU5 EU4 (BS4)
Displacement cm 3 1199 1199
Power output kW at rpm 55/4000 55/4000
Torque Nm at rpm 180/1500 … 3450 180/1500 … 3450
Bore ∅ mm 79,5 79,5
Stroke mm 80,5 80,5
Cylinder / valves per cylinder 3/4 3/4
Compression ratio 16,5 : 1 16,5 : 1
Firing order 1-2-3 1-2-3
Catalytic converter yes yes
Diesel particle filter yes no
Exhaust gas recirculation with ra‐ yes yes
diator
Turbocharging yes yes
Charge air cooler yes yes
Balancing shaft module yes yes
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1. Technical data 1
Fabia II 2007 ➤
01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations and direc‐
tions
1.1 Self-diagnosis
This Rep.-Gr. is deleted.
For this use the “Vehicle self-diagnosis”, “Measuring method” and
“Fault finding” ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.
1.2 Supplementary instructions and assem‐

bly work on vehicles with an air condi‐
tioning system
WARNING
Risk of injury through refrigerant.

♦ Refrigerant circuit of the air conditioning system must not
be opened.
Caution
Risk of damaging the condensor, the refrigerant lines and ho‐

ses.
♦ Do not over-tension or buckle refrigerant lines and hoses.
Steps which should be taken in order to remove and install the

engine without opening the refrigerant circuit:
– Unscrew the holding clamp(s) on the refrigerent lines
– Remove V-ribbed belt ⇒ page 23 .
– Remove AC compressor from the bracket for auxiliary units
⇒ page 22 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
2 Rep. Gr.01 - Self-diagnosis

Fabia II 2007 ➤
1.3 Regulations concerning safety precau‐

tions when working on the fuel system
WARNING
When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds in such a way that the original line
guide is re-established.
♦ Ensure that there is adequate free access to all moving or
hot components.
♦ The fuel or the fuel lines in the fuel system can become
very hot (risk of burning)!
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
For reasons of safety the current supply to the fuel pump must
be interrupted before opening the fuel system. Otherwise the
fuel pump is activated when opening the driver's door. One of
the following options must be used to interrupt the current sup‐
ply:
♦ Disconnect battery
or
♦ Take out fuse for fuel pump relay -J17-
or
♦ Disconnect the plug on the flange of the fuel delivery unit
Caution
In order to avoid the fuel high pressure pump to run dry and to
achieve a quick engine start after parts are replaced, the fol‐
lowing points must be observed:
♦ If the fuel system was opened, starting with the fuel tank
through to the fuel high pressure pump, the ventilation of
the fuel system must be carried out before starting the en‐
gine. For this purpose, switch on the ignition and only
switch it off once the fuel pump has come to a standstill.
Repeat this procedure at least “5 times”.
♦ If the fuel high pressure pump is removed or replaced, the
initial fuel filling of the fuel high pressure pump must be
carried out before the first engine start ⇒ page 179 .
♦ If the high pressure system was opened, it must be
checked for tightness ⇒ page 180 .
When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
1. Self diagnosis, safety measures, cleanliness regulations and directions 3

Fabia II 2007 ➤
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
If the test and measuring devices are operated from the passen‐
ger seat, the passenger could be injured by the release of the
passenger airbag in the event of an accident.
WARNING
Secure the diagnostic device to the rear seat and operate from
that position.
Observe the following points to prevent injury to persons and/or

damage to the injection and preheating system:
♦ People, who have a heart pacemaker implant, should not bend
over the engine compartment when the engine is running, as
the injection units generate an output high voltage pulse.
♦ No fuel lines must be opened when the engine is running.
♦ Disconnect and connect wires of the preheating and injection
system as well as measuring device wires when the ignition is
switched off.
♦ Do not carry out engine wash unless the ignition is switched
off.
♦ If the engine must be operated at starter speed, without it
starting, unplug the connector -5- at the fuel pressure regulat‐
ing valve -N276- .
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the 4AV control unit.
♦ If the battery is connected, carry out certain additional opera‐
tions ⇒ Electrical System; Rep. Gr. 27 .
1.4 Regulations concerning cleanliness

when working on the fuel supply/fuel in‐
jection system
Carefully observe the following “6 rules” for cleanliness when
working on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: do no use compressed air. Do
not use the vehicle.

Fabia II 2007 ➤
♦ Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately. Replace imme‐
diately any hoses which have suffered damage.
1.5 Regulations concerning cleanliness

when working on the exhaust gas turbo‐
charger
Carefully observe the following “5 rules” for cleanliness when
working on the exhaust gas turbocharger:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: do no use compressed air. Do
not use the vehicle.

Fabia II 2007 ➤
1.6 Fuel hoses in the engine compartment -

removing and replacing
Note
♦ On this engine, the nozzles for the pressurized fuel hoses have
a so-called 3-wave profile (arrows). In this way, the tightness
of the fuel system is improved.
♦ When removing the fuel hoses, in most cases the very thin
barrier layer on the inside of the fuel hose is damaged.
♦ This damage is not visible to the eye. However, it can lead to
leakage of the fuel system after a certain period of time.
♦ When the fuel hoses are refitted on the nozzles, the initial po‐
sition of the hose on the 3 waves cannot be ensured. This
encourages the tendency to leak.
Caution
• After removing the fuel hoses from nozzles with 3-wave

profile, replace these fuel hoses.
-Arrows- 3-wave profile

-1- Return-flow line
-2- Return line support at fuel distributor
-3- Delivery nozzle of the high pressure pump
-4- Quick coupling on the fuel filter
Note
♦ For the above mentioned reasons, always disconnect the

quick coupling when removing the fuel hoses from the fuel filter
⇒ page 134 .
♦ Do not open the spring strap clamp and detach the fuel hose
from the nozzle of the quick coupling.
♦ If other components are only removed: Check whether it is
possible to separate the fuel system on the quick couplings at
the fuel filter or at the connection points in right of engine com‐
partment.
If a fuel hose cannot be disconnected from the hose nozzle by

hand:
Caution
Never push a screwdriver or a similar tool between the hose

and the hose nozzle!
♦ Risk of damage to the nozzle - the component must be
replaced.
– Turn the fuel hose with suitable pliers and detach the hose.

Fabia II 2007 ➤
If a fuel hose can still not be disconnected from the hose nozzle:
– Only cut into the textile layer of the hose lengthwise and detach
the hose.
• Do not cut through the inner rubber layer. If the nozzle is dam‐
aged, it is necessary to replace the complete component.
Note
♦ Before fitting the new fuel hose, thoroughly clean the hose
nozzle from grease, oil and dirt. To do so, do not use any metal
tools which could damage the hose nozzle.
♦ Fit the fuel hose on the nozzle without lubricant and secure
with spring strap clamp.
1.7 General instructions for charge air sys‐

tem
WARNING

hot components.
Caution
In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter, air filter insert and charge air hoses as well
as charge air pipes for soiling.
♦ Check all air guides and charge air cooler for foreign bod‐
ies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
♦ The charge-air system must be tight, check ⇒ page 164 .

♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
♦ Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
♦ Observe the instructions for installing the charge air hoses on
the fluted pipes ⇒ page 160 .
♦ Observe assembly markings on the hoses and components.

Fabia II 2007 ➤
♦ All hose connections of the charge air system are secured with
screw clamps.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ Electronic Catalogue of Original Parts .
♦ After installing the exhaust turbocharger, run engine at idling
speed for about 1 minute to ensure that oil is supplied to the
turbocharger bearing.

Fabia II 2007 ➤
10 – Removing and installing engine

1 Removing and installing engine
1.1 Removing and installing engine trim

panel
Removing
Caution
The bracket for the engine cover on the cylinder head cover
can break off when it is incorrectly disassembled.
♦ It is therefore necessary to remove the engine cover ac‐
cording to the following instruction.
– Successively slacken the engine cover in the marked se‐

quence -1 ... 4- from the fixing points. To do so, grip the engine
cover from underneath as far as possible in the area of the
-arrows- and pull it upwards out of the attachment.
Install
Caution
Before installing the engine cover, check the correct fitting po‐
sition of the 4 fixing elements (ball sockets). If necessary, move
them back into the correct position. Otherwise this can lead to
damage to the engine cover.
– If necessary, adjust the ball sockets of the engine cover to the

correct position.
– Position the engine cover onto the fixing points and press it in
at the corners until it clicks into place.
1.2 Removing engine

Special tools and workshop equipment required
♦ Removal tool for the inner lining of the door panel -MP8-602/1
-
1. Removing and installing engine 9

Fabia II 2007 ➤
♦ Engine mount -T40076-

♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Catch pan , e.g. -VAS 6208-
♦ Double ladder , e. g. -VAS 5085-
♦ Pliers for spring strap clamps
♦ Bolt M10 x 50
♦ Nut M12
Note
♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
♦ Collect drained coolant in a clean container for proper disposal
or reuse.
WARNING

gine compartment because of its cramped construction, please
hot components.
Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .
Observe the instructions for the fuel hose in the engine compart‐
ment ⇒ page 6 .
– If present, take the adapter for the anti-theft wheel bolts out of
the luggage compartment.
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐
trical System; Rep. Gr. 27 .
– Only slacken the nut of the right drive shaft.
– Remove front wheels.
– Remove the right and left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66 .
– Drain coolant ⇒ page 112 .
10 Rep. Gr.10 - Removing and installing engine

Fabia II 2007 ➤
– Unscrew the positive cable -1- at the positive terminal on the

battery.
– Remove engine cover ⇒ page 9 .
– Remove air intake hose.
– Remove the battery with the battery tray ⇒ Electrical System;
Rep. Gr. 27 .
– Remove vacuum lines with brackets -1- from air filter.

– Release plug -3- from charge pressure control solenoid valve
-N75- .
– Unscrew bracket -2- with charge pressure control solenoid
valve -N75- .
– Place the charge pressure control solenoid valve -N75 - with
vacuum lines on the engine.
– Remove air filter with air mass meter -G70- and inlet hose
⇒ page 202 .
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. Gr.
34 .
– Remove pressure line from breather/slave cylinder ⇒ Gear‐
box; Rep. Gr. 30 .
Caution
After separating the hydraulic line, do not operate the clutch

pedal.
– Unplug connector -arrow- from speedometer sender -G22- (if

available).
– Detach vacuum line at brake servo unit.
– Remove the engine control unit ⇒ page 204 .
– Unplug the plug of the engine wiring harness and disconnect
from the engine control unit.

Fabia II 2007 ➤
– Disconnect plug connection -arrow-.
– Carefully slacken the engine wiring harness on its fixing points

-arrows-.
– Place the engine wiring harness on the engine.
– Disconnect plug -arrow 1- from reversing light switch -F4- .

– Remove connector -arrow 2- and cable -arrow 3- from the
starter.
– Expose cables.
– Disconnect the plug connection below the starter.
– Remove the coolant hoses at the top radiator and secure to
the engine.
– Collect the fuel which flows out with a cleaning cloth.

Fabia II 2007 ➤
– Pull off fuel hoses -1, 2, 5 and 6-. To do so, push the quick
couplings onto the nozzles, press in the securing elements
(hold pressed) and detach the quick couplings.
– Unplug connector -4-.
– Unscrew expansion bottle -3-.
– Place the expansion bottle with connected coolant hoses and
fuel hoses on the engine.
– Remove fan shroud with radiator fan -V7- ⇒ page 126 .
– Remove right charge air pipe to throttle valve control unit
⇒ page 163 .
– Remove right drive shaft ⇒ Chassis; Rep. Gr. 40 .
– Unscrew left drive shaft from the flange shaft of the gearbox
and tie up.
Vehicles with air conditioning
WARNING

be opened.
Caution

ses.
– Remove the AC compressor from the bracket for auxiliary

units and secure it with connected refrigerant hoses to the
body.
Continued for all vehicles
Vehicles with diesel particle filter
– Remove diesel particle filter:
♦ Left-hand drive ⇒ page 210 .
♦ Right-hand drive ⇒ page 217 .
Vehicles without diesel particle filter
– Remove pre-exhaust pipe ⇒ page 224 .

Fabia II 2007 ➤
– Disconnect plug connection for exhaust gas temperature

sender 1 -G235- .
– Remove the coolant hoses at the heat exchanger and secure
to the engine.
– Disconnect plug at oil level and oil temperature sender -
G266- .
– Remove coolant temperature sender at radiator outlet -G83-
( ⇒ page 117 , Pos. 26).
– Remove noise insulation -2- for oil pan. To do this:

- Release screws -1-.
- Remove 2-part clips -arrows-.
- Remove cable fixings at the noise insulation.
– Release screw -6-.

Fabia II 2007 ➤
– Tighten engine mount -T40076- with nut -1- at the cylinder

block to approx. 20 Nm.
– Place nut M12 -3- between engine mount -T40076- and cyl‐
inder block.
– Fix the engine mount -T40076- with a screw M10 x 50 -2- to
the cylinder block.
– Insert engine/gearbox jack -V.A.G 1383 A- in the engine
mount -T40076- and slightly raise.
– Position the engine mount -T40076- in the engine/gearbox
jack -V.A.G 1383/A- .
Note
Use the double ladder to release the screws for the engine/gear‐
box mounting.
– Successively release screws for engine mounting -arrows-.

• The nut -2- must not be released.
– Successively release screws for gearbox mounting -arrows-.
Note
♦ Check whether all hose and line connections between engine,

gearbox and body are released.
♦ When lowering carefully guide the engine with the gearbox, in
order to avoid damage.
– Carefully lower engine with gearbox. During this procedure,

turn or move the engine with the gearbox depending upon the
constriction.
– Remove the gearbox from the engine.
1.3 Securing the engine to the assembly

stand
♦ Engine mount -MP1-202-
♦ Hook -MP1-202/10-
♦ Assembly stand -MP9-101-
♦ Lifting device -MP9-201 (2024A)-
♦ Bushing -T30010 (VW 540/1B)-

Fabia II 2007 ➤
♦ Workshop crane , e.g. -VAS 6100-

• Separate engine from gearbox.
WARNING
Use securing pins on the hooks and rig pins to prevent release.
– Hook on lifting device -MP9-201 (2024A)- at engine and at

workshop crane .
– Lift engine with installed engine mount -T40076- out of the
engine/gearbox jack using the workshop crane .
– Remove engine mount -T40076 - .
– For carrying out assembly work, attach the engine with engine
mount -MP1-202- , adapter -MP1-202/10- and sleeves -
T30010- to the assembly stand -MP9-101- . The figure shows
the 1.9 ltr./47 kW SDI Engine. The fixing system is identical.
1.4 Installing the engine

♦ Grease -G 000 100-
• Fit engine and gearbox using engine mount to the engine/
gearbox jack .
Installation is performed in the reverse order, pay attention to the
following points:

Fabia II 2007 ➤
Note
♦ If the toothed belt is replaced when carrying out engine repair

(apart from regular change interval), it should be entered in the
⇒ Service Schedule !
♦ Observe all safety measures and notes for assembly work on
the fuel and injection system, the charge air system as well as
the rules for cleanliness ⇒ page 2 .
♦ Replace self-locking nuts.
♦ Replace screws which have been tightened firmly to a torquing
angle.
♦ Always replace gasket rings and seals.
♦ All cable straps should be fastened again in the same place
when installing.
♦ Secure all hose connections with corresponding hose clamps
⇒ Electronic Catalogue of Original Parts .
WARNING

gine compartment because of its cramped construction, please
hot components.
Note
♦ Clean the drive shaft serration and hub serration on a used

clutch disc, remove corrosion and only apply a very thin layer
of grease -G 000 100- on the serration. Subsequently move
the clutch disc up and down on the drive shaft until the hub fits
smoothly on the shaft. Always remove excess grease.
♦ After installing the coupling, check the centering of the clutch
disc ⇒ Gearbox; Rep. Gr. 30 .
♦ Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ Gearbox; Rep. Gr. 30 .
– Check whether the dowel sleeves for centering the engine/

gearbox are present in the cylinder block; insert if necessary.

Fabia II 2007 ➤
– Ensure that the intermediate plate has been inserted on the

sealing flange and is pushed onto the dowel sleeves
-arrows-.
– Screw on gearbox to engine ⇒ gearbox; Rep. Gr. 34 .
– Insert engine/gearbox assembly in the body.
– Align the engine/gearbox unit free of stress and attach firmly
⇒ page 19 .
• When tightening the new screws for engine and gearbox
mounts, engine and gearbox support brackets must be resting
fully against mount.
– Remove engine mount -T40076- from engine.
– Install pre-exhaust pipe with diesel particle filter:
– Install pre-exhaust pipe ⇒ page 224 .
– Install the right drive shaft and attach the left drive shaft to the
flange shaft ⇒ Chassis; Rep. Gr. 40 .
– Connect hydraulic line to breather/clutch slave cylinder and
bleed the clutch hydraulic ⇒ Gearbox; Rep. Gr. 30 .
– Attach shift mechanism to gearbox and adjust ⇒ Gearbox;
Rep. Gr. 34 .
– Attach AC compressor to holder for auxiliary units
⇒ page 22 .
– Install the V-ribbed belt ⇒ page 23 .
– Connect all hoses to the engine.
– Connect electrical connections and attach cables ⇒ Current
flow diagrams and Fitting locations.
– Check oil level, top up oil if necessary ⇒ Maintenance ; Fabia
II .
– Connect vehicle diagnosis system, measurement and infor‐
mation system -VAS 505X- and carry out the targeted function
“filling and bleeding the high pressure pump and the fuel sys‐
tem” ⇒ Vehicle diagnosis, testing and information system VAS
5051.
– Top up coolant ⇒ page 112 .
– Install the noise insulation ⇒ Body Work; Rep. Gr. 50 .
– Install the left and right wheelhouse liner ⇒ Body Work; Rep.
Gr. 66 .
– Carry out cohesive work when reconnecting the battery ⇒
Electrical System; Rep. Gr. 27 .
– Perform a test drive.
– Interrogate all fault memories, if necessary rectify any faults
existing and erase the fault memory ⇒ Vehicle diagnosis, test‐
ing and information system VAS 5051.

Fabia II 2007 ➤
Note
After deleting the fault memory of the engine control unit the read‐
iness code must be checked, if necessary re-generated.
Tightening torques
Component Nm
Screws or nuts M6 9
M7 13
M8 20
M10 40
M12 70
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. Gr. 34
Screws for assembly bracket ⇒ page 19
1.5 Assembly bracket
1 - Screw
❑ replace
❑ tightening order and
tightening torque
⇒ page 20
2 - Engine support bracket
❑ removing and installing
⇒ page 38
3 - Screw
❑ replace
tightening torque
⇒ page 20
4 - 20 Nm + torque a further 90°
(1/4 turn)
❑ replace
5 - Engine mounting
(1/4 turn)
❑ replace
7 - Pendulum support
❑ Fitting position
⇒ page 20
(1/4 turn)
❑ replace
(1/4 turn)
❑ replace

Fabia II 2007 ➤
10 - 40 Nm + torque a further 90° (1/4 turn)

❑ replace
❑ replace
12 - Gearbox mount
13 - 25 Nm
❑ Nut of bracket for diesel particle filter/pre-exhaust pipe
❑ replace
Engine support - tightening order and tightening torque

– Tighten the new screws in 3 stages in the sequence shown:
Stage Screws Tightening torque/torquing angle
1 -1 … 3- 7 Nm
2 -1 … 3- 40 Nm
3 -1 … 3- torque a further 180°
Fitting position - pendulum support

– Position the screws -A- in the elongated holes of the pendulum
support in such a way that there is maximum distance between
the gearbox and the assembly carrier.
• The screw -arrow- must not be loosened.

Fabia II 2007 ➤
13 – Crankgear
1 Removing and installing V-ribbed belt
1.1 V-ribbed belt drive - Summary of com‐

ponents
1.1.1 Vehicles without air conditioning
1 - Crankshaft-belt pulley
❑ with vibration damper
⇒ page 25
2 - 25 Nm
3 - Generator
⇒ Electrical System;
Rep. Gr. 27
4 - Bracket for auxiliary units
⇒ page 42
5 - V-ribbed belt
⇒ page 22
❑ replace
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it.
1. Removing and installing V-ribbed belt 21

Fabia II 2007 ➤
1.1.2 Vehicles with air conditioning
⇒ page 25
2 - 25 Nm
3 - Generator
⇒ Electrical System;
Rep. Gr. 27
⇒ page 42
5 - 20 Nm + torque a further
180° (1/2 turn)
❑ replace
6 - Tensioning element
❑ for the V-ribbed belt
⇒ page 24
7 - AC compressor
⇒ Heating, Air Condi‐
tioning; Rep. Gr. 87
8 - 45 Nm
9 - Dowel sleeves
❑ pay attention to correct
fit in the holder
10 - V-ribbed belt
⇒ page 23
❑ check for wear
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ do not kink
❑ pay attention to the correct position on the belt pulley when installing it.
1.2 Removing and installing V-ribbed belt
1.2.1 Removing and installing V-ribbed belt

for vehicles without air conditioning sys‐
tem
Note
The repair kit for the V-ribbed belt includes the assembly tool -
T10367- and an illustrated ⇒ work procedure .
22 Rep. Gr.13 - Crankgear

Fabia II 2007 ➤
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
Gr. 50 .
– Remove the right wheelhouse liner ⇒ Body Work; Rep. Gr.
66 .
– Cut through the V-ribbed belt.
Install
following points:
– The following work procedure is described in the illustrated ⇒
work procedure .
– Start engine and check ribbed V-belt run.
1.2.2 Removing and installing V-ribbed belt

for vehicles with air conditioning system
♦ Locking pin -T10060 A-
Removing
66 .
– Remove right charge air pipe ⇒ page 163 .
Caution
Risk of damage through reversing the rotation direction of an

already used V-ribbed belt.
♦ If it is intended to re-install the V-ribbed belt, mark the di‐
rection of rotation with chalk or a felt-tip pen before re‐
moving it.
– Loosen the V-ribbed belt by swivelling the tensioning element

in -the direction of the arrow-.

Fabia II 2007 ➤
– Align the holes -arrows- and lock the tensioning element using
the locking pin -T10060 A- .
– Remove the V-ribbed belt.
Install
following points:
Note
Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.
– Lay the V-ribbed belt onto the V-ribbed belt pulleys.

1- Crankshaft belt pulley with vibration damper
2- Tensioning element
3- Generator
4- AC compressor
– Hold the tensioning element with the ring spanner and pull out
the locking pin -T10060 A- .
– Release the tensioning element.
– Check correct positioning of the V-ribbed belt.
– Start engine and check ribbed V-belt run.
1.3 Removing and installing tensioning ele‐

ment for V-ribbed belt
Removing

Fabia II 2007 ➤
– Release screws of coolant lines -arrows-.
WARNING

be opened.
Caution

ses.

body.
– Release the screw -2- and remove the tensioning element for
V-ribbed belt -1-.
Install
following points:
– Replace the screw for the tensioning element.
Tightening torque: 20 Nm + torque a further 180° (1/2 turn)
– Attach AC compressor to holder for auxiliary units
⇒ page 22 .
– Install the V-ribbed belt ⇒ page 23 .
1.4 Removing and installing crankshaft-belt

pulley
Removing
– Release screws of coolant lines -arrows-.
– Lay the coolant lines a little to the side.

Fabia II 2007 ➤
– Loosen the screws -arrows- for the crankshaft belt pulley. To

do so, counterhold with a ring spanner at the screw for the
crankshaft timing belt sprocket.
– Release screws and remove crankshaft-belt pulley.

Install
following points:
– Install the crankshaft belt pulley with new screws ⇒ Electronic
Catalogue of Original Parts . The assembly is only possible in
one position.

Fabia II 2007 ➤
2 Removing and installing toothed belt
2.1 Timing belt drive - Summary of components
1 - Toothed belt
❑ before removing mark
running direction
❑ check for wear
❑ do not kink
⇒ page 29
Note

90° (1/4 turn)
❑ replace
❑ Neither oil nor grease
thread or collar.
❑ tightening may occur in
successive stages
3 - Toothed belt gear
❑ at the crankshaft
4 - 20 Nm
5 - Guide pulley, bottom
(1/8 turn)
7 - Tensioning pulley
❑ for removing and instal‐
ling, remove engine
support ⇒ page 38
8 - 25 Nm
❑ replace
❑ on the camshaft Volkswagen Technical Site: http://vwts.ru http://vwts.info
10 - 25 Nm
11 - 100 Nm
❑ to release and tighten use counterholder -T10051 -
12 - Hub
❑ for camshaft
❑ to remove use extractor -T10052-
❑ removing and installing ⇒ page 85
13 - Rear toothed belt guard
❑ replace
❑ for attaching the high pressure pump
2. Removing and installing toothed belt 27

Fabia II 2007 ➤
15 - 10 Nm
❑ replace
16 - Guide pulley, top
❑ attached to the bracket for auxiliary units
❑ replace
❑ for guide pulley, middle (without position number)
❑ screwed into the bracket for auxiliary units
18 - Hub
❑ for high pressure pump
19 - 95 Nm
❑ on the high pressure pump
❑ replace
22 - Coolant pump
23 - 15 Nm
24 - Timing belt guard - top part
25 - Timing belt guard - bottom part
26 - 10 Nm
❑ insert using locking agent -D 000 600 A2-
❑ replace
29 - 5 Nm
30 - Protection plate
31 - Screw
❑ replace
❑ tightening order and tightening torque ⇒ page 38

Fabia II 2007 ➤
Attach toothed belt guard - bottom part

– Insert screws with locking agent -D 000 600 A2- .
– Tighten screws -arrows- to 9 Nm.
2.2 Removing and installing toothed belt

♦ Rig pin for diesel injection pump -3359 - (2x)
♦ Crankshaft arrester -T10050-
♦ Locking pin -T10060 A-
♦ Counterholder -T10172 - with bolts -T10172/4- and bolts -
T10172/8-
♦ Offset screwdriver -T10264-
♦ Rig tool -T10265-
♦ Socket insert XZN 10 -T10385-
2.2.1 Removing
WARNING

hot components.

Fabia II 2007 ➤
Note
♦ If the toothed belt is replaced beyond the change interval, it

should be entered in the ⇒ Service Schedule !
♦ Observe safety measures when working on the fuel system
⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .
♦ The engine support does not have to be removed in order to
remove the camshaft sprocket.
– Put the shift lever into Neutral in order to turn the crankshaft.
– Switch off ignition and withdraw ignition key.
Gr. 66 .
– Remove crankshaft-belt pulley ⇒ page 25 .
Note
Do not lock tensioning element for V-ribbed belt.
– Remove top part of toothed belt guard; to do so release re‐

taining clips -arrows-.
– Release screws -arrows-.

– Remove bottom part of toothed belt guard.
Note
The engine support must be removed to replace the tensioning

pulley ⇒ page 38 .

