Service

Workshop Manual
Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine
Engine ID
CBZ CBZ
A B
Edition 02.10

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Service Department. Technical Information

 Service
List 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 system
20 - Fuel Supply
21 - Turbocharging
24 - Fuel Formation, Injection
26 - Exhaust System
28 - Ignition system

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 ŠKODA AUTO a. s. D3E802BE98F

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Self diagnosis, safety measures, cleanliness regulations, directions . . . . . . . . . . . . . . . . . . 3
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Release pressure in the high pressure area of the fuel system . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Rules of cleanliness to observe when working on the fuel supply system . . . . . . . . . . . . . . 5
1.5 Safety measures to apply when working on the fuel injection and ignition system . . . . . . 5
1.6 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.9 Additional instructions when undertaking assembly work on the air-conditioning system . . 8

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

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1 V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1 V-ribbed belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3 Removing and installing bracket for top auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Removing and installing bracket for bottom auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Camshaft drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Removing and installing the top timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Removing and installing the bottom timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4 Removing and installing crankshaft belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.5 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2 Inspect piston, piston rings and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
15 - Cylinder Head, Valve Gear by ŠKODA
unless authorised . . . . AUTO
. . .A.. S.. ŠKODA
. . . .AUTO
. . .A.. S.. does
. . .not. guarantee
. . . . .or.accept
. . .any
. .liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
. . . . . . . . . 53
1 Cylinder head - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Test timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Contents i
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.4 Removing and installing timing chain and drive chain for oil pump . . . . . . . . . . . . . . . . . . 62
2 Cylinder head - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Removing and installing cylinder head cover and camshaft . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.3 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.4 Check combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1 Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.2 inspect camshaft, axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.4 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.2 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.1 Coolant regulator - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.2 Removing and installing belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.4 Removing and installing coolant recirculation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.1 Parts of cooling system on the side next to the body - Summary of components . . . . . . . . 100
3.2 Removing and installing fan shroudunless andauthorised
radiator fan V7AUTO. A.. .S..ŠKODA
. . . . AUTO
. . . .A..S.. does
. . . not
. .guarantee
. . . . . or
. .accept
101any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA
3.3 Removing and installing radiator . . with . . .respect
. . . .to.the
. .correctness
. . . . . .of. information
. . . . . .in. this
. . document.
. . . . . .Copyright
. . . . .by. .ŠKODA
. . . AUTO
102 A. S.�
3.4 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1 Fuel tank and fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Fuel tank - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.2 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.3 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.5 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 112
1.6 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2 Electronic Engine Power Control (Electronic throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 Activated charcoal container system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.1 Activated charcoal container system - Summary of components . . . . . . . . . . . . . . . . . . . . 122
3.2 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

21 - Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.1 Charge air system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

ii Contents
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

24 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1 Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Intake manifold and fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.2 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 138
2.3 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.4 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.1 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.2 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1 High pressure pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.1 Removing and installing injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.2 Replace Teflon gasket ring and supporting washer at injection valve . . . . . . . . . . . . . . . . 150
6 Testing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.1 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Catalytic converter and component parts - Summary of components . . . . . . . . . . . . . . . . 159
1.2 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Removing and installing catalytic converter with pre-exhaust pipe . . . . . . . . . . . . . . . . . . 161
1.4 Replacing middle or rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.6 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.1 Ignition system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Contents iii
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

iv Contents
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

00 – Technical data
1 Technical data

1.1 Engine number

The engine number (“engine identification character” and “serial
number”) is located on the engine directly above the joint sepa‐
rating the engine/gearbox.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

In addition, the “engine identification character” and the “serial

number” are indicated on the vehicle data sticker -arrow- which is
located on the air guide pipe.
♦ As of letter “C”, four-digit engine identification characters are
used.
♦ 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 together with the serial number
on the cylinder block.
♦ The fourth digit indicates the output and the torque of the en‐
gine and depends upon the engine control unit.

1.2 Engine characteristics

Engine identification characters CBZA CBZB
Manufactured 03.10 ? 03.10 ?
Emission levels in accordance with EU5 EU5
Displacement cm 3 1197 1197
Power output kW at rpm 63/4800 77/5000
Torque Nm at rpm 160/1500-3500 175/1550-4100
Bore ∅ mm 71,0 71,0
Stroke mm 75,6 75,6
Compression 10:1 10:1
Cylinder / valves per cylinder 4/2 4/2
RON unleaded 95 1) unleaded 95 1)
Ignition system, fuel injection Simos 10 Simos 10
Type of fuel preparation Direct injection homoge‐ Direct injection homoge‐
neous neous

1. Technical data 1
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Engine identification characters CBZA CBZB

Knock control 1 sensor 1 sensor
Lambda control 2 Lambda probes 2 Lambda probes
3-way catalytic converter yes yes
Exhaust gas recirculation no no
Intake manifold change-over no no
Camshaft adjustment no no
Secondary air system no no
Exhaust gas turbocharger yes yes
Balancing shaft no no
1) At least 91 RON in exceptional cases, although engine output
is reduced

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2 Rep. Gr.00 - Technical data

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations, directions

1.1 Self-diagnosis
This repair group is no longer applicable.
For this use “Vehicle self-diagnosis”, “Measuring method” and
“Targeted fault finding” ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051.

1.2 Safety precautions when working on the

fuel supply system

WARNING

♦ The safety measures for the pressure reduction in the high

pressure area of the fuel system must be observed
⇒ page 4 .
♦ The fuel system is under pressure! Wear safety goggles
and safety clothing, in order to avoid injuries and skin con‐
tact with fuel. Place a clean cleaning cloth around the
connection point before detaching wiring. Reduce pres‐
sure by carefully removing the wiring.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

♦ The fuel delivery unit is activated by switching on the ignition

and the door contact switch of the driver door. Before opening
the fuel system and for reasons of safety, if the battery is not
disconnected, the plug -2- must be disconnected from the fuel
pump control unit.

Caution

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 (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

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‐
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!

1.3 Release pressure in the high pressure

area of the fuel system

WARNING

♦ The injection system consists of a high pressure part

(maximum 12 MPa/120 bar) and a low pressure part (ap‐
prox. 0.6 MPa/6 bar).
♦ Before opening the high pressure area, e.g. removing the
high pressure pump, the fuel distributor, the injection
valves, the fuel pipes or the fuel pressure sender -G247
- , the fuel pressure in the high pressure area with a re‐
maining pressure of approx. 0.6 MPa (6 bar) must be
reduced. The procedure for this is described below.

– Connect the ⇒ Vehicle diagnosis, testing and information sys‐

tem VAS 5051 and carry out the targeted function “remove
high fuel pressure”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Switch off ignition. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4 Rep. Gr.01 - Self-diagnosis

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– For safety reasons before opening the fuel system disconnect

the plug from the fuel pump control unit -2-.

WARNING

The fuel lines are pressurized! Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.
Before opening the high pressure part lay cleaning cloths
around the connection point.

– Now lay a clean cleaning cloth around the connection point

and carefully open it up, in order to reduce the remaining pres‐
sure of approx 0.6 MPa (6 bar). Collect the fuel which flows
out.

Note

♦ Interrogate the fault memory of the engine control unit at the

end of the following work and delete all the fault entries.
♦ If the fault memory was erased, the readiness code must be
generated ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.

1.4 Rulesunless
of authorised
cleanliness
Protected by copyright. Copyingtofor observe when
private or commercial purposes, in part or in whole, is not permitted
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
working withon the
respect to thefuel supply
correctness system
of information in this document. Copyright by ŠKODA AUTO A. S.�

Carefully observe the following 5 rules for cleanliness when work‐

ing 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. in tool boxes).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.

1.5 Safety measures to apply when working

on the fuel injection and ignition system

WARNING

♦ The safety measures for the pressure reduction in the high

pressure area of the fuel system must be observed
⇒ page 4 .
♦ The fuel system is under pressure! Wear safety goggles
and safety clothing, in order to avoid injuries and skin con‐
tact with fuel. Place a clean cleaning cloth around the
connection point before detaching wiring. Reduce pres‐
sure by carefully removing the wiring.

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

damage to the injection and ignition system:

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

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

♦ Do not touch or remove ignition leads and ignition coils with

power output stages with the engine running or at start speed.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure,
open lid of fuse carrier in the engine compartment and unplug
fuse for Motronic current supply relay -J271- ⇒ Current flow
diagrams and Fitting locations.
♦ The fuel delivery unit is activated by switching on the ignition
and the door contact switch of the driver door. Before opening
the fuel system and for reasons of safety, if the battery is not
disconnected, the plug -2- must be disconnected from the fuel
pump control unit.

Caution

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 (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

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 pas‐
senger seat, the passenger could be injured by the release of
the passenger airbag in the event of an accident.

1.6 General notes on the injection system

Repairing ignition ⇒ page 166 .
♦ The engine control unless
unit authorised
is equipped with a self-diagnosis sys‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
tem. Before repairs and also for
with respect to thefault finding,
correctness first ofin all
of information this inter‐
document. Copyright by ŠKODA AUTO A. S.�
rogate the fault memory. Also check the vacuum hoses and
connections (unmetered air).
♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ electronic catalogue of original parts .
The use of clamp-type or screw-type clips is not allowed.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
♦ When opening the driver door the fuel pump is activated for 2
seconds in order to build up the pressure in the fuel system.

6 Rep. Gr.01 - Self-diagnosis

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

♦ Certain inspections may cause the control unit to detect and

store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
Safety measures ⇒ page 5 .

1.7 General notes on the ignition system

♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the 4AV control unit.
♦ The engine control unit is equipped with a self-diagnosis sys‐
tem; inspect ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
Safety measures ⇒ page 5 .
Test data, spark-plugs ⇒ Maintenance ; Roomster .

1.8 General instructions

Protected forforcharge
by copyright. Copying air sys‐
private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
tem with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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 (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.

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

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Caution

In case of mechanical damage to the exhaust turbocharger,

e.g. damage of the gyroscope compressor, it is not sufficient
to only replace the exhaust turbocharger. In order to avoid
consequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change the engine oil and replace the oil filter
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
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.

♦ Replace self-locking nuts.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before being installed.
♦ Only use clamps for securing the hose connections ⇒ Elec‐
tronic Catalogue of Original Parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Before connecting the oil feed line, fill the exhaust turbocharg‐
er via the connection fitting with engine oil.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.

1.9 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system

WARNING

Do not open the refrigerant circuit of the air conditioning sys‐

tem.

Note

In order to avoid damage to the condenser as well as to the re‐

frigerant lines and hoses, ensure that the lines and hoses are not
over-tensioned, kinked or bent.

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 AC compressor from the bracket ⇒ page 19 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

8 Rep. Gr.01 - Self-diagnosis

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

10 – Removing and installing engine

1 Removing and installing engine

1.1 Removing engine

Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Engine mount -T10416-
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-

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 fitted again in the same location
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 reuse or proper
disposal.

Caution

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 (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

Observe all safety measures and notes for assembly work on the
fuel, injection and ignition system and the charge air system as
well as rules for cleanliness ⇒ page 3 .

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Before disconnecting the battery, if necessary

Protected by copyright. remove the or commercial purposes, in part or in whole, is not permitted
Copying for private
adapter for the anti-theft wheel unless
boltsauthorised
from the luggage
by ŠKODA AUTOcom‐
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
partment. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Remove battery ⇒ Electrical System ⇒ Rep. Gr. 27 .

– Remove air filter ⇒ page 142 .

1. Removing and installing engine 9

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Remove battery tray ⇒ Electrical System ⇒ Rep. Gr. 27 .

– Remove the right and left wheelhouse liner ⇒ Body Work ⇒
Rep. Gr. 66 .
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Drain coolant ⇒ page 94 .
– Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box.
– Unscrew the nut of the left coupling rod -2- and press the cou‐
pling rod off the anti-roll bar.
– Unscrew the nuts from the left steering joint -3- and press the
steering joint out of the suspension arm.

– Unscrew the nut -2- from the front left track control arm on
installed front left vehicle level sensor -G78- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Turn steering to full left lock. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Swivel the steering joint outwards and secure the drive shaft
-1- with strap -A- in the wheelhouse.

– Detach coolant hoses -2- and -5-.

– Remove fuel line (press in the securing ring to the top) -3- and
-4-. Collect escaping fuel with a cloth.

10 Rep. Gr.10 - Removing and installing engine

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Loosen retaining clip for coolant hose -3-.

– Slacken the clamp -1- and detach the coolant hose -2- from
the engine.

– Detach the coolant hoses at the heat exchanger -arrows-.

– Detach vacuum hose -1- from intake manifold.

– Slacken clamps -2- and detach coolant hoses -3 ... 5-.
For models with automatic gearbox
– Remove the selector lever control cable from the gearbox ⇒
Gearbox ⇒ Rep. Gr. 34 .
For vehicles with manual gearbox
– Remove shift mechanism from gearbox ⇒ gearbox ⇒ Rep.
Gr. 34 .
– Remove hydraulic clutch control from gearbox ⇒ Gearbox ⇒
Rep. Gr. 34 .

WARNING

After removing the slave cylinder or after separating the hy‐

draulic line, do not depress the clutch pedal.

Continued for all vehicles

– Remove/unclamp
Protected by all electrical
copyright. Copying lines from
for private the gearbox,
or commercial purposes, gener‐
in part or in whole, is not permitted
ator and starter motorbyand
unless authorised ŠKODA uncover
AUTO A. S. them.
ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove/unclamp all other necessary electrical cables from
the engine.
– Disconnect the vacuum and bleeder hoses from the engine.

1. Removing and installing engine 11

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Disconnect the plug of the engine line wiring harness -1- from
the engine control unit ⇒ page 157 .
– Disconnect plug connection -2-.
– Unclip cable clip -3- -arrows-.
– Remove engine wiring harness and attach to engine control
unit.

– Disconnect plugs -1 and 2- and release cable strap -5-.

– Remove catalytic converter with pre-exhaust pipe
⇒ page 161 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Unscrew the screws -1, 3- and remove the bottom
with respect coolant
to the correctness pipe in this document. Copyright by ŠKODA AUTO A. S.�
of information
-2-.

– Unbolt the pendulum support -arrows-.

For vehicles with air conditioning
– Remove V-ribbed belt ⇒ page 22 .

12 Rep. Gr.10 - Removing and installing engine

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Disconnect connector -1- for magnetic coupling at AC com‐

pressor.

WARNING

Risk of injury through refrigerant.

♦ Do not open the refrigerant circuit of the air conditioning
system.

Caution

Risk of damaging refrigerant lines and hoses.

♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.

– Release screws -arrows- for AC compressor.

– Attach AC compressor to lock carrier.
Continued for all vehicles

In order to lower the engine with the gearbox, the engine holder
-T10416- with the adapters -/1-, -/2- and -/3- is required.

– Turn the adapter T10416/1 up to the stop in the cylinder block.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Removing and installing engine 13

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Fit the engine mount -T10416- with the adapters -/2- and -/3-
to the cylinder block.
– Attach the engine mount -T10416- with the screw -1- by hand
at the cylinder block.
– Tighten all screws on the engine mount -T10416- to 20 Nm.
– Place the engine and gearbox jack - V.A.G 1383 A- on the
engine mount -T10416 - and slightly raise the engine with the
gearbox.

Note

♦ Check whether all hose and line connections between engine,

gearbox and body are released, if necessary release them.
♦ Use the double ladder -VAS 5085- for removing the fixing
bolts.

– Unscrew nut -3- and disconnect earth lead -4- from engine
mount.
– Release screws -2- from engine mount -1-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Release screws -2- from gearbox mount -1-.

Note

♦ The engine/gearbox assembly should be lowered with the help

of a second mechanic.
♦ Carefully lower engine with gearbox in order to avoid damage.

– Pull engine/gearbox unit as far forward as possible and lower

carefully and slowly downwards.
– Remove the gearbox from the engine ⇒ gearbox ⇒ Rep. Gr.
34 .

1.2 Securing the engine to the assembly

stand
Special tools and workshop equipment required
♦ Lifting device -MP 9-201 (2024 A)-
♦ Engine mount -MP 1-202-
♦ Assembly stand -MP 9-101-
♦ Adapter -MP1-202/8-
♦ Adapter -MP1-202/9-
♦ Workshop crane , e.g. -VAS 6100-

14 Rep. Gr.10 - Removing and installing engine

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Work procedure
• Separate engine from gearbox.
– Attach lifting device -MP9-201 (2024 A)- at workshop crane
(e.g. -VAS 6100- ) and at engine as shown. (The figure shows
the 1.4 ltr./90 kW TSI Engine; the engine mounting is identi‐
cal).

WARNING

Use securing pins on the hooks and rig pins to prevent release.
Use securing pins on the hooks and rig pins -arrows-, in order
to avoid injuries and damages to the engine.

– Lift off engine with installed -T10416- with workshop crane

(e.g. -VAS 6100- ) from engine/gearbox jack - V.A.G 1383 A- .
– Remove engine mount -T10416- .

– Screw engine mount -MP 1-202- with adapters -MP1-202/8-

and -MP1-202/9- to engine -arrows- and secure to the assem‐
bly stand -MP 9-101- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1.3 Installing the engine

Special tools and workshop equipment required
♦ Double ladder , e. g. -VAS 5085 -
♦ Catch pan for workshop crane , e.g. -VAS 6208 -
♦ Pliers for spring strap clamps
♦ Grease -G 000 100-
♦ Cable strap
Condition
• Engine and gearbox with mounted engine mount -T10416- to
engine and gearbox jack -V.A.G 1383 A- .
Work procedure
Installation is carried out in the reverse order. Pay attention to the
following:

1. Removing and installing engine 15

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Caution

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 (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

Note

♦ All cable straps should be fastened again in the same place

when installing.
♦ Secure all hose connections with hose clamps ⇒ Electronic
Catalogue of Original Parts .
♦ When performing installation work replace the self-locking
nuts and screws.
♦ Replace screws which have been tightened firmly to a torquing
angle as well as gasket rings and seals.

Observe all safety measures and notes for assembly work on the
fuel, injection and ignition system and the charge air system as
well as rules for cleanliness ⇒ page 3 .
– Check whether the dowel sleeves for centering the engine/
gearbox are present in the cylinder block; insert if necessary.
– Ensure that the intermediate plate has been inserted on the
sealing flange and is pushed onto the dowel sleeves
-arrows-.
For vehicles with manual gearbox
– Clean the serration on the drive shaft and if the clutch disc has
been used clean the hub serration, remove corrosion and only
apply a very thin layer of grease -G 000 100- to the serration
on the drive shaft. 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 .
For models with automatic gearbox

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

16 Rep. Gr.10 - Removing and installing engine

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Replace the needle bearing -arrow- in the crankshaft

⇒ page 46 .
– Attach the selector lever control cable at the gearbox ⇒ Gear‐
box ⇒ Rep. Gr. 34 .
Continued for all vehicles
– Screw on gearbox to engine ⇒ gearbox ⇒ Rep. Gr. 34 .
– When installing the engine/gearbox assembly, ensure clear‐
ance to the assembly carrier, AC compressor as well as to the
radiator fan.
– Tighten the new screws by hand for attaching the engine/
gearbox assembly at the engine and gearbox mounts.
– Adjust assembly bracket and tighten screws ⇒ page 18 .
– Install pendulum support ⇒ page 18 .
– Install drive shafts ⇒ Chassis ⇒ Rep. Gr. 40 .
For vehicles with air conditioning
– Install AC compressor ⇒ page 19 .
– Install the V-ribbed belt ⇒ page 22 .
Continued for all vehicles
– Install slave cylinder ⇒ Gearbox ⇒ Rep. Gr. 30 .
– Attach shift mechanism and adjust if necessary ⇒ Gearbox ⇒
Rep. Gr. 34 .
– Install the engine wiring harness and connect to the engine
control unit ⇒ page 157 .
– Install catalytic converter with exhaust pipe ⇒ page 161 .
– Install the battery and pay attention to the necessary work after
re-connecting the battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Checking the oil level ⇒ Maintenance ; Roomster .
– Top up and bleed cooling system ⇒ page 94 .
– Interrogate all fault memories and delete all fault entries, which
are caused by removing and installing the engine ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
After deleting the fault memory of the engine control unit the
readiness code must be re-generated.
– Perform a test drive.
– Then perform a vehicle system test and if necessary eliminate
the resulting faults.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Tightening torques unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Component Nm
Screws/nuts M6 10
M7 13
M8 20
M10 45
M12 60
deviations:
Engine/gearbox connecting screws ⇒ gearbox ⇒ Rep. Gr. 34
Screws for assembly bracket ⇒ page 18

1. Removing and installing engine 17

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.4 Assembly bracket

Note

♦ When installing, first of all insert all screws for bracket and
screw in by hand by at least two - three turns.
♦ Tighten screws for bracket in the sequence according to the
numerical marking in the figs.

