Skoda Karoq 2018 to 2020 - Service Manual - Repair Manual

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SKODA KAROQ (2018-2020) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for vehicles Skoda Karoq 2018 to 2020.
 

CONTENTS:


1,0 85 KW TSI ENGINE

00 – Technical data
- 1 Denomination
- 2 Safety instructions
- 3 Repair instructions

10 – Removing and installing engine
- 1 Removing and installing engine
- 2 Assembly bracket

13 – Crankshaft group
- 1 Cylinder block (pulley end)
- 2 Cylinder block on gearbox side
- 3 Crankshaft
- 4 Pistons and conrods

15 – Cylinder head, valve gear
- 1 Cylinder head
- 2 Toothed belt drive
- 3 Valve gear
- 4 Inlet and exhaust valves

17 – Lubrication
- 1 Sump, oil pump
- 2 Engine oil cooler
- 3 Crankcase ventilation
- 4 Oil filter, oil pressure switch

19 – Cooling
- 1 Cooling system, coolant
- 2 Coolant pump, regulation of cooling system
- 3 Coolant pipes
- 4 Coolers, radiator, radiator fan

21 – Turbocharging/supercharging
- 1 Exhaust gas turbocharger
- 2 Charge-air system

24 – Mixture preparation - injection
- 1 Injection system
- 2 Injection valves
- 3 Air filter
- 4 Intake manifold
- 5 Senders and sensors
- 6 Engine control unit
- 7 High pressure pump
- 8 Lambda probe

26 – Exhaust system
- 1 Exhaust pipes/silencers
- 2 Cleansing exhaust emissions

28 – Ignition system
- 1 Ignition system

1,5 110 KW TSI EVO ENGINE

00 – Technical data
- 1 Denomination
- 2 Safety instructions
- 3 Repair instructions

10 – Removing and installing engine
- 1 Removing and installing engine
- 2 Assembly bracket
- 3 Engine trim panel

13 – Crankshaft group
- 1 Cylinder block (pulley end)
- 2 Cylinder block on gearbox side
- 3 Crankshaft
- 4 Pistons and conrods

15 – Cylinder head, valve gear
- 1 Cylinder head
- 2 Toothed belt drive
- 3 Valve gear
- 4 Inlet and exhaust valves

17 – Lubrication
- 1 Sump, oil pump
- 2 Engine oil cooler
- 3 Crankcase ventilation
- 4 Oil filter, oil pressure switch

19 – Cooling
- 1 Cooling system, coolant
- 2 Coolant pump, regulation of cooling system
- 3 Coolant pipes
- 4 Coolers, radiator, radiator fan

21 – Turbocharging/supercharging
- 1 Exhaust gas turbocharger
- 2 Charge-air system

24 – Mixture preparation - injection
- 1 Injection system
- 2 Injection valves
- 3 Air filter
- 4 Intake manifold
- 5 Senders and sensors
- 6 Engine control unit
- 7 High pressure pump
- 8 Lambda probe

26 – Exhaust system
- 1 Exhaust pipes/silencers
- 2 Cleansing exhaust emissions

28 – Ignition system
- 1 Ignition system

1.8 132KW 2.0 132KW 162KW 206KW TSI ENGINE

00 – Technical data
- 1 Identification
- 2 Safety instructions
- 3 Repair instructions

10 – Removing and installing engine
- 1 Removing and installing engine
- 2 Assembly bracket
- 3 Engine trim panel

13 – Crankshaft group
- 1 Cylinder block (pulley end)
- 2 Cylinder block on gearbox side
- 3 Crankshaft
- 4 Balancing shaft
- 5 Pistons and conrods

15 – Cylinder head, valve gear
- 1 Cylinder head
- 2 Cover for timing chain
- 3 Chain drive
- 4 Valve gear
- 5 Inlet and exhaust valves

17 – Lubrication
- 1 Sump, oil pump
- 2 Engine oil cooler
- 3 Crankcase ventilation
- 4 Oil filter, oil pressure switch

19 – Cooling
- 1 Cooling system, coolant
- 2 Coolant pump, regulation of cooling system
- 3 Coolant pipes
- 4 Coolers, radiator, radiator fan