Fabia II 2007 ➤
– Rotate the crankshaft on TDC in direction of rotation of the

engine, secure the crankshaft timing belt sprocket with the
crankshaft arrester -T10050- . Slide the crankshaft arrester
from the front side of the crankshaft timing belt sprocket into
its teeth.
Note
The markings on the crankshaft - toothed belt sprocket -2- and on

the crankshaft arrester -T10050- -1- must be aligned. The bolt of
the crankshaft arrester -T10050- must engage at the same time
in the hole of the sealing flange.
• The arrow on the camshaft sprocket must be close to the “12

o'clock” position.
If the arrow is close to the “6 o'clock” position, torque the
crankshaft by 1 turn (360°).
– Successively release screws -1- for camshaft sprocket, re‐
place screws and do not fully screw in the new screws.
– Successively unscrew the screws -2- of the toothed belt

sprocket of the high pressure pump with the socket insert XZN
10 -T10385- , replace the screws and do not fully screw in the
new screws.
– Loosen nut -1- for tensioning pulley.

– Turn the eccentric of the tensioning pulley with the offset
screwdriver -T10264- in -direction of arrow- (anti-clockwise)
until the tensioning pulley can be interlocked with the rig tool
-T10265- .

Fabia II 2007 ➤
– Then turn the eccentric of the tensioning pulley with the offset
screwdriver -T10264- in the -direction of arrow- up to the stop
and tighten the nut -1- by hand.
Caution
Risk of damage through reversing the rotation direction of an

already used toothed belt.
♦ If the toothed belt is re-installed, mark the direction of ro‐
tation with chalk or a felt-tip pen before removing it.
– First of all remove the toothed belt from the large guide pulley
and then from the remaining toothed belt gears.
2.2.2 Installing (set the timing)
Note
♦ Adjusting work on the timing belt must only be performed on

a cold engine, as the position of the pointer at the tensioning
element is temperature dependent.
♦ If it is intended to replace the tensioning pulley, the engine
support must be removed ⇒ page 38 .
Conditions
• Tensioning pulley locked with rig tool -T10265- and fixed with
nut up to right stop.
• Lock the crankshaft with the crankshaft arrester -T10050- .
• The screws for the camshaft sprocket and the toothed belt
gear on the high pressure pump are replaced and loosely
tightened. It must still be possible to just turn the toothed belt
sprockets, however they must not tilt.

Fabia II 2007 ➤
Note
If necessary, turn the hub of the camshaft using the counterholder

-T10172- with bolts -T10172/4- until it can be locked. To do so
tighten at least one fixing screw -1- by hand.
– Lock hub for camshaft with rig pin for injection pump -3359- .
To do so, slide the rig pin through the open elongated hole on
the outside of the cylinder head.
– Loosen again the screws which were tightened by hand.
– Lock hub for high pressure pump with rig pin for injection pump
-3359- . To do so, insert the rig pin into the hole of the timing
belt gear from the outside.
Note
If necessary, use a screwdriver to turn the hub of the high pres‐

sure pump at the screw heads -1- until the hub can be locked with
the rig pin.

Fabia II 2007 ➤
– Turn the camshaft sprocket -3- and the toothed belt sprocket
on the high pressure pump -5- clockwise in their elongated
holes as far as the stop.
– Fit the timing belt in the following order.
1- Crankshaft - toothed belt sprocket
2- Tensioning pulley
3- Camshaft sprocket
4- Timing belt gear on the coolant pump
5- Toothed belt gear on the high pressure pump
6- Guide pulley
– Loosen nut -1- for tensioning pulley and remove rig tool -
T10265- .
Note
Pay attention to correct fitting of the tensioning pulley in the rear

toothed belt guard -arrow-.
– Fit counterholder -T10172- with bolts -T10172/4 - onto cam‐

shaft sprocket.
– Push the counterholder in -direction of arrow- and keep it pre‐
tensioned.
– First of all tighten the screws -1- for the camshaft sprocket and
the screws -2- for the toothed belt gear on the high pressure
pump in this position to 20 Nm.
Note
The screws must be further turned after the setting and testing of
the timing have been carried out ⇒ page 37 .

Fabia II 2007 ➤
– Turn the eccentric of the tensioning pulley with the offset

screwdriver -T10264- clockwise -arrow- until the pointer -2- is
in the centre of the base plate in front of the gap.
• The nut -1- must not turn along.
– Hold tensioning pulley in this position and tighten nut.
– Remove rig pins for diesel injection pump -3359- and crank‐
shaft arrester -T10050- .
Test timing
– Turn the crankshaft at the central screw for crankshaft toothed
belt sprocket by 2 turns in the direction of rotation of the engine
until the crankshaft is positioned shortly before “TDC”.
– Position the crankshaft arrester -T10050- on the crankshaft

toothed belt sprocket.
– Turn the crankshaft in the direction of rotation of the engine
until the bolt -arrow- of the crankshaft arrester engages during
this rotary movement in the sealing flange.
Note
The removal of the crankshaft and camshaft is limited in the fol‐

lowing test. The removal point of the hub of the high pressure
pump is always difficult to find again. A slight difference -arrow-
does not influence the engine running.
Conditions

Fabia II 2007 ➤
• The hub of the camshaft must be locked with the rig pin for
diesel injection pump -3359- .
• The pointer of the tensioning pulley -2- must be in the area
-a- of the base plate -1-.
If the conditions are not fulfilled:
– Correct timing ⇒ page 36 .
If the conditions are fulfilled:
– Continued if the timing is correctly set ⇒ page 37 .
Correct timing
– Push the crankshaft arrester -T10050- until its locking bolt
pushes out of the hole in the sealing flange.
– Turn the crankshaft against the running direction of the engine
slightly before the “TDC”.
– Now slowly turn with the crankshaft in the running direction of
the engine, until the hub of the camshaft can be locked during
this rotary movement with the rig pin for the injection pump
-3359- .
– Slacken the fixing screws of the pulley when the hub of the
camshaft sprocket is locked.

Fabia II 2007 ➤
– Check the position of the bolt -arrow- of the crankshaft arrester

-T10050- to the hole in the sealing flange:
If the bolt -arrow- of the crankshaft arrester -T10050- is positioned
to the left of the hole:
– Slowly turn the crankshaft in the direction of rotation of the
engine until the bolt of the crankshaft arrester -T10050- en‐
gages into the hole in the sealing flange.
– Pre-tighten the fixing screws for the camshaft sprocket to 20
Nm.
Note
The screws must be further turned according to the setting of the

timing ⇒ page 37 .
If the bolt of the crankshaft arrester -T10050- is positioned to the

right behind the hole:
– First of all turn the crankshaft slightly against the direction of
rotation of engine until the bolt is positioned to the left in front
of the hole.
– Slowly turn the crankshaft in the direction of rotation of the
engine until the bolt of the crankshaft arrester -T10050- en‐
gages into the hole in the sealing flange.
– Pre-tighten the fixing screws for the camshaft sprocket to 20
Nm.
Note
The screws must be further turned according to the setting of the

timing ⇒ page 37 .
Procedure if the timing is correctly set

– Remove rig pin -3359- and crankshaft arrester -T10050- .
– Once again test timing ⇒ page 35 .
If the hub of the camshaft sprocket can now be secured:
– Tighten fixing screws of toothed belt sprockets with a rigid
wrench as follows:
♦ Camshaft sprocket:
– 45° (torque a further 45° (1/8 turn). Counterhold with counter‐

holder -T10172- with bolts -T10172/4 - .
♦ Toothed belt sprocket on the high pressure pump:

Fabia II 2007 ➤
– 90° (torque a further 45° (1/4 turn). Counterhold with counter‐

holder -T10172- with bolts -T10172/8 - .
Further installation occurs in reverse order to removal.
Tightening torques: ⇒ page 27
2.3 Removing and installing engine support

♦ Supporting device -MP9-200 (10-222A)-
♦ Adapter -MP9-200/3 (10-222A/3)-
♦
Removing
Note
Do not open fuel lines and coolant lines. The coolant expansion
reservoir remains closed.

Gr. 50 .
– Unscrew screws -2 and 3- and remove holder for diesel parti‐
cle filter at the top.
– Unscrew screws -4- and nuts -5- and remove bracket for pre-
exhaust pipe at the bottom.
– Unclip hoses at coolant expansion reservoir.
– Disconnect plug from coolant expansion reservoir.

Fabia II 2007 ➤
– Disconnect plug -1- at differential pressure sender -G505-

– Unscrew differential pressure sender -G505- from bracket and
lay to the side.
– Disconnect plug -2- at fuel temperature sender -G81- .
– Unbolt the coolant expansion bottle.
– Remove the fuel filter -1- upwards out of the bracket.

– Lay coolant expansion reservoir and fuel filter with lines to the
side.
– Fit supporting device -MP9-200- . For this purpose, position

the supports -A- next to the screw -arrow 1- and the support
of the front flap -arrow 2- as shown.
Note
♦ The assembly bracket must only be removed if the engine is

supported with the supporting device -MP9-200- !
♦ Only release the engine support if the assembly bracket is re‐
moved.

Fabia II 2007 ➤
– Unscrew securing bolts -arrows-.
Caution
The nut -2- must not be released.
– Remove the complete engine mounting.
WARNING
Make sure that no components/hoses are damaged, over‐

stretched or torn off when lifting and lowering the engine with
the supporting device -MP9-200- .
– Slacken screws of engine support in the sequence -3 … 1-.

– Remove the engine support upwards.
Install
– Place the engine support from the top.
Caution
The tightening sequence and the tightening torque of the

screws for the engine support must definitely be respected.
Otherwise stress of the engine support occurs, which results
in the breaking of the engine support.
– Screw in new screws and tighten in 3 stages in the sequence

shown.
Stage Screws Tightening torque/torquing angle
1 -1 … 3- 7 Nm
2 -1 … 3- 40 Nm
3 -1 … 3- 180° (torque a further 90° (1/2 turn)

Tightening torque of the engine mounting: ⇒ page 19

Fabia II 2007 ➤
3 Cylinder block
3.1 Cylinder block - Summary of components
1 - Cylinder block
❑ Removing and installing
sealing flanges and fly‐
wheel ⇒ page 49
❑ Removing and installing
crankshaft, piston and
conrod ⇒ page 62
2 - Knock sensor -G61-
3 - 20 Nm
❑ the tightening torque in‐
fluences the knock sen‐
sor function
4 - Engine speed sender -G28-
⇒ page 60
5 - 5 Nm
❑
6 - Gasket
❑ replace
7 - Oil filter holder
❑ disassembling and as‐
sembling ⇒ page 98
8 - Screws for balancing shaft
module
⇒ page 46
(1/4 turn)
❑ replace
❑ tighten crosswise
10 - 15 Nm
11 - 4/2 way valve with coolant regulator
12 - O-ring
❑ replace
13 - Balancing shaft module
14 - Oil pan
15 - 15 Nm
16 - Screw
❑ for bracket for auxiliary units ⇒ Item 19 (page 42)
❑ replace
❑ loosen and tighten ⇒ page 42
Volkswagen Technical Site: http://vwts.ru http://vwts.info 3. Cylinder block 41

Fabia II 2007 ➤
17 - Screw
❑ replace
18 - Screw
❑ replace
❑ for engine support, guide pulleys of timing belt, AC generator, AC compressor and tensioning element
of the V-ribbed belt
❑ pay attention to the dowel sleeves between the bracket for auxiliary units and the cylinder block
20 - 25 Nm
21 - Lifting eye
22 - Screw
❑ replace
23 - Screw
❑ replace
25 - Bracket for pre-exhaust pipe
26 - 23 Nm
27 - 40 Nm
❑
28 - Heat shield
❑ for right drive shaft
3.2 Removing and installing bracket for aux‐

iliary units
Removing
– Remove the high pressure pump ⇒ page 194 .

Fabia II 2007 ➤
– Remove alternator ⇒ Electrical System; Rep. Gr. 27 .

WARNING

be opened.
Caution

ses.

body.
– Remove guide pulleys -1 and 2- and release the screw

-arrow- of the rear timing belt guard.
– Release screw -1- of engine support.
3. Cylinder block 43
Fabia II 2007 ➤
– Release screws in the sequence -6 … 1- and remove bracket

for auxiliary units.
Install
following points:
Note
♦ A dowel sleeve must be located between the bracket for aux‐

iliary units and the cylinder block in the screw hole -6-.
♦ Replace all the screws of the bracket for auxiliary units and the
engine support, which have been tightened to a torquing an‐
gle.
♦ Before tightening the fixing screws of the bracket for auxiliary
units, screw in the screw of the engine support by hand.
– Screw in the new screws of the bracket for auxiliary units.

Screws -1- and -2- M10 x 52
screws -3- and -4- M10 x 30
screws -5- and -6- M10 x 60
– Gradually tighten the new fixing screws for auxiliary units in
the sequence -1…6-:
1. Screw in all the screws by hand.
2. Tighten all bolts initially to 40 Nm.
3. Torque the screws with a rigid wrench as follows:
Torque screws -1 and 2- a further 90° (1/4 turn.)
– Tighten the new screw of the engine support -3-.

– Install high pressure pump ⇒ page 194 .
– Install alternator ⇒ Electrical System; Rep. Gr. 27 .
– Install AC compressor ⇒ page 22 .
– Fill up the fuel system ⇒ page 179 .

Fabia II 2007 ➤
4 Balancing shaft module
4.1 Balancing shaft module - Summary of components
Note
The balancing shaft module with oil pump can only be replaced completely.
1 - Cover
❑ clean if soiled
2 - 8 Nm
180° (1/2 turn)
❑ tighten crosswise from
the inside outwards in
several stages
180° (1/2 turn)
5 - Balancing shaft module with
oil pump
❑ must be replaced com‐
pletely
❑ before installing, check
whether the dowel
sleeve is present for
centering in the cylinder
block and the O-ring is
inserted in the balancing
shaft module
⇒ page 46
6 - O-ring
❑ replace
❑ check for correct posi‐
tion, is inserted in the
balancing shaft module
❑ lightly oil for assembly
7 - Cylinder block
8 - Fitting sleeve
9 - Chain tensioner with ten‐
sioning rail
❑ to remove lock with locking pin -T40011-
❑ replace
11 - Assembly aid
❑ Rig pin -T40011-
12 - Chain
❑ check fitting position ⇒ “4.2 Removing and installing balancing shaft module”, page 46
4. Balancing shaft module 45

Fabia II 2007 ➤
13 - 23 Nm
14 - Deflection chain sprocket
4.2 Removing and installing balancing shaft

module
♦
♦ Locking pin -T40011-
♦ Socket insert -T10061-
Removing
– Removing toothed belt ⇒ page 29 .
– Removing the oil pan ⇒ page 99 .
– Remove sealing flange on belt pulley side ⇒ page 50 .
– Remove cover of balancing shaft module.
– Lock the chain tensioner with the locking pin -T40011-
-arrow-.
– Release screw from deflection chain sprocket -1- and remove
deflection chain sprocket.
– Release screws -2- from chain tensioner and remove chain
tensioner.
– Remove chain from chain sprockets and place on a clean sur‐
face.
– Unscrew balancing shaft module from cylinder block and place
down on a clean surface.
Install
– Check all the components of the chain drive for wear.
Note
When installing the balancing shaft module, ensure that the dowel
sleeve is inserted in the cylinder block and the O-ring in the bal‐
ancing shaft module.
– Tighten the balancing shaft module to the cylinder block by

hand.

Fabia II 2007 ➤
– Align the balancing shaft module in such a way that it is flush

with the outer edge of the cylinder block on the belt pulley side.
Caution
Under no circumstances the balancing shaft module must be

installed as shown in the picture detail with -arrow 1 and 2-.
– Replace the screws of the balancing shaft module and tighten

crosswise from the inside outwards in several stages.
– Clean the chain with a non-fluffing cleaning cloth.
– Fit the chain onto the chain sprocket of the crankshaft, the oil
pump and the balancing shaft as shown.
• While doing so, the marking on the chain sprocket of the
crankshaft must be opposite the individual colour-marked
chain link -top arrow-.
• The marking on the chain sprocket of the balancing shaft must
be between the 2 colour-marked chain links -bottom arrow-.
• The colour markings are only located on the outer tabs of the
chain. They must point to the outside. Thus the original direc‐
tion of rotation of the chain is ensured.
– Insert the deflection chain sprocket into the chain and tighten
at the balancing shaft module to 23 Nm.
– Install chain tensioner.
– Replace screws -2- and tighten as follows.

1. middle screw 8 Nm
2. Screw to oil pump 8 Nm
3. Screw to guide rail 8 Nm
4. middle screw 90° (torque a further
90° (1/4 turn)
5. Screw to oil pump 90° (torque a further
90° (1/4 turn)
6. Screw to guide rail 90° (torque a further
90° (1/4 turn)
– Remove the locking pin -T40011- from the chain tensioner.
4. Balancing shaft module 47

Fabia II 2007 ➤
– Check, if the markings on the chain sprocket of the crankshaft

and the balancing shaft are correctly positioned to the colour-
marked chain links -arrows-.

Fabia II 2007 ➤
5 Removing and installing sealing

flange and flywheel
5.1 Sealing flanges and flywheel - Summary of components
Note
The sealing flange on the belt pulley side -2- is made of plastic. The sealing ring -1- and a circumferential silicone
seal for the cylinder block and for the oil pan is integrated in it ⇒ page 50 .
1 - Sealing ring
❑ Only possible to replace
complete with sealing
flange ⇒ page 50
❑ Do not additionally lubri‐
cate or grease sealing
lip of the gasket ring
❑ before installing, re‐
move oil residues on
crankshaft journal and
cylinder block with a
clean cloth
2 - Sealing flange
❑ on belt pulley side
❑ replace
⇒ page 50
3 - Cylinder block
4 - The two-mass flywheel
⇒ page 58
❑ Assembly is only possi‐
ble in one position
through offset holes.
(1/4 turn)
❑ replace
6 - Intermediate plate
❑ must be positioned on
dowel sleeves
❑ do not damage/bend
during assembly work
❑ hang on the sealing
flange ⇒ page 50
7 - 15 Nm
❑ replace
8 - Sealing flange
❑ on gearbox side
❑ can only be replaced complete with gasket ring and with rotor of engine speed sender -G28-
❑ replace ⇒ page 53
5. Removing and installing sealing flange and flywheel 49

Fabia II 2007 ➤

Sealing flange on the belt pulley side with silicone seal and seal‐
ing ring
The sealing flange on the belt pulley side with integrated sealing
ring and integrated silicone seal can only be replaced completely
⇒ page 50 .
♦ -1-: Sealing ring
♦ -Arrows-: circumferential silicone seal for the cylinder block
and the oil pan
Installing intermediate plate

– Insert intermediate plate on sealing flange and push onto the
dowel sleeves -arrows-.
5.2 Removing and installing the sealing

flange on the belt pulley side
♦ Counterholder -T30004 (3415)-
♦ Assembly device -T10053-
♦ Old oil collecting and suction equipment , e.g. -V.A.G 1782-
♦ Silicone sealant -D 176 501 A1-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing
• Engine installed.

Fabia II 2007 ➤
– Remove crankshaft - toothed belt sprocket. To this end lock

the toothed belt gear with counterholder -T30004 (3415)- .
– Unscrew the sealing flange on the belt pulley side, if necessary
release by applying slight blows with a rubber-headed ham‐
mer.
Install
following points:
WARNING
Use protective gloves and protective googles when working

with sealant and grease remover!
– Remove the remaining sealant on the cylinder block and on

the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
– Slide the guide bushing -T10053/1- onto the crankshaft.

– Fit sealing flange and lightly tighten all screws.
– Tighten the screws of the sealing flange alternately and cross‐
wise to 15 Nm.
– Installing the oil pan ⇒ page 51 .
Installing the oil pan

Fabia II 2007 ➤
Note
♦ The following description for the installation of the oil pan only
applies if the sealing flange on the belt pulley side was re‐
placed.
♦ If the silicone seal -arrows- is damaged, it must be replaced.
Then the work procedure ⇒ page 99 must be carried out.
♦ Pay attention to the use by date of the silicone sealant -D 176
501 A1- .
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).
– Apply the silicone sealant -D 176 501 A1- to the clean sealing
surface of the oil pan, as shown. The sealant bead must be:
• Run past the area around the bolt holes on the inside
-arrows-.
Caution
Risk of blockage of the lubrication system through excess seal‐

ant.
♦ Do not apply a thicker sealant bead than indicated.
• Thickness of sealant bead: 2…3 mm
Note
After applying the sealant, install the oil pan within 5 minutes.
– Position oil pan.
Note
♦ The oil pan must be flush to the gearbox flange at the inter‐
mediate plate.
♦ When installing the oil pan with the engine removed, ensure
that the oil pan is flush with the cylinder block at the flywheel
side.

Fabia II 2007 ➤
– Tighten the screws of the oil pan in 3 stages as follows.

Stage Screws Tightening torque
1 -1 … 16- crosswise to 5 Nm
2 -Arrows- 40 Nm
The further assembly is carried out in the reverse order, while
paying attention to the following:
♦ After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
– Installing the timing belt ⇒ page 29 .
– Fill with engine oil and check the oil level ⇒ Maintenance ;
Fabia II .
5.3 Replace sealing flange on the gearbox

side
♦ Feeler gauges
♦ Steel straightedge
♦ Screw M6 x 35 (3x)
♦ Screw M7 x 35 (2x)
5.3.1 Removing
• Gearbox is removed.
– Remove the two-mass flywheel ⇒ page 58 .
– Remove the intermediate plate from the dowel sleeves and
unhook from sealing flange -arrows-.
– Position crankshaft to TDC for cylinder 1 ⇒ page 29 .
– Remove engine speed sender -G28- -Pos. 1-.

– Unscrew the fixing screws of the sealing flange.

Fabia II 2007 ➤
– Screw 3 screws M6 x 35 mm into the threaded bores of the

sealing flange -arrows-.
– Remove the sealing flange together with rotor from the crank‐
shaft by alternately screwing in the press-off screws.
5.3.2 Install
Note
♦ The sealing flange with PTFE gasket ring is provided with

sealing lip supporting ring. This supporting ring is intended as
an assembly sleeve and must not be removed before instal‐
ling.
♦ Do not separate or turn the sealing flange and rotor after re‐
moving them from the spare part package.
♦ The rotor is given its fitting location by fixing the assembly de‐
vice -T10134- to the positioning pin.
♦ The sealing flange and gasket ring form one unit and must be
replaced together with the rotor.
♦ The rotor has an elastomer layer on its sealing surface with
the crankshaft. This layer must not be brought into contact with
dirt or grease.
♦ The assembly device -T10134- is given its fitting location to
the crankshaft by means of a guide bolt, which is guided into
the threaded bore of the crankshaft.
A - Mounting sealing flange with rotor on the assembly device -

T10134-
A - Hexagon nut
B - Clamping surface
C - Assembly cup
D - Allan screw
E - Guide bolts (with red handle - for fuel engine)
F - Positioning pin
G - Guide bolts (with black handle - for diesel engine)

Fabia II 2007 ➤
– Grip assembly device -T10134- on clamping surface -B- of the

threaded spindle in a vice.
– Push assembly cup -C- down until it rests on the hexagon nut
-A-, -arrow-.
• The inner part of the assembly device and the assembly cup
must be flush.
– Remove the securing clip -arrow- from the new sealing flange.
Note
Do not remove or turn the rotor from the sealing flange.
– Lay the front side of the sealing flange on a clean and level
surface.
– Press down sealing lips supporting ring -A- in
-direction of the arrow-, until it rests on the level surface.
Note
The top edge of the rotor and the front edge of the sealing flange
must be flush.
The locating hole -B- on the rotor -C- must be flush with the mark‐
ing -A- on the sealing flange.

Fabia II 2007 ➤
– Lay the sealing flange with the front side on the assembly de‐
vice -T10134- in such a way that the positioning pin -A- en‐
gages into the hole -B- of the rotor.
Note
Make sure the sealing flange lies flat on the assembly device.
– When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly device -
T10134- in such a way that the positioning pin can no longer
slide out of the rotor hole.
B - Mounting the assembly device -T10134- with sealing flange
on the crankshaft flange
• The crankshaft flange must be free of grease and oil
• Crankshaft is at TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.
– Screw assembly device -T10134- with Allan screws -A- up to

the stop onto the crankshaft flange.
– Screw in 2 screws M7 x 35 mm -A- by about 3 thread turns for

the sealing flange guide into the cylinder block.

Fabia II 2007 ➤
– Move the assembly cup -C- by hand in the

-direction of the arrow- until the rotor -B- rests on the crank‐
shaft flange -A-. Subsequently insert the guide bolt with black
handle -D- fully into the threaded bore of the crankshaft. If the
guide bolt is correctly pushed in, then the handle has a dis‐
tance of approx. 10 mm from the assembly cup -C-. This gives
the rotor its final fitting location.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.
Note
The guide bolt for petrol engines (red handle) -F- must not be fitted
into the threaded hole of the crankshaft.
C - Pressing the rotor onto the crankshaft flange
– Tighten the hexagon nut of the assembly device -T10134 -

using a torque wrench with adapter.
Tightening torque: 35 Nm
Note
After tightening the hexagon nut to 35 mm there must still be a

narrow air gap between the cylinder block and the sealing flange.
D - Inspecting the fitting position of the rotor on the crankshaft
– Unscrew hexagon nut -E- up to the end of the threaded spin‐

dle.
– Release 2 screws -A- to the guide from the cylinder block.
– Release 3 knurled screws -B- from the sealing flange.
– Unscrew 2 Allan screws and remove assembly device.
– Remove sealing lips supporting ring.
The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- = 0.5 mm between the crankshaft flange
-A- and the rotor -B-.

Fabia II 2007 ➤
– Position the steel striaghtedge onto the crankshaft flange.

– Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
– Press down rotor ⇒ page 58 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing alternately cross‐
wise.
– Install engine speed sender -G28- -Pos. 1-.

– Installing the oil pan ⇒ page 99 .
– Fit intermediate plate.
– Install two-mass flywheel with new screws.
Tighten fixing screws to 60 Nm + torque a further 90° (1/4 turn).
E - Pressing down the rotor
– Screw assembly device -T10134- with Allan screws up to the

stop onto the crankshaft flange.
– Screw in 3 knurled screws -B- into the flange.
– Insert the guide bolt with black handle -D- fully into the threa‐
ded bore of the crankshaft.
• If the guide bolt is correctly positioned, then the handle has a
distance of approx. 10 mm from the assembly cup -C-.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup.
– Tighten the hexagon nut of the assembly device using a torque

wrench with adapter.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 57 .
If the dimension -a- is again too small:
– Tighten the hexagon nut of the assembly device to 45 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 57 .
5.4 Removing and installing the two-mass

flywheel
♦ Counterholder -MP1-223 (3067)-
or

Fabia II 2007 ➤
♦ Engine mount -MP1-202 (VW 540)-

♦ Bushing -T30010 (VW 540/1B)-
♦ Flywheel lock -MP1-504-
Removing
• Gearbox is removed.
Engine installed
– Insert the counterholder -MP1-223 (3067)- into the bore hole
on the cylinder block.
• Fitting position of the counterholder:
A - for tightening
B - for slackening
Engine removed
– Position the flywheel lock -MP1-504- on the starter ring gear
and turn crankshaft until it rests against the sleeve -T30010 - .