1.4.1 Tightening torques

Assembly bracket - engine
2 - 20 Nm + torque a further 90° (1/4 turn) - replace

3 - 30 Nm + torque a further 90° (1/4 turn) - replace

4 - 16 Nm

Note

The assembly bracket is supplemented by a dynamic vibration

damper -1-. This vibration damper is a component part of the as‐
sembly bracket - it is not removed.

Assembly bracket - gearbox

Note

Tighten screws -1- in the following sequence: rear, front and then
upwards.

1 - 50 Nm + torque a further 90° (1/4 turn) - replace

2 - 40 Nm + torque a further 90° (1/4 turn) - replace

Pendulum support

Note

Before tightening the screws -1- press off gearbox in the elonga‐
ted holes of the pendulum support to the front in such a way that
there is maximum distance between the gearbox and the assem‐
bly carrier.

1 - 30 Nm + torque a further 90° (1/4 turn) - replace

2 - 40 Nm + torque a further 90° (1/4 turn) - replace

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

18 Rep. Gr.10 - Removing and installing engine

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

13 – Crankgear
1 V-ribbed belt drive

1.1 V-ribbed belt - Summary of components

1.1.1 Summary of components - Vehicles without air conditioning

1 - V-ribbed belt
❑ Routing of the ribbed V-
belt ⇒ page 20
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ removing and installing
⇒ page 22
2 - Fixing screw
❑ for crankshaft belt pulley
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ tighten ⇒ page 37 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
3 - Belt pulley for crankshaft
❑ Clamping surfaces must
be free of oil and grease.
4 - Diamond coated washer
❑ replace
5 - 20 Nm
❑ When loosening and
tightening, counterhold
with the wrench for the
water pump and power-
assisted steering -MP
1-308 (V.A.G 1590)- to
this end rework wrench
for the water pump and
power-assisted steering
- MP 1-308 (V.A.G 1590)- ⇒ page 97
6 - Belt pulley - coolant pump
❑ removing and installing ⇒ page 37
7 - 9 Nm
8 - Vacuum hose
❑ to solenoid valve for coolant circuit -N492- at intake manifold
9 - Coolant pump
❑ removing and installing ⇒ page 98

1. V-ribbed belt drive 19

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

10 - 25 Nm
11 - Generator
❑ removing and installing ⇒ Electrical System ⇒ Rep. Gr. 27
❑ to facilitate positioning, drive the threaded bushings for the screws at the generator slightly backwards
12 - Bracket for auxiliary units
❑ for tensioning device and AC compressor
❑ removing and installing ⇒ page 25
13 - 40 Nm + torque a further 90° (1/4 turn)
❑ replace
14 - 25 Nm
15 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with wrench to slacken the V-ribbed belt
❑ Secure tensioning device with a 4 mm hexagon wrench or locating pin -T10060 A- .
❑ to remove, release screw -Pos. 12-

Routing of the V-ribbed belt

1 - Belt pulley - coolant pump
2 - Tensioning pulley
3 - Belt pulley - AC generator
6 - Belt pulley - crankshaft

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

20 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.1.2 Summary of components - Vehicles with air conditioning

1 - V-ribbed belt
❑ Routing of the ribbed V-
belt ⇒ page 22
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ removing and installing
⇒ page 22
2 - Fixing screw
❑ for crankshaft belt pulley
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
❑ tighten ⇒ page 37
3 - Belt pulley for crankshaft
❑ Clamping surfaces must
be free of oil and grease.
4 - Diamond coated washer
❑ replace
5 - 20 Nm
❑ When loosening and
tightening, counterhold
with the wrench for the
water pump and power-
assisted steering -MP
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
1-308 (V.A.G
with respect 1590)-
to the to of information in this document. Copyright by ŠKODA AUTO A. S.�
correctness
this end rework wrench
for the water pump and
power-assisted steering
- MP 1-308 (V.A.G 1590)- ⇒ page 97
6 - Belt pulley - coolant pump
❑ removing and installing ⇒ page 37
7 - 9 Nm
8 - Vacuum hose
❑ to solenoid valve for coolant circuit -N492- at intake manifold
9 - Coolant pump
❑ removing and installing ⇒ page 98
10 - 25 Nm
11 - Guide pulley, 40 Nm
12 - Generator
❑ removing and installing ⇒ Electrical System ⇒ Rep. Gr. 27
❑ to facilitate positioning, drive the threaded bushings for the screws at the generator slightly backwards
13 - 40 Nm + torque a further 90° (1/4 turn)
❑ replace

1. V-ribbed belt drive 21

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

14 - 25 Nm
15 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning ⇒ Rep. Gr. 87
16 - 25 Nm
17 - Fitting sleeve
18 - Bracket for auxiliary units
❑ for tensioning device and AC compressor
❑ removing and installing ⇒ page 25
19 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with wrench to slacken the V-ribbed belt
❑ Secure tensioning device with a 4 mm hexagon wrench or locating pin -T10060 A- .
❑ to remove, release screw -Pos. 12-

Routing of the V-ribbed belt

1 - Belt pulley - coolant pump
2 - Guide pulley
3 - Belt pulley - AC generator
4 - Tensioning pulley
5 - Belt pulley - AC compressor
6 - Belt pulley - crankshaft

1.2 Removing and installing V-ribbed belt

Special tools and workshop equipment required
♦ Locking pin -T10060 A-
Removing
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .

Caution
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Risk of damage through reversing the rotation direction of an
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
already used V-ribbed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the V-ribbed belt.

22 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

For vehicles with air conditioning

– Loosen the V-ribbed belt by swivelling the tensioning device
using the ring spanner SW 16 -in direction of arrow-.
– Interlock the tensioning element with the locking pin -T10060
A- .
For vehicles without air conditioning
– Swivel the tensioning device with the locating pin -T10060 A-
and lock, the V-ribbed belt is therefore slackened.
Continued for all vehicles
– Remove the V-ribbed belt.
Install

Note

♦ Before fitting the V-ribbed belt make sure that all assemblies
(AC generator, AC compressor, coolant pump) are securely
mounted.
♦ Pay attention to the correct position and rotation direction of
the V-ribbed belt in the belt pulley when installing it.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– First of all place the ribbed V-belt ontoto the
with respect thecorrectness
crankshaft - beltin this document. Copyright by ŠKODA AUTO A. S.�
of information
pulley. Then shift the belt onto the tensioning roller.
Further installation occurs in reverse order to removal.
– Start engine and check ribbed V-belt run.

1.3 Removing and installing bracket for top

auxiliary units
Removing
Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Hose binding claw
Removing
– Remove V-ribbed belt ⇒ page 22 .
– Remove alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Drain the coolant from the engine cooling system
⇒ page 94 .
– Remove lambda probe -G39- -1-.

1. V-ribbed belt drive 23

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unscrew screws -arrows- and remove heat shield -1-.

– Open the spring strap clamp -1- with the hose binding claw
and detach the coolant hose.

Note

When removing the oil feed line, make sure that the oil does not
penetrate into the generator! Therefore, cover the generator with
a clean cloth!

– Unscrew hollow screw -2- and fixing screw -3- and remove the
oil feed line. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Unscrew fixing screws -1- and remove bracket.

Install

– Fit the bracket for auxiliary units to the cylinder block.

– Tighten fixing screws -1- to 25 Nm.
– Install oil feed line.
Tightening torques:
Component Nm
Fixing screw to exhaust turbocharger 8 Nm
Hollow screw (replace gasket rings) 20 Nm

24 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Connect the coolant hose -1- on the engine oil cooler and at‐
tach.
– Top up and bleed cooling system ⇒ page 94 .
– Inspect coolant level in the expansion reservoir, top up with
coolant if necessary.
– Install alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install the V-ribbed belt ⇒ page 22 .
Further installation occurs in reverse order to removal.

1.4 Removing and installing bracket for bot‐

tom auxiliary units
Removing
– Remove V-ribbed belt ⇒ page 22 .
– Remove alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .

WARNING

Risk of injury through refrigerant.

♦ Do not open the refrigerant circuit of the air conditioning
system.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Caution with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Risk of damaging refrigerant lines and hoses.

♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.

– Remove AC compressor from the bracket ⇒ page 19 .

– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
– Unscrew fixing screws -1- and remove holder with tensioning
element.
Install
– Fit the bracket for auxiliary units to the cylinder block.

1. V-ribbed belt drive 25

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Tighten fixing screws -1- to 25 Nm.

Tightening torque of tensioning device: ⇒ page 19
Further installation occurs in reverse order to removal.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

26 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

2 Camshaft drive

2.1 Camshaft drive - Summary of compo‐

nents

Note

♦ Before assembly oil all bearing and contact surfaces.

♦ If considerable quantities of metal swarf or abrasion is found
when carrying out engine repairs, this can be subject to dam‐
age to the crankshaft and conrod bearings. In order to avoid
consequential damage, after the repair perform the following
tasks:

– Carefully clean the oil galleries.

– Replace oil spray jets.
– Replace engine oil cooler.
– Replace oil filter.

1 - Cylinder head with cylinder

head cover
❑ Removing and installing
cylinder head
⇒ page 75
❑ Removing and installing
cylinder head cover
⇒ page 68
❑ Do not rework the seal‐
ing surface
2 - Cylinder block
❑ Disassembling and as‐
sembling pistons and
conrods ⇒ page 48
3 - Bracket for bottom auxiliary
units
❑ for tensioning device
and AC compressor
❑ removing and installing
⇒ page 25
4 - 25 Nm
5 - Oil pan
❑ removing and installing
⇒ page 88
❑ fit with silicone sealant D
176 600 A1
6 - 13 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
7 - 150 Nm + torque a further unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
180° (1/2 turn) with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.

2. Camshaft drive 27
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10
❑ insert oiled (thread)
❑ Secure belt pulley with counterholder -3415- to prevent it from turning
8 - Belt pulley
❑ Pay attention to tightening process ⇒ page 37
❑ Clamping surfaces must be free of oil and grease.
❑ Secure belt pulley with counterholder -T30004 (3415)- with bolts -T30004/2 (3415/2)- to prevent it from
turning
9 - Diamond coated washer
❑ replace
10 - Sealing ring
❑ replace
❑ removing and installing ⇒ page 36
11 - 50 Nm
12 - Engine support bracket
13 - 20 Nm + torque a further 90° (1/4 turn)
❑ replace
14 - Sprocket
❑ for oil pump drive
❑ Clamping surfaces must be free of oil and grease.
❑ Lock chain sprocket with counterholder -T10172-
15 - Drive chain for oil pump
❑ mark running direction (installed position) before removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
16 - Bottom cover unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
17 - 5 Nm + torque a further 30°
❑ Screw: M6x40
18 - 5 Nm + torque a further 30°
❑ Screw: M6x20
19 - Bottom timing case
❑ removing and installing ⇒ page 31
20 - Bearing bolt - 18 Nm
21 - Guide rail
❑ for timing chain
22 - Bearing bolt - 18 Nm
23 - 50 Nm + torque a further 90° (1/4 turn)
❑ replace
24 - Tensioning rail
❑ for timing chain
25 - 8 Nm
26 - Top timing case
❑ removing and installing ⇒ page 29

Caution
Pay attention to tighten‐
ing process!

28 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

27 - Timing chain
❑ removing and installing ⇒ page 62
28 - Sprocket
❑ Lock chain sprocket with counterholder -T10172-
29 - Chain tensioner - 60 Nm
❑ for timing chain
30 - Sealing ring
❑ replace

2.2 Removing and installing the top timing

case
Special tools and workshop equipment required
♦ Hose binding claw
♦ Sealant -D 176 501 A1-
♦ Screw M6x70 (2x): screws with sawn off head
♦ 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
– Drain coolant ⇒ page 94 .
– Slacken clamps -1- and -2- and detach coolant hoses.
– Unlatch the clamp -3- and pull it towards the top with the cool‐
ant hoses.
– Place the coolant hoses to the rear.

– Unscrew all the fixing screws from the top timing case -1-.
– Carefully remove top timing case.
Install
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Installation is performed in the reverse order, by
unless authorised pay attention
ŠKODA AUTO A. to the AUTO A. S. does not guarantee or accept any liability
S. ŠKODA
following points: with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Camshaft drive 29
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– To better guide the timing case, screw 2 pin screws M6x70

-1- into the cylinder head cover.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove residual sealant from the sealing surfaces on the top

timing case and at the cylinder head with chemical sealant re‐
mover.
– Degrease the sealing surfaces.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).

Note

♦ The installation procedure must not last longer than 6 minutes

from the moment the sealant is applied until the moment the
fixing screws are tightened to 8 Nm.
♦ The sealant begins to harden after 6 minutes.
♦ Ensure that the tightening process of the fixing screws is car‐
ried out in 2 steps.

– Apply sealant - D 176 501 A1- on the sealing surface -1-.

– Apply a little more sealant in the area of the -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Position the timing case -1- onto the pin screws -2-.
Push the timing case cover -1- up against the cylinder head cover.
Make sure that the timing case cover does not tilt.
– Release the stud bolts and screw in the fixing screws by hand.
Stage l of the tightening process.

30 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Tighten the fixing screws to 5 Nm in the specified order -A- to

-E-.
Stage ll of the tightening process.

– Tighten the fixing screws to 8 Nm in the specified order -A- to

-G-.

– Push the clamp -3- from above fully into the bracket.
– Fit on the coolant hoses and attach the spring strap clamps
-1- and -2-.
– Top up coolant ⇒ page 94 .

2.3 Removing and installing the bottom tim‐

ing case
Special tools and workshop equipment required
♦ Assembly device -T10417/1-
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ 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
♦ Sealant - D 176 600 A1-
Removing
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove the front right wheelhouse linerto⇒theBody
with respect Work
correctness ⇒ Rep.in this document. Copyright by ŠKODA AUTO A. S.�
of information
Gr. 66 .

2. Camshaft drive 31
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Remove V-ribbed belt ⇒ page 22 .

– If present, remove dust cap -1-.
– Remove guide pulley -2-.
– Remove belt pulley for coolant pump, to do so counterhold the
belt pulley with the water pump wrench -V.A.G 1590- .
– Remove belt pulley for crankshaft ⇒ page 37 .
– Removing the oil pan ⇒ page 88 .

– Unscrew all the fixing screws from the timing case -1-.
– Carefully remove timing case.
Install
Installation is performed in the reverse order, pay attention to the
following points:

WARNING

Wear protective gloves when working with sealant and grease

remover!

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

tom timing case and at the cylinder block with chemical sealant
remover.
– Degrease the sealing surfaces.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).

Note

♦ The installation procedure must not last longer than 6 minutes

until the moment the fixing screws are tightened to 5 Nm +
torqued a further 30°.
♦ The sealant begins to harden after 6 minutes.
♦ Insert new fixing screws.

– Apply sealant -D 176 600 A1- on the sealing surface -1-.

The sealant bead must be 2…3 mm thick and must run past
the area of the bolt holes all around the holes.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

32 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Fit the assembly device -T10417/1- on the crankshaft journal.

– Carefully slide the bottom timing case -1- together with the
gasket ring over the assembly device.
– Remove the assembly device from the crankshaft journal.

– Slide the bottom timing case onto the dowel pins -arrows- until
it rests against the cylinder block.
Make sure that the timing case does not tilt.

Caution

Pay attention to the tightening torque of the fixing screws!

When installing, use new screws.

– First of all tighten the new fixing screws of the timing case
evenly by hand.

– Tighten the fixing screws in the specified order -A- to -M-.

Tightening torque: 5 Nm + torque a further 30°
Install the crankshaft belt pulley ⇒ page 37 .
Tightening torques
Belt pulley for coolant pump: 20 Nm
Guide pulley: 40 Nm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Camshaft drive 33
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

3 Sealing flanges and flywheel

3.1 Summary of components

1 - 150 Nm + torque a further

180° (1/2 turn)
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
❑ Secure belt pulley with
counterholder -T30004
(3415)- with bolts -
T30004/2 (3415/2)- to
prevent it from turning
2 - Belt pulley
❑ removing and installing
⇒ page 37
❑ Clamping surfaces must
be free of oil and grease.
3 - Diamond coated washer
❑ replace
4 - Sealing ring
❑ replace
5 - Engine
6 - 60 Nm + torque a further 90°
(1/4 turn)
❑ replace
7 - Flywheel
❑ on vehicles with auto‐
matic gearbox DSG -
two-mass flywheel ver‐
sion
❑ removing and installing
⇒ page 35
8 - Intermediate plate
❑ must be positioned on dowel sleeves
❑ do not damage/bend during assembly work
9 - 10 Nm
❑ replace
10 - Sealing flange on the gearbox side
❑ Only replace sealing flange complete with gasket ring and rotor
❑ replace ⇒ page 40
11 - Engine speed sender -G28- , 5 Nm
❑ with captive screw
❑ removing and installing ⇒ page 167
12 - 5 Nm
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

34 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

3.2 Removing and installing flywheel

Special tools and workshop equipment required
♦ Flywheel lock -MP1-223 (3067)-
or

♦ Engine mount -MP 1-202 (VW 540)-

♦ Bushing -T30010 (VW 540/1B)-
♦ Flywheel lock -MP 1-504-
Removing
• Gearbox is removed.
– Remove clutch on vehicles with manual gearbox ⇒ Gearbox;
Rep. Gr. 30 .
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

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Engine removed
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Position the flywheel lock -MP 1-504- on the ring gear of the
flywheel and turn crankshaft until the lock rests against the
sleeve -T30010 - .

3. Sealing flanges and flywheel 35

 Roomster 2006 ➤
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Vehicles with two-mass flywheel

– 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 the screw head
does not jam on the secondary side -A- of the two-mass fly‐
wheel, otherwise the flywheel will be damaged.

Continued for all

– Release screws and remove flywheel.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

Use new screws for attaching.

Vehicles with two-mass flywheel

– 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-.
Continued for all
1. Screw in all the screws by hand.
2. Tighten all the screws crosswise to 60 Nm.
3. Torque all the screws crosswise a further 90° (1/4 turn).

3.3 Replacing crankshaft seal on belt pulley

side
Special tools and workshop equipment required
♦ Gasket ring extractor -T30003 (3240)-
♦ Assembly device -T10417-
♦ Thrust piece -T30015 (3161)-
Removing
– Remove V-ribbed belt ⇒ page 22 .
– Rotate the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 55 .
– Remove belt pulley for crankshaft ⇒ page 37 .

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

36 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
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– Push the thrust piece -T30015 (3161)- into the gasket ring ex‐
tractor -T30003 (3240)- .
– Unscrew the inner part of the gasket ring extractor -T30003
(3240)- up to the beginning of the thread and lock with the
knurled screw.

– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Slacken knurled screw and turn inner side in
-direction of arrow- against the crankshaft until the gasket ring
is pulled out.
Install

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Position the sleeve -T10417/1- on the crankshaft stub and

push the gasket ring over the sleeve.
– Remove the sleeve -T10417/1- from the crankshaft stub.