21 – Turbocharging/supercharging
- 1 Exhaust gas turbocharger
- 2 Charge-air system

24 – Mixture preparation - injection
- 1 Injection system
- 2 Injection valves
- 3 Air filter
- 4 Intake manifold
- 5 Senders and sensors
- 6 Engine control unit
- 7 High pressure pump
- 8 Lambda probe

26 – Exhaust system
- 1 Exhaust pipes/silencers
- 2 Cleansing exhaust emissions

28 – Ignition system
- 1 Ignition system

2.0 110KW 130KW 140KW TDI CR ENGINE

00 – Technical data
- 1 Identification
- 2 Safety instructions
- 3 Repair instructions

10 – Removing and installing engine
- 1 Removing and installing engine
- 2 Assembly bracket
- 3 Engine trim panel

13 – Crankshaft group
- 1 Cylinder block (pulley end)
- 2 Cylinder block on gearbox side
- 3 Crankshaft
- 4 Pistons and conrods

15 – Cylinder head, valve gear
- 1 Cylinder head
- 2 Toothed belt drive
- 3 Valve gear
- 4 Inlet and exhaust valves

17 – Lubrication
- 1 Sump, oil pump
- 2 Engine oil cooler
- 3 Oil filter, oil pressure switch

19 – Cooling
- 1 Cooling system, coolant
- 2 Coolant pump, regulation of cooling system
- 3 Coolant pipes
- 4 Coolers, radiator, radiator fan

21 – Turbocharging/supercharging
- 1 Exhaust gas turbocharger
- 2 Charge-air system

23 – Mixture preparation - injection
- 1 Injection system
- 2 Vacuum system
- 3 Injection units/high pressure reservoir (rail)
- 4 Air filter
- 5 Intake manifold
- 6 Senders and sensors
- 7 Engine control unit
- 8 High pressure pump
- 9 Lambda probe

26 – Exhaust system
- 1 Exhaust pipes/silencers
- 2 Cleansing exhaust emissions
- 3 SCR system (Selective Catalytic Reduction)
- 4 Exhaust temperature regulation
- 5 Exhaust gas recirculation

28 – Glow plug system
- 1 Glow plug system

AIR CONDITIONING SYSTEM

00 – Technical data
- 1 General notes on the air conditioning system
- 2 General instructions for refrigerant circuit
- 3 Legal texts and legal regulations
- 4 Refrigerant circuit
- 5 Working with the A/C service station
- 6 Leak detection on the refrigerant circuit
- 7 Removing contaminants from the refrigerant circuit
- 8 Complaints
- 9 Check the pressure in the refrigerant circuit (with the A/C service station)
- 10 Replace components of the refrigerant circuit
- 11 Tools and materials, which are available from the importer
- 12 Tools and materials, which are commercially available

BODY REPAIRS

00 – Technical data
- 1 Basic instructions
- 2 Vehicle identification data
- 3 Safety measures
- 4 Foam moulds
- 5 Vibration damping
- 6 Galvanised body parts, high/ultra high-strength and hot-formed body panels
- 7 Laser welding
- 8 Gap sizes
- 9 Vehicle body dimensions
- 10 Tools
- 11 Straightening square set
- 12 Portal gauge

50 – Body - front
- 1 Replace engine mount
- 2 Replacing support block for assembly carrier
- 3 Replacing the front bumper holder
- 4 Replacing the outer top frame side rail -part-
- 5 Replacing the inner top frame side rail
- 6 Replacing the front wheelhouse
- 7 Replacing the front wheelhouse -part-
- 8 Replacing front frame side rail -part-
- 9 Replacing front frame side rail -part-

51 – Body - centre
- 1 Replacing the roof
- 2 Replacing the roof rail
- 3 Replacing outer A pillar -cutoff part-
- 4 Replace front mudguard bracket
- 5 Replacing reinforcement of A-pillar - part-
- 6 Replacing outer B-pillar -cutoff part-
- 7 Replacing reinforcement of B pillar
- 8 Replacing the outside bottom side rail -cutoff part-
- 9 Replace the bottom side rail reinforcement