Fabia II 2007 ➤
Continued for all engines

– Rotate the secondary side -A- of the two-mass flywheel in such
a way that the screws -B- are positioned in the middle of the
holes -arrows-.
Caution
When unscrewing the screws -B-, ensure that no screw head

catches on the secondary side -A- of the two-mass flywheel,
otherwise it will be damaged.
– Release screws -B- and remove two-mass flywheel.

Install
Installation occurs in reverse order to removal. Pay attention to
the following:
Note
Use new screws for attaching.
– Rotate the secondary side -A- of the two-mass flywheel in such

a way that the fixing screws -B- are positioned in the middle of
the holes -arrows-.
1. Screw in all the screws -B- by hand.
2. First of all tighten all the screws -B- crosswise to 60 Nm.
3. Then torque all the screws -B- crosswise a further 90° (1/4
turn.)
5.5 Removing and installing engine speed

sender -G28-
Gr. 50 .
– Disconnect plug -1- at engine speed sender -G28- with as‐
sembly device -T10118- .

Fabia II 2007 ➤
– Release the screw -arrow- and pull out the engine speed
sender -G28- .
Installation occurs in reverse order to removal. Pay attention to
the following:
♦ Tightening torque for screw of engine speed sender -G28- : 5
Nm

Fabia II 2007 ➤
6 Crankshaft, Piston and Conrod
6.1 Crankshaft - Summary of components
1 - Bearing shells 1, 2 and 4

❑ for bearing cap without
lubricating groove
❑ for cylinder block with lu‐
bricating groove
❑ do not mix up used bear‐
ing shells (mark)
(1/4 turn)
❑ replace
3 - Bearing caps
❑ Bearing cap 1: on belt
pulley side
4 - Crankshaft
❑ with chain sprocket for
balancing shaft and oil
pump drive
❑ Axial play when new:
0.07…0.17 mm
Wear limit: 0,37 mm
❑ Crankshaft bearing
pins: ∅ 54.00 mm
❑ Conrod bearing: ∅
47.80 mm
5 - Bearing shell 3
❑ for bearing cap without
lubricating groove
❑ for cylinder block with lu‐
bricating groove
6 - Thrust washers
❑ Fitting position for bear‐
ing 3 ⇒ page 62
Fitting position of thrust washer for bearing 3

Fabia II 2007 ➤
6.2 Disassembling and assembling pistons and conrods
1 - Piston rings
❑ Offset joint 120°
❑ use piston ring pliers for
removing and installing
❑ marking “TOP” faces
piston crown
❑ Inspect gap clearance
⇒ page 64
❑ Inspect end clearance
⇒ page 65
2 - Piston
❑ with combustion cham‐
ber
❑ Mark the installation po‐
sition and the assign‐
ment to cylinder
⇒ page 64
❑ arrow on piston crown
faces towards the belt
pulley
❑ replace the piston if
there is any sign of crack
formation
❑ Inspecting piston
⇒ page 65
❑ Piston dimension: ∅
79.45 mm
❑ use piston ring tension‐
ing strap for installing
❑ inspect piston projection
at TDC ⇒ page 66
3 - Piston pin
❑ if stiff, heat piston to ap‐
prox. 60°C
❑ use drift -VW 222A- for removing and installing
4 - Circlip
❑ replace
5 - Conrod
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Markings -B- point towards the belt pulley side
❑ with a split bearing cap
❑ separate new conrod ⇒ page 67
❑ Axial play wear limit: 0.37 mm
6 - Bearing shell
❑ Fitting position ⇒ page 66
❑ mark used bearing shells for reinstalling, however do not mark the contact surface
❑ Observe version: top bearing shell (towards the piston) must be made from a long lasting material, rec‐
ognition feature for new bearing shells: black marking on the contact surface near the separation point
❑ insert in middle ⇒ page 66
❑ check for firm seating
6. Crankshaft, Piston and Conrod 63

Fabia II 2007 ➤
7 - Cylinder block
❑ Inspect cylinder ⇒ page 65
❑ Cylinder dimension: ∅ 79.50 mm
8 - Conrod bearing cap
❑ Check fitting position
❑ cracked cover fits only in one position at the relevant conrod
9 - Oil injection nozzle
❑ for piston cooling
10 - Pressure valve, 27 Nm
❑ replace without sealant
❑ replace
❑ Oil thread and contact surface
Installation position and assignment of piston/cylinder

• The arrow on the piston crown -arrows- faces towards the belt
pulley side.
Inspecting piston ring gap clearance

♦ Feeler gauges

Fabia II 2007 ➤
– Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder. To insert
use piston without rings.
Piston ring New Wear limit
(dimensions in mm)
1. Compression ring 0,20 … 0,40 1,00
Oil scraper ring 0,25 … 0,50 1,00
Inspect piston ring end clearance

♦ Feeler gauges
– Clean before inspecting the annular grooves of the piston.
Piston ring New Wear limit
(dimensions in mm)
Oil scraper ring 0,03 … 0,06 0,15
Inspecting pistons

♦ External micrometer
– Measure about 10 mm from the lower edge, offset at right an‐
gles to the piston pin shaft.
• Max. deviation from specified dimension: 0,04 mm.
Inspecting cylinder bore

♦ Internal precision measuring instrument
– Measure cylinder at 3 points crosswise in transverse direction
-A- and lengthwise -B-.

Fabia II 2007 ➤
• Max. deviation from specified dimension: 0.10 mm

Fitting position of the bearing shells in the conrods
– Insert bearing shell in the conrod or in the centre of the conrod
bearing cap.
• Dimension -a- = 2.5 mm
Oil spray nozzle and pressure valve

1- Screw with pressure valve
2- Oil spray nozzle (for cooling piston)
• Fitting position: Align the guide edge of the oil spray nozzle to
the edge of the cylinder block being worked on.
Note
♦ The oil injection nozzles must not be bent.

♦ Replace the oil injection nozzles if they are bent.
6.3 Checking piston projection in TDC

♦ Measuring tool for liner pretension -MP1-107-
Test sequence
– Attach the measuring tool for liner pretension -MP1-107- to the
cylinder block as shown in the illustration.
– Measure the projection for each cylinder at 2 points.
Note
♦ When fitting new pistons or a partial engine, check the piston

projection in TDC on all pistons.
♦ If different values are measured during the projection meas‐
urement of the piston, the greatest dimension applies for the
seal assignment.
Depending on the piston projection fit the relevant cylinder head

seal in accordance with the table below.
Piston projection over Marking
cylinder block - top side number of bores
mm
0,91 … 1,00 1
1,01 … 1,10 2
1,11 … 1,20 3

Fabia II 2007 ➤
Identification of the cylinder head gasket

♦ -Arrow 1-: part number
♦ -Arrow 2-: bores
♦ -Arrow 3-: ignore
6.4 Separating new conrod

It can happen that on new conrods, the provided separation point
is not completely cracked. If the conrod bearing cap cannot be
removed by hand, then proceed as follows:
– Mark the assignment of the conrod to the cylinder.
– Slightly tension the conrod, as shown in the illustration, in a
vice provided with aluminium protective jaws.
Note
♦ Only tension the conrod slightly in order to avoid damage.

♦ The conrod is clamped beyond the breaking point, which is
shown in the figure with a broken line.
– Unscrew both screws -arrows- by approx. 5 turns.
– Knock against the conrod bearing cap with a plastic hammer

in -direction of arrow- in order to loosen it.

Fabia II 2007 ➤
15 – Cylinder Head, Valve Gear

1 Cylinder head
1.1 Cylinder head cover - Summary of components
1 - 5 Nm
2 - Heat shield
3 - Crankcase ventilation hose
❑ to suction hose
⇒ page 201
4 - Rubber grommet
❑ for screw for clamping
claw
❑ replace
5 - Sealing ring
❑ for injection unit
❑ replace
❑ replace without tool
❑ Observe fitting location
of the pegs
⇒ page 70
6 - Gasket
❑ for cylinder head cover
❑ replace if damaged or
leaking
7 - Screw, 10 Nm
❑ Replace seal if dam‐
aged
tightening torque
⇒ page 68
8 - Cylinder head cover
⇒ page 69
Cylinder head cover - tightening torque and tightening order

– Tighten the screws for the cylinder head cover in the sequence
-1 ... 6- to 10 Nm.
68 Rep. Gr.15 - Cylinder Head, Valve Gear

Fabia II 2007 ➤
1.2 Removing and installing cylinder head

cover
fuel supply and injection system as well as the rules for cleanli‐
ness ⇒ page 2 .
Removing
– Remove the injection units ⇒ page 187 .
– Detach vacuum lines with bracket from the cylinder head cover
-arrows-.
– Remove top part of toothed belt guard, to do so release clips

-arrows-.
– Slacken fixing screws of cylinder head cover in the sequence

-6 ... 1-.
– Remove cylinder head cover.
Install
following points:
Note
Replace all the gaskets.
1. Cylinder head 69
Fabia II 2007 ➤
-1…6- by hand.
-1 ... 6- to 10 Nm.
– Check fuel system for tightness ⇒ page 180 .
1.3 Removing and installing the gasket

rings for the injection units in the cylinder
head cover
♦ Key set for lambda probe -3337-
♦ Set of tools -T10055-
♦ Assembly device -T10208/2-
fuel supply and injection system as well as the rules for cleanli‐
ness ⇒ page 2 .
Removing
– Remove the injection units on which the gasket ring should be
replaced ⇒ page 187 .
– Lay the concerned return lines slightly to the side.
Caution
Pay particular attention in order to avoid unnecessary installa‐

tion work or consequential damage.
Pay attention to cleanliness.
♦ No dirt must get into the removed return lines and the
connections of the injection units.
♦ No dirt must get into the holes for the injection units in the
cylinder head cover.
– Remove the concerned gasket ring of the injection unit.

– Check if the spring ring is still present on the removed old
gasket ring.
Note
If the spring ring is no longer present on the old gasket ring, make
sure the spring ring does not remain in the hole for the injection
unit.
Install
following points:

Fabia II 2007 ➤
– Check the cylinder head cover for damage.

– Insert new gasket ring by hand.
Observe fitting location of the pegs of the gasket ring.
1.4 Cylinder head - summary of components
Note
♦ Do not remove the plastic bases supplied as a protection for the open valves until just before fitting on the
cylinder head.
♦ When replacing the cylinder head, replace all the coolant ⇒ page 112 .
1 - 25 Nm
2 - Lifting eye
3 - Gasket
❑ replace
4 - Vacuum pump
WARNING
The vacuum pump must
on no account be disas‐
sembled, otherwise the
proper operation of the
pump vacuum part is no
longer assured. This will
result in a failure of the
brake booster.

⇒ page 82
5 - 9 Nm
6 - 9 Nm
7 - Coolant temperature send‐
er -G62-
8 - Connection fittings
❑ for coolant
9 - Sealing ring
❑ replace
10 - Clamp
❑ check tightness
11 - 23 Nm
12 - Support
13 - Cylinder head gasket
❑ replace
❑ Pay attention to the marking ⇒ page 72
14 - Cylinder head
❑ after replacing fill entire system with fresh coolant
1. Cylinder head 71
Fabia II 2007 ➤
15 - Pencil type glow plug, 17 Nm

16 - Cylinder head bolt
❑ pay attention to sequence for loosening and tightening ⇒ page 73
❑ before fitting insert washers in the cylinder head
17 - Oil pressure switch -F1- , 22 Nm
❑ Marking: green
❑ Switching pressure 0.03 ... 0.06 MPa (0.3 ... 0.6 bar)
❑ Cut open gasket ring if leaking and replace
❑ check ⇒ page 108
Inspecting the cylinder head for distortion

– Inspect cylinder head at several points for distortion using a
knife-edge straightedge and feeler gauge.
• Max. permissible distortion: 0.05 mm
Note
It is not permissible to rework the cylinder heads of diesel engines.
Identification of the cylinder head gasket

♦ Part number -arrow 1-
♦ Control code -arrow 2- (ignore)
♦ Bores -arrow 3-
Note
♦ Differing thicknesses of cylinder head gaskets are inserted

according to the piston projection. If only the gasket is re‐
placed, then it must be replaced with a new gasket with the
same marking.
♦ When installing new pistons or a partial engine, determine the
piston projection at TDC ⇒ page 66 .
1.5 Removing and installing Hall sender -

G40-
Removing

Fabia II 2007 ➤
– Disconnect the plug -arrow- from the hall sender -G40- .
– Unscrew the bracket -arrow- for the plug of the Hall sender -
G40- , remove the plug from the bracket and place down the
cable.
– Loosen the retaining lugs of the cable guide with a screwdriver

and remove the cover of the “repair opening” -arrows-.
– Unscrew the Hall sender -G40- -arrow- from the cylinder head
and guide its plug through the “repair opening” in the toothed
belt guard.
Install
following points:
♦ Close the repair opening in the toothed belt guard with a rubber
plug ⇒ Electronic Catalogue of Original Parts .
– install toothed belt and set the timing ⇒ page 29 .
1.6 Removing and installing cylinder head

♦ Guide bolt -MP1-208 (3070)-
♦ Rig pin for diesel injection pump -3359 - (2x)
♦ Crankshaft arrester -T10050-
♦ Counterholder -T10051 -
1. Cylinder head 73
Fabia II 2007 ➤
♦ Extractor -T10052-
♦ Set of tools 17 mm -T10395-
♦ Tensioning strap -T10038- (2x)
♦ Open ring spanner 17 mm
WARNING

hot components.
1.6.1 Removing
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .
ment ⇒ page 6 .
– Remove left charge air pipe ⇒ page 163 .
– Remove the plenum chamber cover and partition panel ⇒
Body work; Rep. Gr. 66 .
– Detach vacuum line at brake servo unit.
– Screw out screws -arrows- and remove pulsation dampener
-2-.

Fabia II 2007 ➤
– Disconnect plug -1- at oil pressure switch -F1- .

– Detach vacuum line -2- and release screw -arrow- of vacuum
line.
– Disconnect plug -4- at the coolant temperature sender -G62- .
– Remove the coolant hoses from the connection fitting, to do

so slacken the hose clamps -1- and -2-
♦ Left-hand drive: ⇒ page 210 .
Note
Support assembly carrier on right and left with tensioning strap -

T10038- .

– Release screws of coolant return-flow line -arrows- and lay the

coolant return-flow line to the side.
Note
Collect the fuel which flows out with a cleaning cloth.
1. Cylinder head 75
Fabia II 2007 ➤
– Detach fuel hoses -2 and 5-. To do so, push the quick cou‐
plings onto the nozzles, press in the securing elements (hold
pressed) and detach the quick couplings.
– Remove cylinder head cover ⇒ page 69 .
Note
Collect the fuel which flows out with a cleaning cloth.
– Remove high pressure line -2- between fuel distributor and

high pressure pump.
– Unclip the engine pre-wiring from the holder -arrow-.

– Disconnect all the remaining plug connections at the engine.
– Lay the engine pre-wiring to the side.
– Release screw -arrow- for oil dipstick.

Fabia II 2007 ➤
– Remove the connection pipes -A- for exhaust gas recircula‐

tion.
– Collect escaping engine oil with the old oil collecting and suc‐
tion equipment -V.A.G 1782- .
– Slacken union nut -1- with open ring spanner 17 mm -A-.

– Release screws -2, 3, 5 and 6-.
– Remove oil feed line -7-.
– Remove the support for exhaust turbocharger -4- from the oil
return-flow line -8-.
– Disconnect the plug -arrow- from the hall sender -G40- .

– Remove the toothed belt from the camshaft sprocket and from
the toothed belt gear of the high pressure pump
⇒ “2.2 Removing and installing toothed belt”, page 29 .
– Remove camshaft sprocket.
– Counterhold the hub with the counterholder -T10051- and

slacken the fixing screw -1- of the hub.
– Turn bolt attaching the hub out about 2 turns.
1. Cylinder head 77
Fabia II 2007 ➤
– Position the extractor -T10052- and align it with the hub bores.
– Tighten fixing screws -1-.
– Slacken the hub of the toothed belt sprocket from the camshaft
cone by uniformly tightening the screw of the extractor -2-.
Note
Hold the extractor firmly using a wrench SW 30.
– Remove hub from cone of camshaft.
– Unscrew the fixing screw -arrow- of the rear toothed belt

guard.
– Unscrew nut -1- for tensioning pulley.

– Release cylinder head screws.

Fabia II 2007 ➤
– Follow the sequence -1 … 8- for loosening the cylinder head

screws.
Note
♦ The assistance of a second mechanic is required for removing

the cylinder head.
♦ The timing belt tensioning pulley is removed from the pin screw
when lifting out the cylinder head.
– First of all raise the cylinder head on the gearbox side and
thread it out of the rear toothed belt guard. Make sure that the
timing belt tensioning pulley does not fall down.
Caution
Risk of damage to the glow plugs when placing down the cyl‐
inder head.
♦ If the cylinder head is removed with installed glow plugs,
do not place it down on the sealing surface since the glow
plugs protrude slightly beyond the sealing surface.
– Place down the cylinder head in such a way that the oil return
flow line does not bend, if necessary place a wooden wedge
under the exhaust manifold.
1.6.2 Install
Note
♦ There must not be any oil or coolant present in the threaded

holes for the cylinder head bolts.
♦ Always replace the cylinder head bolts.
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the seal with the utmost care. Damage to the silicone
layer and in the surrounding area result in leakages.
– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.
WARNING
Wear protective gloves when working with sealant and grease

remover!
Note
Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder, the oil and cool‐
ant galleries or into the threaded holes.
– Carefully remove old sealant residue from the cylinder head

and cylinder block using a chemical sealant remover.
1. Cylinder head 79
Fabia II 2007 ➤
– Remove the crankshaft arrester -T10050- before placing on

the cylinder head and turn the crankshaft in the opposite di‐
rection of rotation of engine until all the pistons are almost
evenly positioned at the same height.
– Pay attention to the identification of the cylinder head gasket:
♦ -Arrow 1-: part number
♦ -Arrow 2-: bores
♦ -Arrow 3-: ignore
Note
♦ Install new cylinder head gasket with the same identification

-arrow 2-.
♦ If parts of the crankshaft drive were replaced, then the new
cylinder head gasket must be redefined by measuring the pro‐
trusion of the piston in TDC ⇒ page 66 .
– Position the cylinder head gasket with the marking to the top.
– For centering, screw in guide bolts -MP1-208 (3070)- into the

outer holes on the suction side.
Note
♦ The assistance of a 2nd mechanic is required for fitting on the

cylinder head.
♦ Guide the cylinder head into the toothed belt guard.
♦ By doing so, the cylinder head must not grind down the dowel
sleeves -A-.
♦ The tensioning roller must be fitted onto the pin screw when
placing on the cylinder head.
– Insert the cylinder head.

– Insert the 6 cylinder head bolts and tighten by hand.
– Remove the guide bolts by screwing out with a bolt tightener
from MP1-208 through the screw holes and screw in the 2 re‐
maining cylinder head screws.

Fabia II 2007 ➤
– Tighten the cylinder head in four stages in the indicated tight‐

ening sequence:
Stage Tightening torque
I – Pre-tighten with the torque wrench to 30 Nm.
II – Pre-tighten with the torque wrench to 50 Nm.
III – Using a rigid wrench torque a further 90° (1/4
turn).
IV – Using a rigid wrench torque a further 90° (1/4
turn).
– Attach rear toothed belt guard at cylinder head.
– Install the hub and the camshaft sprocket.
– Lock the camshaft and the high pressure pump with the rig
pins for diesel injection pump -3359- .
– Rotate the crankshaft on TDC in direction of rotation of the

engine, interlock with the crankshaft arrester -T10050- .
Further installation occurs in reverse order for removal, while
Note

♦ The tightening torques can be found in the corresponding
summaries of components.
– Install cylinder head cover ⇒ page 69 .

– Install the oil feed line and the support for the exhaust turbo‐
charger ⇒ page 153 .
– Install diesel particle filter ⇒ page 210 .
– Install pre-exhaust pipe ⇒ page 224 .
– Check oil level, top up oil if necessary ⇒ Maintenance ; Fabia
II .
ment ⇒ page 6 .
– Fill up the fuel system ⇒ page 179 .
Note
If the cylinder head was replaced, refill the entire system with
coolant.
1. Cylinder head 81
Fabia II 2007 ➤
1.7 Removing and installing the vacuum

pump
WARNING
The vacuum pump must on no account be disassembled, oth‐

erwise the proper operation of the pump vacuum part is no
longer assured. This will result in a failure of the brake booster.
Removing
⇒ page 202 .
– Detach the vacuum line -1- from the vacuum pump -2-.
– Unscrew the fixing screws of the left charge air pipe and af‐
terwards press the left charge air pipe slightly downwards in
order to reach the rear bolted connection of the vacuum pump.
– Unscrew securing bolts -arrows-.

– Remove vacuum pump -2- from cylinder head.
Install
following points:
Note
♦ Ensure that the coupling of the vacuum pump is correctly seat‐

ed in the camshaft.
♦ Replace the gasket of the vacuum pump.
– Install vacuum pumps and tighten fixing screws to 10 Nm.

– Connect the vacuum line of the brake servo unit to the nozzle
-1- of the vacuum pump.
1.8 Testing the compression

– Connect the vehicle diagnosis, measurement and information
system -VAS 505X- and select the function “Self-diagnosable
systems” in the “Targeted fault finding” ⇒ Vehicle diagnosis,
testing and information system VAS 5051.

Fabia II 2007 ➤
2 Valve gear
2.1 Valve gear - Summary of components
Note
♦ Cylinder heads with cracks between the valve seats may continue to be used without any reduction in the
life time provided the cracks are slight and max. 0.5 mm wide.
♦ After installing the camshafts, the engine must not be cranked or started for about 30 minutes. The hydraulic
clearance compensation elements must settle (otherwise the valves would strike the pistons).
♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no
valve touches the piston when the engine is started.
1 - Sealing ring
❑ Do not additionally lubri‐
cate or grease sealing
lip of the gasket ring
❑ before fitting remove oil
residues on the cam‐
shaft studs with a clean
cloth
⇒ page 84
2 - 10 Nm
❑ pay attention to se‐
quence for loosening
and tightening
⇒ “2.3 Removing and in‐
stalling camshafts”,
page 85
3 - Dowel pins, 10 Nm
❑
4 - Bearing frame
❑ seal with silicone seal‐
ant -D 176 501 A1-
5 - Camshaft
❑ for exhaust valves
⇒ page 85
6 - Camshaft
❑ for inlet valves
⇒ page 85
7 - Roller rocker arm
❑ with locking clip
❑ Mark installation position
❑ do not interchange
❑ Check smooth operation of cylindrical-roller bearings
❑ oil contact surfaces
2. Valve gear 83
Fabia II 2007 ➤
8 - Hydraulic balancing element

❑ Mark installation position
❑ oil the contact surfaces before installing
9 - Cylinder head
❑ pay attention to the notes ⇒ page 83
❑ check for distortion ⇒ page 71
❑ after replacing fill entire system with fresh coolant ⇒ page 112
10 - Hall sender -G40-
11 - Valve
❑ do not rework, only grinding in is permissible
❑ mark the fitting position for re-installation
❑ Valve dimensions ⇒ page 95
❑ inspecting valve guides ⇒ page 95
12 - Pin screw, 15 Nm
13 - Valve stem seal
14 - Valve spring
15 - Valve spring retainer
16 - Collets
17 - Screw cap
❑ replace
❑ removing: plunge into the installed bearing frame using a screwdriver and lever out
❑ installing: drive in without sealant using a suitable thrust piece until flush
2.2 Removing and installing gasket ring for

camshaft
♦ Insertion tool -MP1-214 (10-203)-
♦ Gasket ring extractor -T30003 (3240)-
♦ Screw M12 x 1.5 x 75 from the insertion tool -MP1-214
(10-203)-
Removing
– Detach the toothed belt from the camshaft sprocket and from
the toothed belt gear of the high pressure pump ⇒ page 29 .
– Remove camshaft sprocket and hub ⇒ page 85 .

Fabia II 2007 ➤
– Insert thrust piece -3240/1- into the camshaft.

– Turn inner part of gasket ring extractor -3240- 2 turns (approx.
3 mm) out of the outer part and lock with knurled screw.
– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Release knurled screw and turn the inner side against the
camshaft until the gasket ring is pulled out.
Install
Note
The sealing lip of this gasket ring must be neither oiled nor
greased.
– Remove oil residue on the camshaft stud with a clean cloth.
– Fit the guide bushing from -MP1-214 (10-203)- onto the cam‐
shaft as shown in the illustration.
– Carefully slide the gasket ring -1- over the guide bushing onto
the camshaft.
– Press in the gasket ring with the thrust piece of the insertion
tool -MP1-214 (10-203)- and the screw M12 x 1.5 x 75 up to
the stop.
– Install the hub and the camshaft sprocket ⇒ page 85 .
2.3 Removing and installing camshafts

2. Valve gear 85
Fabia II 2007 ➤
♦ Camshaft-insertion tool -T40094-

♦ Support -T40095-
♦ Tensioning tool -T40096/1-
Removing
• Cylinder head fitted.
– Detach the toothed belt from the camshaft sprocket and from
the toothed belt gear of the high pressure pump ⇒ page 29 .
– Screw out the fixing screws -1- of the camshaft sprocket.
– Remove camshaft sprocket from the hub.
– Slacken screw -1- for the hub of the camshaft, to do so coun‐

terhold with counterholder -T10051- .
– Release screw by about 2 turns.
– Position the extractor -T10052- at the hub of the camshaft and

screw the screws -1- into the hub.
– Slacken the hub of the toothed belt sprocket from the camshaft
cone by uniformly tightening the screw of the extractor -2-.
Note
While doing so, hold the extractor firmly using a wrench SW 30.
– Remove hub of toothed belt sprocket from cone of camshaft.

– Remove vacuum pump ⇒ page 82 .