– Press the gasket ring with the assembly device -T10417- by

striking uniformly up to the stop in the timing case.
Install the crankshaft belt pulley ⇒ page 37 .
Further installation occurs in reverse order to removal.

3.4 Removing and installing crankshaft belt

pulley
Special tools and workshop equipment required
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ Locating screw -T10340-

3. Sealing flanges and flywheel 37

 Roomster 2006 ➤
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Note

♦ In order to avoid that the tightening torque of the fixing screw

for the crankshaft-belt pulley is inaccurate due to slip, the fixing
screw -T10340- must be used in addition to the counterholder
-T30004- .
♦ The crankshaft is only locked in direction of rotation of engine
using the fixing screw -T10340- .

Caution

Risk of engine damage!

♦ The fixing screw -T10340- must not be used to slacken the
fixing screw for the crankshaft-belt pulley - only for tight‐
ening!
♦ The locating screw -T10340- must only be screwed in the
“TDC” position of the crankshaft.

Removing
– Remove V-ribbed belt ⇒ page 22 .
– Rotate the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 55 .
– Counterhold belt pulley with counterholder -T30004 (3415)-
with bolt -T30004/2 (3415/2)- and release fixing screw for belt
pulley.
Install

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

Note

♦ Make sure that all the clamping surfaces of the fixing screw
are free of oil and grease up to the chain sprocket of the crank‐
shaft.
♦ Always use a new screw of the crankshaft belt pulley.

– Install the belt pulley and tighten the new fixing screw by hand.

38 Rep. Gr.13 - Crankgear

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– Release screw plug -arrow- at cylinder block.

Note

Using the fixing screw should prevent the crankshaft from turning
when tightening to the tightening torque.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing screw -T10340 - cannot be screwed in up to the

stop, the crankshaft is not in the correct position!
In this case proceed as described below.

– Unscrew the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

Caution

Absolutely use the counterholder -T30004 (3415)- with bolt -

T30004/2 (3415/2)- when tightening the fixing screw of the belt
pulley in order to avoid damage to the fixing screw.

– Counterhold belt pulley with counterholder -T30004 (3415)-

with bolt -T30004/2 (3415/2)- and tighten fixing screw for belt
pulley.
Tightening torque: 150 Nm + torque a further 1/2 turn (180°)

– Release the fixing screw -T10340- from the cylinder block.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Sealing flanges and flywheel 39

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Screw the screw plug again into the cylinder block. Tightening
torque: 30 Nm.

– Install bracket for coolant pipe -2- and tighten screws -1-.
Tightening torque
Screw M6 = 10 Nm
Screw M8 = 20 Nm
– Install the V-ribbed belt ⇒ page 22 .
Further installation occurs in reverse order to removal.

3.5 Replace sealing flange on the gearbox

side
Special tools and workshop equipment required
♦ Assembly device -T10134-
♦ Feeler gauges
♦ Steel straightedge
♦ Screw M6x35 (3x)
♦ Screw M7x35 (2x)

3.5.1 Removing
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
• Gearbox is removed.
– Remove the flywheel.
– Remove intermediate plate.
– Position engine on TDC of cylinder 1 ⇒ page 55 (do not re‐
move the caps for the camshafts).
– Removing the oil pan ⇒ page 88 .
– Remove engine speed sender -G28- -arrow-.
– Unscrew the fixing screws of the sealing flange.

Note

Sealing flange and rotor are pressed together with 3 M6x35 mm

screws from the crankshaft.

40 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
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– Screw three screws M6x35 into the threaded bores of the

sealing flange -arrows-.
– Screw the screws alternately (max. 1/2 turn (180°) per screw)
in the sealing flange and press the sealing flange together with
the rotor from the crankshaft.

3.5.2 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 assembly device -T10134- is given its fitting location to
the crankshaft by means of a guide bolt, which is guided into
a hole of the crankshaft.

Assembly device -T10134-

A -Protected
Hexagon nut Copying for private or commercial purposes, in part or in whole, is not permitted
by copyright.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
B - Clamping
with respect to surface
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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)
A - Mounting sealing flange with rotor on the assembly device -
T10134-

– Screw the hexagon nut -A- right up to the clamping surface

-B- and grip the assembly device -T10134- on the clamping
surface -B- of the threaded spindle in a vice.

3. Sealing flanges and flywheel 41

 Roomster 2006 ➤
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– 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 side of the rotor and the front side of the sealing flange
must be flush.

• The locating hole -B- on the rotor -C- must be flush with the
marking -A- on the sealing flange.

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– 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.

42 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly device in
such a way that the positioning pin cannot slide out of the rotor
hole.
B - Mount the assembly device -T10134- 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 two M6x35 mm screws -A- by about 3 turns for seal‐

ing flange guide into the cylinder block.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– 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 red
ball -F- 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.
C - Pressing the rotor onto the crankshaft flange
– Screw in hexagon nut by hand onto the threaded spindle until
it rests against the assembly cup.

3. Sealing flanges and flywheel 43

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Tighten the hexagon nut of the assembly device 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.
– Unscrew two M6x35 mm screws -A- from the cylinder block.
– Release three knurled screws -B- from the sealing flange.
– Unscrew two Allan screws and remove assembly device -
T10134- .
– 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-.

– 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 45 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing alternately cross‐
wise.
Tightening torque: 10 Nm.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

44 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Install engine speed sender -arrow-.

Tightening torque: 5 Nm.
– Installing the oil pan ⇒ page 88 .
– Installing intermediate plate.
– Install flywheel with new screws.
E - Pressing down the rotor

– Screw assembly device -T10134- with Allan screws up to the

stop onto the crankshaft flange.
– Screw in three knurled screws -A- into the flange.
– Subsequently insert the guide bolt with red ball -E- fully into
the threaded bore of the crankshaft. If the guide bolt is correctly
slipped on, then the handle has a distance of approx. 10 mm
from the assembly cup -B-.

– Tighten the hexagon nut of the assembly device using a torque

wrench with adapter.
Tightening torque: 40 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 44 .
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
⇒ pageby44
Protected .
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Sealing flanges and flywheel 45

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

4 Crankshaft

Caution

The crankshaft must not be removed. Merely releasing the

screws of the crankshaft bearing cover will result in deforma‐
tions of the bearing seats of the cylinder block. These defor‐
mations will reduce the bearing clearance. If the bearing shells
are not replaced, the changed bearing clearance may cause
damage to the bearing.
If the bearing cover screws have been released, replace the
complete cylinder block together with the crankshaft.
It is not possible to measure the crankshaft bearing clearance
with workshop tools.

4.1 Replace needle bearing for crankshaft

Only on vehicles fitted with automatic gearbox.
Special tools and workshop equipment required
♦ Centering mandrel -T30029 (3176)-
♦ Interior extractor -Kukko 21/2-
♦ Countersupport - Kukko 22/1-
Removing
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– Pull out needle bearing with interior
unless extractor
authorised by ŠKODA -Kukko
AUTO A. S.21/2-
ŠKODAand AUTO A. S. does not guarantee or accept any liability
countersupport -Kukko 22/1- .
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Install

Note

The marked side of the needle bearing should be legible when in

its installed condition.

– Drive in the needle bearing using the centering pin -T30029- .

• Fitting position: The marked side of the needle bearing should
be legible when in its installed condition.

46 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Depth of installation of the needle bearing:

• Dimension -a- = 1.5 up to 2 mm

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4. Crankshaft 47
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

5 Pistons and conrods

5.1 Summary of components

Note

Before assembly oil all bearing and contact surfaces.

1 - Circlip
2 - Piston pin
❑ if stiff, heat piston to 60°
C
❑ use drift -T10046- for re‐
moving and installing
3 - Piston
❑ check ⇒ page 50
❑ mark installation posi‐
tion and matching cylin‐
der
❑ arrow on piston crown
faces towards the belt
pulley
❑ use piston ring tension‐
ing strap for installing
❑ Piston ∅: 70,95 mm
(nominal dimension)
❑ Cylinder ∅: 71,00 mm
(nominal dimension)
4 - Gasket rings
❑ Offset joint 120°
❑ use piston ring pliers for
removing and installing
compression rings
❑ Marking “TOP” faces
piston crown
❑ Inspect gap clearance
⇒ page 49
❑ Inspect end clearance
⇒ page 50
5 - Oil scraper rings
❑ carefully remove and in‐
stall 3-part oil scraper rings by hand
❑ Inspect gap clearance ⇒ page 49
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❑ End clearance cannot be measured unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6 - 30 Nm + torque a further 90° (1/4 turn)
❑ replace
❑ Oil thread and contact surface
7 - Conrod bearing cap
❑ as a result of the conrods separated in the cracking process, the cover fits only in one position and only
to the relevant conrod
❑ Mark the assignment of the cylinder before removal -A-

48 Rep. Gr.13 - Crankgear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10
❑ Fitting position: Marking -B- points to the belt pulley side (mark before removing if marking is missing)
8 - Bearing shell
❑ pay attention to correct installation position ⇒ page 49
❑ do not mix up used bearing shells
9 - Pressure relief valve, 27 Nm
❑ Opening pressure: 0,2 MPa (2,0 bar)
10 - Oil injection nozzle
❑ for piston cooling
❑ Align the guide edge of the oil injection nozzle -arrow- to the area of the cylinder block being worked on.
11 - Conrod
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Marking -B- points to the belt pulley side (mark before removing if marking is missing)
❑ located axially by pistons
❑ separate new conrod ⇒ page 51

Bearing shell installation position

Bearing shell -1- with oil drilling -arrow- for conrod.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Bearing shell -2- without oil drilling for conrod bearing cap.
– Insert bearing shells in the conrod and in the conrod bearing
cap centred.
The dimension -a- must be the same on the right and left.

5.2 Inspect piston, piston rings and cylinder

bore
Inspecting piston ring gap clearance

Special tools and workshop equipment required

♦ Feeler gauges
– Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder.
Piston ring New Wear limit
dimensions in mm
1. Compression ring 0,20…0,40 1,0
2. Compression ring 0,40…0,60 1,0
Oil scraper ring 0,25…0,75 no wear indication
possible

5. Pistons and conrods 49

 Roomster 2006 ➤
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Inspect piston ring end clearance

Special tools and workshop equipment required

♦ Feeler gauges
– Clean ring groove before inspecting.
Piston ring New Wear limit
dimensions in mm
1. Compression ring 0,03…0,09 0,15
2. Compression ring 0,02…0,06 0,15
Oil scraper ring cannot be measured
Inspecting pistons

Special tools and workshop equipment required

♦ External micrometer 75...100 mm
– Measure about 7 mm from the lower edge and offset 90° to
piston pin axis.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

50 Rep. Gr.13 - Crankgear

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1.2/63 kW; 77 kW TSI engine - Edition 02.10

• Deviations from specified dimension: max. 0,04 mm

Inspecting cylinder bore

Special tools and workshop equipment required

♦ Internal precision measuring instrument 50...100 mm
– Measure at 3 points crosswise in a transverse direction -A- and
lengthwise -B-.
• Deviations from specified dimension: max.by 0.08
Protected mm
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

Do not measure the cylinder bore if the cylinder block is fixed to

the assembly stand -MP 1-202- with the engine mount -MP 9-101
- , as this may result in incorrect measurements.

5.3 Separating new conrod

It can happen that the predetermined breaking point on the new
conrod is not completely pierced. If the conrod bearing cap cannot
be removed by hand, then proceed as follows:
– Mark the assignment of the conrod to the cylinder.
– Slightly clamp the conrod in a vice provided with aluminium
protective jaws, as shown in the illustration.

Note

♦ Only tension the conrod slightly in order to avoid damage.

♦ The conrod is clamped beyond the broken line.

– Unscrew both screws -arrows- by approx. 5 turns.

5. Pistons and conrods 51

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Carefully knock against the conrod bearing cap with a rubber

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

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

52 Rep. Gr.13 - Crankgear

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1.2/63 kW; 77 kW TSI engine - Edition 02.10

15 – Cylinder Head, Valve Gear

1 Cylinder head - part 1

1.1 Summary of components

Testing compression pressure ⇒ page 78 .

Note

♦ When installing a replacement cylinder head, all the contact

surfaces between the hydraulic supporting elements, roller
rocker arms and the cam tracks must be oiled before installing
the cylinder head cover.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ If the cylinder head is replaced, also the entire coolant must
be replaced.
♦ Before assembly moisten all bearing and contact surfaces with
oil.
♦ Removing and installing intake manifold ⇒ page 140 .

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cylinder head - part 1 53

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1 - 8 Nm
2 - High pressure pump
❑ for fuel supply
❑ with fuel pressure regu‐
lating valve -N276-
❑ removing and installing
⇒ page 144
3 - 10 Nm
4 - Hall sender -G40-
❑ with O-ring
❑ replace the O-ring if it is
damaged
5 - 20 Nm
6 - Lifting eye
7 - 8 Nm + torque a further 90°
(1/4 turn)
❑ replace
❑ order of tightening
⇒ page 68
8 - Cylinder head cover
❑ removing and installing
⇒ page 68
9 - 10 Nm
10 - Coolant temperature
sender -G62-
❑ before removing, re‐
duce pressure in cooling
system
11 - O-ring
❑ replace
12 - Cylinder head gasket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ replace with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ metal gasket
❑ after replacing fill entire system with fresh coolant
13 - Cylinder head
❑ removing and installing ⇒ page 75
❑ check for distortion ⇒ page 55
❑ Sealing surfaces must be free of oil and grease
❑ after replacing fill entire system with fresh coolant
14 - Hydraulic supporting element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ oil contact surfaces
15 - Oil pressure switch -F1- , 20 Nm
❑ check ⇒ page 91
❑ Cut open gasket ring if leaking and replace
16 - Roller rocker arm
❑ inspect roller bearings for smooth operation
❑ oil contact surfaces

54 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
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❑ to install clip onto the supporting element with the locking clips
17 - Cylinder head bolt
❑ replace
❑ observe the mounting instructions and sequence for loosening and tightening ⇒ page 75
18 - Roller tappet
❑ Lightly moisten the contact surface with engine oil
19 - O-ring
❑ replace
❑ moisten with oil before inserting

Inspecting the cylinder head for distortion

Check with straightedge 500 mm , e. g. -VAS 6075- and feeler
gauge.
• Max. permissible distortion: 0.05 mm

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1.2 Test timing

Special tools and workshop equipment required
♦ Locking bolt -T10414-
♦ Locating screw -T10340-
Test sequence
– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

– Release screw plug -arrow- at cylinder block.

1. Cylinder head - part 1 55

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– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing screw -T10340 - cannot be screwed in up to the

stop, the crankshaft is not in the correct position!
In this case proceed as described below.

– Unscrew the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

– Pull off both coolant hoses -1- from the non-return valve.
– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.

The grooves in the camshaft -arrows- must be in the position

shown.

– Insert the locking bolt -T10414- up to the stop into the cylinder
head cover.
If the locking bolt -T10414- cannot be inserted up to the stop into
the camshaft opening, the timing is not correct and must be set
⇒ page 57 .
The timing is O.K., if the locking bolt -T10414- can be pushed up
to the stop into the cylinder head cover.
– Remove locking bolt -T10414- and fixing screw -T10340- .
Further installation occurs in reverse order to removal.

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

56 Rep. Gr.15 - Cylinder Head, Valve Gear

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1.3 Setting the timing

Special tools and workshop equipment required
♦ Locking bolt -T10414-
♦ Locating screw -T10340-
♦ Counterholder -T10172 -
Work procedure
– Drain coolant ⇒ page 94 .
– Remove top timing case ⇒ page 29 .
– Pull off both coolant hoses -1- from the non-return valve.
– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.

– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

– Release screw plug -arrow- at cylinder block.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cylinder head - part 1 57

 Roomster 2006 ➤
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– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing screw -T10340 - cannot be screwed in up to the

stop, the crankshaft is not in the correct position!
In this case proceed as described below.

– Unscrew the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .
– Removing the oil pan ⇒ page 88 .

– Pull off the cover -1- from the oil pump.

– Release chain tensioner -arrow- for timing chain.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

58 Rep. Gr.15 - Cylinder Head, Valve Gear

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– Hold the camshaft sprocket with the counterholder -T10172-

and slacken the fixing screw -1- of the camshaft sprocket.
– Remove the camshaft sprocket together with the fixing screw.

– Place the chain sprocket -1- down on the integrated peg

-arrow- in the timing case.

Note

The integrated peg on the inner side of the timing case prevents
the chain sprocket from falling down.

– Position the camshaft sprocket -1- on the camshaft and tighten

the fixing screw -2- to 50 Nm.
– Hold the camshaft sprocket with the counterholder -T10172-
when tightening.
– Then turn back the crankshaft 90° (1/4 turn) in the opposite
direction of rotation of the engine.

Note

When subsequently adjusting the camshaft, damage to the valves

is prevented by turning the crankshaft in the opposite direction of
rotation of the engine.

– Turn the camshaft until the grooves -arrows- are in the position
shown.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cylinder head - part 1 59

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– Insert the locking bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.
– Turn crankshaft up to the stop in direction of rotation of engine.

– Lift up the timing chain with the assembly device -T10118- .

– Check the correct position of the timing chain -1- on the crank‐
shaft gear from below.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Place the timing chain -1- onto the chain sprocket -2-.
The timing chain must rest in the area of the sliding rail -3- and
be slightly tensioned.

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– Hold the camshaft sprocket with the counterholder -T10172-

and tighten the fixing screw -1- of the camshaft sprocket to 50
Nm.

Note

The fixing screw is only turned a further 90° (1/4 turn) after check‐
ing the timing at the end of the work procedure.

– Install chain tensioner and tighten to 60 Nm.

– Remove the locking bolt -T10414 - from the camshaft.
– Unscrew the fixing screw -T10340- from the cylinder block.
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the fixing screw -T10340- up to the stop in the cylinder
block.
– Turn crankshaft up to the stop in direction of rotation of engine.
The timing is O.K., if the locking bolt -T10414- can be inserted in
the camshaft.
If the timing is not O.K., the setting of the timing must be repeated.

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Remove locking bolt -T10414- and fixing screw -T10340- .
– Install top timing case ⇒ page 29 .

– Install non-return valve. Tightening torque of the fixing screw

-2-: 8 Nm.
– Fit on hoses -1-.
– Install oil pan ⇒ page 88 .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cylinder head - part 1 61

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– Install screw plug. Tightening torque: 30 Nm

– Top up coolant ⇒ page 94 .
Further installation occurs in reverse order to removal.

1.4 Removing and installing timing chain

and drive chain for oil pump

Note

First of all, the timing chain must be removed in order to remove

the drive chain
Protected for oil Copying
by copyright. pump.for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Remove timing chain ⇒ page 62
Remove and install the drive chain for oil pump ⇒ page 65
Install timing chain ⇒ page 66
Special tools and workshop equipment required
♦ Locking bolt -T10414-
♦ Locating screw -T10340-
♦ Counterholder -T10172 -
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ Assembly device -T10417/1-

1.4.1 Remove timing chain

– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Drain coolant ⇒ page 94 .
– Remove the front right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Remove V-ribbed belt ⇒ page 22 .
– Remove top timing case ⇒ page 29 .
– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

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– Release screw plug -arrow- at cylinder block.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing screw -T10340 - cannot be screwed in up to the

stop, the crankshaft is not in the correct position!
In this case proceed
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for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Unscrew the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

– Pull off both coolant hoses -1- from the non-return valve.
– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.

– Insert the locking bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.
– Removing the oil pan ⇒ page 88 .

1. Cylinder head - part 1 63

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– If present, remove dust cap -1-.

– Remove guide pulley -2-.
– Remove belt pulley for coolant pump, to do so counterhold the
belt pulley with the water pump wrench -V.A.G 1590- .
– Remove belt pulley for crankshaft ⇒ page 37 .