53 – Body - rear
- 1 Replacing outer rear side part -cutoff part-
- 2 Replacing the outer wheelhouse -part-
- 3 Replacing the support of the tail light
- 4 Replacing sealing channel -part-
- 5 Replacing the end cover cross member
- 6 Replacing the end cover plate
- 7 Replace luggage compartment, four-wheel drive
- 8 Replacing the end cover plate
- 9 Replacing rear frame side rail -part-

BRAKE SYSTEMS

00 – Technical data
- 1 Safety instructions
- 2 Denomination
- 3 Technical data
- 4 Brake inspection

45 – Anti-lock brake system
- 1 General points
- 2 Installation location overview
- 3 Control unit and hydraulic unit
- 4 Sensors

46 – Brakes - mechanism
- 1 Front brakes
- 2 Rear brakes
- 3 Handbrake
- 4 Brake pedal

47 – Brakes - hydraulics
- 1 Front brake calipers
- 2 Rear brake caliper
- 3 Brake servo unit and master brake cylinder
- 4 Vacuum system
- 5 Brake lines
- 6 Hydraulic system

CHASSIS AXLES STEERING

00 – Technical data
- 1 Safety instructions
- 2 Repair instructions
- 3 Accident vehicle assessment
- 4 Disposal

40 – Front suspension
- 1 Front axle
- 2 Assembly carrier
- 3 Suspension strut, upper suspension link
- 4 Bottom track control arm, suspension link
- 5 Wheel bearing
- 6 Drive shaft

42 – Rear suspension
- 1 Rear axle
- 2 Assembly carrier
- 3 Anti-roll bar
- 4 Suspension link, track rod for rear axle
- 5 Suspension strut/shock absorber, spring
- 6 Wheel bearing, trailing arm
- 7 Drive shaft

43 – Self-levelling suspension
- 1 Electronically controlled damping
- 2 Vehicle level sensor

44 – Wheels, tyres, vehicle geometry
- 1 Wheels, Tyres
- 2 Carry out axle alignment
- 3 Adaptive Cruise Control
- 4 Front camera for driver assistance systems

48 – Steering
- 1 Steering wheel
- 2 Steering column
- 3 Steering gear
- 4 Sensors

COMMUNICATION

00 – Technical data
- 1 Safety instructions
- 2 Repair instructions

91 – Communication
- 1 Infotainment system
- 2 Sound system
- 3 Aerial systems
- 4 Radio
- 5 Telephone system
- 6 Navigation system
- 7 Rear view camera system
- 8 Multi-functional steering wheel
- 9 Connection for external multimedia devices
- 10 Mobile services online

DIESEL ENGINE FUEL SYSTEM

00 – Technical data
- 1 Denomination
- 2 Safety instructions
- 3 General points
- 4 Repair instructions

20 – Fuel supply system
- 1 Procedure in case of misfuelling
- 2 Fuel tank
- 3 Fuel delivery unit, fuel gauge sender
- 4 Quick couplings
- 5 Fuel filter
- 6 Accelerator control
- 7 Fuel pump
- 8 Senders and sensors
- 9 Guide

DSG GEARBOX 02Q

00 – Technical data
- 1 Safety instructions
- 2 Identification
- 3 Repair instructions
- 4 Technical data
- 5 Overview of Transmission System
- 6 Electrical components

30 – Clutch
- 1 Clutch operation
- 2 Clutch

34 – Controls, housing
- 1 Angle gearbox
- 2 Shift mechanism
- 3 Removing and installing the gearbox
- 4 Assembly bracket
- 5 Transporting the gearbox
- 6 Disassembling and assembling the gearbox
- 7 Gearbox housing, clutch housing
- 8 Attachment at engine and gearbox mount
- 9 Gear oil

35 – Gears, shafts
- 1 Output shaft
- 2 Output shaft

39 – Final drive - differential
- 1 Gear oil
- 2 Sealing rings
- 3 Differential
- 4 Setting overview
- 5 Bevel gear components

ELECTRICAL SYSTEM

00 – Technical data
- 1 Safety instructions
- 2 Repair instructions
- 3 Battery

27 – Starter, current supply, CCS
- 1 Battery
- 2 Alternator
- 3 Starter
- 4 Cruise control system (CCS)
- 5 start-stop system
- 6 Adaptive Cruise Control