Fabia II 2007 ➤
– Loosen the screws for the bearing frame in the sequence

-20...1-.
– Unscrew screws and carefully separate the bearing frame
from the cylinder head.
– Mark the camshafts for reinstalling and remove.
Install
WARNING

– Remove residual sealant on the bearing frame and cylinder

head using a chemical sealant remover.
– Clean sealing surfaces, they must be free of oil and grease.
– Oil contact surfaces of camshafts.
Caution
The camshafts must only be installed using the camshaft-in‐

sertion tool -T40094- as described below. Otherwise the axial
bearing in the bearing frame can be destroyed and the cylinder
head must be replaced.
Set up the camshaft-insertion tool -T40094- as follows:
– Remove the supports -T40094/3- , -T40094/4- and -T40094/5

- from the base plate. The screws are located at the bottom.
Note
If the components of the camshaft-insertion tool -T40094- are not

yet marked, they must be marked for the subsequent refitting. For
this use e.g. blow counts.
– Tighten the supports -T40094/9- and -T40094/12- (with bear‐

ing bracket -T40094/11- ) to the base plate as shown in the
illustration.
2. Valve gear 87
Fabia II 2007 ➤
– Place the support -T40094/2- on the position -A- and the sup‐
port -T40094/1- on the position -D-.
– Insert the inlet camshaft in the supports -T40094/1- and -
T40094/2- .
• The recess -arrow- for the cylinder head screw must point to
the outside.
– Fit on a feeler gauge of 0.50 mm and slide the support -
T40094/8- into the groove of the inlet camshaft.
– Insert the outlet camshaft in the supports -T40094/9 - and -
T40094/12- and lock with serration of detent bracket -
T40094/11-
• The peg on the detent bracket -T40094/11- must engage in
the groove of the camshaft.
– Position the tensioning tool -T40096/1- on the pinions of the

outlet camshaft in such a way that each clamping arm engages
in a pinion.
• The wider clamping arm must engage in the wider pinion.
– Tension the tensioning tool -T40096/1- with the knurled wheel
until the tooth flanks of both wheels are aligned.
– Slide the outlet camshaft to the inlet camshaft until the serra‐
tions are in mesh.

Fabia II 2007 ➤
– Position the bearing frames onto the camshafts.

• All of the camshaft bearings must rest on the camshafts.
– Position the holder -T40095- , as shown in the figure, and fix
the camshafts in the bearing frame.
– Remove the detent bracket -T40094/11- and push the support
-T40094/8 - out of the groove of the inlet camshaft.
Note
Pay attention to the use by date on sealant.

2 mm).
Caution
Risk of contamination of the camshaft bearings through excess

sealant.
♦ Do not apply thicker sealant beads than indicated.
– Apply sealant onto the clean sealing surface of the cylinder

head as shown in the illustration.
• Thickness of the sealant beads: 2…3 mm
• Pay attention that the oil supply hole for the bearing frame is
not closed through excess sealant.
Note
The bearing frame with camshafts must be installed within 5 mi‐

nutes after applying the silicone sealant.
– Install new screw cap ( ⇒ page 83 , Pos. 17) on cylinder head

until flush.
– Remove the camshafts together with the bearing frame, holder
-T40095- and tensioning tool -T40096/1- from the camshaft-
insertion tool -T40094- and carefully insert into the bearings in
the cylinder head.
2. Valve gear 89
Fabia II 2007 ➤
– Insert the screws of the bearing frame and first tighten in the
sequence -1 … 20- by hand.
• The ladder frame must rest on the cylinder head with its com‐
plete contact surface.
– Tighten the screws of the bearing frame in the sequence
-1…20-.
– Remove bracket -T40095- and tensioning tool -T40096/1- .
– Replacing camshaft gasket ring ⇒ page 84 .
– Install the hub for the camshaft timing gear and tighten the
screw -1- to 100 Nm. To do so, counterhold with counterholder
-T10051- .
– Push camshaft sprocket onto the hub.
Note
While doing so, the arrow on the camshaft sprocket must be close
to the “12 o'clock” position.
– Screw in screws -1- by hand.
– Lock hub with locking pin -3359- .

– Install vacuum pump ⇒ page 82 .
– Install cylinder head cover ⇒ page 69 .
Note
♦ After installing the camshafts, the engine must not be cranked

or started for about 30 minutes. The hydraulic clearance com‐
pensation elements must settle (otherwise the valves would
strike the pistons).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.

Fabia II 2007 ➤
2.4 Measuring the axial play of the cam‐

shafts
♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Dial gauge, e.g. -VAS 6079-
Work procedure
– Remove bearing frame ⇒ page 85 .
– Attach the dial gauge with the universal dial gauge holder -
MP3-447 (VW 387)- to the bearing frame as shown in the
illustration.
– Press the camshaft by hand against the dial gauge.
– Position dial gauge to “0”.
– Press the camshaft off the dial gauge and read the value.
Axial play of inlet and outlet camshaft:
• Wear limit 0.17 mm
2.5 Checking hydraulic balancing elements
Note
♦ The hydraulic balancing elements cannot be repaired.

♦ Irregular valve noises when starting engine are normal.
♦ If the irregular valve noises disappear but occur regularly dur‐
ing short journeys, then the oil pressure must be checked
⇒ page 108 .
♦ The valve for oil pressure control is integrated in the oil pump.

♦ Feeler gauges
Work procedure
– Start engine and allow to run until the radiator fan starts.
– Increase speed to about 2500 rpm for 2 minutes and under‐
take a test drive if necessary.
If the valve noises occur irregularly, determine the defective hy‐
draulic balancing element as follows:
– Turn the crankshaft until the cam of the hydraulic balancing
element to be tested is positioned on top.
2. Valve gear 91
Fabia II 2007 ➤
– Press down the hydraulic balancing element using a wooden

or plastic wedge.
– Determine the play between the cam and the roller of the valve
lever.
If a 0.20 mm feeler gauge can be slipped between the cam and
the roller of the valve lever, the hydraulic balancing element is
defective:
– Replace the hydraulic balancing element. To do so, remove
camshafts ⇒ page 85 .
Note
♦ After installing the camshafts, the engine must not be started

for about 30 minutes. The hydraulic clearance compensation
elements must settle (otherwise valves would strike the pis‐
tons).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.
2.6 Replacing valve stem seals

♦ Valve stem seal extractor -MP1-230 (3364)-
♦ Valve stem seal insertion tool -MP1-233 (3365)-
♦ Disassembly and assembly device for valve collets -VAS
5161- with knurled spacer ring -VAS 5161/23-1- and guide
plate -VAS 5161/23-
♦ Screw M6 x 30 (2 pieces)
Work procedure
– Remove all glow plugs ⇒ page 232 .
– Remove the camshafts ⇒ page 85 .
– When installing again, mark the assignment of the roller rocker
arms and the hydraulic clearance compensation elements.
– Remove the roller rocker arms together with the hydraulic bal‐
ancing elements and lay aside on a clean surface.
– Put the piston of the relevant cylinder at “bottom dead centre”.
– Position the guide plate -VAS 5161/23 - onto the cylinder head.
– Screw the guide plate at the side of the intake manifold with
the knurled screw -VAS 5161/12- to the cylinder head and with
2 screws M6 x 30 -1- by hand until it fits on tightly.

Fabia II 2007 ➤
– Screw the sealing bolt -VAS 5161/10- into the guide plate.
– Screw adapter -VAS 5161/11 - into the threaded hole of the
glow plug by hand.
– Insert the impact drift -VAS 5161/3 - into the guide plate and
slacken the tightly fitted valve collets using a plastic hammer.
– Screw the detent part -VAS 5161/6- and the interlocking fork
-VAS 5161/5- into the guide plate.
– Slide the knurled spacer ring -VAS 5161/23-1- onto the as‐
sembly cartridge -VAS 5161/8- .
– Connect the adapter -VAS 5161/11 - to the compressed air
with a commercially available intermediate piece and apply
constant pressure.
• Minimum pressure: 0.6 MPa (6 bar)
– Hook the pressure fork -VAS 5161/2 - onto the detent part and
push the assembly cartridge downwards.
– Turn simultaneously the knurled screw of the assembly car‐
tridge to the right, until the tips click into the valve collets.
– Rotate the knurled screw to the left and to the right, by doing
so the valve collets are pressed apart and are installed in the
assembly cartridge.
– Release the pressure fork.
– Remove the assembly cartridge with the knurled spacer ring.
– Remove the valve spring with the valve spring retainer.
2. Valve gear 93
Fabia II 2007 ➤
– Pull off valve stem seal with extractor for valve stem seal
-3364- .
– Fit the plastic protective sleeve -A-, which is attached to the

new valve stem seals -B-, onto the valve stem.
– Lightly oil the sealing lip of the new valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool -3365 - onto the valve guide.
– Remove plastic sleeve.
If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device -
VAS 5161/18- .
• The large diameter of the valve collets points to the top.
– Insert the valve spring and the valve spring retainer.
– Press the assembly cartridge -VAS 5161/8- from the top onto
the insertion device for valve collets -VAS 5161/18- and lift up
the valve collets.

Fabia II 2007 ➤
– Re-insert the assembly cartridge into the guide plate -

VAS 5161/23- .
– Press down the pressure fork and turn the knurled screw to
the left while pulling it upwards – by doing so the valve collets
are inserted.
– Release the pressure fork on tightened knurled screw.
– Repeat the procedure for each valve.
Assembling together
following points:
Note
Ensure that all the roller arms are correctly positioned on the valve
stem ends and are clipped in place on the relevant hydraulic bal‐
ancing elements.
– Install camshafts ⇒ page 85 .

– Install glow plugs ⇒ page 232 .
2.7 Valve dimensions
Note
Valves must not be reworked. Only grinding in is permissible.
Dimension Inlet valve Exhaust valve

∅a mm 26,50 … 26,70 24,4 … 24,60
∅b mm 5,968 … 5,982 5,958 … 5,972
c mm 99,30 99,10
α ∠° 45 45
2.8 Inspect valve guides

♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Dial gauge, e.g. -VAS 6079-
2. Valve gear 95
Fabia II 2007 ➤
Test sequence
Note
♦ If the valves are replaced when carrying out repair work, use
new valves for the measurement.
♦ Because of the different stem diameters only use inlet valve
in inlet guide or outlet valve in outlet guide.
– Insert valve into valve guide. The end of valve stem must be
flush with guide.
• Valve rock: max. 1.3 mm
Note
If the wear limit is exceeded, repeat measurement with new

valves. If the wear limit is again exceeded, replace cylinder head.
The valve guides cannot be replaced.

Fabia II 2007 ➤
17 – Lubrication
1 Removing and installing parts of the
lubrication system
Note
♦ The oil level must not be above the max. marking - risk of
damage to catalytic converter!
♦ If considerable quantities of metal swarf as well as abrasion is
found in the engine oil when carrying out engine repairs, care‐
fully clean the oil galleries in order to avoid consequential
damage and additionally replace the engine oil cooler as well
as the oil filter element.
Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Fabia II .
1.1 Parts of the lubrication system - Summary of components
1 - Cylinder block
2 - Gasket
❑ replace
❑ must not be oiled
❑ insert in the grooves at
the oil filter holder
3 - Oil filter holder with engine
oil cooler
❑ Summary of compo‐
nents ⇒ page 98
(1/4 turn)
❑ replace
5 - Dipstick
❑ with guide pipe
❑ oil level must not exceed
max. marking
6 - 9 Nm
7 - Noise insulation
8 - 9 Nm
9 - 8 Nm
10 - Left charge air pipe
11 - Oil pan
⇒ page 99
12 - Bracket for coolant pipe
13 - 10 Nm
❑
1. Removing and installing parts of the lubrication system 97

Fabia II 2007 ➤
14 - Oil level and oil temperature sender -G266 -

❑ check ⇒ Vehicle diagnosis, testing and information system VAS 5051
15 - O-ring
❑ replace
16 - 15 Nm
17 - Oil drain plug, 30 Nm
❑ with captive seal
❑ replace
18 - 5 Nm
19 - Cover
❑ for balancing shaft module
❑ clean if soiled
20 - Balancing shaft module
❑ with oil pump
❑ must be replaced completely
21 - 15 Nm
22 - Sealing flange
❑ on belt pulley side
❑ replace
❑ must be positioned on dowel sleeves
1.2 Oil filter holder and engine oil cooler - Summary of components
Caution
The gaskets ⇒ Item 8 (page 99) and ⇒ Item 11 (page 99)

are made out of various materials depending on the medium
to be sealed (coolant or oil).
• They must not be oiled. The sealing area for coolant would
otherwise swell up.
98 Rep. Gr.17 - Lubrication

Fabia II 2007 ➤
Oil pressure switch -F1- ⇒ page 71 , Pos. 17.
1 - Screw cap, 25 Nm
❑ with oil filter recircula‐
tion valve
❑ slacken and tighten with
oil filter wrench -3417-
2 - O-ring
❑ replace
3 - O-ring
❑ replace
4 - O-ring
❑ replace
5 - Oil filter element
❑ remove from the cap
⇒ Item 1 (page 99)
❑ replace O-rings
⇒ Item 2 (page 99) ,
⇒ Item 3 (page 99) ,
⇒ Item 4 (page 99) if oil
filter element is changed
❑ Keep to change inter‐
vals ⇒ Maintenance ;
Fabia II
6 - Engine oil cooler
❑ connection diagram for
coolant hoses
⇒ page 112
⇒ page 106
7 - 11 Nm
8 - Gasket
❑ replace
❑ do not oil
❑ insert in the grooves at the oil filter holder
❑ replace
10 - Oil filter holder
❑ with integrated return-flow check tube
11 - Gasket
❑ replace
❑ do not oil
❑ insert in the grooves at the oil filter holder
1.3 Removing and installing oil pan


Fabia II 2007 ➤

Removing
Gr. 50 .
66 .
– Disconnect plug -arrow- at oil level and oil temperature sender
-G266- .
– Remove noise insulation -2- for oil pan.

To do this:
♦ Unscrew bolts -1-.
♦ Remove 2-part clips -arrows-.
♦ Remove the attachment of the cable on the noise insulation.

Fabia II 2007 ➤
– Screw out screws -arrows- for oil dipstick guide pipe.

– Pull out the oil dipstick guide pipe upwards.
– Screw out screws -arrows- of oil pan/gearbox.

– Release the screws -1 … 16- of the oil pan with the socket
insert -T10058- crosswise.
– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.
Install
• The sealing flange on the belt pulley side was not replaced.
Install oil pan, if the sealing flange on the belt pulley side was
replaced ⇒ page 50 .
Caution
The sealing flange on the belt pulley side is made of plastic and
has an integrated silicone seal. In order to reliably seal the oil
pan on the sealing flange, from which the silicone seal was
removed, the following work procedure must absolutely be
kept.
WARNING

– Remove residual sealant from the sealing surfaces on the cyl‐

inder block and on the oil pan with chemical sealant remover.

Fabia II 2007 ➤
– Remove residual sealant and silicone seal -arrows- at the old

sealing flange on the belt pulley side with chemical sealant
remover.
Note
Pay attention to the use by date of the silicone sealant -D 176 501
A1- .

3 mm).
– Apply the silicone sealant -D 176 501 A1- to the clean sealing
surface of the oil pan, as shown.
• The sealant must be run past on the inside in the area of the
bolt holes -arrows-.
Caution
Risk of blockage of the lubrication system through excess seal‐

ant.
♦ Do not apply a thicker sealant bead than indicated.
Note
The bottom surface of the sealing flange on the belt pulley side
has a displacement of approx. 1 mm to the bottom cylinder block
surface after removing the old silicone seal, which must be com‐
pensated for by applying the required sealant on the correspond‐
ing area of the oil pan sealing surface.

Fabia II 2007 ➤
Thickness of sealant beads on the oil pan:

♦ In the area of the sealing surfaces of the cylinder block and
the sealing flange on the gearbox side -between arrows 1-:
2 … 3 mm
♦ In the area of the sealing surface of the sealing flange on the
belt pulley side -between arrows 2-: 3 … 4 mm
• The old silicone seal, which is no longer present, must be re‐
placed in the area of the sealing flange on the belt pulley side
with the sealant bead equal to the height and width of the sil‐
icone seal.
Note
After applying the sealant, install the oil pan within 5 minutes.
– Position oil pan.
Note
♦ The oil pan must be flush to the gearbox flange at the inter‐
mediate plate.
♦ When installing the oil pan with the engine removed, ensure
that the oil pan is flush with the cylinder block at the flywheel
side.
– Tighten the screws of the oil pan in 3 stages as follows.

Stage Screws Tightening torque
21 -Arrows- 40 Nm
1) When installing the oil pan on a removed engine, this work step
is not carried out. Make sure however that the pan is flush with
the cylinder block on the flywheel side.
Note
After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
– Fill with engine oil and check the oil level ⇒ Maintenance ;
Fabia II .
1.4 Removing and installing the oil filter

holder with the engine oil cooler
♦ Removal tool for the inner lining of the door panel -MP8-602/1
-
♦ Old oil collecting and suction equipment , e.g. -V.A.G 1782 -

Fabia II 2007 ➤

Removing
– Remove 4/2 way valve with coolant regulator ⇒ page 120 .
– Remove oil filter insert -3-.
– Release screws -arrows- from the connection for the oil dip‐
stick guide pipe.
– Pull out the oil dipstick guide pipe upwards.

Fabia II 2007 ➤
– Remove coolant hose, to do so detach hose clamp -arrow-.

– Place an old oil collecting and suction equipment -V.A.G 1782-
under the engine.
– Screw out screws -arrows- and remove oil filter holder with
engine oil cooler.
Install
following points:
Note
♦ Replace gaskets, gasket rings and O-rings.

♦ Replace screws which have been tightened firmly to a torquing
angle.
♦ Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
– Insert the new gasket in the grooves at the oil filter holder.
– Insert new screws -arrows- of oil filter holder.

– Tighten the screws crosswise in 2 stages as follows:
First the screw at the top left, then the screw at the bottom right
and subsequently tighten the screws crosswise.
Stage Tightening torque/torquing angle
1 14 Nm
2 90° (torque a further 90° (1/4 turn)
– Install oil filter insert, fill with engine oil and check the oil level
⇒ Maintenance ; Fabia II .
Note
If the engine oil cooler was replaced, refill the entire system with
coolant.

Fabia II 2007 ➤
1.5 Removing and installing engine oil cool‐

er
Removing
– Remove connecting hose from right charge air pipe to throttle
valve control unit.
– Remove oil filter insert -3-.
– Remove coolant hose, to do so detach hose clamp -arrow-.

– Place an old oil collecting and suction equipment -V.A.G 1782-
under the engine.

Fabia II 2007 ➤
– Release screws -arrows-.

– Remove engine oil cooler from oil filter holder.
Install
following points:
– Insert the new gasket -1- in the grooves at the oil filter holder.
– Carefully position the engine oil cooler on the centering pins.
– Press the engine oil cooler onto the flange of the oil filter holder
in such a way that it lies flat and the ends of the centering pins
-1- protrude out of the guide bores.
– Insert the screws -arrows-, first fully screw in by hand, then

gradually tighten crosswise in 2 stages, as described in the
following:
Stage Tightening torque
1 5 Nm
2 11 Nm
– Install oil filter insert, fill with engine oil and check the oil level
⇒ Maintenance ; Fabia II .
Note
If the engine oil cooler was replaced, refill the entire system with
coolant.

Fabia II 2007 ➤
1.6 Testing oil pressure and oil pressure

switch
♦ Oil pressure tester , e.g. - V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527 B -
♦ Measuring tool set , e.g. -V.A.G 1594 C -
Test conditions
• Oil level o.k.
• Coolant temperature approx. 80°C
Test preparations
– Remove oil pressure switch -F1- ⇒ page 109 .

Fabia II 2007 ➤
– Screw the connection of the oil pressure tester -V.A.G 1342-

into the hole for the oil pressure switch.
– Screw the oil pressure switch -2- into the oil pressure tester.
Testing oil pressure switch
– Connect brown cable -1- of oil pressure tester to earth (-).
– Unclamp the voltage tester with its auxiliary cables out of the
measuring tool set on the oil pressure switch and plus (+) ter‐
minal on the battery.
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch.
If the LED does not light up:
– Start engine.
Note
Observe the testing equipment and the LED while actuating the
starter since the switching point of the oil pressure switch can
already be exceeded when starting up.
• At a pressure of 0.03...0.06 MPa (0.3...0.6 bar) the LED should

light up.
If the LED does not light up:
– Replace oil pressure switch.
Testing oil pressure
– Start engine.
• Oil pressure when engine idling: at least 0,08 MPa (0,8 bar).
• Oil pressure at 2000 rpm: min. 0.15 MPa (1.5 bar).
If the specified values are not reached: Oil pump defective.
– Replace balancing shaft module with oil pump.
• Oil pressure at a higher engine speed: max. 0,5 MPa (5,0 bar).
If the specified value is exceeded, the pressure control valve is
defective.
– Replace balancing shaft module with oil pump.
Note
♦ After testing the oil pressure switch -F1 - or checking the oil
pressure, remove the oil pressure tester -V.A.G 1342- and re‐
install the oil pressure switch -F1- with a new gasket ring.
♦ The tightening torque of the oil pressure switch -F1- is 22 Nm.
1.7 Removing and installing oil pressure

switch -F1-
Removing

Fabia II 2007 ➤
– Remove the hose for the crankcase ventilation -3-, to do so

press together the release buttons.
– Detach vacuum hose -2- with bracket from suction hose -1-'.
– Detach suction hose -1- from air mass meter -G70- .
– Unscrew screw -4- (captive), swivel suction hose -1- with con‐
nection fitting towards the rear and detach from exhaust gas
turbocharger.
– Unscrew screws -2- and -3- and remove engine lifting eye
-1-.
– Disconnect plug -arrow-.
– Screw out oil pressure switch -F1- .
Install
following points:
Note
Replace gasket ring.
– Tighten oil pressure switch -F1- to 20 Nm.

– Install suction hose ⇒ page 202 .

Fabia II 2007 ➤
19 – Cooling
1 Cooling system
WARNING
Hot steam or hot coolant may escape when the compensation

bottle is opened. Cover the cap with a cloth and open carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ Secure all hose connections with spring strap clamps.
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ The arrows affixed to the coolant pipes and the coolant hoses
must stand opposite to each other.
1. Cooling system 111

Fabia II 2007 ➤
1.1 Connection diagram for coolant hoses
1 - Expansion reservoir
❑ with cap
❑ Testing the pressure re‐
lief valve in the cap
⇒ page 115
2 - Coolant recirculation pump
2 -V178-
3 - Radiator for exhaust gas re‐
circulation
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 112
⇒ page 230
4 - Heat exchanger of heating
system
❑ with quick couplings
ant ⇒ page 112
5 - Cylinder head and cylinder
block
ant ⇒ page 112
6 - Engine oil cooler
ant ⇒ page 112
⇒ page 106
7 - Top coolant hose
❑ to ATF radiator
8 - Radiator
9 - Bottom coolant hose
❑ to ATF radiator
11 - Coolant pump
1.2 Draining and filling up coolant

112 Rep. Gr.19 - Cooling

Fabia II 2007 ➤
♦ antifreeze tester
Draining
Note
Collect drained coolant in a clean container for proper disposal or

reuse.
WARNING
Hot steam may escape when the compensation bottle is

opened.
eye injuries and scalding.
♦ Cover the cap with a cloth and open carefully.
– Open the cap of the coolant expansion reservoir.

Gr. 50 .
– Remove the left charge air hose, to do so slacken the screw
clamps -arrows-.
Caution
Shut off the opening of the charge air cooler, e.g. with a clean
foam piece, so that no coolant can penetrate.
– Place a catch pan under the engine.
– Detach coolant hoses -arrows-.

Fabia II 2007 ➤
– Detach the bottom coolant hose from the radiator.

Filling up
– Re-connect all the coolant hoses and the left charge air hose.
Select the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts or from the list of allowed coolant ad‐
ditives ⇒ Maintenance ; Fabia II .
– In a clean reservoir mix drinking water and coolant additive in
the correct mixing ratio ⇒ Maintenance ; Fabia II .
– Top up coolant in the expansion reservoir, until the max. mark‐

ing of the coolant level is reached.
– Switch off the heating, and if present, the air conditioning sys‐
tem.
– Start engine, run for not more than 3 minutes at approx. 2000
rpm and while doing so continuously top up coolant in the ex‐
pansion reservoir.
– Tighten cap at expansion reservoir.
– Run engine until radiator fan starts.
WARNING
Hot steam may escape when the compensation bottle is

opened.
– Check the level of coolant when the expansion reservoir is

closed and top up if necessary when the engine is cooled
down.
• When the engine is at operating temperature the coolant level
must be at the -max- marking, while the level must lie in the
middle of the criss-crossed field if the engine is cold (between
the -min- and -max- markings).
1.3 Checking the coolant system for leak‐

tightness
1.3.1 Checking with the cooling system test‐

ing device -V.A.G 1274-
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter , e.g. -V.A.G 1274/8 -
♦ Adapter , e.g. -V.A.G 1274/9 -
Test condition
• The engine is at operating temperature.

Fabia II 2007 ➤
Test sequence
WARNING

bottle is opened.
– Open compensation bottle.

– Position the cooling system testing device -V.A.G 1274- with
adapter -V.A.G 1274/8- on the coolant expansion reservoir.
– Generate a pressure of approx. 0.1 MPar (1.0 bar) for testing
the cooling system.
If the pressure drops:
– Determine position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Position the cooling system testing device -V.A.G 1274- with

adapter -V.A.G 1274/9- on the cap.
– Generate a pressure for testing the pressure valve in the screw
cap.
• The pressure valve should open at a pressure of 0.14...0.16
MPa (1.4...1.6 bar).
If the valve does not open in the prescribed pressure range:
– Replace cap.
1.3.2 Checking with the cooling system test‐

ing device -V.A.G 1274 B-
♦ Cooling system testing device , e.g. -V.A.G 1274 B-
♦ Adapter , e.g. -V.A.G 1274/8-
♦ Adapter , e.g. -V.A.G 1274/9-
Test condition
• The engine is at operating temperature.

Fabia II 2007 ➤
Test sequence
WARNING

bottle is opened.
– Open compensation bottle.

– Screw the adapter -V.A.G 1274/8- into the coolant expansion
reservoir.
– Connect the connecting piece -V.A.G 1274 B/1- to the adapter
-V.A.G 1274/8- .
– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Using the hand pump of the testing device generate a pressure
of approx. 0.1 MPa (1.0 bar).
WARNING
Risk of scalding!
♦ Before the cooling system testing device -V.A.G 1274 B-
is separated from the connecting hose or the connecting
piece -V.A.G 1274 B/1- , the existing pressure must ab‐
solutely be released.
♦ For this step, press the pressure relief valve on the cooling
system testing device -V.A.G 1274 B- and hold it pressed
until the pressure gauge indicates the value “0”.
If the pressure drops:

– Search position of the leak and repair fault.
Test the pressure valve in the cap
– Screw the screw cap into the adapter -V.A.G 1274/9- .
– Connect the connecting piece -V.A.G 1274 B/1- to the adapter
-V.A.G 1274/9- .
– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Generate a pressure for testing the pressure valve in the screw
cap.
• The pressure valve should open at a pressure of 0.14...0.16
MPa (1.4...1.6 bar).
If the valve does not open in the prescribed pressure range:
– Replace cap.