– Slacken all the fixing screws of the timing case -1- carefully
remove the timing case.

– Release chain tensioner -arrow- for timing chain.

– Mark with a felt-tip pen the direction of rotation of the timing
chain.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Hold the camshaft sprocket with the counterholder -T10172-
and slacken the fixing screw -1- of the camshaft sprocket.
– Remove the camshaft sprocket together with the fixing screw.
– Remove timing chain downwards.
Install timing chain ⇒ page 66

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1.4.2 Removing and installing the drive chain

for oil pump
Removing
– Pull off the cover -1- from the oil pump.
– Mark with a felt-tip pen the direction of rotation of the drive
chain for oil pump.

– Unscrew the fixing screws -arrows- of the oil pump.

– Remove the complete oil pump from the drive chain.

– Remove the drive chain for oil pump -1- from the rear ring gear
-2- of the crankshaft gear.
Install

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Place the drive chain for oil pump -1- on the rear ring gear
-2- of the crankshaft gear.

1. Cylinder head - part 1 65

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– Hook the oil pump with the chain sprocket into the drive chain
and tighten the new screws -arrows- to 14 Nm + torque a fur‐
ther 90° (1/4 turn.).

1.4.3 Installing timing chain

– Position the timing chain -1- from below at the front ring gear
-2- and guide it upwards between the sliding rail and the ten‐
sioning rail.
– Secure the timing chain, for example with a screwdriver -3-,
against falling down.

– Place the timing chain -1- onto the chain sprocket -2-.
The timing chain must rest in the area of the sliding rail -3- and
be slightly tensioned.

– Hold the camshaft sprocket with the counterholder -T10172-

and tighten the fixing screw -1- of the camshaft sprocket to 50
Nm.

Note

The fixing screw is only turned a further 90° (1/4 turn) after check‐
ing the timing at the end of the work procedure.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

66 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Tighten chain tensioner -arrow- to 60 Nm.

– Remove the locking bolt -T10414 - from the camshaft.
– Unscrew the fixing screw -T10340- from the cylinder block.
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Test timing ⇒ page 55 .
If timing is o.k.:

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Install bottom timing case ⇒ page 31 .

– Fit the cover -1- on the oil pump.

– Install oil pan ⇒ page 88 .
– Install the crankshaft belt pulley ⇒ page 37 .
– Install the V-ribbed belt ⇒ page 22 .
– Install top timing case ⇒ page 29 .
– Top up coolant ⇒ page 94 .
Further installation occurs in reverse order to removal.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cylinder head - part 1 67

 Roomster 2006 ➤
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2 Cylinder head - part 2

2.1 Removing and installing cylinder head

cover and camshaft

Note

The camshaft is located in the cylinder head cover.

Special tools and workshop equipment required

♦ Locking bolt -T10414-
♦ Locating screw -T10340-
♦ Counterholder -T10172 -
♦ Sealant - D 154 103 A1- (cylinder head cover/cylinder head)
♦ Sealant - D 189 500 A1- (cylinder head cover/cylinder head)
♦ 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
♦ Screw M6x70 (2x) : adapt the screws by sawing off the heads

2.1.1 Remove cylinder head cover

– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐
trical System ⇒ Rep. Gr. 27 .
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Drain coolant ⇒ page 94 .
– Remove top timing case ⇒ page 29 .
– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Release screw plug -arrow- at cylinder block.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.

Caution

If the fixing screw -T10340 - cannot be screwed in up to the

stop, the crankshaft is not in the correct position!
In this case proceed as described below.

– Unscrew the fixing screw.

– Turn crankshaft 90° (1/4 turn) in direction of rotation of engine.

– Turn the fixing screw -T10340- up to the stop in the cylinder

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

– Pull off both coolant hoses -1- from the non-return valve.
– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.

– Insert the locking bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.
– Removing the oil pan ⇒ page 88 .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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2. Cylinder head - part 2 69

 Roomster 2006 ➤
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– Pull off the cover -1- from the oil pump.

– Release chain tensioner -arrow- for timing chain.

– Hold the camshaft sprocket with the counterholder -T10172-

and slacken the fixing screw -1- of the camshaft sprocket.
– Remove the camshaft sprocket together with the fixing screw.

– Place the chain sprocket -1- down on the integrated peg

-arrow- in the timing case.

Note

The integrated peg on the inner side of the timing case prevents
the chain sprocket from falling down.

– Detach hose to air filter from cylinder head cover.

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70 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Release screws -1- and remove retaining clip.

– Disconnect plug -2- at charge pressure sender -G31- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338- and then from the exhaust gas turbocharger.
– Fold open the cover and release the fixing screw -4-.

– Disconnect all the spark plug connectors -arrows- from the

spark plugs using the extractor -T10112 A- and lay the ignition
cables to the rear.
– Remove the high pressure pump ⇒ page 145 .
– Unplug connectors from the fuel injection valves.

– Release the screws -arrows- and disconnect the fuel distribu‐

tor from the injection valves.
– Remove exhaust turbocharger ⇒ page 126 .
– Disconnect the plug from the Hall sender -G40- .
– Pull out oil dipstick.
– Slacken the fixing screws of the cylinder head cover crosswise
from outside to inside and unscrew.
– Carefully remove the cylinder head cover.

Note

Ensure that no dirt and sealant residues get into the cylinder head.

Remove and install camshaft ⇒ page 71 .

Install cylinder head cover ⇒ page 73 .

2.1.2 Removing and installing camshaft

Removing
– Remove locking bolt -T10414- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Place the cylinder head cover on the work bench as shown.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Cylinder head - part 2 71

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– Release the fixing screws for the bearing frame in the specified
order -A- to -J-.
– Remove bearing frame.

– Lift the camshaft -1- out of the cylinder head cover -2-.
Install

Note

Before fitting, moisten the camshaft and the camshaft bearings

lightly with engine oil.

– Place the camshaft -1- in the cylinder head cover -2-.

– Insert the locking bolt -T10414 - into the nuts of the camshaft
and tighten the screw by hand.
– Position the bearing frame onto the bearing surfaces of the
camshaft.
The bearing frame is put into the correct position by means of the
centering pins -arrows-.

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Tighten the fixing screws to 8 Nm in the specified order -A- to

-J-.
Install cylinder head cover ⇒ page 73 .

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2.1.3 Install cylinder head cover

Caution

Before installing the cylinder head cover, screw in the pin

screws (M 6 x 70) at the cylinder head.
The pin screws guide the cylinder head cover and prevent the
roller rocker arms sliding off from the supporting elements.

Condition
• The pistons must not be positioned at top dead centre.

WARNING

Wear protective gloves when working with sealant and grease

remover!

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

inder head cover and at the cylinder head with chemical
sealant remover.
– Degrease the sealing surfaces.
– Screw in two pin screws (M 6 x 70) -1- into the cylinder head
before fitting on the cylinder head cover.

Caution

The cylinder head cover is sealed with 2 different sealants!

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Note

The sealant must not be applied too thickly, as otherwise excess

sealant may penetrate into the oil bores and possibly cause en‐
gine damage.

– Apply sealant -D 189 500 A1 - on the sealing surface -1-.

The sealant bead must be 2…3 mm thick and must run past
the area around the bolt holes on the inside.
– Apply a thin layer of sealant -D 154 103 A1 - evenly to the
gridded sealing surfaces -2-.
– Check if the roller rocker arms rest on the supporting elements.
– Carefully fit the cylinder head cover over the pin screws and
position the dowel pins onto the cylinder head.

2. Cylinder head - part 2 73

 Roomster 2006 ➤
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– Tighten the new fixing screws of the cylinder head cover in the
specified order -A- to -J-.
Tightening torque: 8 Nm + torque a further 90° (1/4 turn).

Caution

The sealant for the cylinder head cover must absolutely be re‐
moved in the area of the -arrows-.
In order to avoid leakage, the sealant for the cylinder head
cover and the sealant for the timing case must not mix.

– Remove excess sealant in the area of the -arrows-.

– Turn crankshaft up to the stop in direction of rotation of engine.

– Lift up the timing chain with the assembly device -T10118 - .

– Check the correct position of the timing chain -1- on the crank‐
shaft gear from below.

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

74 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Place the timing chain -1- onto the chain sprocket -2-.
The timing chain must rest in the area of the sliding rail -3- and
be slightly tensioned.

– Hold the camshaft sprocket with the counterholder -T10172-

and tighten the fixing screw -1- of the camshaft sprocket to 50
Nm.

Note

The fixing screw is only turned a further 90° (1/4 turn) after check‐
ing the timing at the end of the work procedure.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Tighten chain tensioner to 60 Nm.
– Remove the locking bolt -T10414 - from the camshaft.
– Release the fixing screw -T10340- from the cylinder block.
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the fixing screw -T10340- up to the stop in the cylinder
block.
– Turn crankshaft up to the stop in direction of rotation of engine.
The timing is O.K., if the locking bolt -T10414- can be inserted in
the camshaft.
If the timing is not O.K.:
– Repeat the setting of the timing ⇒ page 57 .

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Remove locking bolt -T10414- and fixing screw -T10340- .
– Install top timing case ⇒ page 29 .
– Install exhaust turbocharger ⇒ page 126 .
– Installing the oil pan ⇒ page 88 .
– Install the crankshaft belt pulley ⇒ page 37 .
– Install high pressure pump ⇒ page 145 .
– Install fuel lines ⇒ page 144 .
Further installation occurs in reverse order to removal.

2.2 Removing and installing cylinder head

Special tools and workshop equipment required

2. Cylinder head - part 2 75

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

♦ Supporting device -MP9-200 (10-222A)-

♦ Support -T10358-
♦ 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
Requirements
• The engine temperature should not exceed 35°C, because the
cylinder head could be twisted when slackening the screws.
• The pistons must not be in TDC.
Observe safety measures ⇒ page 3 .
Observe rules for cleanliness ⇒ page 5 .

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Drain coolant ⇒ page 94 .

– Remove coolant regulator housing from cylinder head.
– Remove top timing case ⇒ page 29 .
– Remove bottom timing case ⇒ page 31 .
– Remove exhaust turbocharger ⇒ page 126 .
– Removing the intake manifold ⇒ page 140 .
– Fit supporting device -MP9-200 (10-222A)- .
– Unscrew the fixing screw for the gearbox and screw down the
bracket -T10358- as shown. (The figure shows the version
with the 1.4 ltr./90 kW TSI Engine; the engine mounting is
identical).
– Support the engine via the spindle in its installed position and
slightly pre-tension.

– Separate fuel lines -3- and -4-. To do so press the release

buttons.

WARNING

The fuel feed line is pressurized! Wear safety goggles and

safety gloves, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
hose connections. Then reduce the pressure by carefully re‐
moving the hose.

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76
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Rep. Gr.15 - Cylinder Head, Valve Gear
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unscrew nut -1- and disconnect earth lead -2- from engine
mount.
– Unscrew screws -arrows- and remove engine mounting.
– Remove cylinder head cover ⇒ page 68 .
– Remove the tensioning rail and the sliding rail of the timing
chain.
– Remove the roller rocker arm together with the supporting el‐
ements and lay aside on a clean surface.
– Ensure that the roller rocker arms and the supporting elements
are not mixed up.

– Release the cylinder head bolts in the specified sequence and

remove.
– Carefully remove the cylinder head.
Install

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Cylinder head - part 2 77

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Tightening torque of non-return valve -arrow-: 7 Nm.

Condition
• The pistons must not be in TDC.

Note

♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the new gasket with the utmost care. Any damage will
result in leaks.
♦ There must be no oil or coolant in the blind holes of the cylinder
head bolts in the cylinder block.

– 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!

– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
– Carefully remove old Protected
sealantbyresidue from the
copyright. Copying cylinder
for private headpurposes, in part or in whole, is not permitted
or commercial
and cylinder block using
unlessaauthorised
chemical sealant
by ŠKODA AUTOremover.
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Position piston of cylinder 1 to top dead centre and slightly turn
the crankshaft anticlockwise again.
– Position the new cylinder heads. The legend (part number)
must be legible.
– Insert the cylinder head. Pay attention to the centering pins in
the cylinder block.
– Insert new cylinder head bolts and tighten by hand.

– Tighten cylinder head bolts in the tightening order shown as

follows:
♦ Tighten all screws to 40 Nm.
♦ Then, torque all bolts further to 90° (1/4 turn) with a rigid
wrench.
♦ Then once again turn all bolts through a further 90° (1/4 turn).

– Insert the supporting elements in the cylinder head and posi‐

tion the relevant roller rocker arm on the valve stem ends or
supporting elements.
– Install cylinder head cover ⇒ page 68 .
– Setting the timing ⇒ page 57 .
Further installation occurs in reverse order to removal.
– Top up and bleed cooling system ⇒ page 94 .

2.3 Testing the compression

Special tools and workshop equipment required

78 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
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♦ Spark plug wrench -3122 B-

♦ Compression tester -V.A.G 1763-
♦ Extractor -T10112 A-
Test condition
• Engine oil temperature must be at least 30°C.
Work procedure
– Pull out the spark plug connector -arrows- with the extractor -
T10112 A- .
– Unscrew the spark plugs with the spark plug wrench -3122 B- .
– Open lid of fuse carrier in the engine compartment and unplug
the fuse for fuel pump control unit ⇒ Current flow diagrams and
Fitting locations.
– Check compression pressure using the compression tester -
V.A.G 1763- .

Note

Use of tester ⇒ Operating Instructions .

– Operate starter until the tester no longer indicates a pressure

rise.
Compression readings
New engine Wear limit Difference between
cylinders
1...1.5 MPa 0.7 MPa 0.3 MPa
(10...15 bar) (7 bar) (3 bar)
If the specified values are not reached, test the combustion cham‐
ber for tightness ⇒ page 79 .
Further installation occurs in reverse order to removal. Pay at‐
tention to the following:
– Delete the contents of the fault memory for the engine control
unit at the end of the work as error messages were stored due
to disconnecting the plugs ⇒ Vehicle diagnosis, testing and
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
information
with respectsystem VAS 5051.
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2.4 Check combustion chamber for tight‐

ness
Special tools and workshop equipment required
♦ Pressure hose -MP1-210 (VW 653/3)- (replace gasket ring
with a spark plug gasket ring)
♦ Extractor -T10112 A-
♦ Spark plug wrench -3122 B-
Test sequence
– Unscrew the spark plugs with the spark plug wrench -3122 B- .
– Position piston of the relevant cylinder to top dead centre
(TDC).
– Screw the pressure hose MP 1-210 into the spark plug thread.
– Connect pressure hose to compressed air.

2. Cylinder head - part 2 79

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– With the assistance of a second mechanic, lock the screw at

the crankshaft on TDC position in order to avoid the displace‐
ment of the piston after pressure build-up.
– Build up a pressure of approx. 0.3 MPa (3 bar) in the com‐
bustion chamber.
– Determine how the pressure escapes:
1- Via the inlet valve(s) - the pressure enters the throttle valve.
2- Via the outlet valve(s) - the pressure enters the exhaust
system.
3- Via the piston rings – the pressure enters the cylinder block.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

80 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

3 Valve gear

3.1 Valve gear - Summary of components

1 - 50 Nm + torque a further 90°

(1/4 turn)
❑ replace
2 - Camshaft sprocket
❑ take note of the position
when installing the tim‐
ing chain
3 - 10 Nm
4 - Hall sender -G40-
❑ with O-ring
❑ replace the O-ring if it is
damaged
5 - Cylinder head cover
❑ removing and installing
⇒ page 68
6 - Non-return valve
7 - 10 Nm
8 - O-ring
❑ replace if damaged
❑ before fitting moisten
lightly with engine oil
9 - Camshaft
❑ removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ page 68 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Inspecting axial play
⇒ page 82
❑ moisten with oil before
installing (also axial
bearing collar)
10 - Valve collet
11 - Valve spring retainer
12 - Valve stem seal
❑ replace
13 - Valve spring
❑ with the cylinder head removed, remove and install with blank holder -3362-
❑ (with cylinder head installed) ⇒ page 83
14 - Valve guide
❑ check ⇒ page 82
15 - Cylinder head
❑ removing and installing ⇒ page 75
16 - Valves
❑ do not rework, only grinding in is permissible
❑ Valve dimensions ⇒ page 82

3. Valve gear 81
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

17 - 15 Nm
18 - Gasket
❑ replace
19 - Dowel pins
20 - 8 Nm
❑ observe the order of tightening up
❑ removing and installing ⇒ page 68
21 - Bearing frame
❑ for camshaft
❑ removing and installing ⇒ page 68

3.2 inspect camshaft, axial play

Special tools and workshop equipment required
♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge
Perform measurement with the cylinder head cover installed.
Checking the axial play of the camshaft
• Wear limit: 0,4 mm

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Valve dimensions

Note

Valves must not be reworked. Only grinding in is permissible.

Dimension Inlet valve Exhaust valve

∅a mm 35,5 30,0
∅b mm 5,98 5,96
c mm 98,67 98,36
α ∠° 44° 50' 44° 50'

3.3 Inspect valve guides

Special tools and workshop equipment required
♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge

82 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Work procedure

Note

If the valve is replaced when carrying out repair work, use a new
valve for the measurement.

– Insert valve into guide. End of valve stem must be flush with
guide. Because of the different stem diameters only use inlet
valve in inlet guide or outlet valve in outlet guide.
– Determine valve rock.
• Wear limit: 0.8 mm

Note

If the wear limit is exceeded, repeat measurement with new

valves.

If the valve rock is exceeded:

– Replace the cylinder head.

3.4 Replacing valve stem seals

Special tools and workshop equipment required
♦ Spark plug wrench -3122 B-
♦ Valve lever -MP 1-211 (VW 541/1A/5) -
♦ Pressure hose -MP 1-210 (VW 653/3)-
♦ Assembly device -MP 1-213 (2036)-
♦ Valve supporting plate -MP 1-218-
♦ Valve stem seal insertion tool - MP 1-233 (3365)-
♦ Valve stem seal extractor -MP 1-230 (3364)-
Removing
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Note
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

With cylinder head removed, use valve lever -MP 1-211- , as‐
sembly device for valves -MP 1-213- and valve supporting plate
-MP 1-218- .

With cylinder head installed:

– Remove cylinder head cover ⇒ page 68 .
– Remove roller rocker arm and place on a clean surface. Make
sure the roller rocker arms are not interchanged.
– Unscrew the spark plugs with the spark plug wrench -3122 B- .
– Put the piston of the relevant cylinder at “bottom dead centre”.

3. Valve gear 83
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Screw the assembly device -MP 1-213 (2036)- onto the cylin‐
der head.
– Screw the pressure hose -MP 1-210 (VW 653/3)- in the spark
plug thread.
– Connect pressure hose to compressed air [min. 0.6 MPa (6
bar) overpressure] and remove the valve spring with valve
lever -MP 1-211 (VW 541/1A/5) - and pressure plate -VW
541/7- .
– Pull off valve stem seal with extractor for valve stem seal -MP
1-230 (3364)- .
Install
– Insert the supplied plastic bushings on the relevant valve stem.
This will prevent any damage to the new valve stem seals.

– Insert the new valve stem seal -1- into the insertion tool for
valve stem seal -MP 1-233 (3365)- .
– Oil the sealing lip of the valve stem seal and carefully slide
over the valve -2- onto the valve guide.
– Installing camshaft housing ⇒ page 68 .
Further installation occurs in reverse order to removal.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

84 Rep. Gr.15 - Cylinder Head, Valve Gear

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

17 – Lubrication
1 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 or abrasion is found
when carrying out engine repairs, this can be subject to dam‐
age to the crankshaft and conrod bearings. In order to avoid
consequential damage, after the repair perform the following
tasks:

– Carefully clean the oil galleries.

– Replace oil spray jets.
– Replace engine oil cooler.
– Replace oil filter.
Inspecting oil pressure ⇒ page 91 .
Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Roomster .