90 – Gauges, instruments
- 1 Dash panel insert
- 2 Horn

92 – Windscreen wash/wipe system
- 1 Windscreen wiper and washer system
- 2 Windscreen washer system
- 3 Rear window wiper system
- 4 Rear window washer system
- 5 Headlamp cleaning system
- 6 Washer fluid lines

94 – Lights, bulbs, switches - exterior
- 1 Headlight
- 2 Automatic headlight range control
- 3 Lights in the exterior mirror
- 4 Tail light
- 5 Additional brake light
- 6 Registration number lighting
- 7 Entry and start authorisation
- 8 Switch unit on the steering column
- 9 Parking aid
- 10 Park steering assistant
- 11 Trailer coupling

96 – Lights, bulbs, switches - interior
- 1 Lamps
- 2 Controls
- 3 Anti-theft warning system
- 4 Immobiliser
- 5 Lane change assist
- 6 Front camera for driver assistance systems
- 7 Cigarette lighter, socket

97 – Wiring
- 1 Relay carrier, fuse holder, E-boxes
- 2 Control units
- 3 Connectors
- 4 Unlocking and disassembling the socket housing
- 5 Clean the contact surfaces
- 6 Optical fibre
- 7 Vehicle diagnosis, testing and information systems

GENERAL BODY REPAIRS, INTERIOR

68 – Interior equipment
- 1 Storage areas/covers
- 2 Equipment
- 3 Centre console
- 4 Front armrest
- 5 Interior rear-view mirror

69 – Passenger protection
- 1 Seat belts
- 2 Inspect seat belts
- 3 Airbag system
- 4 Airbag control unit
- 5 Airbag on driver side
- 6 Airbag front passenger side
- 7 Side airbags
- 8 Head airbags
- 9 Knee airbags
- 10 Crash sensors for airbag

70 – Trim, insulation
- 1 Front door trim panels
- 2 Rear door trim panels
- 3 Dash panel
- 4 Cross member for dash panel
- 5 Interior trim panels
- 6 Luggage compartment trim panels
- 7 Roof trim panels

72 – Seat frames
- 1 Front seats
- 2 Rear seats

74 – Seat - padding, covers
- 1 Covers and upholstery of the front seats
- 2 Rear covers and seat upholstery

GENERAL INFORMATION - BODY REPAIRS,

1 Safety measures
- 1.1 Fuel tanks and fuel-carrying lines.
- 1.2 Air Conditioning
- 1.3 Electronic control units
- 1.4 Battery
- 1.5 High-voltage conducting components / electric motors
- 1.6 Safety instructions when performing repair work in bodyshells and liquefied petroleum gas systems (LPG)
- 1.7 Safety instructions
- 1.8 Safety measures
- 1.9 Working on the alignment frame
- 1.10 Disassembly of parts
- 1.11 Welding work
- 1.12 Paintwork, glass, upholstery, trims
- 1.13 Airbag system
- 1.14 Safety instructions for belt tensioners
- 1.15 Warning signs

2 Fundamentals of bodywork repairs
- 2.1 Fundamentals of bodywork repair
- 2.2 Galvanised body parts
- 2.3 Removing residues
- 2.4 New parts
- 2.5 Foam moulds
- 2.6 Original welding
- 2.7 Diagnosis of accident vehicles
- 2.8 Finishing work on the body
- 2.9 Repairing higher-strength body panels
- 2.10 High-strength/ultra-strength, warm-formed body panels
- 2.11 Body Work - Glued joints
- 2.12 Removing underbody protection and sealing seams

3 Explanation of symbols
- 3.1 Symbols, structure
- 3.2 Symbols, preparation
- 3.3 Symbols, welding
- 3.4 Symbols, riveting
- 3.5 Symbols, corrosion protection

4 Vehicle body structure features
- 4.1 Multimedia mix

5 Damage assessment
- 5.1 General points
- 5.2 Check weld seams and body connections
- 5.3 Force reduction during impact
- 5.4 Measuring methods / damage diagnostics
- 5.5 Overview of the materials used
- 5.6 Passive safety

6 Methods of thermal connection
- 6.1 Methods of thermal connection
- 6.2 Spot welding (RP)
- 6.3 Hole seams - shielding gas
- 6.4 Seal with SG full seam (shielding gas) and quilting seam
- 6.5 MIG welding
- 6.6 Laser welding
- 6.7 Laser soldering
- 6.8 Replacement gap method during repair (steel)