Fabia II 2007 ➤
2 Coolant lines, coolant temperature

sender, coolant pumps and coolant
regulator
2.1 Coolant pipes, coolant temperature sender and coolant recirculation pump
2 - Summary of components
1 - Coolant hose
❑ from the expansion res‐
ervoir
2 - Coolant hose
❑ to the expansion reser‐
voir
3 - 8 Nm
4 - Coolant return-flow line
5 - Coolant return hose
6 - Bypass line
❑ to 4/2 way valve
7 - Coolant hose
❑ from heat exchanger of
heating system
8 - Coolant hose
❑ to heat exchanger of
heating system
9 - 15 Nm
❑
10 - 9 Nm
11 - Coolant temperature
sender -G62-
12 - O-ring
❑ replace
13 - Retaining clip
❑ check tightness
14 - Coolant connection fitting
❑ at cylinder head
15 - O-ring
❑ replace
16 - Connecting hose
❑ to coolant recirculation pump 2
2. Coolant lines, coolant temperature sender, coolant pumps and coolant regulator 117
Fabia II 2007 ➤
17 - Coolant recirculation pump 2 -V178-

18 - 8 Nm
19 - Spacer
20 - 8 Nm
21 - Washer
❑ to radiator for exhaust gas recirculation
23 - Radiator for exhaust gas recirculation
24 - Coolant pipe
❑ with bracket for coolant recirculation pump 2 -V178-
26 - Coolant temperature sender at radiator outlet -G83-
27 - 8 Nm
❑ to coolant pipe to radiator for exhaust gas recirculation
29 - Coolant hose
❑ Feed line and return line to coolant radiator
30 - 15 Nm
32 - O-ring
❑ replace

Fabia II 2007 ➤
2.2 Coolant pump and 4/2 way valve with coolant regulator - Summary of com‐
ponents
1 - 15 Nm
2 - Coolant pump
⇒ page 119
3 - O-ring
❑ replace
4 - O-ring
❑ replace
5 - 4/2 way valve with coolant
regulator
❑ check ⇒ Vehicle diagno‐
sis, testing and informa‐
tion system VAS 5051
♦ -A-: Return line from heat
exchanger of heating sys‐
tem
♦ -B-: Bypass line to cooler
feed line
♦ -C-: Return line from ex‐
pansion reservoir
♦ -D-: Cooler return-flow line
6 - 15 Nm
2.3 Removing and installing coolant pump

Removing
Fabia II 2007 ➤
– Release screws -1- and remove coolant pump -2-.

– Remove O-ring -3-.
Install
following points:
Note
Replace O-ring.
– Clean sealing surface for O-ring, if necessary smoothen.
– Moisten the new O-ring -3- with coolant.

– Attach the coolant pump -2-.
• Fitting position: Plug in housing points down.
– Tighten screws -1- of coolant pump to 15 Nm.
2.4 Removing and installing 4/2 way valve

with coolant regulator
♦ Flexible-head wrench SW 10 -3185-
♦ Refractometer -T10007- or -T10007A -
Removing
– Remove left charge air pipe ⇒ page 163 .
Note
Utmost care should be taken to guide the generator past the ra‐
diator, in order not to damage it.

Fabia II 2007 ➤
– Remove alternator ⇒ Electrical System; Rep. Gr. 27 .
– Release screws of coolant return-flow line -arrows-.
– Disconnect the plug -5- from the throttle valve control unit -
J338 - .
– Remove throttle valve control unit -J338- -arrows-.
Fabia II 2007 ➤
– Disconnect plugs -1- from hall sender -G40 - .

– Disconnect plug -2- from knock sensor -G61- .
– Unscrew bracket -arrow- of hall sender -G40- .
– Detach coolant hose -arrow-.
– Detach coolant hoses -B-, -C- and -D-.

Fabia II 2007 ➤
– Slacken the screws -3- of the 4/2 way valve -2- with the flexi‐
ble-head wrench SW 10 -3185- and unscrew them with the
socket insert -T10058- .
– Turn 4/2 way valve -2- with O-ring -1- 90° to the left and re‐
move from the connection fitting.
Install
– Clean sealing surface for O-ring, if necessary smoothen.
– Moisten the new O-ring -1- with coolant.
– Insert the hose -A- behind the oil filter holder.

Apply only slight force when carrying out the next 2 working steps.
Make sure that no damage occurs.
– Insert 4/2 way valve in -direction of arrow- between bracket for

auxiliary units and oil filter holder.
– Insert the connection fitting -2- of the 4/2 way valve with O-ring
-1- in the cylinder block with slight rotary movements.
– Screw in fixing screws -3- with flexible-head wrench SW 10
-3185- and tighten to 15 Nm.
– Install throttle valve control unit -J338- and tighten the screws
to 10 Nm.
Fabia II 2007 ➤
3 Radiator and radiator fan
3.1 Radiator with radiator fan - Summary of components
1 - Clamp
2 - Top coolant hose
❑ connection diagram for
coolant hoses
⇒ page 112
3 - Expansion reservoir
❑ Check the cooling sys‐
tem for tightness
⇒ page 114
4 - Screw cap
❑ Check pressure relief
valve ⇒ page 114
5 - 2 Nm
6 - Connector
7 - Coolant hose
8 - Radiator bearing
9 - 8 Nm
10 - Clamp
11 - Radiator
⇒ page 127
ant ⇒ page 112
12 - Fan shroud with radiator
fan -V7-
❑ Summary of compo‐
nents ⇒ page 125
⇒ page 126
13 - Bottom coolant hose
14 - Charge air cooler
❑ can only be removed and installed together with the radiator ⇒ page 127
15 - Bottom bearing
16 - Clamp
17 - Connector
❑ for radiator fan -V7-
18 - Thermo-switch for radiator fan -F18- , 35 Nm
❑ switching temperatures:
• 1. Stage on: 92 ... 97 °C; off: 84 ... 91 °C
• 2. Stage on: 99 ... 105 °C; off: 91 ... 98 °C
19 - Sealing ring
❑ replace

Fabia II 2007 ➤
20 - Condenser
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. Gr. 87
3.2 Fan shroud with radiator fan -V7- - Summary of components
1 - 8 Nm
❑ replace
2 - Supporting sleeve
3 - Fan shroud
4 - Radiator fan -V7-
5 - The fan ring
❑ attached to the fan
shroud by means of in‐
tegrated expanding riv‐
ets -arrow-
3. Radiator and radiator fan 125

Fabia II 2007 ➤
3.3 Removing and installing fan shroud with

radiator fan -V7-
Removing
– Screw out screws -arrows- for connection fitting -1-. Remove
connecting hose -2- to air filter.
Gr. 50 .
– Remove right charge air hose and left charge air hose
⇒ page 160 .
– Disconnect plug for radiator fan -V7- ⇒ Item 17 (page 124) .
– Release the fan shroud with the radiator fan -V7- on the right
and left catch hooks using a suitable tool.
– Push the fan shroud with the radiator fan -V7- upwards out of
the supports and remove downwards.
Remove the radiator fan from the fan shroud
– Disconnect the plug connection for the radiator fan -V7- from
the holder.
– Push the pins back out of the expanding rivets -arrows-

⇒ page 125 .
– Carefully slacken the fan ring on the reverse side of the shroud
using a suitable tool.
– Remove fan ring.

Fabia II 2007 ➤
– Unscrew the nuts -arrows- and remove the radiator fan -V7-
from the shroud.
Install
following points:
♦ Tightening torque of nuts for radiator fan -V7- ⇒ page 125 .
– Insert the fan shroud with radiator fan -V7- from below and
slide into all 4 supports on the radiator from above.
• The fan shroud must click audibly into place in the supports
on the top right and left.
– Check that the fan shroud with the radiator fan -V7- catches
correctly in the installation position.
3.4 Removing and installing radiator

♦ Broad cross-head screwdriver
Removing
– Remove front bumper ⇒ Body Work; Rep. Gr. 63 .
– Disconnect plug from thermo-switch for radiator fan -F18- .
– Detach top coolant hose from connection fitting of radiator.
– Press off filler neck for windscreen washer system from brack‐
et.
– Remove bracket for windscreen washer system.
To do so, press in the catch in -direction of arrow 1- and at the
same time push the bracket upwards in
-direction of arrow 2-.

Fabia II 2007 ➤
– Release the screw -2- for the radiator bearing on the right and
left.
– Push the radiator to the rear and remove the right and left ra‐
diator bearing ⇒ Item 8 (page 124) .
Vehicles without air conditioning
– Push the radiator together with the charge air cooler upwards
out of the lower rubber bearings and remove it laterally down.
WARNING

be opened.
Caution

ses.

body.
– Mark the installation position of the screws -1- on the right and
left and only slacken them.
– Push the radiator together with the charge air cooler and the
condensor upwards out of the lower rubber bearings.
To do so, pull the plastic housing of the lock carrier down‐
wards. There is little space on the right between the refrigerant
line and the body.
– Lay the radiator with the condensor to the rear.
– Release the screws -arrows- of the condensor -2- from the

radiator -1-.
– Draw the condensor forwards and attach to the lock carrier.
– Remove the radiator together with the charge air cooler later‐
ally down.
Separate the charge air cooler from the radiator.
Caution
To prevent damage to the charge air cooler, the separation of

the charge air cooler from the radiator must be carried out by
2 mechanics.

Fabia II 2007 ➤
– Slide a broad cross-head screwdriver into the left catch from

the front and the rear. Carefully open the catch of the charge
air cooler -1- at the radiator by turning the screwdriver.
– Pull the left charge air cooler slightly down in this position.
– Push the charge air cooler -1- to the right out of the catch of
the radiator -2-.
Install
following points:
– On vehicles with air conditioning system, push the plastic

housing of the lock carrier upwards into the initial position and
tighten the screws -1- on the right and left.

Fabia II 2007 ➤
20 – Fuel Supply
fuel supply system
Note
♦ Fuel lines are secured with quick-release couplings.

♦ Fuel hoses must only be secured with spring-type clips ⇒
electronic catalogue of original parts .
♦ Use pliers for spring strap clips to fit the spring strap clips.
Observe safety measures ⇒ page 3 .

Observe rules for cleanliness ⇒ page 4 .
ment ⇒ page 6 .
1.1 Behaviour in case of misfuelling
Caution
Fueling with incorrect fuel can result in irreversible damage to

the high pressure components, in particular to the fuel high
pressure pump, because of inadequate fuel lubricity and the
dirt contained in the fuel.
♦ The initial damage is caused by the rubbing of the moving
parts, which results in the formation of a large quantity of
fine metal swarf.
♦ Thus, free metal particles contaminate the injection sys‐
tem and quickly damage other parts, especially the fuel
pressure regulating valve and the injection units.
Here are 2 examples which show the consequences of misfuel‐

ing.
Example 1
Misfueling was noticed BEFORE starting the engine, the engine
was NOT started.
Example 2
Misfueling was noticed AFTER starting the engine. Contaminated
or incorrect fuel was drawn in and is present in the high pressure
components.
Note
Collect the incorrect fuel which was drained from the fuel tank and
the diesel fuel which was used for cleaning the fuel tank and dis‐
pose.
130 Rep. Gr.20 - Fuel Supply

Fabia II 2007 ➤
Behaviour in case of example 1
Caution
Do not switch on the ignition.

The engine must not be started.
– Completely empty the fuel tank ⇒ page 134 .

– Fill the fuel tank with 5 ltr. of diesel fuel and empty it again.
– Completely fill up the fuel tank with diesel fuel.
– Perform a test drive.
Behaviour in case of example 2
– Completely empty the fuel tank ⇒ page 134 .
– Remove fuel delivery unit ⇒ page 138 .
– Check the fuel tank for dirt and fine metal swarf, if necessary
clean with great care.
– Install fuel delivery unit ⇒ page 138 .
– Fill the fuel tank with 5 ltr. of diesel fuel and empty it again.
– Replace fuel filter in engine compartment ⇒ page 141 .
– Replace the following high pressure components:
♦ High pressure pump ⇒ page 194
♦ High pressure lines ⇒ page 185
♦ Fuel distributor ⇒ page 191
♦ Fuel pressure regulating valve -N276 - ⇒ page 183
♦ Fuel pressure sender -G247- ⇒ page 193
♦ Injection units ⇒ page 187
♦ Fuel return-flow lines
⇒ “2.2 Fuel system - Summary of components”, page 174
– Completely fill up the fuel tank with diesel fuel.
– Filling and bleeding the high pressure pump and the fuel sys‐
tem ⇒ page 179 .
1. Removing and installing parts of the fuel supply system 131

Fabia II 2007 ➤
1.2 Fuel tank with component parts - Summary of components
1 - Screw cap
2 - 2 Nm
3 - Fuel tank lid unit
❑ with rubber bowl
⇒ Body Work; Rep. Gr.
55
4 - Earth connection
5 - Gravity valve
❑ to remove, unclip valve
at top and lift out of filler
neck.
❑ inspect valve for block‐
age:
♦ Valve in a horizontal posi‐
tion: valve open
♦ Valve tilted 45°: valve
closed
6 - 8 Nm
7 - Vent line
❑ clipped in place on fuel
tank
8 - Fuel tank
❑ when removing, support
with the engine/gearbox
jack e.g. -V.A.G 1383 A
-
⇒ page 136
(1/4 turn) Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ replace
10 - Tensioning strap
11 - Additional fuel filter
❑ if present
❑ the side with the 2 connections must point to the rear
❑ Position the connection with the dummy nozzle upwards
12 - Support
❑ for additional fuel filter
❑ if present
13 - Fuel delivery unit
❑ note the installed position of the fuel tank ⇒ page 138
❑ inspecting fuel pump ⇒ page 142
❑ with sender for fuel gauge display -G -
❑ Removing and installing the sender for fuel gauge display -G- ⇒ page 138
❑ Clean strainer if dirty

Fabia II 2007 ➤
14 - Sealing ring
❑ replace if damaged
❑ insert dry into the opening of the fuel tank
❑ only moisten from the inside the seal of the flange with fuel for installation purposes
15 - Union nut, 80 Nm
❑ use wrench -MP1-227 (3217)- for removing and installing
16 - Bypass return line
❑ if present
17 - Feed line
❑ to fuel filter
❑ black
❑ clipped in place on fuel tank
18 - Return-flow line
❑ from the high pressure pump
❑ blue
❑ clipped in place on fuel tank
19 - Vent valve
❑ to remove, unclip valve at side and take out of filler neck.
❑ before installing, unscrew cap ⇒ Item 1 (page 132)
20 - O-ring
❑ replace
Inspect vent valve

Lever in off position: valve closed
Lever pushed in direction of arrow: valve open
Note
Before installing the vent valve, unscrew the cap from the filler
neck.

Fabia II 2007 ➤
1.3 Fuel filter - Summary of components
Note
♦ The feed lines ⇒ Item 2 (page 134) and ⇒ Item 3 (page 134) must only be separated at the quick couplings.
♦ Do not detach the hoses from the quick couplings. Otherwise the feed lines must be replaced ⇒ page 6 .
1 - Fuel filter
❑ the arrows engraved on
the filter identify the fuel
inlet and the fuel outlet
⇒ page 141
❑ Change intervals
⇒ Maintenance ; Fabia
ll
❑ pay attention to part
number ⇒ Electronic
catalogue of original
parts
❑ on vehicles complying
with exhaust emission
standard EU-4/BS-4
with drain plug, tighten‐
ing torque 2 Nm
❑ Drain fuel filter ⇒ Main‐
tenance ; Fabia II
2 - Feed line
❑ from the fuel delivery
unit
❑ white marking
❑ detach at the quick cou‐
pling
3 - Feed line
❑ to fuel high pressure
pump
❑ white marking
❑ detach at the quick cou‐
pling
4 - O-ring
❑ replace
5 - O-ring
❑ replace, included in the scope of delivery of the fuel temperature sender -G81-
6 - Fuel temperature sender -G81-
7 - Support
❑ for fuel filter
8 - 20 Nm
1.4 Extract fuel from the fuel tank

♦ Hose adapter , e.g. -V.A.G 1318/16-

Fabia II 2007 ➤
♦ Adapter , e.g. -V.A.G 1318/17-

♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Battery
♦ Fuel tank
Note
If the fuel delivery unit is defective, suction off fuel using a fuel
suction device , e.g. -VAS 5190- .
Work procedure
Note

⇒ page 3 .
– Switch off ignition and withdraw ignition key.

– Position right rear seat vertically ⇒ Body Work; Rep. Gr. 72 .
– Lift cover of fuel delivery unit.
Note
On vehicles with auxiliary heating, the plug connection for the

dosing pump -V54- must be disconnected additionally.
– Unplug the 5-pin connector -1- and the black feed line -2-.
Note
Press in the securing ring in order to unlock the lines.

Fabia II 2007 ➤
– Connect the adapter set -V.A.G 1318/17- to the hose adapter

-V.A.G 1318/16- and attach the “suction line” thus prepared to
the feed support of the fuel pump.
– Keep “suction line” in a suitable fuel tank.
– Connect the battery and the contacts of the fuel pump with
cables -A- from the measuring tool set as follows:
Battery positive terminal (+) to contact -1- of the fuel pump.
Battery negative terminal (+) to contact -5- of the fuel pump.
The fuel pump runs and suctions off fuel.
WARNING
In order to prevent an overflow of fuel, the fuel pump must not

run unattended.
1.5 Removing and installing the fuel tank

♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
Conditions
• All electrical components are switched off and the ignition key
is withdrawn.
• The fuel tank must not be more than 1/4 full ⇒ page 134 .
Removing
Note

⇒ page 3 .
– Unscrew the cap from the filler neck.


Fabia II 2007 ➤

– Remove rear axle ⇒ Chassis; Rep. Gr. 42 .
– Remove rear part of exhaust system ⇒ page 222 .
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
Gr. 66 .
– Remove left heat shield.
– Disconnect the fuel feed line -1- and the front right fuel return-
flow line -2- at the fuel tank.
Note
– Unscrew bolts on filler neck -arrows-.

– Support fuel tank using the engine/gearbox jack -
V.A.G 1383 A - .
– Release the securing bolts of the fuel tank -arrows-.

– Pull the filler neck out of the rubber bowl and lower the fuel
tank.
Install
following points:
Note
♦ Lay the fuel lines avoiding any kinks.

♦ Do not mix-up the fuel feed line (black) and the fuel return-flow
line (blue).
♦ Make sure the fuel line connections fit tightly.
♦ Check feed line and return-flow line at fuel tank for firm seating.

Fabia II 2007 ➤
– Check earth connection of fuel tank/body at filler neck and if

necessary remove corrosion.
– Check the fitting position of the earth lead:
• The plug -1- on the metal plate ring -2- must be pushed on
firmly.
• The contact tab -4- must be hung on the fuel tank -3- and se‐
cured with the spacer bush -5-.
Tightening torques: ⇒ page 132
Before starting the engine, the fuel system must be bled as fol‐
lows:
– Switch on the ignition and only switch it off once the fuel pump
has come to a standstill. Repeat this procedure at least “5
times”.
1.6 Removing and installing fuel delivery

unit
♦ Wrench for union nut -MP1-227 (3217)-
♦ Fuel extraction device , e. g. -VAS 5190-
Conditions
• All electrical components are switched off and the ignition key
is withdrawn.
• The fuel tank must not be more than 3/4 full ⇒ page 134 .
Removing
Note

⇒ page 3 .


Fabia II 2007 ➤
– First of all check the plug -arrow- for firm seating. Pull on the
plug without pressing the locking mechanism. If the plug was
not correctly plugged in, it may have caused a fault.
– Detach the fuel feed line -4- and the fuel return-flow line -2-.
Note
– Remove the bypass return line -3- (if present) from the fuel
delivery unit. To do so, open the warm-type clamp.
– Unscrew union nut with wrench for union nut -MP1-227 - .

– Pull the fuel delivery unit and the gasket ring out of the opening
of the fuel tank.
Note
The old delivery unit must be emptied before disposing of it if it

should be replaced.
Install
If the fuel delivery unit is replaced on the fuel system with bypass
return line:
– Cut off the tip -2- on the marking -arrow-.

• Dimension -a-: 25 mm
– Remove protective caps -1-.
following points:

Fabia II 2007 ➤
Note
♦ Do not damage the sender for fuel gauge display when instal‐
ling it.
♦ Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the fuel
delivery unit.
♦ Pay attention to the installed position of the fuel delivery unit:
The marking on the flange must be aligned with the marking
on the fuel tank -arrows-.
♦ Make sure the fuel lines fit tightly.
♦ The bypass return line is attached to the support -1- with a
spring strap clamp.
♦ After installing the fuel delivery unit, check whether the lines
are also clipped in place on the fuel tank.
Before starting the engine, the fuel system must be bled as fol‐
lows:
– Switch on the ignition and only switch it off once the fuel pump
has come to a standstill. Repeat this procedure at least “5
times”.
1.7 Removing and installing the sender for

fuel gauge display -G-
Removing
– Unlatch and disconnect the plugs of the electrical cables -1-
(black), -2- (blue) and -3- (brown).
– Press together the securing tabs -arrows- and remove the
sender for fuel gauge display -G- upwards.
Install
– Insert the sender for fuel gauge display -G- in the guides at the
fuel delivery unit and press downwards until it latches into po‐
sition.
– Connect the lines -1, 2 and 3- and fix in the holding slots.
– Install fuel delivery unit ⇒ page 138 .

Fabia II 2007 ➤
1.8 Removing and installing fuel filter

Removing
– Disconnect the fuel feed lines at the quick couplings from the
fuel filter -1-. To do so, push the quick couplings onto the noz‐
zles, press in the securing elements (hold pressed) and detach
the quick couplings.
– Unclip the fuel filter -1- from the bracket.
– Remove fuel filter from the top.
Install
Installation is carried out in the reverse order. Pay attention to the
following:
♦ Pay attention to the fitting position of the fuel filter. The arrows
engraved on the filter identify the fuel inlet and the fuel outlet.
♦ Lay the fuel hoses avoiding any kinks.
♦ Make sure the quick couplings fit tightly. Check for secure
catch by tightening it in the opposite direction.
– Connect vehicle diagnosis, measurement and information
system -VAS 505x- and carry out the function “filling/bleeding
the high pressure pump and the fuel system” ⇒ Vehicle diag‐
nosis, testing and information system VAS 5051.

Fabia II 2007 ➤
2 Testing fuel pump
2.1 Testing the voltage supply of the fuel

pump
♦ Vehicle diagnosis, measurement and information system -
VAS 505x-
♦ Hand multimeter , e.g. -V.A.G 1526 D-
♦ Adapter for measuring method/DSO (5-pin) , e.g. -VAS 5565-
Test conditions
• Battery voltage at least 12 V.
• Fuses o.k. ⇒ Current flow diagrams and Fitting locations.
• All electrical consumers such as the lights and rear window
heater must be switched off.
Test sequence
– Connect the adapter for measuring method/DSO (5-pin) -VAS
5565- between the plug and the flange.

Fabia II 2007 ➤
– Connect the handheld multimeter -V.A.G 1526 D- to the test

contacts -1- and -5- of the adapter.
system -VAS 505x- and carry out the function “check the high
pressure pump”.
Note
The fuel pump is actuated for 30 seconds.
– Read off voltage value at handheld multimeter -V.A.G 1526

D- .
• Specified value: battery voltage - 0.5 V
If voltage is not present:
– Test control of fuel pump relay ⇒ Vehicle diagnosis, testing
and information system VAS 5051.
– Test cable connections for open circuit and for short circuit
⇒ Current flow diagrams and Fitting locations.
Voltage supply is O.K.:
– Check power consumption of the fuel pump ⇒ page 148 .
2.2 Test feed pressure of fuel pump

♦ Pressure gauge , e.g. -VAS 6551-
♦ Hose adapter , e.g. -VAS 6551/1-
VAS 505x-
Test conditions
• Battery voltage at least 12 V.
• Fuses o.k. ⇒ Current flow diagrams and Fitting locations.
• Fuel tank at least 3/4 full.
• Horizontal position of the vehicle.
• Flow path in the fuel hoses and the lines in the engine com‐
partment and at the underbody not interrupted due to damage
(kinks).
• All electrical consumers such as the lights and rear window
heater must be switched off.
Test sequence
Note

⇒ page 3 .

– Collect the fuel which flows out with a cloth.
2. Testing fuel pump 143

Fabia II 2007 ➤
– Disconnect the push-fit coupling of the fuel feed line to the high
pressure pump ( ⇒ page 134 , Pos. 3) at the fuel filter outlet.
– Incorporate the pressure gauge -VAS 6551- with the lines -
VAS 6551/1- and -VAS 6551/2- in the fuel circuit.
– Switch on the pressure gauge -VAS 6551- by pressing the
button On/Off .
– Open the shut-off cocks “A” and “B” of the pressure gauge -
VAS 6551- , close the shut-off cock “C”.
system -VAS 505x- and carry out the function “filling/bleeding
the high pressure pump and the fuel system”.
– Read the pressure on the pressure gauge:
• Specified value: min. 0.45 MPa (4.5 bar)
– Start engine and run in idle.
– Position the pressure gauge -VAS 6551- on the windscreen in
such a way that it is legible from inside.
– Increase the idling speed to 2500 rpm.
Repeat the test at the feed line to the fuel filter if the specified
value is not reached. This will determine whether the fuel filter is
not clogged.
– Re-connect the fuel feed line to the high pressure pump at the
fuel filter outlet.
– Disconnect the push-fit coupling of the fuel feed line
( ⇒ page 134 , Pos. 2) at the fuel filter inlet.

Fabia II 2007 ➤
– Connect the pressure gauge -VAS 6551- with the lines -VAS
6551/1- and -VAS 6551/2- to the open ends.
– The pressure measurement is carried out in the same way as
the previous test.
• Now the pressure value must be at least 0.46 MPa (4.6 bar).
If the prescribed pressure values are reached, the difference
however of the measured pressure values upstream and down‐
stream of the filter is 0.04 MPa (0.4 bar) or higher:
– Replace the fuel filter ⇒ page 141 .
If the prescribed pressure value is not reached:
If present, check the additional fuel filter ( ⇒ page 132 , Pos. 11)
at the fuel tank.
To do so, carry out a measurement directly at the fuel delivery unit
as described below:
– Re-connect fuel feed line at fuel filter inlet.
– Disconnect the fuel feed line -4- from the fuel delivery unit.