1.1 Summary of components

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Lubrication system 85
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1 - Screw cap
❑ replace damaged gas‐
ket
2 - Oil feed line
❑ to turbocharger
3 - Dipstick
❑ oil level must not exceed
max. marking!
4 - Bracket for top auxiliary
units
❑ removing and installing
⇒ page 23
5 - Gasket
❑ replace if damaged
6 - Guide bushing
7 - Oil filter, 20 Nm

Note

When removing, make sure that the

oil does not penetrate into the gen‐
erator! Therefore, cover the gener‐
ator with a clean cloth!
❑ with gasket rings
❑ with non-return valve
❑ slacken and tighten with
oil filter wrench -3417-
❑ Keep to change inter‐
vals ⇒ Maintenance ;
Roomster
8 - 25 Nm
9 - Gasket
❑ replace if damaged
10 - 8 Nm + torque a further 90° (1/4 turn)
❑ replace
11 - Engine oil cooler
❑ removing and installing ⇒ page 90
12 - 8 Nm
13 - Top timing case
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ removing and unless
installing ⇒ page
authorised by ŠKODA 29AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Caution
Pay attention to tighten‐
ing process!

14 - 25 Nm
15 - Bottom timing case
❑ removing and installing ⇒ page 31
16 - 5 Nm + torque a further 30°
❑ Screw: M6x20

86 Rep. Gr.17 - Lubrication

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

17 - 5 Nm + torque a further 30°

❑ Screw: M6x40
18 - Drive chain
❑ removing and installing ⇒ page 62
❑ for oil pump
❑ mark running direction (installed position) before removing
19 - 150 Nm + torque a further 180° (1/2 turn)
❑ replace
❑ The clamping surface of the fixing screw must be free of grease and oil.
❑ insert oiled (thread)
❑ Secure belt pulley with counterholder -3415- to prevent it from turning
20 - Belt pulley
❑ Pay attention to tightening process ⇒ page 37
❑ Clamping surfaces must be free of oil and grease.
❑ Secure belt pulley with counterholder -T30004 (3415)- with bolts -T30004/2 (3415/2)- to prevent it from
turning
21 - Diamond coated washer
❑ replace
22 - Sealing ring
❑ replace
❑ removing and installing ⇒ page 36
23 - Bottom cover
24 - 20 Nm + torque a further 90° (1/4 turn)
25 - Sprocket
❑ for oil pump drive
❑ Clamping surfaces must be free of oil and grease.
❑ Lock chain sprocket with counterholder -T10172-
26 - Oil pump
❑ removing and installing ⇒ page 90
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ authorised
unless must be replaced
by ŠKODA AUTO A. completely
S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
27 - 13 Nm
❑ replace
❑ slacken and tighten only the bolts at the gearbox side with socket insert -T10058-
28 - 10 Nm
29 - Oil level and oil temperature sender -G266 -
❑ replace if damaged
❑ check ⇒ Current flow diagrams and Fitting locations
30 - Sealing ring
❑ replace if damaged
31 - Drain plug, 30 Nm
❑ with captive seal
❑ replace
32 - Oil pan
❑ removing and installing ⇒ page 88

1. Lubrication system 87
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

33 - 14 Nm + torque a further 90° (1/4 turn)

34 - Sealing ring
❑ replace
35 - Suction line
36 - 8 Nm
37 - 8 Nm
38 - Oil separator
install with sealant -D 176 501 A1-

1.2 Removing and installing oil pan

Special tools and workshop equipment required
♦ Socket insert -T10058-
♦ 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
♦ Silicone sealant -D 176 600 A1-
♦ Catch pan , e.g. -VAS 6208-
Removing
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Drain engine oil ⇒ Maintenance ; Roomster .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Remove catalytic converter
unless authorised by ŠKODAwith pre-exhaust
AUTO A. S. ŠKODA AUTOpipeA. S. does not guarantee or accept any liability
⇒ page 161 . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Disconnect plug at oil level and oil temperature sender -
G266- .

88 Rep. Gr.17 - Lubrication

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Release screw -1- from bracket for coolant pipe.

– Unscrew both fixing screws -3- and remove the bottom cover
plate.
– Loosen bolts for oil pan crosswise and release.
– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.

WARNING

Wear protective gloves 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.
Install

Note

♦ Replace M6 oil pan bolts.

♦ Pay attention to the use by date on sealant.
♦ The oil pan must be installed within 5 minutes after applying
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
the silicone sealant. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).
– Apply silicone sealant to the clean sealing surface of the oil
pan, as shown in the illustration. The sealant bead must be:
♦ 2 ... 3 mm thick
♦ run past the area around the bolt holes on the inside
-arrows-

Note

The sealant bead must not be thicker otherwise excess sealant

may get into the oil pan and block the strainer in the oil suction
pipe.

– Fit oil pan immediately and lightly tighten all oil pan screws.
– Tighten the screws of the oil pan to 13 Nm.
– Tighten the fixing screws of the cover plate at the gearbox to
40 Nm.
Further installation occurs in reverse order to removal.

Note

After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.

– Topping up with engine oil ⇒ Maintenance ; Roomster .

1. Lubrication system 89
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.3 Removing and installing oil pump

Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
– Removing the oil pan ⇒ page 88 .
– Pull off the cover -1- from the oil pump.

– Unscrew the fixing screws -arrows- of the oil pump.

– Remove the complete oil pump from the drive chain.
Install

– Hook the oil pump with the chain sprocket into the drive chain
and tighten the new screws -arrows- to 14 Nm + torque a fur‐
ther 90° (1/4 turn.).
Tightening torque of the suction line: 8 Nm
– Install oil pan ⇒ page 88 .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1.4 Removing and installing engine oil cool‐

er
Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Hose binding claw
Removing
– Drain coolant ⇒ page 94 .

90 Rep. Gr.17 - Lubrication

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Loosen the spring strap clamp -2- with the hose binding claw
and detach the coolant hose -1-.
– Release the 4 fixing screws from the engine oil cooler and re‐
move the engine oil cooler.
Install

Note

Replace gasket if damaged.

– Position the engine oil cooler -2- at the bracket and tighten the
fixing screws crosswise to 8 Nm + torque a further 90° (1/4
turn).
– Place the coolant hose -1- onto the oil cooler fitting and attach
it with the spring strap clamp -2-.
– Top up and bleed cooling system ⇒ page 94 .
– Inspect coolant level in the expansion reservoir, top up with
coolant if necessary.

Note

If the engine oil cooler was replaced, it must be filled with fresh
coolant.

1.5 Testing oil pressure and oil pressure

switch
Special tools and workshop equipment required
♦ 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-
♦ Vehicle diagnosis, measurement and information system -
VAS 5051-
Conditions
• Engine oil level o.k., test ⇒ Maintenance ; Roomster .
• Coolant temperature at least 80°C (radiator fan must have run
at least once).

Note
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Functional test and repair of the visual and acoustic oil pressure
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
display ⇒ Current flow diagrams and Fitting locations, ⇒ Vehicle
diagnosis, testing and information system VAS 5051.

1. Lubrication system 91
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Test sequence
– Disconnect plug -1- and remove the oil pressure switch -2-.

– Screw oil pressure switch into the test equipment.

– Screw tester in the cylinder head instead of the oil pressure
switch.
– Connect brown cable of tester to earth (-).
– Connect voltage test to battery positive and to oil pressure
switch.
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch -F1- .
If the LED does not light up:
– Start engine and slowly increase engine speed.
• The LED must light up at an oil overpressure of 0.03…0.07
MPa (0.3...0.7 bar), if not replaceProtected
oil pressure switch.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Increase engine speed further. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

• At 2000 rpm and an oil temperature of 80°C the oil overpres‐

sure should be at least 0.2 MPa (2.0 bar).
At a higher engine speed the oil overpressure must not be greater
than 0.7 MPa (7 bar).
Tightening torque of the oil pressure switch: 20 Nm

92 Rep. Gr.17 - Lubrication

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

19 – Cooling system
1 Cooling system

WARNING

Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. 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.
♦ The hose connections are secured with spring-type clips. In
case of repair only assign the spring strap clamps via the ⇒
Electronic catalogue of original parts .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Use pliers for unless
spring strap clamps to fit the spring strap clips.
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Always replace seals and gasket rings.

♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection and hose).
♦ The arrows which are on the coolant pipes and the coolant
hose ends must stand opposite to each other.

1.1 Connection diagram for coolant hoses

Note

♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
♦ The radiator and the charge air cooler are removed and in‐
stalled together ⇒ page 102 .

1. Cooling system 93
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1 - Expansion reservoir
2 - Coolant recirculation pump
-V50-
❑ removing and installing
⇒ page 99
3 - Charge air cooler
❑ in the intake manifold
⇒ page 130
4 - Coolant regulator housing
5 - Heat exchanger for heating
6 - Throttle valve
❑ in the coolant hose, not
visible from the outside
7 - Radiator
❑ removing and installing
⇒ page 102
8 - Charge air cooler
9 - Cylinder head/cylinder
block
❑ fill with fresh coolant af‐
ter replacing
10 - Non-return valve
❑ in the coolant hose, not
visible from the outside
11 - Engine oil cooler
12 - Coolant pump
❑ removing and installing
⇒ page 98

1.2 Draining and filling up coolant

Special tools and workshop equipment required
♦ Catch pan , e.g. - VAS 6208-
♦ Pliers for spring strap clamps
♦ Refractometer -T10007-
Draining

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Collect drained coolant in a clean container for reuse or proper
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

disposal.
♦ Observe the disposal instructions.

94 Rep. Gr.19 - Cooling system

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

WARNING

Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.

– Open compensation bottle.

– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Place a catch pan - VAS 6208- under the radiator.

Note

♦ Depending on the components which must be removed

⇒ page 93 , the coolant from the engine cooling system, from
the charge air cooling system or from both cooling systems
must be drained.
♦ If the coolant must be replaced, it should be drained from both
cooling systems.

Drain the coolant from the engine cooling system

– Open spring strap clamp -arrow- and pull off the bottom cool‐
ant hose at the engine radiator connection.

Note

Observe all the disposal instructions!

Drain the coolant from the charge air cooling system

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cooling system 95
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Open spring strap clamp -arrow- and pull off the bottom cool‐
ant hose at the connection of the additional radiator for the
charge air system.

Note

Observe all the disposal instructions!

Top up and bleed cooling system.

Select the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts or from the list of allowed coolant ad‐
ditives ⇒ Maintenance ; Roomster .
– In a clean reservoir mix water with coolant in the correct ratio
⇒ Maintenance ; Roomster .
– Reposition the removed coolant hose onto the relevant sup‐
port.
– Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Switch off the air-conditioning system and the heating.

Caution

In order to secure the refrigerating capacity of the charge air

cooling system, the following work steps must absolutely be
observed.

– Fill up coolant slowly up to the top max. marking on the com‐

pensation bottle.
– Seal expansion reservoir.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Start the engine and maintain the engine speed for about 3
minutes at approx. 2000 r.p.m.
– Run engine until radiator fan -V7- starts.

WARNING

Hot steam may escape when the compensation bottle is

opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.

– Check the level of coolant when the expansion reservoir is

closed and if necessary top up with missing coolant when the
engine has cooled down.
• When engine is at operating temperature the coolant level
must be at the max. marking, when engine is cold between the
min. and the max. markings.

96 Rep. Gr.19 - Cooling system

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

2 Parts of cooling system engine side

2.1 Coolant regulator - Summary of components

1 - Cylinder head
2 - O-ring
❑ replace
3 - Coolant pipe
4 - O-ring
❑ replace
5 - Retaining clip for coolant
pipe
6 - 11 Nm
7 - Coolant regulator housing
8 - Gasket
❑ replace
9 - Coolant temperature send‐
er -G62-
❑ before removing, re‐
duce pressure in cooling
system if necessary
10 - 10 Nm
11 - O-ring
❑ replace

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
2.2 Removing and installing belt pulley for
coolant pump
Special tools and workshop equipment required
♦ Water pump wrench -MP 1-308 (V.A.G 1590) -

2. Parts of cooling system engine side 97

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Modify water pump wrench -MP 1-308-

– Because of modified fixing screws for the belt pulley of the
coolant pump, these 3 curvatures must be filed open.
-a- at least 1 mm
Removing
– Remove V-ribbed belt ⇒ page 22 .

– Release screws -arrows- and remove holder from timing case.

Note

The bracket at the timing case only serves as transport security

of the engine before the first installation and must not be refitted.

– Release the screws for the belt pulley for coolant pump, to do
so counterhold with water pump wrench -V.A.G 1590- .
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ Tightening torque: 20 Nm

2.3 Removing and installing coolant pump

Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
Removing

Note

♦ The integrated gasket of the coolant pump must not be sepa‐

rated from the coolant pump.
♦ If damage and leak present, replace coolant pump with gasket
completely.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Drain
withthe coolant
respect from the
to the correctness engine incooling
of information system
this document. ⇒ page
Copyright by ŠKODA 94AUTO. A. S.�
– Remove belt pulley for control pump ⇒ page 97 .
– Disconnect the vacuum line -1- of the solenoid valve for cool‐
ant circuit -N492- from the coolant pump.

98 Rep. Gr.19 - Cooling system

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Release screws -arrows- and remove coolant pump.

Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ Tightening torque: 9 Nm
– Install belt pulley for coolant pump ⇒ page 97 .
– Top up and bleed cooling system ⇒ page 94 .

2.4 Removing and installing coolant recircu‐

lation pump -V50-
Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094) -
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-
Removing
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Gr. 50 .with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Unplug plug connection -1-.
– Release screw -3- and remove coolant recirculation pump -
V50- from bracket.
– Place a catch pan - VAS 6208- under the engine.
– Disconnect coolant hoses -2- with hose clamps -MP7-601-
and detach from the pump -V50- .

Install
♦ Tightening torque: 8 Nm.
Installation is performed in the reverse order, pay attention to the
following points:
– Inspect coolant level, if necessary top up cooling system and
bleed ⇒ page 94 .

2. Parts of cooling system engine side 99

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

3 Radiator and radiator fan

3.1 Parts of cooling system on the side next

to the body - Summary of components

Note

♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
♦ The radiator and the charge air cooler are removed and in‐
stalled together ⇒ page 102 .

1 - Radiator
❑ removing and installing
⇒ page 102
❑ after replacing fill entire
system with fresh cool‐
ant
2 - Coolant hose
❑ to exhaust gas turbo‐
charger
3 - Coolant hose
❑ to radiator for charge-air
system
4 - Coolant hose
❑ to exhaust gas turbo‐
charger
5 - Coolant hose
❑ to charge-air cooler in
the intake manifold
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6 - The fan ring
7 - Coolant hose
❑ to coolant pipe below
the intake manifold
8 - Coolant hose
❑ to engine oil cooler
9 - Expansion reservoir
❑ with coolant shortage
warning light sender -
G32-
❑ Check the cooling sys‐
tem for tightness
⇒ page 104
10 - Connector
11 - Screw cap
❑ Testing the pressure relief valve in the cap ⇒ page 104

100 Rep. Gr.19 - Cooling system

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

12 - 5 Nm
13 - Plastic inserts
❑ for fixing screws
14 - Support
15 - Coolant hose
❑ at coolant recirculation pump -V50-
16 - Radiator fan -V7-
❑ with radiator fan control unit -J293-
❑ removing and installing ⇒ page 101
17 - Fan shroud
❑ removing and installing ⇒ page 101
18 - 2 Nm
❑ mounted up to 05.10
19 - Heat shield
❑ mounted up to 05.10
20 - 8 Nm
21 - Bottom radiator bearing
22 - Charge air cooler
23 - Coolant hose
❑ at coolant regulator housing
24 - Thermo-switch for radiator fan -F18- , 35 Nm
❑ for fan
25 - O-ring
❑ replace if damaged
26 - Top radiator bearing
27 - 5 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
28 - Coolant hose with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ to the expansion reservoir

3.2 Removing and installing fan shroud and

radiator fan -V7-
Removing
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Disconnect the plug connection -arrow-.

3. Radiator and radiator fan 101

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Open the retaining clamps of the coolant hose -1- at the fan
shroud -2-.

– Release the support for the top right fan shroud and lift the fan
shroud out of the supports.
– Remove fan shroud downwards.

– Remove heat shield -arrows-.

– Remove fan ring Pos. 6 ( ⇒ page 100 , Pos. 6).

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Detach the electrical cable -1- from the cable straps.

– Unscrew nuts -arrows- and remove radiator fan -V7 - .
Install
Installation is performed in the reverse order, pay attention to the
following points:
Tightening torques:
Component Nm
Radiator fan at fan shroud 8
Heat shield 2

3.3 Removing and installing radiator

Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Pliers for spring strap clamps

102 Rep. Gr.19 - Cooling system

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Removing
– Remove front bumper ⇒ Body Work ⇒ Rep. Gr. 63 .
– Drain coolant ⇒ page 94 .
– Remove fan shroud with radiator fan -V7- ⇒ page 101 .
– Disconnect plug from thermo-switch for radiator fan -F18- .
– Detach top coolant hose from radiator connection fitting.
– Detach top coolant hose from connection fitting of charge air
cooler.
– Unscrew right and left screw -2- for radiator bearing.
– Push the radiator to the rear and remove the right and left ra‐
diator bearing ( ⇒ page 100 , Pos. 26).
Vehicles without air conditioning
– Push the radiator together with the charge air cooler upwards
out of the bottom rubber bearings and remove it laterally down.
Vehicles with air conditioning
– Remove V-ribbed belt ⇒ page 22 .

WARNING

Risk of injury through refrigerant.

♦ Refrigerant circuit of the air conditioning system must not
be opened.

Caution

Risk of damaging the condenser as well as the refrigerant lines

and hoses.
♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.

– Remove the AC compressor from the bracket for auxiliary

units and secure it with connected refrigerant hoses to the
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 bottom rubber bearings.
To do so, pull the plastic bushing for the lock carrier down‐
wards. There is very little space on the right between the
refrigerant line and the body.
– Lay the radiator with the condensor to the rear.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Radiator and radiator fan 103

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unscrew the screws -arrows- for the condensor -2- from the
radiator -1-.
– Draw the condensor forwards and attach to the lock carrier.
– Remove radiator together with charge air cooler laterally
down.

– Push the radiator -1- in -direction of arrow- out of the lateral

brackets on the charge-air cooler -2-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

– On vehicles with air conditioning system, push the plastic

bushing for the lock carrier upwards into the initial position and
tighten the screws -1- on the right and left.
Tightening torque: 8 Nm
– Top up coolant ⇒ page 94 .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

3.4 Checking the coolant system for leak‐

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

tightness
Special tools and workshop equipment required
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/9-
Test condition
• Engine must be warm.
Test sequence

WARNING

Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.

104 Rep. Gr.19 - Cooling system

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– 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.
– Using the hand pump of the testing device generate an over‐
pressure of approx. 0.1 MPa (1.0 bar).
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.
– Operate the handpump.
• The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).
If the pressure relief valve does not open:
– Replace cap.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
3. Radiator and radiator fan 105
 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

20 – Fuel Supply
1 Fuel tank and fuel delivery unit

Note

♦ Fuel hoses at the engine must only be secured with spring-

type clips ⇒ electronic catalogue of original parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.