7 Cold connection methods
- 7.1 Gluing
- 7.2 Rivet
- 7.3 Overview - Pairing riveting tools
- 7.4 FDS screws (flow drill screws)
- 7.5 Pressing through

8 Cutting techniques for body repairs; areas of application
- 8.1 Bore
- 8.2 Cutting
- 8.3 Sanding
- 8.4 Milling
- 8.5 Remove adhesive bonds

9 Repairing surfaces
- 9.1 Bulking sheet steel techniques
- 9.2 Metal and aluminium mastic
- 9.3 Lead-free tin processing
- 9.4 Definition of “properly shaped surface” / Delivery to the paint shop

10 Straightening the vehicle
- 10.1 Alignment
- 10.2 Separation cuts
- 10.3 Bodyshell offcut sections and parts

11 Corrosion prevention
- 11.1 Long-term body protection
- 11.2 Body long-term protection if filling is needed

12 Plastic repair
- 12.1 Plastic repair
- 12.2 Repairing indentations
- 12.3 Repairing scratches
- 12.4 Repairing a crack (up to 100 mm length)
- 12.5 Repairing a hole (up to 30 mm diameter)
- 12.6 Plastic repair (GRP)

13 Glass repair
- 13.1 Front window repair

14 Repairing thread
- 14.1 Repairing thread

15 Repairing the thread for the attachment of the assembly carrier
- 15.1 Repairing the thread for the attachment of the assembly carrier
- 15.2 Contents of the thread repair set
- 15.3 Drilling thread
- 15.4 Cutting the thread
- 15.5 Inserting the threaded insert

16 Tools
- 16.1 List of tools

17 Decorative and protective foils
- 17.1 Decorative and protective foils
- 17.2 Training videos

MAINTENANCE

1 General points
- 1.1 Vehicle identification number
- 1.2 Type plate
- 1.3 Storage of ŠKODA new vehicles
- 1.4 Vehicle handover from stock
- 1.5 Additional customer information regarding inspection and maintenance
- 1.6 Determine the age of the vehicle
- 1.7 Checking the vehicle log book

2 Inspections
- 2.1 Pre-Delivery Inspection -PDI- (Export)
- 2.2 Pre-sales Inspection - domestic (Czech Republic)
- 2.3 Delivery Inspection (Export)
- 2.4 Inspection
- 2.5 Oil change service
- 2.6 Country allocation due to fuel quality, dust content and temperature
- 2.7 service intervals

3 Engines
- 3.1 Engine overview
- 3.2 Engine fitted
- 3.3 Visual inspection of engine and parts in the engine compartment for leaks and damage
- 3.4 Replace engine oil filter
- 3.5 Replacing toothed belt for camshaft drive and tensioning pulley
- 3.6 Replacing toothed belt for coolant pump drive
- 3.7 Inspecting engine oil level
- 3.8 Drain off or suction off engine oil; top up engine oil
- 3.9 Cooling system: check
- 3.10 V-ribbed belt: check condition
- 3.11 Replacing the V-ribbed belt
- 3.12 Routing of V-ribbed belt
- 3.13 Replace spark plugs
- 3.14 Replace air filter element
- 3.15 Replacing the fuel filter (diesel engines)
- 3.16 Drain fuel filter
- 3.17 Checking diesel particle filter
- 3.18 Reduction agent (AdBlue®): fill, replace
- 3.19 Multipurpose additive for petrol engines
- 3.20 Multi-purpose additive for diesel engines

4 Gearbox
- 4.1 Check final drive and joint boots for leaks and damage
- 4.2 Changing the oil in the four-wheel drive clutch
- 4.3 Change gear oil: dual-clutch gearbox (DSG) 0GC

5 Chassis
- 5.1 Inspecting thickness of front and rear brake pads/linings
- 5.2 Inspecting brake system for leaks and damage
- 5.3 Change brake fluid
- 5.4 Brake fluid level: check.
- 5.5 Front and rear axles: check
- 5.6 Tyres: check
- 5.7 Tightening wheel bolts to specific torque
- 5.8 Tyre pressure monitoring indicator: calibration
- 5.9 Breakdown kit: check