Fabia II 2007 ➤
– Connect the connection -A- of the pressure gauge -VAS 6551-

with the line -VAS 6551/1- to the open nozzles of the fuel
delivery unit.
– Close the shut-off cocks “B” and “C” of the pressure gauge -
VAS 6551- .
– Switch on the pressure gauge -VAS 6551- by pressing the
button On/Off .
pressure pump”.
Note

• Specified value: 0,67…0,77 MPa (6,7…7,7 bar)
If the specified pressure is reached:
– Replace the additional fuel filter with the integrated pressure

regulator.
Note
♦ On this fuel system, the additional fuel filter only fulfills the
function of a pressure regulator.
♦ The fuel is not filtered.
♦ Check fitting position. An incorrect installation can cause the
following problems:
♦ Impermissible increase in the fuel pressure.

♦ Lifetime reduction of the fuel delivery unit.
♦ Noises of the fuel delivery unit.
If the specified pressure is not reached, the pressure is interrup‐
ted again, the following faults may have occurred:
♦ Battery voltage too low.
♦ Voltage supply of fuel pump not O.K., check ⇒ page 142 .
♦ Fuel flow rate of fuel pump too low, check ⇒ page 146 .
♦ Power consumption of fuel pump too low, check
⇒ page 148 .
♦ Filter strainer of fuel delivery unit soiled. Remove, in order to
check the fuel delivery unit ⇒ page 138 .
♦ Quick coupling in the fuel delivery unit faulty. Remove, in order
to check the fuel delivery unit ⇒ page 138 .
2.3 Checking the fuel flow rate of the fuel

pump
♦ Pressure gauge , e.g. -VAS 6551-

Fabia II 2007 ➤

VAS 505x-
♦ Measuring vessel, 3 litres or more
Test conditions
• Feed pressure of fuel pump tested ⇒ page 143 .
• Battery voltage at least 12,5 V.
• Fuel filter O.K.
• Fuel tank at least 3/4 full.
• Ignition off.
Test sequence
Note

⇒ page 3 .

– Disconnect the fuel feed line -4- from the fuel delivery unit.

Fabia II 2007 ➤
– Connect the connection -A- of the pressure gauge -VAS 6551-

with the line -VAS 6551/1- to the open nozzles of the fuel
delivery unit.
– Close the shut-off cocks “B” and “C” of the pressure gauge -
VAS 6551- .
– Starting at the connection “B”, guide the hose adapter -VAS
6551/2- in a measuring vessel and hold it in position.
pressure pump”.
Note
– Read the pressure on the pressure gauge.

– Set a pressure of 0.4 ... 0.6 MPa (4 ... 6 bar) by carefully closing
and opening the shut-off cock.
– Empty measuring vessel.
– Repeat the function “Test fuel pump” and collect the delivered
fuel in the measuring vessel:
• Specified value of fuel flow rate in 30 seconds: min. 1 000 ml
If the specified value is not reached, this may be due to the fol‐
lowing causes:
♦ Battery voltage too low.
♦ Fuel lines crimped, carry out a visual inspection.
♦ Voltage supply of fuel pump not O.K., check ⇒ page 142 .
♦ Power consumption of fuel pump too low, check
⇒ page 148 .
♦ There is a leak in the fuel system, check for tightness.
♦ Filter strainer of fuel delivery unit soiled. Remove, in order to
check the fuel delivery unit ⇒ page 138 .
2.4 Checking the power consumption of the

fuel pump
VAS 505x-
♦ Hand multimeter , e.g. -V.A.G 1526 D-
♦ Amps clamp , e.g. -V.A.G 1526B/2-
♦ Adapter for measuring method/DSO (5-pin) , e.g. -VAS 5565-
Note
♦ The battery voltage as well as the temperature of the diesel

fuel have a major influence on the power consumption of the
fuel pump. For this reason it is necessary to ensure that the
battery voltage is at least 12.5 V when testing.
♦ Depending on the season, it is necessary to ensure that the
vehicle is fueled with “winter diesel”.

Fabia II 2007 ➤
Test conditions
• Battery voltage at least 12.5 volts
• Fuel temperature above 10 °C

Fabia II 2007 ➤
– Connect the adapter for measuring method/DSO (5-pin) -VAS

5565- to the plug and to the fuel delivery unit.
– Connect the current probe -A- on the red cable with the in‐
scription “current probe” of the adapter for measuring method/
DSO (5-pin) -VAS 5565- .
Note
The current probe of the hand-held multimeter -V.A.G 1715- can

also be used.

pressure pump”.
Note
– Read off power consumption at handheld multimeter -V.A.G

1526 D- .
• Specified value: 8.0 ... 14.0 A
If the measured value is outside the range of the nominal value:
– Check whether the electric wiring between the flange and fuel
pump is connected and test for continuity.
If there is no open circuit in the wiring:
– Replace fuel delivery unit ⇒ page 138 .

Fabia II 2007 ➤
3 Accelerator control
3.1 Accelerator pedal module - Summary of components
1 - Bearing bracket
⇒ Chassis; Rep. Gr. 46
2 - Connector
❑ 6-pin, black
3 - Accelerator pedal module
❑ with accelerator pedal
position sender -G79-
and accelerator pedal
position sender 2 -
G185-
❑ to remove the sender re‐
move the bottom part of
the dash panel on the
driver's side
❑ not adjustable
❑ check ⇒ Vehicle diagno‐
sis, testing and informa‐
tion system VAS 5051
4 - 9 Nm
3. Accelerator control 151

Fabia II 2007 ➤
21 – Turbocharging
1 Exhaust gas turbocharger
1.1 Exhaust turbocharger - Summary of components
Note

♦ Observe general instructions for charge-air system ⇒ page 7 .
♦ Oil feed line and oil return-flow line for exhaust gas turbocharger - Summary of components ⇒ page 153 .
1 - Inlet connection
2 - 9 Nm
❑ captive at the inlet con‐
nection
3 - O-ring
❑ replace
4 - 15 Nm
5 - Support
❑ for electrical cable
6 - Heat shield
7 - Gasket
❑ replace
8 - Exhaust gas turbocharger
❑ can only be replaced
complete with exhaust
manifold and vacuum
setting element
⇒ page 154
9 - 24 Nm
❑ replace
10 - Exhaust gas temperature
sender 1 -G235- , 45 Nm
❑ the thread of a new
sender must be coated
with assembly paste
❑ coat thread with hot bolt
paste -G 052 112 A3-
before installing a used
sender
❑ installing ⇒ page 158
11 - Connection fittings
❑ for oil feed line
❑ must not be released, when removing the union nut of the oil feed line counterhold at the hexagon of the
connection fitting with adapted lateral wrench 14 mm
152 Rep. Gr.21 - Turbocharging

Fabia II 2007 ➤
12 - 24 Nm
❑ replace
13 - Heat shield
14 - Retaining loop
❑ can only be installed in one position
15 - O-ring
❑ replace
16 - 9 Nm
17 - Pulsation dampener
1.2 Oil feed line and oil return-flow line for exhaust gas turbocharger - Summary
of components
Note

1 - Oil return-flow line
Caution
Before installing, check
whether the bellows of
the oil return-flow line is
not bent or overstretch‐
ed. If this is the case, mi‐
crocracks might occur
which can result in leaks.
Replace damaged oil re‐
turn-flow line or support
for exhaust gas turbo‐
charger.
2 - Gasket
❑ replace
3 - 20 Nm
4 - O-rings
❑ replace
5 - 20 Nm
6 - Support for exhaust gas tur‐
bocharger
❑ for oil return-flow line
7 - 9 Nm
8 - O-rings
❑ different diameters, ob‐
serve fitting position
1. Exhaust gas turbocharger 153

Fabia II 2007 ➤
❑ replace
9 - Hollow screw, 60 Nm
❑ replace
10 - Gasket rings
❑ replace
11 - Hollow screw, 30 Nm
❑ replace
12 - Gasket
❑ replace
13 - Connecting pipe
Caution
Pay attention that the
bellows of the connec‐
tion pipe is not bent or
overstretched. There is a
risk of crack formation.
14 - 23 Nm
❑ replace
15 - 9 Nm
16 - Gasket
❑ replace
17 - Oil feed line
❑ check continuity
❑ before installing, fill the bearing housing of the exhaust gas turbocharger on the connection fitting with
engine oil
❑ Tighten the union nut using the wrench -T40055 - , tightening torque 22 Nm
1.3 Removing and installing exhaust gas

turbocharger
♦ Tensioning strap -T10038- (2x)

Fabia II 2007 ➤
Removing
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. In order to prevent
consequential damage to the engine, perform the following
tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter, air filter insert and charge air hoses as well
as charge air pipes for soiling.
♦ Check all air guides and charge air cooler for foreign bod‐
ies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
Note

♦ Observe general instructions for charge-air system
⇒ page 7 .

Note
Support assembly carrier on right and left with tensioning strap -

T10038- .
– Disconnect plug -1- from position sender for charge pressure

regulator -G581- .
⇒ page 202 .

Fabia II 2007 ➤
– Loosen the clamp -1- from the connecting hose to the pulsa‐
tion dampener.
– Unscrew the screws -arrows- from the charge air pipe (cap‐
tive).
– Detach the connecting hose to the pulsation dampener as far
as possible.
– Remove pulsation dampener -1-.
– Remove connection pipe -2- to exhaust gas recirculation ra‐

diator.
– Remove exhaust temperature sender 1 -G235- -1-.


Fabia II 2007 ➤
– Slacken union nut -1- with open ring spanner 17 mm -A-. To

do so, counterhold the connection on the hexagon with the
adapted fixed spanner 14 mm.
– Remove heat shield ( ⇒ page 152 , Pos. 13) at exhaust mani‐
fold.
– Release nuts of exhaust manifold.

Fabia II 2007 ➤
– Turn exhaust gas turbocharger -1- as shown and remove be‐

tween body and assembly carrier. If necessary, lower the
assembly carrier on the right side a further 2 cm.
Caution
♦ If the assembly carrier is lowered further, there is the risk that

the hydraulic hoses of the power-assisted steering are dam‐
aged.
♦ Pay attention when removing the exhaust gas turbocharger
that the oil return-flow line is not bent.
Install
following points:
Caution
Before installing, check whether the bellows of the oil return-

flow line is not bent or overstretched. If this is the case, micro‐
cracks might occur which can result in leaks.
Replace damaged oil return-flow line or support for exhaust
gas turbocharger.
Note

nuts.
♦ Fill exhaust turbocharger with engine oil through the connec‐
tion fitting of the oil feed line.
♦ Remove oil and grease from the charge air pipes and hoses
and from their connections before installing.
♦ Secure all hose connections with screw clamps.
♦ Tightening torques ⇒ page 152 and ⇒ page 153 .
– Checking the oil level ⇒ Maintenance ; Fabia II .
Note
After installing the exhaust turbocharger, run engine at idling

speed for about 1 minute to ensure that oil is supplied to the tur‐
bocharger bearing.
1.4 Installing exhaust temperature sender 1

-G235-
♦ Key -T10395/7-

Fabia II 2007 ➤
Caution
• In this case, the setting of the torque wrench must be 28

Nm.
The correct tightening torque of 45 Nm is achieved by the “ex‐
tension” of the torque wrench using the wrench -T10395/7 - .
Grease the thread of the sender with hot bolt paste -G 052 112
A3- .
– Screw in exhaust gas temperature sender 1 -G235- by hand.
– Tighten sender with torque wrench together with wrench -
T10395/7- to 28 Nm.

Fabia II 2007 ➤
2 Charge air system with exhaust gas

turbocharger
2.1 Charge air cooling - Summary of components
Note

♦ Observe tightening torques of screw clamps for hose connections ⇒ page 162 .
Charge air cooling - Overview
Charge air cooling - Summary of components

Fabia II 2007 ➤
1 - Charge air cooler

❑ can only be removed to‐
gether with the radiator
⇒ page 127
2 - Right charge air hose
3 - Screw clamp
Caution
A too low, but also a too
high tightening torque,
may result in the charge
air hose slipping off the
fluted tube of the charge
air pipe while driving.
❑ Tightening torque
⇒ page 162
4 - 5 Nm
5 - Intake air temperature
sender -G42-
6 - 8 Nm
7 - Right charge air pipe
8 - Rubber grommet
9 - Connecting hose
❑ to throttle valve control
unit -J338-
❑ to pulsation dampener
11 - Left charge air pipe
12 - Left charge air hose Volkswagen Technical Site: http://vwts.ru http://vwts.info
2. Charge air system with exhaust gas turbocharger 161

Fabia II 2007 ➤
2.2 Hose connections with screw clamps
Note
♦ Connections, charge air pipes and hoses of charge air system

must be free of oil and grease before being installed.
♦ Only install approved screw clamps for securing the hose con‐
nections ⇒ Electronic Catalogue of Original Parts .
♦ In order to secure the charge air hoses on their connection
fittings, the threads must be treated with rust solvent if the
screw clamps have been used beforehand.
♦ After a repair, check all the charge air pipes, charge air hoses
and vacuum lines for tight connection and leaktightness.
Caution
The screw clamps -A- on the charge air hoses must definitely
be precisely tightened in accordance with the specifications
⇒ page 162 .
♦ A too low or on the contrary, a too high tightening torque
of the screw clamps, may result in the charge air hose
slipping off the fluted pipe or the charge air pipe while
driving.
Tightening torques of screw clamps

1- Screw clamp -a- = 12 mm: 5.5 Nm
2- Screw clamp -b- = 9 mm: 3 Nm
2.3 Removing and installing charge air cool‐

er
The charge-air cooler is located below the radiator:
The charge-air cooler can only be removed together with the ra‐
diator ⇒ page 127 .

Fabia II 2007 ➤
2.4 Removing and installing left charge air

pipe
Removing
– Remove the battery with the battery tray ⇒ Electrical System;
Rep. Gr. 27 .
⇒ page 202 .
Gr. 50 .
– Remove the left charge air hose, to do so slacken the screw
clamps -arrows-.
– Remove coolant hoses and wiring looms from left charge air
pipe
– Loosen the clamp -1- from the connecting hose to the pulsa‐
tion dampener.
– Unscrew the screws (captive) -arrows- from the left charge air
pipe.
– Remove bottom left charge air pipe.
Install
following points:
– Replace damaged cable straps and clips.
♦ Tightening torque of left charge air pipe: 8 Nm
2.5 Removing and installing right charge air

pipe
Removing
– Disconnect plug -3- from intake air temperature sender -G42- .
Gr. 50 .

Fabia II 2007 ➤
– Remove right charge air hose -arrows-.
– Loosen clamp -2-.

– Unscrew the screws (captive) -arrows- from the right charge
air pipe.
– Remove right charge air pipe.
Install
following points:
♦ Tightening torque of right charge air pipe: 8 Nm
2.6 Checking the charge-air system for

leaktightness
♦ Charge-air system testing device , e. g. -V.A.G 1687-
♦ Adapter , e.g. -V.A.G 1687/10-
♦
Test sequence
– Remove the intake hose -1- from the air filter.
– Fit adapter -1687/10- into the intake hose -1- and secure with
a hose clamp.
Prepare tester -V.A.G 1687- as follows:

Fabia II 2007 ➤
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect tester for charge-air system -V.A.G 1687- to adapter

-1687/10 - as shown.

Fabia II 2007 ➤
– Connect the feed hose for the compressed air -1- to the tester.
Note
If there is water in the inspection glass, drain water via the drain
plug -6-.
– Open valve -3-.

– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
Caution
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary regulate the pressure to 0.05 MPa (0.5 bar).
– Charge-air system:
♦ by looking,
♦ by listening,
♦ by touching,
♦ with a commercially available leak search spray, or
♦ with ultrasonic measuring device , e.g. -V.A.G 1842- ,
check for leak points.
Note
♦ Minor leaks are permissible on the suction side of the turbo‐

charger, because the intake hoses are not designed for over‐
pressure.
♦ A small amount of air penetrates via the inlet valves into the
engine. For this reason no pressure test is possible.
♦ Use of ultrasonic measuring device -V.A.G 1842- ⇒ operating
instructions .
♦ In case of a leak point, observe the instructions for charge air
system ⇒ page 7 during the installation.
♦ Before removing the adapter -1687/10- by loosening the hose
clamp, release the pressure in the test circuit.
2.7 Connection diagram for vacuum hoses
Caution
When routing the vacuum lines, make sure that the lines are
not kinked, twisted or crimped. Otherwise this can lead to
breakdown.

Fabia II 2007 ➤
Note
♦ Blue = vacuum control line for exhaust gas recirculation

♦ Grey = ventilation line to air filter
♦ Green = vacuum control line for exhaust gas turbocharger
♦ Red = vacuum supply line of the vacuum pump
1 - Vacuum setting element

❑ at exhaust gas turbo‐
charger
❑ with position sender for
charge pressure regula‐
tor -G581-
2 - Vacuum line
❑ To the brake servo unit
3 - Air intake hose
❑ with connecting piece
for ventilation line
4 - Solenoid valve for charge
pressure control -N75 -
❑ removing ⇒ page 168
5 - Vacuum pump
6 - Ventilation line
❑ To intake hose
7 - Changeover valve for radi‐
ator of exhaust gas recircula‐
tion -N345-
❑ Check change-over
⇒ page 229
8 - Vacuum line
❑ to cylinder head cover
with vacuum reservoir
9 - Vacuum line
❑ to vacuum setting ele‐
ment at radiator for ex‐
haust gas recirculation
10 - Vacuum setting element
❑ the radiator flap for ex‐
11 - Vacuum line
❑ to vacuum setting element at exhaust gas turbocharger
12 - Vacuum connection
❑ at the cylinder head cover with vacuum reservoir

Fabia II 2007 ➤
Remove charge pressure control solenoid valve -N75-

– Unscrew nuts -1 and 2-.
– Remove vacuum lines complete with bracket -1- from air filter.
2.8 Inspect the vacuum system
Caution
When routing the vacuum lines, make sure that the lines are
not kinked, twisted or crimped. Otherwise this can lead to
breakdown.

♦ Hand vacuum pump , e.g. -VAS 6213-
Work procedure
– Check all the vacuum lines in the complete vacuum system
for:
♦ tears
♦ marten bites
♦ Crimps and deformations
♦ porous points and other leaks
– Check vacuum lines to solenoid valves as well as from sole‐
noid valves to the corresponding vacuum setting elements.

Fabia II 2007 ➤
Note
In order to generate “vacuum”, push the ring -1- for the hand vac‐
uum pump -VAS 6213- into position -A-.
– In the event of a fault memory entry, check the vacuum lines

to the mentioned component and also the remaining vacuum
lines to the other components.
If it is not possible to build up vacuum using the hand vacuum
pump -VAS 6213- or the vacuum drops immediately:
– Check hand vacuum pump and connecting hoses for tight‐
ness.

Fabia II 2007 ➤
23 – Fuel Formation, Injection

1 Diesel direct injection system - fitting
locations
The control unit is equipped with a fault memory. Before repairs,
setting operations and fault finding, interrogate the fault memory
and execute a self-diagnosis ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
Note
♦ Faults can be detected by the control unit as checking and

adjustment work is being undertaken and then saved. It is
therefore absolutely necessary to delete the fault memory af‐
ter completing all checking and adjustment work ⇒ Vehicle
diagnosis, testing and information system VAS 5051
⇒ page 3 .
♦ Observe the instructions for the fuel hose in the engine com‐
partment ⇒ page 6 .
170 Rep. Gr.23 - Fuel Formation, Injection

Fabia II 2007 ➤
1.1 Overview of fitting locations
1 - Differential pressure sender

-G505-
❑ only for vehicles with
diesel particle filter
2 - Coolant recirculation pump
2 -V178-
3 - Connector
❑ for exhaust gas temper‐
ature sender 1 -G235-
(only on vehicles with
diesel particle filter)
❑ for lambda probe -G39-
4 - Hall sender -G40- (cam‐
shaft position sensor)
sender 4 -G648-
❑ only for vehicles with
diesel particle filter
6 - lambda probe -G39- with
heating for lambda probe -Z19-
7 - Injection units (solenoid in‐
jectors)
❑ Injection valve for cylin‐
der 1 -N30-
❑ Injection valve for cylin‐
der 2 -N31-
❑ Injection valve for cylinder 3 -N32-
8 - Exhaust gas temperature sender 1 -G235-
9 - Position sender for charge pressure regulator -G581 -
10 - Exhaust gas return valve -N18-
❑ consists of:
♦ mechanical valve (electrically operated)
♦ EGR control motor -V338-
♦ EGR potentiometer -G212-
1. Diesel direct injection system - fitting locations 171

Fabia II 2007 ➤
11 - Oil pressure switch -F1-

12 - Air mass meter -G70-
13 - Engine control unit -J623-
14 - Solenoid valve for charge pressure control -N75 -
15 - Control valve for fuel pressure -N276-
16 - Coolant temperature sender -G62-
17 - Intake manifold flap motor -V157-
18 - Thermoswitch for radiator fan -F18-
20 - Glow plugs
❑ Glow plug 1 -Q10-
21 - Charge pressure sender -G31-
22 - Throttle valve control unit -J338-
23 - Changeover valve for radiator of exhaust gas recirculation -N345-
24 - Knock sensor 1 -G61-
25 - Coolant temperature sender at radiator outlet -G83-
26 - Fuel high pressure pump with fuel dosage valve -N290-
27 - Intake air temperature sender -G42-
28 - Fuel pressure sender -G247-

Fabia II 2007 ➤
2 Fuel system - Overview
2.1 System overview
WARNING
Absolutely observe the safety precautions when working on

the fuel system ⇒ page 3 .
1 - Fuel dosage valve -N290-

❑ do not open
2 - Fuel high pressure pump
⇒ page 194
3 - Fuel pressure sender -
G247-
⇒ page 193
4 - Fuel distributor
⇒ page 191
5 - Control valve for fuel pres‐
sure -N276-
❑ replace after each re‐
moval
⇒ page 183
6 - Injection units (solenoid in‐
jectors)
⇒ page 187
7 - Fuel return-flow lines
❑ must not be disassem‐
bled
8 - Fuel tank
❑ with fuel pump for pre‐
delivery -G6-
9 - Fuel filter
❑ Fuel filter - Summary of
components ⇒ page 134
❑ Change intervals ⇒ Maintenance ; Fabia ll
❑ pay attention to part number ⇒ Electronic catalogue of original parts
❑ on vehicles according to BS-4 standard with drain plug, tightening torque 2 Nm
❑ Drain fuel filter ⇒ Maintenance ; Fabia II
2. Fuel system - Overview 173

Fabia II 2007 ➤
2.2 Fuel system - Summary of components
Caution
In order to avoid the fuel high pressure pump to run dry and to
achieve a quick engine start after parts are replaced, the fol‐
lowing points must be observed:
♦ If the fuel system was opened, starting with the fuel tank
through to the fuel high pressure pump, the basic setting
“Test fuel pump” must be carried out “once” before the
engine start ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
♦ If the high pressure system was opened, it must be
checked for tightness ⇒ page 180 .
ment ⇒ page 6 .
1 - O-ring
⇒ page 176
2 - Fuel return-flow lines
❑ to high pressure pump
❑ they must not be kinked,
damaged or blocked
❑ do not disassemble
❑ after an exchange, the
engine must run at idling
speed for approx. 2 mi‐
nutes in order to vent the
fuel system; afterwards
check the fuel return-
flow lines for tightness
3 - High pressure lines, 15 Nm
+ torque a further 60° (1/6 turn)
❑ between fuel distributor
and injection units
❑ do not interchange
Note
• The sealing cone of the rel‐

evant high pressure line is
not deformed or cracked.
• The line boring is not de‐
formed, constricted or dam‐
aged.
♦ Corroded lines must no lon‐
ger be installed.
❑ install free of stress

Fabia II 2007 ➤
4 - Connecting hose
5 - Spring strap clamp
6 - Fuel pressure regulating valve -N276- , 80 Nm
❑ replace after each removal
7 - Fuel distributor
8 - 9 Nm
9 - 22 Nm
10 - Fuel pressure sender -G247- , 100 Nm
11 - Fuel return-flow line
❑ to fuel feed
12 - High pressure line, 15 Nm + torque a further 60° (1/6 turn)
❑ between the high pressure pump and the fuel distributor
Note
• The sealing cone of the high pressure line is not deformed or cracked.
• The line boring is not deformed, constricted or damaged.
♦ A corroded high pressure line must not be reinstalled.
❑ install free of stress
13 - Fuel high pressure pump
❑ with fuel dosage valve -N290- (do not open)
❑ after the installation, an initial fuel filling must be carried out (absolutely avoid it to run dry) ⇒ page 179
❑ replace
❑ replace
16 - 25 Nm
❑ on the high pressure pump
18 - 95 Nm
19 - Hub
20 - Copper disc
❑ replace
21 - Clamping claw
❑ replace

Fabia II 2007 ➤
23 - Injection unit (solenoid injector)

❑ List of parts and gaskets or O-rings which must be replaced each time when removing and installing:
“copper disc”, “O-ring of bore for injection unit”, “O-ring for fuel return-flow line”.
❑ List of parts and gaskets or O-rings which must be replaced each time when replacing the injection unit:
“clamping claw”, “copper disc”, “O-ring of bore for injection unit”, “O-ring for fuel return-flow line”.
❑ before re-using the “high pressure line” carry out a visual inspection of the sealing cones for damage,
e.g. cross chamfers and corrosion, always replace if damaged
❑ Injection units, high pressure lines and clamping claws, which are re-installed, may only be mounted
again at the same cylinder.
2.2.1 Replacing O-rings for fuel return-flow

line
Removing
Note
Proceed with utmost care. Avoid damage to the fuel return-flow

line.
– Carefully remove the old O-rings from the connections of the

fuel return-flow line. While doing so, do not work with sharp-
edged tools.
Install
Note
♦ When cleaning, do not use any solvent or anything similar

which damages the graphite coating on connections of the fuel
return-flow line.
♦ Proceed with utmost care in order to avoid damage to the O-
rings or the fuel return-flow line.
♦ The O-rings must not be twisted in the slots of the fuel return-
flow line.
– Clean the seating surfaces for the O-rings on the connections

of the fuel return-flow line with great care.
– Carefully push new O-rings into the slots on the connections
of the fuel return-flow line.