1.1 Fuel tank - Summary of components

1 - Fuel tank
❑ support with engine/
gearbox jack -
V.A.G 1383 A- when re‐
moving
❑ removing and installing
⇒ page 109
2 - Sealing ring
❑ replace if damaged
3 - Fuel delivery unit
❑ Fitting position of flange
of fuel delivery unit
⇒ page 108
❑ removing and installing
⇒ page 111
❑ inspecting fuel pump
⇒ page 113
❑ Clean strainer if dirty
4 - Union nut
❑ slacken and tighten with
wrench for union nut -
MP1-227 (3217)-
5 - Return-flow line
❑ from the fuel delivery
unit to the fuel filter
❑ blue
6 - Feed line
❑ from fuel filter to fuel de‐
livery unit
❑ black
7 - Overflow hose Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
8 - Screw cap
9 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work ⇒ Rep. Gr. 55
10 - Earth connection
11 - O-ring
❑ replace

106 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

12 - Vent valve
❑ check ⇒ page 108
13 - Gravity valve
❑ to remove, unclip valve and lift up and out of the filler neck
❑ inspect valve for blockage:
❑ Valve open vertically
❑ Valve tilted 45°, closed
14 - Activated charcoal filter
❑ Summary of components of activated charcoal container system ⇒ page 122
❑ Checking the fuel tank venting ⇒ page 123
15 - Vent line
16 - O-ring
❑ replace
17 - 10 Nm
18 - Circlip
19 - Heat shield
❑ for fuel tank
20 - 25 Nm
❑ replace
21 - Straps
❑ pay attention to different lengths
22 - Fuel feed line
❑ black
❑ from fuel filter to fuel distributor at intake manifold
23 - Fuel filter
❑ with integrated pressure limiting valve for fuel return-flow line
Opening pressure: 0.40 MPa (4.0 bar)
❑ do not interchange connections
❑ The direction of flow of fuel is marked by arrow
❑ Fitting position: Pin at filter housing must byengage in theA. S.recess of the
A. S.guide
does notat the filter holder
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unless authorised ŠKODA AUTO ŠKODA AUTO guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
24 - Screw clamp
❑ for fuel filter
25 - Vent line
❑ to solenoid valve 1 for activated charcoal filter in engine compartment
26 - Vent line
❑ between activated charcoal filter Pos. 14 and vent line Pos. 25

1. Fuel tank and fuel delivery unit 107

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Fitting location of the fuel delivery unit

Note

The fuel delivery unit can only be installed in this position.

Marking on the flange must be aligned with marking on the fuel

tank.
-Arrow- points in direction of travel.
Connect blue or blue marked return-flow line -1- to the connection
with the marking -R-.
Connect black feed line -2- to connection with marking -V-.

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.

1.2 Extract fuel from the fuel tank

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Special tools and workshop equipment required with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Hose adapter , e.g. -V.A.G 1318 -16 -

♦ Adapter , e.g. -V.A.G 1318 -17-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Battery
♦ Catch pan for fuel

Note

If there are functional problems of the fuel delivery unit suction off
fuel with fuel extraction device, e.g. -VAS 5190- .

Work procedure

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Fold back the middle and right rear seat and position vertically
⇒ Body Work ⇒ Rep. Gr. 72 .

108 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
– Unplug the 5-pin plug from the fuel delivery unit.

WARNING

The fuel feed line is pressurized! Wear safety goggles and

safety clothing, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
cable connections. Reduce pressure by carefully removing the
wiring.

– Pull off the fuel feed line and gather residual fuel in a cloth.

– Connect the adapter -V.A.G 1318/16- with the adapter -V.A.G

1318/17- and fit this “drain pipe” onto the feed support of the
fuel delivery unit.
– Hold the “drain pipe” in a suitable catch pan for fuel.
– Connect the battery and the contacts of the fuel pump with
adapter cables -A- from the adapter cable set -V.A.G 1594/C-
as follows:
Battery positive (+) to contact -1- of the fuel pump
Battery minus (-) to contact -5- of the fuel pump
The fuel pump runs and suctions off fuel.

WARNING

In order to prevent an overflow of fuel in case of a too small

fuel tank, the fuel pump must not run unattended.

1.3 Removing and installing the fuel tank

Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
Removing
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 108 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Fold back the middle and right rear seat and position vertically
⇒ Body Work ⇒ Rep. Gr. 72 .

1. Fuel tank and fuel delivery unit 109

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
– Unplug the 5-pin plug from the fuel delivery unit.
– Clean around the fuel filler neck.
– Unscrew right rear wheel.
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Open fuel tank flap and unscrew cap from filler neck.

– Unscrew fixing screws at tank filler neck -arrows-.

– Remove both ventilation lines ( ⇒ page 122 , Pos. 6 and 7)
from activated charcoal filter.
– Remove rear axle ⇒ Chassis ⇒ Rep. Gr. 42 .
– Remove middle and rear silencer ⇒ page 163 .

WARNING

The fuel feed line is pressurized! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully releasing the connection
point.

Note

Always press in the securing ring in order to unlock the caps of

the fuel lines.

– Disconnect the feed line -1- and the vent line -2-.
– Support the fuel tank using the engine/gearbox jack -V.A.G
1383 A- .
– Unscrew tensioning straps and fixing screw of fuel tank
( ⇒ page 106 , Pos. 20).
– Carefully lower the engine/gearbox jack -V.A.G 1383 A- and
remove the fuel tank with the assistance of a second mechan‐
ic.
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Install unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Check if the earth lead shows traces of oxidation on both con‐
nections, remove if necessary.

110 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
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– Check fitting position of the earth lead -1-.

• The plug -1- on the metal plate ring -2- must be placed on
firmly.
• The contact tab -4- must be hung in the fuel tank -3- and se‐
cured with the spacer bush -5-.
Further installation occurs in reverse order. Pay attention to the
following:
♦ Lay the vent and fuel lines without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.

1.4 Removing and installing fuel delivery

unit
Special tools and workshop equipment required
♦ Wrench for union nut -MP1-227 (3217)-
Removing
• The fuel tank must not be more than 3/4 full.

Note

♦ If necessary, extract fuel from the fuel tank ⇒ page 108 .

♦ Observe the safety instructions before starting fitting work
⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 5 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Switch off the ignition and all
with respect electrical
to the components
correctness of information in thisand takeCopyright by ŠKODA AUTO A. S.�
document.

out the ignition key.

– Fold back the middle and right rear seat and position vertically
⇒ Body Work ⇒ Rep. Gr. 72 .
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
– Disconnect the 5-pin plug, the feed and return flow line from
the flange of the fuel delivery unit.

Note

Press in the securing ring in order to unlock the line.

WARNING

The fuel feed line is pressurized! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully releasing the connection
point.

1. Fuel tank and fuel delivery unit 111

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unscrew union nut with wrench for union nut -MP1-227

(3217)- .

Note

♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.

– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
Installation of the fuel delivery unit occurs in reverse order to re‐
moval. Pay attention to the following:

Note

♦ When inserting the fuel delivery unit, ensure that the fuel
gauge sender is not bent.
♦ Insert dry gasket ring of the fuel delivery unit into the opening
of the fuel tank.
♦ Only moisten gasket ring with fuel before assembly of the fuel
delivery unit.
♦ Pay attention to installed position of flange of fuel delivery unit:
The marking on the flange must be aligned with the marking
on the fuel tank -arrows-.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel hoses fit tightly.
♦ After installing the fuel delivery unit, check whether the feed,
return-flow and vent lines are clipped in place on the fuel tank.

1.5 Removing and installing the sender for

fuel gauge display -G-
Removing
– Remove fuel delivery unit ⇒ page 111 .
– Unlock the catches -arrows- using a screwdriver and pull out
the sender for fuel gauge display -G- towards the top.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

112 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the wiring and check correct installation of the plug.
– 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.
– Install fuel delivery unit ⇒ page 111 .

1.6 Testing fuel pump

Special tools and workshop equipment required
♦ Key -T30101 (3087)-
♦ Pressure gauge , e.g. -V.A.G 1318 -
♦ Adapter , e.g. -V.A.G 1318/11-
♦ Hose adapter , e.g. -V.A.G 1318/16-
♦ Adapter set , e.g. - V.A.G 1318/17A-
♦ Double connection piece , e.g. - V.A.G 1318/23-
♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g.
-V.A.G 1348/3-3 -
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Vehicle diagnosis, measurement and information system -
VAS 5051-
♦ Measuring vessel

Note

♦ The adapter set -V.A.G 1318/17A- replaces the adapter set -

V.A.G 1318/17- .
♦ The figures shown in the descriptions were not changed for
this reason.

1.6.1 Inspecting proper operation and power

supply
Test conditions
• Battery voltage at least 11.5 V.
• Fuel pump fuse O.K. ⇒ Current flow diagrams and Fitting lo‐
cations.
• Fuel pump control unit -J538- O.K.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Fuel tank and fuel delivery unit 113

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Test sequence

Note

The function of the fuel pump is tested with the actuator diagnosis.

– Connect diagnostic unit -VAS 5051- .

– Switch on ignition.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”,“01 - Engine electronics” and “03 - Actuator di‐
agnosis”.
– On the display press the right arrow button up to the actuator
diagnosis of the fuel pump electronics.
• The fuel pump must now run slowly to the maximum speed.

Note

The fuel pump runs very quietly.

– Switch off ignition.

The fuel pump does not run:
– Fold back the middle and right rear seat and position vertically
⇒ Body Work ⇒ Rep. Gr. 72 .
– Disconnect plug from fuel pump control unit -J538- -2-.

– Testing the voltage supply with the voltage tester -V.A.G

1527B- between contact -1- and -6-.
• The LED must light up.
The LED does not light up:
– Determine and remove open circuit in the wiring according to
the current flow diagram ⇒ Current flow diagrams and Fitting
locations.
The LED lights up (power supply O.K.):
– Remove fuel delivery unit ⇒ page 111 .
– Check whether the electric
unlesswiring between the flange andAUTOtheA. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA
fuel delivery unit is connected.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

If there is no open circuit in the wiring:

– Fuel pump defective, replace the fuel delivery unit
⇒ page 111 .

114 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.6.2 Check fuel pressure

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Remove the fuel feed line -3- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– unless
Install the pressure
authorised by ŠKODA AUTO gauge -V.A.G
A. S. ŠKODA AUTO 1318 - with
A. S. does the adapter
not guarantee set
or accept any liability
-V.A.G 1318/17A-
with respect instead
to the correctness of the
of information fuel
in this feed Copyright
document. line. by ŠKODA AUTO A. S.�
– Open shut-off cock of the pressure gauge. The lever then
points in position -A-.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.4…0.7 MPa (4…7.0 bar)
If fuel line is o.k.:
– Test holding pressure ⇒ page 116 .
If the specified pressure is exceeded:
– Check the return line between the fuel filter and fuel pump for
kinks and blockages.
If no fault is found:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.
If the specified value is not reached:

– Check the fuel pressure before the fuel filter. For this step
connect the pressure gauge -V.A.G 1318- with the adapter set
-V.A.G 1318/17A- between the fuel filter and the fuel feed line.
– Open shut-off cock of the pressure gauge. Lever points in di‐
rection of flow.
– Start engine and run in idle.

Caution

The shut-off cock must only be closed slowly. At a fuel pressure

of 0.8 MPa (8 bar), the shut-off cock must be immediately
opened, in order to avoid a damage of the pressure gauge.

1. Fuel tank and fuel delivery unit 115

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Slowly close the shutoff cock of the pressure measuring de‐

vice. The pressure must rise to at least 0.6 MPa (6.0 bar). If
the 0.6 MPa (6.0 bar) is reached, immediately open the shut-
off cock again!
If the pressure has risen:
– Fuel pump O.K., pressure limiting valve in the fuel filter defec‐
tive, replace the fuel filter.
If the pressure does not rise:
– Fuel pump defective, replace the fuel delivery unit
⇒ page 111 .

1.6.3 Test holding pressure

• Fuel pressure O.K. and pressure gauge -V.A.G 1318- con‐
nected in the engine compartment ⇒ page 115 .

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel
Protected supply
by copyright. system
Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ page 5 . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.4…0.7 MPa (4…7.0 bar)
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure drops:
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.

– Immediately close the shutoff cock of the pressure measuring

device. The lever then points in the position -B-.
If the pressure again drops:
– Check the low pressure pipe to the high pressure pump for
tightness.
If no fault is found:
– Replace high pressure pump ⇒ page 145 .
Now the pressure does no longer drop:
– Check the fuel line to the fuel filter for tightness.
If the fuel line is not found to be faulty:

116 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Check the non-return valve in the fuel delivery unit. For this
step connect the pressure measuring device -V.A.G 1318-
with the adapter -V.A.G 1318/17A- between the fuel filter and
the fuel feed line.
– Open shut-off cock of the pressure gauge. Lever points in di‐
rection of flow.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.4…0.7 MPa (4…7.0 bar)

– Immediately close the shut-off cock of the pressure measuring

device after the pressure has built up.
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure drops:
– Non-return valve in the fuel pump faulty, replace fuel delivery
unit ⇒ page 111 .
If the pressure does not drop:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.

1.6.4 Check fuel flow rate

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .
– Disconnect plug from fuel pump control unit -J538- -2-.
– Remove cover -1-.
– Unplug the 5-pin plug from the fuel delivery unit.

1. Fuel tank and fuel delivery unit 117

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Connect the remote control -V.A.G 1348/3A - with adapter ca‐

bles at contact -1(+)- of fuel pump and at contact -1(+)- of 10-
pin plug.
– Connect the contact -6(-)- of the 10-pin plug with the contact
-5(-)- of the fuel pump using an adapter cable from the adapter
cable set -V.A.G 1594 C- .
– Take cap off fuel filler neck.

– Remove the fuel feed line -3- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.

– Connect the pressure gauge - V.A.G 1318- with the double

connection piece -V.A.G 1318/23 - and the adapter set -V.A.G
1318/17A- to the fuel feed line.
– Fit the hose adapter -V.A.G 1318/16 - onto the adapter -V.A.G
1318/11- of the pressure measuring device and hold it in a
measuring vessel.
– Close the shut-off cock of the pressure measuring device. The
lever then points in the position -B-.

WARNING
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Danger of liquid spraying out when opening the shut-off valve.
Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact with fuel. Hold the container in front of
the free connection to the pressure gauge.

– Open shut-off cock of the pressure gauge. The lever then

points in the direction of flow -A-.
– Activate remote control -V.A.G 1348/3A - . While doing so,
slowly close the shut-off cock until the pressure gauge dis‐
plays 0.4 MPa (4 bar) overpressure. Now do not make any
further changes to the position of the shut-off cock.
– Empty measuring glass.
– The fuel flow rate of the fuel pump is dependent on the battery
voltage. Therefore attach the multimeter -V.A.G 1715- with
adapter cables from the measuring tool set -V.A.G 1594 C- to
the vehicle battery.
– Activate remote control for 30 seconds while measuring the
battery voltage.

118 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Compare the fuel rate with the specified value.

*) minimum flow rate 1 cm3/30 s
**) Voltage at the fuel delivery unit when engine not running and
unit operating (approx. 2 volts less than battery voltage).
Read out examples:
During the test a voltage of 12.5 V was measured on the battery.
As the voltage on the fuel pump is approximately 2V less than the
battery voltage, a minimum flow rate of 580 cm 3/30 s is obtained.
If the minimum delivery volume is not reached:
– Check the fuel lines for possible restrictions (kinks) or block‐
ing.
If no fault is found:

– Disconnect the feed hose -1- from the fuel filter inlet.
– Connect pressure gauge -V.A.G 1318- with the adapter set -
V.A.G 1318/17A- to the hose.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
– Replace fuel filter.
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and inspect the filter strainer for
soiling.
If you have still not found any fault up to this stage:
– Replacing fuel delivery unit ⇒ page 111 .
If the required fuel delivery volume has been achieved, but a fault
is still suspected in the fuel supply system (e.g. intermittent break‐
down of the fuel supply):
– Check power consumption of the fuel pump ⇒ page 119 .
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1.6.5 Check power consumption
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Fold up rear seat.

– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.

1. Fuel tank and fuel delivery unit 119

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Connect the current probe -A- of the vehicle diagnosis, meas‐

urement and information system - VAS 5051- on the line -B-
to contact 1 of the 5-pin plug.
– Start engine and run in idle.
– Measure voltage consumption of the fuel pump.
Specified value: max. 9 A

Note

If the fault in the fuel supply system is intermittent then tests can
be undertaken during a test drive but then two people are required
for this.

If the specfied current uptake is exceeded:

– Fuel pump defective, replace the fuel delivery unit
⇒ page 111 .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

120 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

2 Electronic Engine Power Control

(Electronic throttle)

2.1 Accelerator pedal module - Summary of components

1 - Bearing bracket
❑ removing and installing
⇒ Chassis ⇒ Rep. Gr.
46
2 - Connector
❑ black
❑ 6-pin
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
❑ if the accelerator pedal
module is replaced, an
adaptation of the engine
control unitAUTO
has A.toS.be
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA ŠKODA AUTO A. S. does not guarantee or accept any liability
performed
with respect on ofvehicles
to the correctness information in this document. Copyright by ŠKODA AUTO A. S.�
with automatic gearbox
⇒ Vehicle diagnosis,
testing and information
system VAS 5051
4 - 10 Nm

2. Electronic Engine Power Control (Electronic throttle) 121

 Roomster 2006 ➤
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3 Activated charcoal container system

3.1 Activated charcoal container system - Summary of components

Note

♦ The hose connections are secured with spring strap clips or clamp-type clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ Use pliers for spring strap clips to fit the spring strap clips.
♦ Safety precautions when working on the fuel supply system ⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system ⇒ page 5 .

1 - Bleeder hose
2 - Activated charcoal filter sys‐
tem solenoid valve 1 -N80-
with connection line
❑ attached with bracket to
the intake manifold
❑ Valve is actuated
(pulsed) by engine con‐
trol unit -J623- when en‐
gine is warm
❑ check ⇒ Vehicle diagno‐
sis, testing and informa‐
tion system VAS 5051
❑ Valve closed when igni‐
tion is switched off
3 - To the non-return valve
4 - Intake manifold
5 - Activated charcoal filter
❑ Fitting location: in rear
right wheelhouse
❑ attached to the vehicle
body
❑ filled by solenoid valve -
N80- and by gravity
valve
❑ Checking the fuel tank
venting ⇒ page 123
❑ removing:
– Removing the rear right
wheel.
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– Removing theauthorised
unless plasticby ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
wheelhousewithliner ⇒to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
respect
Body Work ⇒ Rep. Gr.
66 .

– Disconnect lines -6- and -7-.

– Remove the activated charcoal filter from the body and push down.
❑ Installing:
– Installation is carried out in the reverse order.

122 Rep. Gr.20 - Fuel Supply

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

6 - Vent line
7 - Vent line with gravity valve
8 - To the fuel filler flap unit

3.2 Checking the fuel tank venting

Special tools and workshop equipment required
♦ Hand vacuum pump, e.g. -V.A.G. 1390- or Hand vacuum
pump -VAS 6213-
Test condition
• The ignition must be switched off.
– Remove the ventilation line -1- from the activated charcoal fil‐
ter to the activated charcoal filter system solenoid valve 1 -
N80- -2-.
– Connect hand vacuum pump -VAS 6213- to vent line -1- as
shown.
– Operate the hand vacuum pump several times. No vacuum
should build up.
If a vacuum builds up.
– Check the ventilation opening below the cap -4- on the acti‐
vated charcoal filter -3- for dirt, clean as required.
If no vacuum builds up:
– Remove the cap -4- and shut off the ventilation opening on the
activated charcoal filter and once again operate the hand vac‐
uum pump several times. A vacuum should build up.
If no vacuum builds up:
– Replace activated charcoal filter.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Activated charcoal container system 123

 Roomster 2006 ➤
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21 – Turbocharging
1 Exhaust gas turbocharger

Note

Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 7 .

1.1 Exhaust turbocharger - Summary of

components
Part I. ⇒ page 125
Part II. ⇒ page 126

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

124 Rep. Gr.21 - Turbocharging

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.1.1 Part I.

1 - Activated charcoal filter sys‐

tem solenoid valve 1 -N80-
with connection line
❑ To intake manifold
2 - Non-return valve
❑ Fitting location: cylinder
head cover
3 - Connecting hose
4 - 8 Nm
5 - Inlet connection
6 - Exhaust turbocharger with
exhaust manifold
❑ with charge pressure
regulator -V465 -

Note

The exhaust turbocharger can only

be replaced complete with exhaust
manifold and charge pressure reg‐
ulator -V465- .
❑ removing and installing
⇒ page 126
7 - O-ring
❑ replace
8 - Connector

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Exhaust gas turbocharger 125

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.1.2 Part Il.