6 Electrical System
- 6.1 Electric consumers: check they are functioning
- 6.2 Front and rear exterior lighting: check
- 6.3 Interior lights: check
- 6.4 Checking battery
- 6.5 Checking proper operation of infotainment radio/navigation
- 6.6 Setting clock
- 6.7 Connect diagnostic unit
- 6.8 Adapt language variants to driver's instructions
- 6.9 Climatronic: set the temperature to 22 °C
- 6.10 Resetting service interval display (SID)
- 6.11 Changing the code of the service intervals
- 6.12 Inspecting headlight beam setting and adjusting if necessary
- 6.13 Checking the operation of the fog lights with the Corner function (static cornering light)
- 6.14 Check for proper operation of automatic light
- 6.15 Check operation of adaptive front headlights, LED headlights
- 6.16 Checking the function of the daylight driving light
- 6.17 Replacing the own power supply of the alarm system
- 6.18 Switch off battery transport mode
- 6.19 Time-delayed locking mechanism after closing the tailgate - activate/deactivate
- 6.20 Replace OCU control unit (control unit for emergency call module and communication unit -J949-)
- 6.21 ERA Glonass: check that the emergency call system is ready
- 6.22 ERA Glonass: run system test
- 6.23 Škoda Connect services

7 Body
- 7.1 Airbag: check for proper operation
- 7.2 Front passenger airbag: check “ON/OFF” is working and switch to “ON”
- 7.3 Inspecting underbody protection for damage
- 7.4 Checking body paintwork and underbody protection for damage (before sale)
- 7.5 Check for corrosion
- 7.6 Inspecting plenum chamber and water drain openings for dirt, cleaning if necessary
- 7.7 Windscreen wash/wipe system: check
- 7.8 Door locks, locking buttons and child lock: check functioning correctly
- 7.9 Replacing the dust and odour filter element
- 7.10 Stick the sticker Škoda Assistance
- 7.11 Check that the panoramic tilting/sliding sunroof is working, check for water drainage, clean and grease guide rails
- 7.12 Front flap lock: lubricate
- 7.13 Attaching the “ŠKODA CONNECT” mirror tag

8 Exhaust-emission analysis
- 8.1 Exhaust-Emission Analysis on Models with Petrol Engines
- 8.2 Exhaust-Emission Analysis on Models with Diesel Engines

9 Miscellaneous
- 9.1 Tow starting/Towing
- 9.2 Road test
- 9.3 Raise vehicle

PAINT GENERAL INFORMATION

00 – Technical data
- 1 Safety instructions
- 2 General Instructions
- 3 Original products
- 4 Workshop equipment
- 5 Repairing rims

PETROL ENGINE FUEL SYSTEM

00 – Technical data
- 1 Denomination
- 2 Safety instructions
- 3 General points
- 4 Repair instructions

20 – Fuel supply system
- 1 Fuel tank
- 2 Fuel delivery unit, fuel gauge sender
- 3 Quick couplings
- 4 Fuel filter
- 5 Activated charcoal filter system
- 6 Accelerator control
- 7 Fuel pump
- 8 Wiring

PROPSHAFT AND REAR FINAL DRIVE

00 – Technical data
- 1 Safety instructions
- 2 Identification
- 3 Repair instructions
- 4 Technical data
- 5 Electrical components

39 – Final drive - rear differential
- 1 Final drive
- 2 Assembly bracket
- 3 Axle oil in final drive
- 4 Sealing rings
- 5 Four-wheel drive clutch
- 6 Propshaft

WHEELS, TYRES

44 – Wheels, tyres, vehicle geometry
- 1 General points for wheels/tyres
- 2 Legal and technical conditions for retrofitting wheel / tyre combinations
- 3 Technical data for tyres
- 4 EU tyre label
- 5 Tyre wear/mileage of the tyre
- 6 Tyre noise
- 7 Rough running due to wheels/tyres - causes
- 8 Vehicle pulls to one side
- 9 Tyre damage
- 10 Rolling resistance optimised tyres
- 11 Rims - basic information
- 12 Wheel fitting
- 13 Vehicles with breakdown set
- 14 Wheel / tyre combinations
- 15 Wheels, Tyres