Fabia II 2007 ➤
2.3 Injection unit with clamping claw - Summary of components
1 - Injection unit (solenoid in‐

jector)
⇒ page 187
❑ List of parts and gaskets
or O-rings which must
be replaced each time
when removing and in‐
stalling: “copper disc”,
“O-ring of bore for injec‐
tion unit”, “O-ring for fuel
return-flow line”.
❑ List of parts and gaskets
or O-rings which must
be replaced each time
when replacing the in‐
jection unit: “clamping
claw”, “copper disc”, “O-
ring of bore for injection
unit”, “O-ring for fuel re‐
turn-flow line”.
❑ before re-using the
“high pressure line” car‐
ry out a visual inspection
of the sealing cones for
damage, e.g. cross
chamfers and corrosion,
always replace if dam‐
aged
❑ Injection units, high
pressure lines and
clamping claws, which
are re-installed, may on‐
ly be mounted again at
the same cylinder.
2 - O-ring
3 - Fuel return-flow line
❑ to high pressure pump
❑ it must not be kinked, damaged or blocked
❑ do not disassemble
❑ after an exchange, the engine must run at idling speed for approx. 2 minutes in order to vent the fuel
system; afterwards check the fuel return-flow line for tightness
4 - gasket in the connector
❑ replace
5 - Connector
❑ if the plug is disconnected, replace gasket ⇒ Item 4 (page 177)
6 - Copper disc
❑ replace
7 - O-ring
❑ replace
8 - Clamping claw

Fabia II 2007 ➤

❑ replace
10 - Threaded neck
❑ for injection unit

Fabia II 2007 ➤
3 Removing and installing, testing fuel

formation, components
Note
♦ If there are any complaints about the engine behaviour and

the engine performance, the primary cause may be insufficient
fuel pressure in the low pressure area of the fuel system. Fuel
pressure-related faults in the high pressure area of the fuel
system may result from a too low fuel pressure in the low
pressure area.
♦ The fuel pressure in the high pressure area of the fuel system
is determined with the diagnosis of the engine control unit
⇒ Vehicle diagnosis, testing and information system VAS
5051.
♦ The fuel pressure in the low pressure area of the fuel system
is measured with the pressure gauge -VAS 6551-
⇒ page 142 .
♦ Components of the fuel high pressure system must be
checked with the vehicle diagnosis, measurement and infor‐
mation system -VAS 505x- in the “Targeted functions”.
3.1 Filling and bleeding the high pressure

pump and the fuel system
VAS 505x-
Caution
Risk of damage to the high pressure pump through running dry.

♦ After installing a new high pressure pump, the high pres‐
sure pump must be filled up with fuel before the first engine
start. Avoid the high pressure pump to run dry.
Note
♦ When installing the high pressure pump, ensure that no dirt

penetrates the fuel system.
♦ Only remove the screw plug immediately before installing the
fuel lines.
Conditions
• The vehicle must be filled up.
• Temperature of the fuel system ≥ 15 °C.
Work procedure
system -VAS 505x- .
– Switch on ignition.
3. Removing and installing, testing fuel formation, components 179

Fabia II 2007 ➤
– Select the “Engine electronics” in the self-diagnosis.

– Then select “006 - Basic setting”.
– Then select “Test fuel pump”.
– Subsequently press on “Start”.
♦ The fuel pump starts running for approx. 60 seconds.
– Repeat this work procedure 3x.
This ensures that the fuel high pressure pump is adequately
filled up with fuel.
WARNING
Wear protective gloves and protective googles when working

with grease remover!
– Degrease the union nuts -1- and -5- of the high pressure pipe
and their surroundings at the pump as well as at the fuel dis‐
tributor.
– Start the engine and let it run at an average speed for a few
minutes.
– Carry out a visual inspection of the fuel system for leaks after
switching off the engine.
If there is leakage despite the correct tightening torque:
– Replace the related component part and repeat the filling/
bleeding procedure.
If no leaks are found:
– Carry out a test drive with minimum one full load acceleration
up to max. speed.
– Afterwards, once again carry out a visual inspection of the fuel
system for leaks.
– Replace the related component part and once again repeat
the filling/bleeding procedure.
– Interrogate and if necessary erase fault memory of engine
control unit ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.
– After deleting the fault memory of the engine control unit the
readiness code must be checked, if necessary re-generated
5051.
3.2 Check the fuel system for tightness

VAS 505x-

Fabia II 2007 ➤
Work procedure
WARNING

– Degrease all fuel connections.

– Let the engine run at idling speed for a few minutes.
– Carry out a visual inspection of the complete fuel system for
leaks after switching off the engine.
– Replace the related component part and repeat the leak
check.
– Carry out a test drive with minimum one full load acceleration
up to max. speed.
– Then once again carry out a visual inspection of the complete
fuel system for leaks.
– Replace the related component part and once again repeat
the leak check.
– Interrogate and if necessary erase fault memory of engine
control unit ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.
– After deleting the fault memory of the engine control unit the
readiness code must be checked, if necessary re-generated
5051.
3.3 Check fuel pressure regulating valve -

N276-
The fuel pressure regulating valve -N276- -5- is located in the fuel
distributor.
On this engine, the fuel pressure regulating valve -N276- has 2
functions:
♦ At cold start, it opens at a certain low temperature. The
warmed fuel from the fuel distributor is then led back into the
feed line in front of the fuel filter. This prevents the fuel filter
from clogging at low temperatures.
♦ During vehicle over-run conditions, it regulates the fuel pres‐
sure in the fuel distributor.

♦ Suitable auxiliary hose for connection to the fuel return-flow
line.
♦ Fuel tank, approx. 200 ml.
Test condition
• If necessary, allow engine to run until fuel temperature is at
least 20 °C.

Fabia II 2007 ➤
Determine fuel temperature:

system -VAS 505x- .
– Select the correct vehicle in the “Targeted fault finding”.
– Press button “Skip”.
– Press “Selected Functions/Components”.
– Select “Drive”.
– Select “Engine CFWA (Rep. Gr. 01; 10-28)”.
– Select “23 - fuel formation, injection”.
– Select “Electrical Components”.
– Select fuel temperature sender -G81 - .
The fuel temperature is displayed.
Work procedure
Caution
The test sequence must be absolutely observed.

• Fuel temperature at least 20 °C.
• The engine must only be idling. Otherwise the fuel pres‐
sure regulating valve -N276- can open and in turn the test
will be inaccurate.
Observe the rules for cleanliness and the instructions when un‐
dertaking all work on the fuel system ⇒ page 2 .
ment ⇒ page 6 .

Fabia II 2007 ➤
– Detach the hose -1- from the fuel return-flow line -2-
⇒ page 6 .
– Close off the open hose end -arrow- with a suitable screw plug.
• The hose connection must withstand a pressure of at least 1
MPa (10 bar).
– Start engine and run for at least 3 minutes at idling speed. In
the event that fuel flows out of the fuel return-flow line, imme‐
diately switch off the engine.
• No fuel must flow out of the fuel return-flow line -2-.
Note
♦ If the engine is switched off, the fuel pressure regulating valve

-N276- opens.
♦ The high pressure in the fuel distributor is removed via the fuel
return-flow line and the fuel flows out. This fuel must be col‐
lected.
After the test:

– Firmly connect an auxiliary hose to the fuel return-flow line
-2- when the engine is running at idling speed.
– Hold the auxiliary hose in a suitable fuel tank.
WARNING
Danger of liquid spraying out from the auxiliary hose of the fuel
return-flow line after switching off the engine!
– Switch off engine.

If fuel has flown out of the fuel return-flow line when the engine
was running, the fuel pressure regulating valve -N276- is defec‐
tive:
– Replace fuel pressure regulating valve -N276- ⇒ page 183 .
Note
Replace fuel hose to fuel return-flow line ⇒ page 6 .
3.4 Removing and installing the fuel pres‐

sure regulating valve -N276-
♦ Open-end wrench 36 mm

Fabia II 2007 ➤
The fuel pressure regulating valve -N276- -5- is located in the fuel
distributor.
Note
The fuel pressure regulating valve -N276- is not reusable.
Removing
WARNING

Note
No grease remover must get into the plug connection, carefully

clean.
– Also clean the thread area of the fuel pressure regulating valve
-N276- with a grease remover. No dirt must get into the hole
of the fuel distributor.
– Dry fuel pressure regulating valve -N276-
– Disconnect the plug at the fuel pressure regulating valve -
N276- .
– Counterhold the fuel pressure regulating valve -N276- on the
hexagon and slacken the screwed connection using a wrench.
– Unscrew the screwed connection by hand and remove the fuel
pressure regulating valve -N276- from the fuel distributor.
– Remove dirt from the thread, the sealing surface and the hole
in the fuel distributor. To do so do not use any mechanical
tools.
Note
Close the fuel distributor hole immediately with a suitable screw

plug in order to prevent dirt from penetrating.

Fabia II 2007 ➤
Install
Note
♦ The fuel pressure regulating valve -N276- does not have a

gasket ring but a biting edge.
♦ The fuel pressure regulating valve -N276- is not reusable.
♦ The O-ring seals the high-pressure side from the low-pressure
side and must be replaced.
♦ Before installing, moisten the O-ring and the hole in the fuel
distributor with diesel fuel.
♦ Pay attention to damage of the biting edge and the thread of
the new fuel pressure regulating valve -N276- .
♦ Also check the sealing surface in the fuel distributor.
– Screw in the screwed connection and tighten by hand.

– Align the fuel pressure regulating valve -N276- in such a way
that the connecting line is routed tension-free after fitting on
the plug.
– Counterhold the fuel pressure regulating valve -N276- on the
hexagon and tighten the screwed connection to 80 Nm using
a wrench.
– After installing, start the engine and let it run at an average
speed for a few minutes.
– Switch off the engine and check the fuel system for tightness
⇒ page 180 .
Note
If the fuel pressure regulating valve -N276- was replaced, the in‐
itialisation values of the regulating valve must be reset ⇒ Vehicle
diagnosis, testing and information system VAS 5051, “Targeted
functions”; “Reset initialisation values of the regulating valve for
the fuel pressure”.
3.5 Installing the high pressure lines

♦ Socket wrench insert -T40055-
♦ Assembly sleeve -T10411-

Fabia II 2007 ➤
Caution
♦ For easier installation of the fuel high pressure pipe, re‐

lease the tension of the fuel distributor. If necessary,
slightly push the fuel distributor.
♦ For easier installation of the injection pipes, release the
tension of the fuel distributor as well as the clamping claws
of the injection units. If necessary, slightly push the fuel
distributor and slightly twist the relevant injection unit.
♦ The pipes must on no account be bent or installed when
under tension. The installation tension can lead to fracture
of the fuel high pressure pipe.
Note
♦ It is not allowed to use tools for aligning the fuel distributor/the

injection units.
♦ Pay attention to the cylinder specific marking when re-using
the high pressure lines.
♦ The high pressure lines can be re-used if:
• The sealing cone of the relevant high pressure line is not de‐
formed or cracked.
• The line boring is not deformed, constricted or damaged.
♦ Corroded lines must no longer be installed.
– Suction off dirt from the sealing cones of the supports at the
fuel distributor.
WARNING

– Clean fuel lines and line connections and blow-dry with com‐
pressed air.
– Coat threads of union nuts with fuel.
Mounting sequence
– First position the injection lines from the fuel distributor to the
injection units free of tension and only tighten the union nuts
by hand.
– Tighten the screws for the clamping claws of the injection units
to 8 Nm and torque a further 180° (1/2 turn).
– Use the socket wrench insert 17 mm -T40055- to tighten the
union nuts of the high pressure lines first on the injection units
and then on the fuel distributor to 15 Nm and torque a further
60° (1/6 turn).

Fabia II 2007 ➤
– For installing the high pressure line between the high pressure
pump and the fuel distributor, slide the assembly sleeve -
T10411 - onto the fuel pressure sender -G247- .
Note
♦ The bracket for the engine mounting must be movable in order

to position the union nut on the high pressure pump, to do so
slacken the screws -4-.
♦ The assembly sleeve -T10411- ensures the correct distance
between the fuel pressure sender -G247- and the high pres‐
sure line.
– Install the high pressure line from the high pressure pump to
the fuel distributor and tighten the union nuts only by hand.
– Use the socket wrench insert 17 mm -T40055- to tighten the

union nuts of the high pressure line -2- between the high pres‐
sure pump and the fuel distributor first at the high pressure
pump -5- and then at the fuel distributor -1- to 15 Nm and tor‐
que a further (1/6 turn).
– Tighten the screws of the fuel distributor to 22 Nm.
– Tighten the screws -3 and 4- of the brackets for the fuel high
pressure line to 9 Nm.
– Tighten the fixing screws of the bracket for the engine mount‐
ing to 23 Nm.
– Remove assembly device -T10411- .
– Fit the plug on the fuel pressure sender -G247- .
3.6 Removing and installing the injection

units
Removing

Fabia II 2007 ➤
– Disconnect plug -1- from position sender for charge pressure

regulator -G581- .
Caution
Pay attention to cleanliness.

• Under no circumstances dirt must get into the removed
return lines and the connections of the injection units.
• It is absolutely necessary to protect the opened fuel con‐
nections from dirt with suitable means.
– Open return-flow line connection. To do so, release the catch

-1-.
– Detach the fuel return-flow line from the injection unit in
-direction of arrow-.
– Disconnect the plug -1- at the injection units to be removed.

– Replace the connector gasket ( ⇒ page 177 , Pos. 4) of the
connectors -1- ⇒ Electronic Catalogue of Original Parts .
– Release the screw of the clamping claw for the injection unit
to be removed.
Caution


Fabia II 2007 ➤
– Position the extractor -T10055- with the extractor -T10426- as

shown.
– Always pull out the injection unit together with the clamping
claw towards the top by tapping it.
Note
Place the removed injection units on a clean cloth.
– Remove the soot particles on the sealing surface of the injec‐

tion unit in the cylinder head and the dirt in the opening with a
cloth soaked in engine oil or in rust solvent, if necessary.
Caution
Make sure the sealing surfaces are not damaged in the proc‐
ess.
Important instructions for the replacement of parts

When reinstalling the injection unit, the following parts must be
replaced:
♦ Copper seal
♦ O-ring of bore for injection unit
♦ Screw for clamping claw
When installing the new injection unit, the following must also be
replaced:
♦ Clamping claw
♦ Injection unit for cylinder
Instructions for reinstalling the injection units
Note
♦ When reinstalling, the injection units, the injection lines and

the clamping claws must only be installed at the same point
where they were removed.
♦ The reinstalled injection units or injection lines must not be
damaged.
– Spray the tip of the injection unit with a rust solvent spray. Re‐
move the soot and grease particles with a cloth after approx.
5 minutes.

Fabia II 2007 ➤
– Remove the old copper seal from the injection unit; to do so,
carefully tighten the copper seal with pliers until the copper
seal does no longer turn. Then pull the injection unit out of the
copper seal with slight turning and pulling movements of the
hand.
• Check the injection units and the fitting positions for cleanli‐
ness before installing.
Mounting sequence
Note
All the O-rings must be coated with engine oil before installing.
– Insert a new copper seal on the injection unit with plastic bush‐
ing.
– Replace the gasket ring of the bore for the injection unit, for
this step use the assembly sleeve -T10377 - .
– Slide the clamping claw onto the injection unit. Check fitting
position ⇒ page 177 .
– Carefully insert the injection unit with the clamping claw into
the bore in the cylinder head.
Caution

– Screw in the new screw of the clamping claw and first tighten
only by hand.
Note
For a tension-free installation of the injection line, it is essential to

align the position of the injection unit by twisting.
– Install high pressure lines ⇒ page 185 .

Further assembly occurs in reverse order.
– Check gasket rings of fuel return-flow lines for wear, if neces‐
sary replace ⇒ page 176 .
– Carefully press the connections of the return-flow lines into the
injection units.
• The cap must click audibly into place.
Note
After replacing the injection units, carry out “Adaptation of cor‐

rection values” in the “Targeted functions” ⇒ Vehicle diagnosis,

Fabia II 2007 ➤
3.7 Removing and installing the fuel distrib‐

utor
Removing
ment ⇒ page 6 .
– Release the screws -3 and 4- of the brackets for the fuel high
pressure.
– Remove fuel high pressure line -2-, to do so slacken the union
nut -5- at the high pressure pump and unscrew the union nut
-1- at the fuel distributor.
– Open the catches -arrows- of the cable guide and expose the
wiring loom.
– Disconnect the plugs at the glow plugs ⇒ page 232 .
– Disconnect plugs -1 ... 6-.

– Replace the connector gasket of the connectors -2, 3 and 4-

Fabia II 2007 ➤
– Release screws -arrows- of fuel return-flow line.

The fuel return-flow line remains attached to the fuel distribu‐
tor.
Caution
♦ Mark the assignment of the high pressure lines to the cyl‐

inders, they must only be re-used on the same cylinder.
♦ Rules of cleanliness when working on the injection sys‐
tem.
♦ Immediately close the open connections with a suitable
screw cap.
– Remove high pressure line between fuel distributor and injec‐

tion units.
– Place the removed high pressure lines on a clean cloth.
– Remove the fuel distributor, to do so release both screws

-arrows-.
Install
following points:
– Screw in the fixing screws -arrows- of the fuel distributor and

first tighten only by hand.
• The fuel distributor must be moved in order to ensure the
stress-free assembly of the high pressure lines.
– Install high pressure lines ⇒ page 185 .
♦ Tightening torques
⇒ “2.2 Fuel system - Summary of components”, page 174 .

Fabia II 2007 ➤
3.8 Removing and installing fuel pressure

sender -G247-
The fuel pressure sender -G247- -6- is located in the fuel distrib‐
utor. It measures the current fuel pressure in the high pressure
system and delivers a voltage signal to the engine control unit -
J623- .
If the sender fails, the pressure regulation is controlled by the en‐
gine control unit via a characteristic diagram.
In the emergency running mode, the maximum engine speed is
limited to approx. 3000 rpm.

Removing
WARNING

Note
No grease remover must get into the plug connection, carefully

clean.
– Before removing the fuel pressure sender -G247 - , clean the

thread area with a grease remover (no dirt must get into the
hole of the fuel distributor).
– Dry the fuel pressure sender -G247- .
– Disconnect plug at fuel pressure sender -G247- .
Caution
Do not slacken the fuel pressure sender using the open-end

wrench or the open ring spanner - Risk of damage!
Use lengthened socket insert.

– Unscrew the fuel pressure sender -G247- .
– Remove dirt from the threaded hole and the sealing surface in
the fuel distributor. To do so do not use any mechanical tools.

Fabia II 2007 ➤
Note
Close the fuel distributor hole immediately with a suitable screw

plug in order to prevent dirt from penetrating.
Install
Note
♦ The fuel pressure sender -G247- has no gasket ring but a bit‐
ing edge for sealing.
♦ Pay attention to damage of the sealing surfaces (biting edge
seal) and the thread of the new fuel pressure sender -G247- .
It is possible to use the fuel pressure sender -G247- again.
♦ Also check the sealing surface of the hole of the fuel distribu‐
tor.
♦ The thread of the fuel pressure sender -G247- is coated with
a lubricating lacquer. The thread must always be free of oil and
grease.
Caution
Do not tighten the fuel pressure sender using the open-end

wrench or the open ring spanner - Risk of damage!
Use lengthened socket insert.
– Screw in the fuel pressure sender -G247- by hand.

– Tighten the fuel pressure sender -G247- .
3.9 Removing and installing the fuel high

pressure pump
♦ Thrust piece -T40064/1-
♦ Bolt -T40064/2-
Removing
ment ⇒ page 6 .
Gr. 50 .

Fabia II 2007 ➤
Caution
Make sure that no cable connection is damaged when discon‐

necting the plugs.
♦ Otherwise, the complete wiring loom must be replaced.
– Disconnect plugs -10, 11 and 12-.

10 - Hall sender -G40-
12 - Fuel temperature sender -G81- in the fuel feed line
– Release screws of coolant return-flow line -arrows-.

– Lay coolant return-flow line to the side.
Way of proceeding if the high pressure pump is not replaced
– Detach the fuel hoses -1 and 6- at the quick couplings. To do

so, push the quick couplings onto the nozzles, press in the
securing elements (hold pressed) and detach the quick cou‐
plings.
If the fuel hoses are not detached from the high pressure
pump, they must not be replaced.
Way of proceeding if the high pressure pump is replaced
Observe the instructions for the fuel hose in the engine com‐
partment ⇒ page 6 .
– Detach the fuel hoses -arrows- at the high pressure pump.

Continue as follows for both procedures

Fabia II 2007 ➤
– Carefully unlock the fuel return-flow line -arrow- at the high

pressure pump.
– Carefully remove the fuel return-flow line from the high pres‐
sure pump.
– Unscrew high pressure line -2- between fuel distributor and

high pressure pump.
– Remove the toothed belts from the toothed belt sprockets of
the camshaft and the high pressure pump ⇒ page 29 .
– Release screws -1- and remove timing belt gear from the high
pressure pump.
– Hold the hub of the fuel high pressure pump with the counter‐
holder -T10051- and unscrew the fixing nut -1-.
Note
Replace the basic pressure plate with the pressure plate -

T40064/1- on the extractor -T40064- .

Fabia II 2007 ➤
– Position extractor -T40064- with pressure plate -T40064/1 -

and bolt -T40064/2- as shown.
– Detach the hub from the high pressure pump. If necessary
counterhold with an open-end wrench 24 mm.
– Release the fixing screws -arrows- of the high pressure pump.

– Remove the high pressure pump.
Install
Caution
Risk of damage to the high pressure pump through running dry.

Note
♦ When installing the high pressure pump, ensure that no dirt

penetrates the fuel system.
♦ Only remove the screw plug immediately before installing the
fuel lines.
Installation occurs in reverse order for removal, while paying at‐

tention to the following:
♦ The screws for the high pressure pump must be replaced.

♦ Tightening torques of fuel system ⇒ page 174 .
♦ Tightening torques of toothed belt drive ⇒ page 27 .
♦ If the fuel hoses -arrows- were removed at the high pressure
pump, they must be replaced ⇒ page 6 .
Note
If the high pressure pump was replaced, the initialisation values

of the fuel pressure regulating valve -N276- must be reset ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051, “Tar‐
geted functions”; “Reset initialisation values of the regulating
valve for the fuel pressure”.
– Filling and bleeding the high pressure pump and the fuel sys‐
tem ⇒ page 179 .

Fabia II 2007 ➤
4 Intake manifold and air filter
4.1 Intake manifold with component parts - Summary of components
1 - Changeover valve for radi‐

ator of exhaust gas recircula‐
tion -N345-
2 - 8 Nm
3 - 8 Nm
4 - Charge pressure sender -
G31-
5 - Gasket
❑ replace
6 - Connecting pipe
❑ to cylinder head/radiator
for exhaust gas recircu‐
lation
Caution
7 - 9 Nm
8 - Warm-type clamp, 4 Nm
❑ replace
9 - Throttle valve control unit -
J338-
10 - 10 Nm
11 - Gasket
❑ replace
❑ single gaskets can also
be installed
12 - Intake manifold
❑ with intake manifold flap motor -V157-
❑ with intake air-intrinsic optimisation
❑ must not be disassembled
13 - 8 Nm
4.2 Removing and installing intake manifold

♦ Socket insert Torx T 30 -T10405-

Fabia II 2007 ➤
Removing
Note

⇒ page 3 .
Caution
Make sure that no cable connection is damaged when discon‐

necting the plugs.
♦ Otherwise, the complete wiring loom must be replaced.
– Release screws -arrows- of fuel return-flow line.
– Carefully unlock the fuel return-flow line -arrow- at the high

pressure pump.
– Carefully remove the fuel return-flow line from the high pres‐
sure pump.
wiring loom.
– Disconnect the plugs at the glow plugs ⇒ page 232 .
4. Intake manifold and air filter 199

Fabia II 2007 ➤
– Release screw -arrow- and lay the changeover valve for radi‐
ator of exhaust gas recirculation -N345- to the side.
– Disconnect plugs -6,7,9,11-.

6 - Intake manifold flap motor -V157-
7 - Charge pressure sender -G31-
9 - Throttle valve control unit -J338-
– Release screws of coolant return-flow line -arrows- and lay the

return line to the side.
– Remove fuel distributor ⇒ page 191 .
– Slacken clamps -1- and -3-.

– Release the fixing screws of the intake manifold
( ⇒ page 198 , Pos. 13) crosswise from the outside inwards.
– Carefully remove intake manifold.
Install
following points:
– Replace gasket.
– Before installing, insert the fixing screws in the holes of the
intake manifold.
– Tighten screws from inside to outside and crosswise to 8 Nm.

Fabia II 2007 ➤
4.3 Air filter - Summary of components
❑ with captive screw,
9 Nm
2 - Clamp
3 - Heating for crankcase ven‐
tilation
❑ for vehicles in cold cli‐
matic zones
4 - Bleeder hose
❑ to charge pressure con‐
trol solenoid valve -N75-
⇒ “2.7 Connection dia‐
gram for vacuum ho‐
ses”, page 166
6 - Suction hose
❑ to exhaust gas turbo‐
charger
7 - Hose
❑ for crankcase ventila‐
tion
❑ to remove, press re‐
lease buttons
8 - 2 Nm
9 - Air mass meter -G70-
10 - O-ring
11 - 8 Nm
12 - Air filter top part
13 - Hose
❑ for preheating Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ for vehicles in cold climatic zones
14 - Filter element
❑ to remove, turn 1/4 turn to the left
❑ pay attention to change intervals ⇒ Maintenance ; Fabia II
15 - 8 Nm
16 - Rubber bearing
17 - Air filter bottom part
❑ screwed onto lock carrier
19 - 2 Nm
20 - Air intake hose
21 - Drain pipe

Fabia II 2007 ➤
22 - Rubber bearing
4.4 Removing and installing air filter

Remove air filter
– Unplug connector -2- from air mass meter -G70- .
– Open clamp -1- and detach suction hose to exhaust gas tur‐
bocharger.
– If present, detach hose for preheating.
– Remove vacuum lines with bracket -1- from air filter.
– Slacken screw -arrow- at air filter.

– Take out air intake hose -4-.
– Take out air filter completely.
Remove suction hose
Note
Due to the poor access of the pliers for spring strap clamps to the
bottom suction hose it is preferable to remove the inlet connection
from the exhaust turbocharger.

Fabia II 2007 ➤
– Remove the hose for crankcase ventilation -3-.

– Detach vacuum hose -2- from suction hose -1- and expose.
Unclip bracket.
– Completely unscrew screw -4- (captive).
– Swivel the inlet connection to the right and remove the suction
hose -1-.
Install suction hose
following points:
– When installing the inlet connection at the exhaust gas turbo‐

charger make sure that the inlet connection is correctly seated
on the bolt of the exhaust gas turbocharger -arrow-.
Install air filter
following points:
– Pull through the drain pipe -arrow- between the gearbox and
the body.
– Check if the drain pipe is correctly routed by looking under the

wing.
♦ Tightening torques ⇒ page 201 .