1 - Gasket
❑ replace
2 - Support
3 - 20 Nm
4 - Exhaust turbocharger with
exhaust manifold
❑ with charge pressure
regulator -V465 -

Note

The exhaust turbocharger can only

be replaced complete with exhaust
manifold and charge pressure reg‐
ulator -V465- .
❑ removing and installing
⇒ page 126
5 - O-ring
❑ replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
6 - Oil return pipewith respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
7 - 8 Nm
8 - 10 Nm
9 - Heat shield
10 - 8 Nm
11 - Coolant pipes
12 - 8 Nm
13 - 18 Nm
❑ observe the order of
tightening up
⇒ page 126
❑ Tightening torque of pin screw in cylinder head: 18 Nm (insert oiled)
14 - Sealing ring
❑ replace
15 - Hollow screw
❑ Tightening torque: 20 Nm
16 - Oil feed pipe
17 - O-ring
❑ replace
18 - 8 Nm

1.2 Removing and installing exhaust gas

turbocharger
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-

126 Rep. Gr.21 - Turbocharging

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

♦ Hot screw paste -G 052 112 A3-

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 the engine oil and replace the oil filter
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
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 rules for cleanliness ⇒ page 3 .

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

Removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Disconnect battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Remove V-ribbed belt ⇒ page 22 .
– Drain coolant ⇒ page 94 .
– Detach hoses -1- and plugs -2- from exhaust gas turbocharg‐
er.

– Release screws -1- and remove retaining clip.

– Disconnect plug -2- at charge pressure sender -G31- with in‐
take air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338- and then from the exhaust gas turbocharger.
– Fold open the cover -4- and release the fixing screw.

1. Exhaust gas turbocharger 127

 Roomster 2006 ➤
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– Disconnect all the spark plug connectors -arrows- using the

extractor -T10112 A- from the spark plugs and lay the ignition
cables to the rear.
– Detach coolant hoses from coolant pipes -1-.

Note

Make sure that the oil does not penetrate into the generator!
Therefore, cover the generator with a clean cloth!

– Unscrew the hollow screw -4- of the oil pipe.

– Release fixing screws -2- and -3- and remove oil and coolant
pipes.
– Remove lambda probe -G39- -5-.
– Release the top fixing screw of the AC generator and press
the generator slightly downwards.
– Release fixing screws -arrows- and remove the heat shield
from the exhaust turbocharger.

– Remove bracket -1-.

– Remove catalytic converter with pre-exhaust pipe
⇒ page 161 .

– Release the fixing screw -1- of the oil return pipe -2- and pull
the oil return pipe out of the exhaust gas turbocharger.
– Release the fixing screws of the heat shield -3- and remove
the panel from the exhaust manifold.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

128 Rep. Gr.21 - Turbocharging

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unscrew all the fixing nuts -arrows- of the exhaust manifold.

– Remove exhaust manifold with turbocharger from cylinder
head.
– Remove the gasket from the stud bolts.
Install
– Position exhaust turbocharger with exhaust manifold and gas‐
ket at cylinder head.

– Tighten the fixing nuts to 18 Nm in the specified order -A- to

-H-.
Further installation occurs in reverse order, while paying attention
to the following:

Note

♦ Replace the gaskets, the sealing rings and the self-locking

nuts.
♦ Fill the exhaust turbocharger with engine oil at the connection
fitting for the oil feed line.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before being installed.
♦ Secure all hose connections with corresponding hose clips.

Tightening torques:
Exhaust gas turbocharger - Summary of components part I.
⇒ page 125
Exhaust gas turbocharger - Summary of components part lI.
⇒ page 126 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Catalytic converter and component
with respect toparts - Summary
the correctness of compo‐
of information in this document. Copyright by ŠKODA AUTO A. S.�
nents ⇒ page 159
– Attach AC generator ⇒ Electrical System; Rep. Gr. 27 ; re‐
moving and installing AC generator .
– Install the V-ribbed belt ⇒ page 22 .
– Top up coolant ⇒ page 94 .
– Connect battery ⇒ Electrical System ⇒ Rep. Gr. 27 .

1. Exhaust gas turbocharger 129

 Roomster 2006 ➤
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2 Charge air system with exhaust gas

turbocharger
Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 7 .

2.1 Charge air system - Summary of com‐

ponents

Note

♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
♦ The radiator and the charge air cooler are removed and in‐
stalled together ⇒ page 102 .

1 - Radiator
❑ removing and installing
⇒ page 102
2 - Intake manifold
❑ removing and installing
⇒ page 140
3 - Seal
❑ pay attention to correct
seating when installing
the charge air cooler
4 - Gasket
❑ replace if damaged
5 - Charge-air cooler in intake
manifold
❑ removing and installing
⇒ page 131
6 - Coolant hose
❑ to exhaust gas turbo‐
charger
7 - 7 Nm
❑ when installing first
tighten evenly by hand,
then tighten crosswise
from the inside to the
outside to the recom‐
mended tightening tor‐
que
8 - Coolant hose
❑ to the expansion reser‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
voir with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

9 - Hose clamp
❑ attached to the timing
case
10 - Coolant hose
❑ to exhaust gas turbocharger

130 Rep. Gr.21 - Turbocharging

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

11 - Coolant recirculation pump -V50-

❑ removing and installing ⇒ page 99
12 - 8 Nm
13 - Support
14 - Connector
15 - 10 Nm
16 - Coolant hose
❑ to engine oil cooler
17 - Coolant pipe
❑ attached to the oil pan
18 - 8 Nm
19 - Bottom coolant hose
20 - Charge air cooler
❑ removing and installing ⇒ page 102

2.2 Removing and installing charge air cool‐

er
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094) -
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Pliers for spring strap clamps

♦ Catch pan , e.g. -VAS 6208-

Note

Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 7 .

2. Charge air system with exhaust gas turbocharger 131

 Roomster 2006 ➤
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Removing
– Disconnect plug -1- and hose -3- from activated charcoal filter
system solenoid valve 1 -N80- .
– Remove the lines with the non-return valve -5- and the acti‐
vated charcoal filter system solenoid valve 1 -N80- from the
intake manifold.
– Pinch off coolant hoses -3- with hose clamps -3094 - and de‐
tach from charge-air cooler.
– Release the fixing screws of the ignition transformer -N152-
and carefully place the ignition transformer onto the cylinder
head cover.
– Release fixing screws at charge air cooler -4-.
– Carefully pull the charge air cooler -4- out of the intake mani‐
fold.

Note

Pour the residual coolant out of the charge air cooler into a col‐
lecting tank.

Install
Installation is performed in the reverse order, pay attention to the
following points:

– Slide the seal -1- in -direction of arrow- onto the edge of the
charge air cooler -2-.
– Check the correct seating of the new gasket at the intake
manifold.
– Slide the charge air cooler into the intake manifold.
– Press down the charge-air cooler up to the stop into the intake
manifold.

Note

Do not tilt the charge-air cooler when installing.

– First tighten the fixing screws uniformly crosswise until the

screw head is positioned.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Tighten the fixing screws crosswise to 7 Nm.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

132 Rep. Gr.21 - Turbocharging

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

24 – Fuel Formation, Injection

1 Fitting location of the injection system

1 - Oil pressure switch -F1-

❑ in the left cylinder head
❑ check ⇒ page 91
2 - Solenoid valve for coolant
circuit -N492-
3 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
4 - Intake manifold pressure
sender -G71- and intake air
temperature sender -G42-
5 - Engine control unit -J623-
❑ removing and installing
⇒ page 157
6 - Control valve for fuel pres‐
sure -N276-
7 - Knock sensor 1 -G61-
❑ at rear cylinder block
❑ 20 Nm
8 - Hall sender -G40-
9 - Ignition transformer -N152-
♦ D ignition transformer = ig‐
nition cable cyl. 1
♦ B ignition transformer = ig‐
nition cable cyl. 2
♦ C ignition transformer = ig‐
nition cable cyl. 3
♦ A ignition transformer = ig‐
nition cable cyl. 4
10 - Injection valves
❑ Injection valve for cylin‐
der 1 -N30-
❑ Injection valve for cylinder 2 -N31-
❑ Injection valve for cylinder 3 -N32-
❑ Injection valve for cylinder 4 -N33-
❑ with Teflon gasket ring and supporting washer
❑ after
Protected removing
by copyright. Copyingthe injection
for private valve,purposes,
or commercial the Teflon
in part orgasket
in whole, isring and the supporting washer must be replaced
not permitted
⇒ page
unless authorised by 150
ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Removing and installing the injection valves ⇒ page 148
11 - Charge pressure sender -G31- with intake air temperature sender 2 -G299-
12 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 138
❑ clean ⇒ page 140
❑ in case of replacement, erase initialisation values and adapt the engine control unit -J623- ⇒ Vehicle
diagnosis, testing and information system VAS 5051.

1. Fitting location of the injection system 133

 Roomster 2006 ➤
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13 - Fuel pressure sender -G247-

❑ check ⇒ page 154
14 - Engine speed sender -G28-
❑ removing and installing ⇒ page 167
15 - Coolant temperature sender -G62-
16 - Thermo-switch for radiator fan -F18- , 35 Nm
❑ for fan
17 - Charge pressure regulator -V465 -

Note

The charge pressure regulator -

V465- can only be replaced com‐
plete with exhaust gas turbocharger
and exhaust manifold.

18 - Lambda probe downstream of catalytic converter -G130- and heater of lambda probe 1 downstream of
catalytic converter -Z29-
19 - Spark plugs, 25 Nm
20 - lambda probe -G39- and heating for lambda probe -Z19-
21 - High pressure pump with fuel pressure regulating valve -N276-
❑ removing and installing ⇒ page 145

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

134 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

2 Intake manifold and fuel distributor

2.1 Intake manifold - Summary of compo‐

nents
Part I. ⇒ page 136
Part II. ⇒ page 137

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Intake manifold and fuel distributor 135

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

2.1.1 Part I.

1 - Connecting hose
❑ at camshaft housing
2 - Connector
❑ for intake manifold pres‐
sure sender -G71-
3 - Connector
❑ for solenoid valve for
coolant pump control
4 - 10 Nm
5 - Non-return valve
❑ for crankcase ventila‐
tion
6 - Connecting hose
❑ to exhaust gas turbo‐
charger
7 - O-ring
❑ replace
8 - Intake manifold
❑ removing and installing
⇒ page 140
❑ with intake manifold
pressure sender -G71-
♦ The intake manifold pres‐
sure sender -G71- is at‐
tached to the intake mani‐
fold only using a plastic clip.
♦ If the plastic clip is dam‐
aged, attach the sender to
the intake manifold with
screws ⇒ Electronic Cata‐
logue of Original Parts .
Tightening torque: 3 Nm.
9 - Connecting hose
❑ to the coolant pump
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
10 - Solenoid valve for coolant circuit -N492-
11 - Connection fittings
12 - Clamp
13 - Fuel hose
❑ to high pressure pump
14 - Solenoid valve 1 for activated charcoal filter -N80-
15 - Connecting hose
❑ to the activated charcoal filter system
16 - Connection line
17 - Connector
❑ for throttle valve control unit -J338-

136 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

18 - Connecting hose
19 - Connector
❑ for Charge pressure sender -G31- with intake air temperature sender 2 -G299-

2.1.2 Part II.

1 - Pressure pipe
2 - 7 Nm
3 - Retaining clip
4 - Fuel pressure sender -
G247- , 22 Nm
❑ Check fuel pressure
sender -G247 -
⇒ page 154
5 - Fuel distributor
6 - 20 Nm
7 - 30 Nm
8 - 25 Nm
9 - 25 Nm
10 - O-ring
❑ replace
11 - Spring element
❑ replace each time the
bottom part of the intake
manifold is removed
❑ check for correct seat‐
ing on injector
12 - Injection valve for cylinder
1 -N30-
❑ Injection valve for cylin‐
der 2 -N31-
❑ Injection valve for cylin‐
der 3 -N32-
❑ Injection valveProtected
for cylin‐
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
der 4 -N33- unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ with Teflon gasket ring
and supporting washer
❑ after removing the injection valve, the Teflon gasket ring and the supporting washer must be replaced
⇒ page 150
❑ Removing and installing the injection valves ⇒ page 148
13 - Cylinder head
❑ removing and installing ⇒ page 75
14 - 20 Nm
15 - Intake manifold
❑ removing and installing ⇒ page 140
❑ with intake manifold pressure sender -G71-
♦ The intake manifold pressure sender -G71- is attached to the intake manifold only using a plastic clip.
♦ If the plastic clip is damaged, attach the sender to the intake manifold with screws ⇒ Electronic Catalogue
of Original Parts . Tightening torque: 3 Nm.

2. Intake manifold and fuel distributor 137

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

16 - Gasket
❑ replace
17 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 138
❑ clean ⇒ page 140
❑ in case of replacement, erase initialisation values and adapt the engine control unit -J623- ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
18 - Adapter
19 - O-ring
❑ replace
20 - 7 Nm
21 - O-ring
❑ replace
22 - Charge pressure sender -G31- with intake air temperature sender 2 -G299-
23 - 5 Nm

2.2 Removing and installing the throttle

valve control unit -J338 -

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Release screws -1- and remove
with retaining
respect to the correctnessclip.
of information in this document. Copyright by ŠKODA AUTO A. S.�

– Connect plug -2- at charge pressure sender -G31- with intake

air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.

– Disconnect the plug -1- from the throttle valve control unit -
J338 - .
– Release the fixing screws -2- and remove the throttle valve
control unit -J338- from the intake manifold.
Install
– Insert a new gasket ring in the groove of the intake manifold.

138 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Position the throttle valve control unit -3- together with the
adapter -2- and the fixing screws -1- onto the intake manifold
-4-.

– Tighten fixing screws -2- to 7 Nm.

– Fit the plug -1- at the throttle valve control unit -3-.

Note

Before fitting the O-rings at the exhaust turbocharger and in the

pressure pipe moisten slightly with engine oil.

– Fit the pressure pipe -3- at the turbocharger.

– Press the pressure pipe -3- onto the throttle valve control unit.
• During this procedure the retaining clips must click audibly into
place.
– Tighten screws -1- of retaining clip to 7 Nm.
– Connect plug -2- at charge pressure sender -G31- with intake
air temperature sender 2 -G299 - .
If a new throttle valve control unit was installed:
– Erase initialisation values and adapt the engine control unit -
J623- to the throttle valve control unit ⇒ Vehicle diagnosis,
testing and information system VAS 5051.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Intake manifold and fuel distributor 139

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

2.3 Clean throttle valve control unit -J338-

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .
♦ If a new engine control unit -J623- is fitted, the throttle valve
control unit must be adapted. The adaptation must only be
carried out with a new or cleaned throttle valve control unit,
because dirt/carbon deposits in the end stop of the throttle
valve can lead to incorrect adaptation values.
♦ The throttle valve support must not be scratched when clean‐
ing.

– Remove the throttle valve control unit ⇒ page 138 .

– Open the throttle valve manually and block the throttle valve
in the opened position with a suitable object (e.g. plastic or
wooden wedge)-arrow-.

WARNING

Acetone is easily inflammable. Observe the accident preven‐

tion regulations and the safety instructions when handling
easily inflammable fluids. Do not use compressed air when
cleaning the throttle valve. Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.

– Thoroughly clean the throttle valve support, in particular the

area of the closed throttle valve -arrows-, with commercially
available acetone and a paint brush.
– Wipe the throttle valve support with a fluffy cloth.
– Let the acetone dry off completely and re-install the cleaned
throttle valve control unit.

2.4 Removing and installing intake manifold

Special tools and workshop equipment required
♦ Pliers for spring strap clamps
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

140 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Remove the throttle valve control unit ⇒ page 138 .
– Disconnect the fuel intake hose -9- and the plug from the ac‐
tivated charcoal filter system solenoid valve 1 -N80- and re‐
move the valve from the intake manifold.
– Disconnect plugs -1- and -4-.
– Release the fixing screws -7- and carefully place the ignition
transformer -N152- -6- onto the cylinder head cover.
– Detach connecting hose -5- from intake manifold.
– Disconnect the vacuum line of the solenoid valve for coolant
circuit -N492- -2- from the coolant pump.
– Pinch off coolant hoses for charge-air cooler with hose clamps
-MP7-601- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Slacken the clamps
unless authorised by ŠKODA -3- andA. detach
AUTO S. ŠKODA theAUTOcoolant
A. S. doeshoses fromor the
not guarantee accept any liability
charge-air cooler.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Slacken the fixing screws -arrows- crosswise and carefully re‐

move the intake manifold upwards.

Note

Pour the residual coolant out of the charge air cooler into a col‐
lecting tank.

Install
Installation is carried out in the reverse order.
♦ Tightening torque of fixing screws for intake manifold: 20 Nm
♦ Tightening torque and tightening sequence for charge-air cool‐
er: ⇒ page 130
– Check, top up and bleed cooling system ⇒ page 94 .

2. Intake manifold and fuel distributor 141

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

3 Air filter

3.1 Air filter - Summary of components

Removing and installing air filter ⇒ page 142 .

1 - O-ring
❑ replace if damaged
2 - Inlet connection
3 - Spring strap clamp
❑ use spring strap clips ,
e.g. -VAS 6340- for re‐
moving and installing
4 - Suction hose
5 - Vacuum hose
❑ replace if damaged
❑ to cylinder head cover
6 - Suction hose with supports
7 - Upper part of air filter hous‐
ing
8 - 2 Nm
9 - Filter element
10 - Rubber-metal bearing
11 - Bottom part of the air filter
housing
❑ removing and installing
⇒ page 142
12 - 8 Nm
13 - Rubber-metal bearing
14 - Water drain hose
15 - Intake air duct
16 - 3 Nm
17 - 10 Nm

3.2 Removing and installing air filter

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Special tools and workshop equipment required
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Pliers for spring strap clamps
Removing
– Remove battery ⇒ Electrical System ⇒ Rep. Gr. 27 .

142 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unscrew the fixing screws -arrows- of the intake air duct and
the inlet connection at the exhaust gas turbocharger.

– Disconnect vacuum hose -1- from suction hose.

– Release the fixing screw -2- and pull the air filter housing to‐
wards the top from the bearing bolts.
Install
– Press the air filter housing from the top onto the bearing bolts.

– Tighten fixing screw -2- to 8 Nm.

– Connect vacuum hose -1- to suction hose.

– Tighten the fixing screws -arrows- of the intake air duct and
the inlet connection at the exhaust gas turbocharger.
– Install battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
Component Nm
Inlet connection at exhaust gas turbocharger 10
Intake air duct 3

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Air filter 143

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

4 High pressure pump

4.1 High pressure pump - Summary of com‐

ponents

WARNING

The injection system consists of a high pressure part (maxi‐

mum 12 MPa/120 bar) and a low pressure part (approx. 0.6
MPa/6 bar).
Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

1 - 15 Nm
2 - Fuel hose
❑ Low pressure
❑ with spring strap clamp
3 - Spring strap clamp
4 - Union nut, 25 Nm
❑ hold the connection fit‐
ting on the high pres‐
sure pump for loosening
5 - Union nut, 25 Nm
❑ hold the connection fit‐
ting on the high pres‐
sure pump for loosening
6 - High pressure pump with
fuel pressure regulating valve -
N276-
❑ removing and installing
⇒ page 145
7 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
8 - Roller tappet
❑ before fitting
Protected moisten
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
lightlywith
with clean engine
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
oil
9 - Connector

144 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

4.2 Removing and installing the high pres‐

sure pump
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
Condition
• The engine must be cold.
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.

WARNING

The injection system consists of a high pressure part (maxi‐

mum 12 MPa/120 bar) and a low pressure part (approx. 0.6
MPa/6 bar).
Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4. High pressure pump 145

 Roomster 2006 ➤
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– Disconnect the plug -1- and the fuel feed line -2- from the high
pressure pump.

Note

Collect the fuel which flows out with a cleaning cloth.

– Slacken the union nuts -3- at the high pressure line.

Note

Hold the screwed connections at the high pressure pump and at

the fuel distributor when slackening the union nuts with a wrench.

– Uniformly release the fixing screws -4- and remove the high
pressure pump with roller tappet from the cylinder head cover.
Install

Note

♦ Moisten the roller tappet of the high pressure pump with clean
engine oil.
♦ Always replace the O-ring of the high pressure pump.

– Slide the roller tappet -1- into the camshaft housing.

– Insert a new, oiled O-ring -2- into the slot of the high pressure
pump -3-.
– Position the high pressure pump -3- on the cylinder head cov‐
er.

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146 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– First of all screw in the fixing screws -4- sufficiently until the
bolt heads are positioned on the flange.
– Then tighten the fixing screws -4- evenly.
Tightening torque: 20 Nm
– Screw on the union nuts of the high pressure line -3- by hand.

Note

Hold the screwed connections at the high pressure pump and at

the bottom part of intake manifold/fuel distributor when tightening
the union nuts with a wrench.

– Tighten the union nuts -3- at the high pressure line to 25 Nm.
– Attach the fuel feed line -2- and the plug -1- on the high pres‐
sure pump.
Further installation occurs in a similar way in reverse order to re‐
moval.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4. High pressure pump 147

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

5 Injection valves

5.1 Removing and installing injection valves

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .
♦ Observe the safety instructions before starting fitting work
⇒ page 5 .

Note

The Teflon gasket ring on the injection valve must be replaced

each time after removing the injection valve ⇒ page 150 .
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Special tools and workshop equipment required
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Set of tools -T10133-

Removing
– Release screws -1- and remove retaining clip.
– Disconnect plug -2- at charge pressure sender -G31- with in‐
take air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
– Remove the high pressure pump ⇒ page 145 .

– Release the fixing screws -arrows- and carefully remove the

fuel distributor from the injection valves.

148 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
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– Press the O-ring upwards by hand as shown and remove it

from the injection valve.
– Screw the striking hammer -T10133/3- with the extractor -
T10133/15- .

– Then insert the extractor -T10133/15- into the groove -arrow-

on the injection valve.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Pull out the injection valve with careful knocks.

Install

– Thoroughly clean the holes of the injection valves in the cyl‐

inder head with the nylon brush -T10133/4- .
– Check the supporting washer made of plastic for damage, re‐
place if necessary ⇒ page 150 .

5. Injection valves 149

 Roomster 2006 ➤
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– Replace the spring element -arrow- as well as the Teflon gas‐

ket ring each time after removing the injection valves
⇒ page 150 .
– Replace O-rings between injection valve and bottom part of
the intake manifold/fuel distributor and moisten lightly with
clean engine oil.

Note

♦ The Teflon gasket ring of the injection valve must neither be

oiled nor greased.
♦ The injection valve must insert easily, if necessary wait until
the gasket ring has been drawn together sufficiently.

– Press the injection valve -1- by hand up to the stop into the
hole of the cylinder head. The injection valve should be press‐
ed evenly into the countersink -2- on the cylinder head.

Note

♦ The injection valve must never rest against the countersink

edge on the cylinder head -arrow A-, but it must always be
pressed evenly into the countersink -2- on the cylinder head.
♦ After installing, carry out a visual inspection of the fitting loca‐
tion of the injection valve.

Further installation occurs in a similar way in reverse order to re‐

moval.

5.2 Replace Teflon gasket ring and support‐

ing washer at injection valve

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .

Special tools and workshop equipment required

♦ Set of tools -T10133-
Work procedure
Replace Teflon gasket ring
– Remove injection valves ⇒ page 148 .
– Carefully clean the injection valve.

150 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Carefully cut open the gasket ring with a knife as shown

-arrow-. Absolutely try to avoid the contact of the knife blade
with the valve body.
– Remove the old gasket ring and clean the gasket ring nut in
the area of the gasket ring -arrow-. Remove the existing de‐
posits (carbon deposits) with a wire brush.

– Fit a new gasket ring -1- onto the assembly cone -T10133/5- .
Slightly push the gasket ring with the assembly sleeve -
T10133/6- (knurling points to the gasket ring -1-) as far as
possible onto the assembly cone -T10133/5 - .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Turn the assembly sleeve -T10133/6 - around (now the knurl‐

ing points away from the gasket ring), and push the gasket ring
-1- up to the end onto the assembly cone -T10133/5 - .
– Now position the assembly cone -T10133/5- with the gasket
ring from the front onto the injection valve. Push the gasket
ring with the assembly sleeve -T10133/6- further onto the in‐
jection valve.

The gasket ring is not yet seated in its groove.

– Remove the assembly sleeve -T10133/6 - and the assembly
cone -T10133/5- .
– Push the gasket ring by hand into the annular groove.
– Fit the spacer sleeve -T10133/11 - onto the valve body.

5. Injection valves 151

 Roomster 2006 ➤
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– Now press the calibration sleeve - T10133/7- via the gasket

ring up to the stop at the spacer sleeve -T10133/11- .
– Pull off again the calibration sleeve -T10133/7- .

– Now press the calibration sleeve - T10133/8- via the gasket

ring up to the stop at the spacer sleeve -T10133/11- .
– Pull off again the calibration sleeve -T10133/8- .
Now the Teflon gasket ring has its correct fitting dimension.
Replace supporting washer

– Remove O-ring -3-.

– Cut open the supporting washer -2- with a small side cutter
and take it off.
– Pull off the spring element at the injection valve -1- and instead
push on the lock washer -T10133/12 - .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Mount a new supporting washer -1- on the assembly cone -

T10133/13- and fit it onto the injection valve as shown.
– Push the supporting washer -1- with the calibration sleeve -
T10133/17- (knurled side points to the injection valve) up to
the first nut -arrow- onto the injection valve.

152 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Now turn the calibration sleeve -T10133/17 - around (knurled

side points away from the injection valve). Push the calibration
sleeve via the supporting washer -1- in -direction of arrow- up
to the stop on the lock washer -T10133/12- .
– Pull off again the calibration sleeve -T10133/17- .
Now the supporting washer has its correct fitting dimension.

– Now fit a new spring element -1- for the lock washer -
T10133/12 - and push a new O-ring -3- in front of the support‐
ing washer -2-.

Note

The Teflon gasket ring -arrow- must not be oiled when installing
the injection valve.

– Install injection valves ⇒ page 148 .

Further installation occurs in reverse order to removal.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5. Injection valves 153

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

6 Testing components

6.1 Check fuel pressure sender -G247 -

Special tools and workshop equipment required
♦ Assembly device -T10118-
♦ Open ring spanner with 3/8" drive, wrench size 27 mm
♦ Pressure sensor tester , e.g. -VAS 6394- (includes digital
manometer -VAS 6394/1- )
♦ Adapter , e.g. -VAS 6394/3-
♦ Test adapter , e.g. -VAS 5570-
♦ Vehicle diagnosis, measurement and information system -
VAS 5051-

WARNING

The injection system consists of a high pressure part (max.

pressure of 12 MPa = 120 bar) and a low pressure part (pres‐
sure of approx. 0.6 MPa = 6 bar).
Before opening the high pressure area, e.g. removing the high
pressure
Protected by pump,
copyright. the fuelfordistributor,
Copying the injection
private or commercial purposes, in valves, the fuel
part or in whole, is not permitted
pipes or the fuel
unless authorised pressure
by ŠKODA AUTO A. sender
S. ŠKODA -G247-
AUTO A. S.,does
thenotfuel pressure
guarantee inany liability
or accept
the high pressure area with a remaining pressure of approx. A. S.�
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

Work procedure
– Disconnect the plug -1- and remove the fuel pressure sender
-G247- -2- with the wrench.

– Moisten the sealing cone of the adapter -VAS 6294/3- with

clean engine oil and screw it into the fuel distributor.
Tightening torque: 22 Nm

154 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Release the screw plug -2- and screw the fuel pressure sender
-G247- into the tester -VAS 6394/1- .
Tightening torque: 22 Nm
– Screw the pressure line -1- of the digital manometer -VAS
6394/1- by hand onto the adapter -VAS 6394/3- .

– Connect the test adapter -VAS 5570- to the fuel pressure

sender -G247- -1- and to the plug.

– Switch on the tester -VAS 6394/1 - , for this step, briefly press
the button -A- once.

Note

♦ If the button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If the tester -VAS 6394/1- does not indicate 0 MPa (0 bar),
carry out a zero point of the balance by means of the ⇒ op‐
erating instructions .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

6. Testing components 155

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Connect the vehicle diagnosis, measurement and information

system -VAS 5051- -1- to the diagnostic connection.
– Switch on ignition.
– On the display press consecutively the following buttons:
Vehicle self-diagnosis

Self-diagnosis ?

01 - Engine Electronics ?

011 - Measured values ?

– Select measured value block 1 4 0 and confirm with Q .

The actual value which is transmitted to the vehicle by the fuel
pressure sender -G247- is shown in the display field 3.
– Start engine.
– Compare the displayed pressure on the digital manometer -
VAS 6394/1- with the actual value on the vehicle diagnosis,
measurement and information system -VAS 5051- .
• The pressures may deviate maximum 0.5 MPa (5 bar) from
one another.
If the deviation is greater than 0.5 MPa (5 bar):
– Perform a vehicle diagnosis, measurement and information
system -VAS 5051- of the guided function “remove high fuel
pressure”.
– Replace fuel pressure sender -G247- .
– Repeat the test with the new fuel pressure sender -G247- and
compare both measured values.
If the measured values do not correspond again:
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– Perform a cable testing ⇒ Vehicle diagnosis, testing and in‐ in this document. Copyright by ŠKODA AUTO A. S.�
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information
formation system VAS 5051.

156 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

7 Engine control unit

7.1 Removing and installing engine control

unit -J623-

Note

♦ Before replacing the engine control unit -J623- first the control
unit identification and hence the coding of the current control
unit must be interrogated ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
♦ If replacing, the throttle valve unit -J338- must be cleaned
⇒ page 140 before adapting a new control unit.

Special tools and workshop equipment required

♦ Body saw, e.g. body saw -V.A.G 1523/A-
Removing
– Switch off ignition.
– Press the bracket -arrows- outwards and pull the engine con‐
trol unit out sideways.
For vehicles with protective cover
– Cut with body saw a slot for the cross-head screwdriver in the
heads of the pull-off screws.

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

7. Engine control unit 157

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

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.

– Screw out the screws.

– Remove protective cover of control unit.
For all vehicles
– Disconnect plug at engine control unit and unplug.
Install
Connect both plugs and lock.
For vehicles with protective cover
– Insert protective cover and fix with new pull-off screws at en‐
gine control unit.
For all vehicles
Insert the control unit into the pressure retaining clips on the body.
– When replacing the control unit, adapt the engine control unit
⇒ Vehicle diagnosis, testing and information system VAS 5051

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

158 Rep. Gr.24 - Fuel Formation, Injection

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

26 – Exhaust System
1 Removing and installing parts of the
exhaust system

1.1 Catalytic converter and component parts - Summary of components

1 - Lambda probe -G39- , 50

Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for a 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 - 23 Nm
❑ replace
❑ Coat pin screws of ex‐
haust manifold with ex‐
haust gas turbocharger
using hot bolt paste -G
052 112 A3-
❑ pay attention to mount‐
ing instructions and or‐
der for tightening
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⇒ page 160 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3 - Catalytic converter with ex‐

haust pipe
removing and installing
⇒ page 161
❑ with decoupling element
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ secure the decoupling
element with the trans‐
port device -T10403- against overtensioning and flexion
❑ pay attention to mounting instructions and order for tightening ⇒ page 160
4 - Gasket
❑ replace
5 - Retaining strap
6 - Double clamp, 25 Nm
❑ Tighten bolted connections evenly
❑ Fitting position ⇒ page 163

1. Removing and installing parts of the exhaust system 159

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

7 - Retaining strap
8 - Gasket
❑ replace
9 - 25 Nm
❑ replace
❑ Coat pin screws of exhaust pipe with hot bolt paste -G 052 112 A3-
10 - 20 Nm
11 - Support
12 - Exhaust gas turbocharger
❑ removing and installing ⇒ page 126
❑ The exhaust gas turbocharger with charge pressure regulator -V465- and exhaust manifold can only be
replaced together
13 - Heat shield
14 - 10 Nm
❑ first of all screw in all fixing screws by hand when installing
15 - Heat shield
16 - 10 Nm
17 - 10 Nm
18 - Lambda probe downstream of catalytic converter -G130- , 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 paste must not
get into the slots of the probe body
19 - 10 Nm
20 - 25 Nm

Catalytic converter with exhaust pipe - mounting instructions and

sequence for tightening
Tighten nuts and screws in 4 stages:
Stage Screws/nuts Tightening torque
1. -Arrows- Tighten nuts by
hand up to contact
surface.
2. -1- 25 Nm
3. -2- 25 NmProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
4. -Arrows- 23 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

160 Rep. Gr.26 - Exhaust System

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.2 Middle and rear silencer - Summary of components

1 - The middle silencer

❑ for first equipment build‐
ing unit with rear silenc‐
er; replace individually
when carrying out re‐
pairs
❑ Align exhaust system
free of stress
⇒ page 164
❑ Separate the exhaust
system ⇒ page 163
2 - Retaining strap
❑ Pay attention to the part
number
❑ replace if damaged
3 - 25 Nm
4 - Rear silencer
❑ for first equipment build‐
ing unit with middle si‐
lencer; replace individu‐
ally when carrying out
repairs
❑ Align exhaust system
free of stress
⇒ page 164
❑ Separate the exhaust
system ⇒ page 163
5 - Rear retaining strap
❑ Pay attention to the part
number
❑ replace if damaged

1.3 Removing and installing catalytic con‐

verter with pre-exhaust pipe
Special tools and workshop equipment required
♦ Ring spanner set for lambda probe
♦ Hot screw paste -G 052 112 A3-

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Removing and installing parts of the exhaust system 161

 Roomster 2006 ➤
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Removing
– Remove lambda probe -G39- -1-.
– Unscrew top fixing screw for generator -2- and press the gen‐
erator downwards.
– Unscrew fixing screws -arrows- and remove the heat shield
from the exhaust turbocharger.

– Unscrew fixing nuts -arrows- at exhaust gas turbocharger.

– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .

– Disconnect plug connection -1- and lambda probe down‐

stream of catalytic converter -G130- .

– Loosen the nuts -arrows- at the front double clamp and push
the clamp onto the middle silencer.
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ Do not bend the decoupling element by pulling it.
♦ Do not damage the wire mesh of the decoupling element.
♦ Secure the decoupling element with the transport device -
T10403- against overtensioning.

162 Rep. Gr.26 - Exhaust System

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Unscrew screws -1- of bracket for catalytic converter.

– Take the bolts of the exhaust pipe out of the retaining straps
-2- and remove the catalytic converter with the pre-exhaust
pipe downwards.
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ pay attention to mounting instructions and order for tightening
⇒ page 160
♦ Tightening torques ⇒ page 159 .

1.4 Replacing middle or rear silencer

Special tools and workshop equipment required
♦ Body saw e.g. -V.A.G 1523 A -
♦ Protective goggles

Note

♦ For individually replacing the front or rear silencer, a separa‐

tion point is provided in the connecting pipe for repairs.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.

WARNING

In order to avoid injuries because of metal swarfs, wear safety

goggles and safety clothing.

– Separate exhaust pipe at right angles at the separation point

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

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– Turn the double clamp in such a way that the ends of the
screws -arrow- do not protrude beyond the bottom edge of the
double clamp.
– Align the rear silencer horizontally and tighten the double
clamp to 25 Nm.
– Align exhaust system in cold condition free of stress
⇒ page 164 .

1. Removing and installing parts of the exhaust system 163

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

1.5 Aligning exhaust system free of stress

Condition
• The exhaust system is aligned when cold.
– Slacken nuts on the front double clamp -1- and align pre-ex‐
haust pipe -2- (-arrow- points in direction of travel).
-a- = 5 mm

The fixing screws must be located on the right. The screws must
not protrude beyond the bottom edge of the double clamp
-arrow-.
– Tighten the front nut by hand.

– Push the middle and rear silencer forward until the dimension
-a- = 3 ... 7 mm is obtained on the retainingProtected
strap/middle
by copyright.si‐
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lencer. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Tighten bolted connections of the double clamp evenly to 25

Nm.

Align exhaust tailpipe

– Align rear silencer in such a way that there is an equal distance
-a- right and left between bumper opening and exhaust tail‐
pipe.
– For centering the exhaust tailpipe, if necessary loosen the
suspension of the rear silencer.

1.6 Inspecting the exhaust system for leak‐

tightness
– Start engine and run in idle.

164 Rep. Gr.26 - Exhaust System

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

– Seal off exhaust tailpipes for the duration of the leak check
(e.g. with cloth or plug).
– Inspect connection points of cylinder head/exhaust manifold,
exhaust gas turbocharger/exhaust pipe etc. for tightness by
listening and visual inspection.
– Eliminate any leak found.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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1. Removing and installing parts of the exhaust system 165

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

28 – Ignition system
1 Ignition system

1.1 Ignition system - Summary of components

1 - Cable guide
2 - 8 Nm
3 - Cap
4 - Connector
5 - Hall sender -G40-
6 - 10 Nm
7 - Ignition cable with spark
plug connector
❑ Remove the spark plug
connector from the
spark plugs using the
extractor -T10112 A- .
♦ D ignition transformer = ig‐
nition cable cyl. 1
♦ B ignition transformer = ig‐
nition cable cyl. 2
♦ C ignition transformer = ig‐
nition cable cyl. 3
♦ A ignition transformer = ig‐
nition cable cyl. 4
8 - Spark plug, 25 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Noteto the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
with respect

♦ When installing new spark plugs,

the spark plug connectors must
be regreased with lubricating
paste -G 052 141 A2- . In doing
so, the sealing hose of the spark
plug connector does not stick to
the spark plug. The lubricating
paste must spread over the
spark plug when fitting on the
spark plug connector
⇒ page 167 .
♦ The new spark plug cables are
supplied greased.

9 - Knock sensor 1 -G61-

❑ at rear cylinder block
❑ 20 Nm
10 - Connector
11 - 20 Nm
❑ The tightening torque influences the knock sensor function

166 Rep. Gr.28 - Ignition system

 Roomster 2006 ➤
1.2/63 kW; 77 kW TSI engine - Edition 02.10

12 - Ignition transformer -N152-

♦ D ignition transformer = ignition cable cyl. 1
♦ B ignition transformer = ignition cable cyl. 2
♦ C ignition transformer = ignition cable cyl. 3
♦ A ignition transformer = ignition cable cyl. 4
13 - Engine speed sender -G28-
❑ removing and installing ⇒ page 167
14 - 5 Nm
15 - 7 Nm

Grease spark plug connector

Note

The new spark plug cables are supplied greased.

– Apply a thin bead of lubricating paste G 052 141 A2 all around

the sealing hose of the spark plug connector -arrow-. The bead
must be 1...2 mm thick.

1.2 Removing and installing engine speed

sender -G28-
Special tools and workshop equipment required
♦ Socket insert -T10370-
Removing
– Disconnect plug -arrow- from engine speed sender -G28- .
– Unscrew fixing screw for engine speed sender -G28- with
socket insert -T10370 - .
– Remove engine speed sender -G28- from cylinder block.
Install
– Install engine speed sender -G28- and tighten the fixing screw
to 5 Nm.
Further installation occurs in reverse order to removal.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Ignition system 167