Fabia II 2007 ➤
5 Engine control unit
5.1 Removing and installing engine control

unit -J623-
Note
If the engine control unit should be replaced, connect the vehicle

diagnosis, measurement and information system -VAS 505x- and
in the “Targeted fault finding” carry out “replace engine control
unit”.
Removing
– Switch off ignition.
– Remove air filter with air mass meter -G70- ⇒ page 202 .
– Open the catches -arrows- and remove the engine control unit.
Vehicles without protective cover
– Disconnect both plugs at the engine control unit -J623- and
remove.
Vehicles with protective cover

Fabia II 2007 ➤
– Cut with body saw slots for the cross-head screwdriver in the
heads of the pull-off screws.
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.
♦ A locking agent is applied to the pull-off screws.
– Disconnect both plugs at the engine control unit -J623- and

remove.
Install
– Connect both plugs and lock.
Vehicles with protective cover
– Fasten protective cover with new pull-off screws.
– Tighten pull-off screws evenly until the heads are pulled off.
– Insert engine control unit -J623- in the bracket and lock se‐
curely.
Note
After replacing the engine control unit -J623 - , the initialisation

values of the differential pressure sender -G505 - must be reset
⇒ Vehicle diagnosis, testing and information system VAS 5051.
5. Engine control unit 205

Fabia II 2007 ➤
26 – Exhaust System
exhaust system
Note
♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ Replace the gaskets and the self-locking nuts.
♦ When performing installation work on the exhaust system,
make sure the exhaust system is not mounted under tension
and has adequate clearance from the vehicle body. If neces‐
sary slacken the double clamp and align the exhaust system
so as to create adequate clearance between these compo‐
nents and the vehicle body, and that the weight of the exhaust
system is evenly distributed over the hangers.
206 Rep. Gr.26 - Exhaust System

Fabia II 2007 ➤
1.1 Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5
standard (left-hand drive) - Summary of components
Note
♦ If the particle filter or the differential pressure sender -G505- is replaced, the differential pressure sender -
G505- must be adapted ⇒ Vehicle diagnosis, testing and information system VAS 5051; “Targeted func‐
tions”; adapt differential pressure sender -G505- .
♦ The exhaust turbocharger and the exhaust manifold are one component part, remove and install
⇒ page 154 .
♦ Double clamp between pre-exhaust pipe and rear part of exhaust system ⇒ page 222 .
1 - Differential pressure sender

-G505-
Caution
Risk of damage!
The
♦ differential pressure
indicator -G505- is very
sensitive. It must not
touch somewhere when
laying it down with the ho‐
ses connected.
Only
♦ detach the hoses
from the differential pres‐
sure sender -G505- if it
must be replaced.

⇒ page 209
2 - 3 Nm
3 - Control line
sender 4 -G648- , 45 Nm
❑ the thread of the new
temperature sender
must be coated with as‐
sembly paste
❑ coat only the thread with
hot bolt paste -G 052
112 A3- for re-used tem‐
perature sender
ling, use wrench
T10395/6
6 - Lambda probe -G39- , 50 Nm
❑ the thread of new lambda probes must be coated with assembly paste
❑ for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3-
❑ the hot bolt paste -G 052 112 A3- must not come into contact with the slots of the probe body
1. Removing and installing parts of the exhaust system 207

Fabia II 2007 ➤
7 - Heat shield
8 - 9 Nm
9 - Pre-exhaust pipe
❑ with oxidation catalytic converter and diesel particle filter
10 - Gasket
❑ replace
❑ replace
12 - 23 Nm
13 - 23 Nm
14 - Support
❑ bolted to engine support
15 - Exhaust gas temperature sender 3 -G495- , 45 Nm
❑ the thread of the new temperature sender must be coated with assembly paste
❑ coat only the thread with hot bolt paste -G 052 112 A3- for re-used temperature sender
❑ for removing and installing, use wrench T10395/6
16 - Support
17 - 23 Nm
18 - Support
❑ for differential pressure sender -G505-
1.2 Installing the exhaust gas temperature

sender 3 -G495- for vehicles according
to EU 5 standard (left-hand drive)
♦ Key -T10395/6-
A3- .
– Tighten the sender with a torque wrench and the wrench -
T10395/6- .
Caution

Nm.

Fabia II 2007 ➤

to EU 5 standard (left-hand drive)
♦ Key -T10395/6-
A3- .
Note
The illustration differs from the vehicle. The arrangement of the

wrenches is correct.

T10395/6- .
Caution

Nm.
1.4 Removing and installing the differential

pressure sender -G505- for vehicles ac‐
cording to EU 5 standard (left-hand
drive)
The differential pressure sender -G505- is connected to the meas‐
uring point in front of the diesel particle filter via a pipe.
The differential pressure sender -G505- determines the volumet‐
ric efficiency of the particle filter volume.
Caution
The differential pressure sender -G505 - is very sensitive to

shock load and leaks.
♦ Therefore the hoses of the sender must only be removed
if the sender is damaged.
♦ Furthermore there is the risk that the hose connections
break off when the hoses are removed.

Fabia II 2007 ➤
Removing
Note
Pull off the hoses carefully and only straight from the connection
fittings. Otherwise the connection fittings of the differential pres‐
sure sender -G505- break off easily.
– Pull off hoses.

– Unscrew screw -3- and remove differential pressure sender -
G505- .
Install
following points:
– Check hoses for soiling.
• If the cross section of the hoses is clearly constricted through
soot deposition, the complete assembly part must be re‐
placed. It consists of the sender with the hoses connected.
Note
♦ Blow out the control line from the differential pressure sender
-G505- to the diesel particle filter before installing (blocked or
iced up by condensation water).
♦ Pay attention to the tight connection and leaktightness of the
hoses.
Perform an adaptation after replacing the differential pressure

sender -G505-
The work procedure for the adaptation is described in the “Tar‐
geted fault finding”. It is also described under “Targeted func‐
tions”.
– Select “01 - Self-diagnosable systems”.
– Select “01 - Engine electronics J623”.
– Select “01 - Engine electronics, functions”.
– Select “01 - Erase initialisation values (Rep. Gr. 21 - 28)”.
1.5 Removing and installing the pre-exhaust

pipe for vehicles according to EU 5
standard (left-hand drive)
♦ Ring spanner set for lambda probe
♦ Set of tools 17 mm -T10395 -
♦ Transport device -T10404 -

Fabia II 2007 ➤
♦ Hot screw paste -G 052 112 A3-

Removing
– Disconnect the following plug connections and expose the ca‐
bles:
♦ -1- Plug connection exhaust gas temperature sender 1 -G235-
(black)
(brown)
(orange)
♦ -4- Plug connection lambda probe -G39- (grey)

Caution
Risk of damage!
♦ The differential pressure indicator -G505- is very sensi‐
tive. It must not touch somewhere when laying it down.
– Attach the differential pressure sender -G505- to the diesel

particle filter with the hoses connected.
– Release Lambda probe -G39- .
– Release exhaust gas temperature sender 3 -G495- using the
wrench -T10395/6- .
– Slacken screw -3- and swivel the bracket towards the front.
– Remove warm-type clamp -1- between pre-exhaust pipe and
exhaust turbocharger.
– Lower the assembly carrier ⇒ Chassis; Rep. Gr. 40 ; “slacken
the assembly carrier in the service position and align”.
Note
♦ Deviating from the specifications provided in the ⇒ Chassis

Workshop Manual, lower the assembly carrier 6 ... 7 cm.
♦ While doing so, the hydraulic lines for the steering must not be
exposed to tension.

Fabia II 2007 ➤
– Release screws -1- and remove cover for right drive shaft.
– Unscrew the exhaust gas temperature sender 4 -G648- -1-

from the pre-exhaust pipe using the wrench -T10395/6- .
– First release the screws -1-, then unscrew the nuts -2-.
– Remove bracket for pre-exhaust pipe.
Note

♦ If the pre-exhaust pipe should be reinstalled, the transport de‐
vice -T10404- -arrow- must be attached to the decoupling
element.

Fabia II 2007 ➤
– Slacken the nuts -arrows- of the double clamp and slide back‐
wards.
– Unhook the pre-exhaust pipe from the retaining straps on the
assembly carrier.
– Carefully remove pre-exhaust pipe. To do so, turn the pre-ex‐

haust pipe -arrow- 180° in -direction of arrow-.
Install
Note

♦ Neither bend nor expose the decoupling element to tension.
♦ Do not damage the wire mesh of the decoupling element.
♦ Secure the decoupling element with the transport device -
T10404- against overtensioning.

Note
Replace gasket and warm-type clamp.
When installing the pre-exhaust pipe with diesel particle filter, ob‐
serve the following sequence:
1. Position diesel particle filter on exhaust gas turbocharger
and loosely fasten clamp -1-.
2. Loosely screw in screws and nuts -2 … 5- by hand.
• It must still be possible to move the diesel particle filter
and the bracket.
3. Tighten clamp -1- to 7 Nm.

4. TIghten screws and nuts -2, 3 and 5- to 23 Nm.
5. Tighten screws -4- to 23 Nm
After replacing the diesel particle filter, the following work must
still be carried out:
♦ Set adaptation of ash mass balance to “0” ⇒ Vehicle diagnosis,
♦ Adapt differential pressure sender -G505- ⇒ page 209 .
– Align exhaust system free of stress ⇒ page 227 .

Fabia II 2007 ➤
1.6 Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5
standard (right-hand drive) - Summary of components
Note
♦ If the particle filter or the differential pressure sender -G505- is replaced, the differential pressure sender -
G505- must be adapted ⇒ Vehicle diagnosis, testing and information system VAS 5051; targeted functions;
adapt differential pressure sender -G505- .
♦ The exhaust turbocharger and the exhaust manifold are one component part, remove and install
⇒ page 154 .
♦ Double clamp between pre-exhaust pipe and rear part of exhaust system ⇒ page 222 .
1 - Lambda probe -G39- , 50

Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3-
❑ the hot bolt paste -G 052
112 A3- must not come
into contact with the
slots of the probe body
2 - Gasket
❑ replace
❑ replace
sender 4 -G648- , 45 Nm
❑ the thread of the new
temperature sender
must be coated with as‐
sembly paste
❑ coat only the thread with
hot bolt paste -G 052
112 A3- for re-used tem‐
perature sender
ling, use wrench
T10395/6
sender 3 -G495-
❑ the thread of the new temperature sender must be coated with assembly paste
❑ coat only the thread with hot bolt paste -G 052 112 A3- for re-used temperature sender
❑ for removing and installing, use wrench T10395/6
6 - Support
❑ for differential pressure sender -G505-

Fabia II 2007 ➤

8 - Control line
9 - Differential pressure sender -G505-
10 - 5 Nm
11 - 23 Nm
12 - 23 Nm
13 - Support
❑ screwed onto the cylinder block
14 - Pre-exhaust pipe
❑ with oxidation catalytic converter and diesel particle filter

to EU 5 standard (right-hand drive)
♦ Key -T10395/6-
A3- .
T10395/6- .
Caution

Nm.

to EU 5 standard (right-hand drive)
♦ Key -T10395/6-
A3- .

Fabia II 2007 ➤

T10395/6- .
Caution

Nm.
1.9 Removing and installing the differential

pressure sender -G505- for vehicles ac‐
cording to EU 5 standard (right-hand
drive)
The differential pressure sender -G505- is connected to the meas‐
uring point in front of the diesel particle filter via a pipe.
The differential pressure sender -G505- determines the volumet‐
ric efficiency of the particle filter volume.
Caution
The differential pressure sender -G505 - is very sensitive to

shock load and leaks.
♦ Therefore the hoses of the sender must only be removed
if the sender is damaged.
♦ Furthermore there is the risk that the hose connections
break off when the hoses are removed.

Fabia II 2007 ➤
Removing
Note
Pull off the hoses carefully and only straight from the connection
fittings. Otherwise the connection fittings of the differential pres‐
sure sender -G505- break off easily.
– Pull off hoses.

– Release nut -1- and remove differential pressure sender -
G505- -2-.
Install
following points:
– Check hoses for soiling.
• If the cross section of the hoses is clearly constricted through
soot deposition, the complete assembly part must be re‐
placed. It consists of the sender with the hoses connected.
Note
♦ Blow out the control lines from the differential pressure sender
-G505- to the diesel particle filter before installing (blocked or
iced up by condensation water).
♦ Pay attention to the tight connection and leaktightness of the
hoses.
Perform an adaptation after replacing the differential pressure

sender -G505-
The work procedure for the adaptation is described in the “Tar‐
geted fault finding”. It is also described under “Targeted func‐
tions”.
– Select “01 - Self-diagnosable systems”.
– Select “01 - Engine electronics J623”.
– Select “01 - Engine electronics, functions”.
– Select “01 - Erase initialisation values (Rep. Gr. 21 - 28)”.

pipe for vehicles according to EU 5
standard (right-hand drive)
♦ Transport device -T10404 -

Fabia II 2007 ➤

Removing
bles:
♦ Plug connection -1- exhaust gas temperature sender 1 -G235-
♦ Plug connection -2- lambda probe -G39-
– Unscrew lambda probe -G39- -1-.

Gr. 50 .

bles:
♦ -2- Plug connection differential pressure sender -G505-
– Unscrew nut -1-.
Caution
Risk of damage!
♦ The differential pressure indicator -G505- is very sensi‐
tive. It must not touch somewhere when laying it down.
– Attach the differential pressure sender -G505- to the diesel

particle filter with the hoses connected.
Note

exposed to tension.

Fabia II 2007 ➤
– Unscrew the exhaust gas temperature sender 3 -G495- -1-

from the pre-exhaust pipe using the wrench -T10395/6- . The
figures show how to tighten the sender.
– Remove the right underfloor trim panel ⇒ Body Work; Rep.

Gr. 66 .
– Remove the cover of the plug connection for the exhaust gas
temperature sender 4 -G648- .

Fabia II 2007 ➤
– Disconnect plug connection for exhaust gas temperature

sender 4 -G648- .
wards.
assembly carrier.

Install

Fabia II 2007 ➤
Note

element.

Note
When installing the pre-exhaust pipe with diesel particle filter, ob‐
serve the following sequence:
1. Position the pre-exhaust pipe with diesel particle filter
-1- at the exhaust gas turbocharger and loosely fasten
the clamp -2-.
• It must still be possible to move the diesel particle filter
and the bracket.

4. Tighten nut -6- to 23 Nm.
5. Tighten screw -7- to 23 Nm.
After replacing the diesel particle filter, the following work must
still be carried out:
♦ Set adaptation of ash mass balance to “0” ⇒ Vehicle diagnosis,
♦ Adapt differential pressure sender -G505- ⇒ page 209 .

Fabia II 2007 ➤
1.11 Rear part of the exhaust system for vehicles according to EU 5 standard -
Summary of components
1 - Rear part of exhaust system

❑ Individually replace the
exhaust pipe and the si‐
lencer when carrying
out repairs ⇒ page 226
❑ The separation point is
marked by indentations
on the exhaust pipe
❑ Align exhaust system
free of stress
⇒ page 227
2 - Retaining strap
❑ 23 Nm
3 - 20 Nm
4 - Tunnel bridge
5 - Double clamp
Double clamp between pre-exhaust pipe and rear part of exhaust

system
– Push the double clamp -1- to the dimension -a- = 5 mm in front
of the marking at the exhaust pipe -2- and tighten the bolted
connections evenly to 23 Nm.

Fabia II 2007 ➤
1.12 Exhaust pipe with oxidation catalytic converter for vehicles according to
EU-4/BS4 standard - Summary of components
Note
The exhaust turbocharger and the exhaust manifold are one component part, remove and install ⇒ page 154 .
1 - Lambda probe -G39- , 50

Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3-
❑ the hot bolt paste -G 052
112 A3- must not come
into contact with the
slots of the probe body
2 - Exhaust pipe
❑ with oxidation catalytic
converter
⇒ page 224
3 - Gasket
❑ replace
❑ replace
5 - 23 Nm
6 - Retaining strap
❑ Pay attention to the part
number
7 - Retaining strap
❑ Pay attention to the part
number
8 - Separation point
9 - Tunnel bridge
10 - 23 Nm
11 - Retaining strap
❑ Pay attention to the part number
12 - 23 Nm
13 - 23 Nm
14 - Support
❑ bolted to engine support

Fabia II 2007 ➤

pipe for vehicles according to EU-4/
BS-4 standard (right-hand drive)
♦ Transport device -T10404-
Removing
bles:
♦ Plug connection -1- exhaust gas temperature sender 1 -G235-
♦ Plug connection -2- lambda probe -G39-
– Unscrew lambda probe -G39- -1-.

Gr. 50 .
Note

exposed to tension.

Fabia II 2007 ➤
wards.
Note
If no double clamp is mounted, separate the exhaust pipe at the

front separation point ⇒ Item 8 (page 223) , ⇒ page 226 .

assembly carrier.

Install
Note

element.

Note

Fabia II 2007 ➤
When installing the pre-exhaust pipe, observe the following se‐

quence:
1. Position the pre-exhaust pipe -1- at the exhaust gas tur‐
bocharger and loosely fasten the clamp -2-.
• It must still be possible to move the pre-exhaust pipe
and the bracket.

1.14 Replacing the middle and rear part of the

exhaust system
♦ Body saw e.g. -V.A.G 1523 A -
♦ Protective goggles
Work procedure
For separating the exhaust pipe and the silencer, a separation
point is provided in the rear part of the exhaust system, which is
marked with recesses.
WARNING
Wear safety goggles.
– Separate exhaust pipe at right angles at the separation point

-arrow 1- with body saw.
– When installing, position double clamp -4- at the side markings
-arrow 2- and -arrow 3-.

Fabia II 2007 ➤
– Install double clamps in such a way that the ends of the screws
do not protrude beyond the bottom edge of the double clamp.
• The bolted connection points to the right.
– Tighten bolted connections of the double clamp evenly to 23
Nm.
1.15 Aligning exhaust system free of stress

Condition
• The exhaust gas system must be cold for aligning.
– Slacken double clamp -1- and align to pre-exhaust pipe -2-
(-arrow- points in direction of travel).
-a- = 5 mm
• The fixing screws must be located on the right. They must not
protrude beyond the bottom edge of the double clamp.
– Tighten the front nut by hand.
– Push the rear part of the exhaust system so far forward until
the initial load -dimension a- on the retaining strap is 3 ... 7
mm.
– Tighten nuts of double clamp evenly to 23 Nm.
1.16 Inspecting the exhaust system for leak‐

tightness
– Start engine and run in idle.
– Seal off exhaust tailpipe for the duration of the leak check (e.g.
with cloths, plugs).
– Connection points: inspect cylinder head/exhaust manifold,
exhaust gas turbocharger/pre-exhaust pipe etc. for leaktight‐
ness by listening.
– Eliminate any leak found.

Fabia II 2007 ➤
2 Exhaust gas recirculation system
2.1 Parts of exhaust gas recirculation - Summary of components
1 - 9 Nm
2 - Connecting pipe
❑ to cylinder head
Caution
3 - 9 Nm
4 - Gasket
❑ replace
5 - Vacuum line
❑ do not change bending
form
❑ Connection diagram for
vacuum hoses
⇒ page 166
6 - 9 Nm
7 - Gasket
❑ replace
8 - Connecting pipe
❑ To intake manifold
Caution
9 - 9 Nm
11 - Radiator
❑ for exhaust gas recirculation
❑ with bypass flap
❑ with integrated exhaust gas recirculation valve -N18- and with exhaust gas recirculation potentiometer -
G212-
❑ Check change-over ⇒ page 229
12 - 9 Nm
13 - Gasket
❑ replace

Fabia II 2007 ➤
14 - Gasket
❑ replace
15 - Connecting pipe
❑ from exhaust manifold
Caution
16 - 22 Nm
17 - 9 Nm
18 - Gasket
❑ replace
2.2 Checking change-over flap for radiator

for exhaust gas recirculation
♦ Hand vacuum pump , e.g. -VAS 6213-
♦
Work procedure
Gr. 50 .
– Remove heat shield collar.
Note
In order to generate “vacuum”, push the ring -1- for the hand vac‐
uum pump -VAS 6213- into position -A-.
2. Exhaust gas recirculation system 229

Fabia II 2007 ➤
– Detach hose from vacuum setting element of change-over flap

and connect the hand vacuum pump -VAS 6213- instead.
– Generate vacuum with the hand vacuum pump.
• The linkage on the vacuum setting element for the change-
over flap for radiator of exhaust gas recirculation must move
-arrows-.
If the linkage does not move or only moves with a sudden motion:
♦ The vacuum setting element for the change-over flap for radi‐
ator of exhaust gas recirculation is defective.
♦ Change-over flap for radiator of exhaust gas recirculation is
sluggish.
– Replace radiator for exhaust gas recirculation ⇒ page 230 .
Note
The heat shield collar should be fitted on again in the same place
when installing.
2.3 Removing and installing radiator for ex‐

♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-
Removing
⇒ page 202 .
– Unclip the vacuum line -2- from the bracket -arrow- and place
downwards.
– Remove right front wheel.
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
Gr. 66 .
Gr. 50 .
♦ Left-hand drive ⇒ page 210
♦ Right-hand drive ⇒ page 217

Fabia II 2007 ➤
– Remove connection pipe -2- to exhaust gas recirculation ra‐

diator.
– Only unscrew connecting pipe -1- at radiator for exhaust gas
recirculation -arrows-.
– Slacken union nut -1- with open ring spanner 17 mm -A-.

– Remove heat protective cover at vacuum setting element.
– Detach hose from vacuum setting element.
– Disconnect the plug on the exhaust gas recirculation valve -
N18- .
– Pinch off coolant hoses to radiator for exhaust gas recircula‐
tion with hose clamps up to ∅ 25 mm -MP7-602- .
– Collect escaping coolant with the catch pan -VAS 6208- .
– Detach coolant hoses from radiator for exhaust gas recircula‐
tion.
– Release screws and remove radiator for exhaust gas recircu‐
lation.
Install
following points:
nuts.
♦ Secure all hose connections with corresponding hose clamps
♦ Tightening torques ⇒ page 228 .
– Inspect coolant level, top up with coolant if necessary
⇒ page 112 .
2. Exhaust gas recirculation system 231

Fabia II 2007 ➤
28 – Glow Plug System

1 Glow Plug System
Note
Check glow plugs ⇒ Vehicle diagnosis, testing and information

system VAS 5051.
1.1 Removing and installing glow plugs

♦ Flexible-head wrench SW 10 , e.g. -3220-
Test conditions
• Engine is cold
• Ignition is switched off
Work procedure
wiring loom.
– Disconnect plug -6- at fuel pressure sender -G247- .
Caution
♦ Carefully disconnect the plug from the glow plugs.

♦ If the plug is damaged when disconnecting it, the complete
wiring loom including the plugs must be replaced (plugs
cannot be replaced separately).
232 Rep. Gr.28 - Glow Plug System

Fabia II 2007 ➤
– Carefully disconnect the plug from the glow plugs. Use the
assembly spanner SW 12 for help.
WARNING

– Clean the glow plug and the hole in the cylinder head with
great care.
Note
No dirt must get into the cylinder.
When cleaning, for example:

1. Suction off heavy dirt using a vacuum cleaner.
2. Spray grease remover and cleaning agent onto the glow
plug and into the hole around the plug, let it take effect for a
short period of time and blow out with compressed air.
3. Clean the glow plug and the channel around the plug with a
cloth soaked in oil.
– Slacken the glow plug with a flexible-head wrench 10 -3220 -
and release.
Install
following points:
Note
♦ Before installing the glow plug, remove dirt and deposits from
the bore in the cylinder head and from the thread.
♦ Do not oil or grease the threaded bore in the cylinder head as
well as the pencil type glow plug thread.
– Screw the glow plugs into the cylinder head by hand using the
flexible-head wrench -3220- .
– Tighten glow plugs to 16 - 18 Nm.
– Fit the plug again onto the relevant glow plug and check for
firm seating.
– Interrogating and erasing fault memory of engine control unit
5051.
Note
After deleting the fault memory of the engine control unit the read‐
iness code must be checked, if necessary re-generated.
1. Glow Plug System 233

Cfwa 1 2 Tdi CR Engine Repair English

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cfwa 1 2 Tdi CR Engine Repair English

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

1.1 Engine number

1.2 Engine characteristics

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.2 Supplementary instructions and assem‐

Risk of injury through refrigerant.

Risk of damaging the condensor, the refrigerant lines and ho‐

Steps which should be taken in order to remove and install the

2 Rep. Gr.01 - Self-diagnosis

1.3 Regulations concerning safety precau‐

When undertaking all installation work, particularly in the en‐

1. Self diagnosis, safety measures, cleanliness regulations and directions 3

Observe the following points to prevent injury to persons and/or

1.4 Regulations concerning cleanliness

4 Rep. Gr.01 - Self-diagnosis

1.5 Regulations concerning cleanliness

1. Self diagnosis, safety measures, cleanliness regulations and directions 5

1.6 Fuel hoses in the engine compartment -

• After removing the fuel hoses from nozzles with 3-wave

-Arrows- 3-wave profile

♦ For the above mentioned reasons, always disconnect the

If a fuel hose cannot be disconnected from the hose nozzle by

Never push a screwdriver or a similar tool between the hose

6 Rep. Gr.01 - Self-diagnosis

1.7 General instructions for charge air sys‐

When undertaking all installation work, particularly in the en‐

In case a mechanical damage to the exhaust gas turbocharger

♦ The charge-air system must be tight, check ⇒ page 164 .

1. Self diagnosis, safety measures, cleanliness regulations and directions 7

8 Rep. Gr.01 - Self-diagnosis

10 – Removing and installing engine

1.1 Removing and installing engine trim

– Successively slacken the engine cover in the marked se‐

– If necessary, adjust the ball sockets of the engine cover to the

1.2 Removing engine

1. Removing and installing engine 9

♦ Engine mount -T40076-

♦ The engine is removed downwards together with the gearbox.

When undertaking all installation work, particularly in the en‐

10 Rep. Gr.10 - Removing and installing engine

– Unscrew the positive cable -1- at the positive terminal on the

– Remove vacuum lines with brackets -1- from air filter.

After separating the hydraulic line, do not operate the clutch

– Unplug connector -arrow- from speedometer sender -G22- (if

1. Removing and installing engine 11

– Disconnect plug connection -arrow-.

– Carefully slacken the engine wiring harness on its fixing points

– Disconnect plug -arrow 1- from reversing light switch -F4- .

12 Rep. Gr.10 - Removing and installing engine

Risk of injury through refrigerant.

Risk of damaging the condensor, the refrigerant lines and ho‐

– Remove the AC compressor from the bracket for auxiliary

1. Removing and installing engine 13

– Disconnect plug connection for exhaust gas temperature

– Remove noise insulation -2- for oil pan. To do this: