Service: 2.0, 1.6, 1.2 - Litre Diesel Engines

Service 80
2.0, 1.6, 1.2 - litre diesel engines

with Common Rail injection system
Service Training
SP_80_GB.indd 1 5.5.2010 10:52:42

The 2.0 ltr. TDI CR, 1.6 ltr. TDI CR and 1.2 ltr. TDI CR diesel engines, which are described in this
workshop manual, are available in all model series of Škoda vehicles.
The 2.0 ltr. TDI engine is produced in two gen-

erations. The first generation includes the high
performance versions with power outputs of
103 kW and 125 kW. The range of engines of the
second generation comprises now the version
with a power output of 81 kW.
The range of diesel engines also includes the

1.6 ltr. TDI CR engine with Common Rail injection
system which can be fitted to all the models of
Škoda vehicles.
The 1.2 ltr. TDI CR engine is offered exclusively

in the Fabia and Roomster model ranges and is
fitted to these models as of 2010.
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Contents
2.0 ltr. TDI engine 4
The fuel system of the 2.0 ltr. TDI engine 10
1.6. ltr. TDI engine 20
1.2 ltr. TDI engine 34
You will find the notes for the assembly and

disassembly, diagnostics as well as detailed
user information in the workshop manuals, the
diagnostic unit VAS 505x and in the onboard
literature.
The time for going to press was on the 01/2010.

This brochure is not subject to an update.
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2.0 ltr. TDI engine
2.0 ltr. TDI CR engine - 1st generation
The 2.0 ltr. TDI engine of the first generation with the Common Rail injection system was incorporated
in the 2.0 ltr. TDI engine assembly with unit injection system. Many engine components were adapted
to the ever-increasing demands on the emission standards, fuel economy and noise development.
Fundamental innovations were made in the construction of the injection system, which has been com-
pletely redesigned for the Common Rail injection system.
The first generation drive unit with Common Rail injection system was made available with power
outputs of 103 kW and 125 kW and was offered in the models Octavia ll RS (model year 2009) and
Superb ll (model year 2008) as well as for the Yeti model (model year 2009).
SP80_40
Technical highlights
• 4-valve technology • metallic glow plugs

• cylinder crankcase made out of cast iron and • a balance shaft module is mounted on the
cylinder head made out of aluminium alloy engine with code letters CBBB
• forged crankshaft with four balancing weights • turbocharger with variable turbine geometry
• adjustable regulating flaps in the intake mani- • particle filter with oxidation catalytic converter
fold • injectors with INCA code
• Common Rail injection system developed by • communication via KWP
the company Bosch • low-temperature cooling of exhaust gas recir-
• piezo valve-controlled injectors culation
• injection pressure up to 180 MPa (1800 bar)
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Technical data
2.0 ltr./103 kW TDI engine 2.0 ltr./125 kW TDI engine

Engine code CBDB CBBB/CEGA
Structure Production engine Production engine
Number of cylinders 4 4
Valves per cylinder 4 4
3
Displacement 1968 cm 1968 cm3
Bore 81mm 81mm
Stroke 95.5 mm 95.5 mm
Compression ratio 16,5 : 1 16,5 : 1
max. power output 103 kW at 4200 rpm 125 kW at 4200 rpm
max. torque 320 Nm at 1750 - 2500 rpm 350 Nm at 1750 - 2500 rpm
Control unit Bosch EDC 17 - CP14 Bosch EDC 17 - CP14
Fuel Diesel fuel according to DIN Diesel fuel according to DIN
Exhaust after treatment Exhaust gas recirculation; oxida- Exhaust gas recirculation; oxida-
tion catalytic converter; particle tion catalytic converter; particle
filter filter
Emission standard EU5 + DPF EU5 + DPF
Power output and torque diagram
110 325 120 375
100 300 110 350
90 275 100 325
80 250 90 300
70 225 80 275
60 200 70 250
M (Nm)
M (Nm)
P (kW)
P (kW)
50 175 60 225
40 150 50 200
30 125 40 175
20 100 30 150
10 75 20 125
0 1000 2000 3000 4000 5000 6000 0 1000 2000 3000 4000 5000 6000
n (min-1) n (min-1)
SP80_53 SP80_54
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2.0 ltr. TDI engine
2.0 ltr. TDI CR - 2nd Generation

During the production of the model ranges Octavia ll, Superb ll and Yeti, the 2.0 ltr. TDI engine with
Common Rail injection system of the first generation is gradually replaced by the second generation.
The 2.0 ltr. TDI engine of the second generation differs from the first generation in several design ele-
ments. Among the most significant changes is the replacement of the piezo valve-controlled injectors
with the electromagnetic valve-controlled injectors.
The 2.0 ltr. TDI engine of the second generation now includes the version with a power output of
81 kW in addition to the versions with power outputs of 103 kW and 125 kW.
SP80_63
• 4-valve technology • plastic intake manifold without regulating flaps
• cylinder crankcase made out of cast iron and • turbocharger with variable turbine geometry
cylinder head made out of aluminium alloy • exhaust gas recirculation module with integrat-
• forged crankshaft with four balancing weights ed valve of exhaust gas recirculation and an
• Common Rail injection system developed by exhaust gas recirculation cooler
the company Bosch • particle filter with oxidation catalytic converter
• electromagnetic valve-controlled injectors • communication via the diagnostic transport
• injection pressure up to 180 MPa (1800 bar) protocol UDS
• metallic glow plugs
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Technical data
2.0 ltr./81 kW TDI engine 2.0 ltr./81 kW TDI engine for

Engine code CFHA CFHF
3
Bore 81mm 81mm
Control unit Bosch EDC 17 - C46 Bosch EDC 17 - C46
filter filter
Emission standard EU5 + DPF / EU4* EU5 + DPF
2.0 ltr./81 kW TDI engine 2.0 ltr./81 kW TDI engine for 4x4 version
100 300 100 300
90 275 90 275
80 250 80 250
70 225 70 225
60 200 60 200
M (Nm)
M (Nm)
P (kW)
P (kW)
50 175 50 175
40 150 40 150
30 125 30 125
20 100 20 100
10 75 10 75
0 1000 2000 3000 4000 5000 6000 0 1000 2000 3000 4000 5000 6000
n (min-1) n (min-1)
SP80_42
* for countries outside the EU
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2.0 ltr. TDI engine
Technical data

Engine code CFHC/CFFB CFJA/CFGB
3
Bore 81mm 81mm
Control unit Bosch EDC 17 - C46 Bosch EDC 17 - C46
filter filter
120 375
100 300 110 350
90 275 100 325
80 250 90 300
70 225 80 275
60 200 70 250
M (Nm)
M (Nm)
P (kW)
P (kW)
50 175 60 225
40 150 50 200
30 125 40 175
20 100 30 150
10 75 20 125
0 1000 2000 3000 4000 5000 6000 0 1000 2000 3000 4000 5000 6000
n (min-1) n (min-1)
SP80_41 SP80_54
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Notes
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The fuel system of the 2.0 ltr. TDI engine
The fuel system of the 2.0 ltr. TDI engine of the first and second
generation
1 - Electric fuel pump G6
Ensures uninterrupted fuel supply to the fuel sup-

ply line.
2 - Fuel filter with preheating valve
The preheating valve prevents the filter from

clogging through paraffin crystals which form at
low outside temperatures.
3 - Additional fuel pump V393
It delivers the fuel from the fuel supply line to the

high-pressure fuel pump. It increases the fuel
pressure to 0.5 MPa (5 bar).
4 - Filter sieve
It prevents harmful dirt particles from penetrating

into the high-pressure fuel pump.
5 - Fuel temperature sender G81
It detects the current fuel temperature.
6 - High-pressure fuel pump
It creates a high fuel pressure up to a value of

180 MPa (1800 bar).
7 - Valve for fuel dosage N290
It controls the quantity of compressed fuel, based

on need.
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8 - Fuel pressure regulator valve N276
It regulates the fuel pressure in the high-pressure

fuel tank (fuel rail).
9 - Fuel rail
It accumulates high-pressure fuel, which is re-

quired for the injection into each cylinder.
10 - Fuel pressure sender - high pressure

G247
It detects the current fuel pressure in the high-

pressure fuel tank (fuel rail) as well as in the
high-pressure area.
11 - Non-return delivery valve
It maintains the pressure in the return line deliv-

ered by the injectors at the following value:
• 2.0 ltr. TDI engine of the first generation -
1 MPa (10 bar)
• 2.0 ltr. TDI engine of the second generation -
0.2 MPa (2 bar)
This pressure is required for the proper function
of the injectors.
12 - Injection valves N30, N31, N32, N33
They inject the fuel into the combustion cham-

bers.
SP80_58
Legend
high pressure (23 up to 180 MPa); (230 up to 1800 bar)
injector return line
supply line and return line
* Non-return valves are available in a broad range of variants and differ in shape
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Common Rail injection system
The Common Rail injection system was developed for the 2.0 TDI engine of the first and second gen-
eration by the company Bosch.
System components:
• engine control unit J623 • fuel pressure regulator valve N276

• injection valves N30 - N33 • high-pressure line
• fuel rail • high-pressure fuel pump
• fuel pressure sender G247
injection valves N30 - N33
fuel pressure regula-

tor valve N276
fuel rail
fuel pressure sender G247
high-pressure fuel pump
SP80_52
The figure shows the Common Rail injection system of the 2.0 ltr. TDI engine of the
first generation.
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High-pressure fuel pump
The high-pressure fuel pump fitted to the 2.0 ltr. During the work cycle of the respective cylinder,
TDI engine of the first and second generation is the pressure is produced synchronously with the
a piston pump driven by the crankshaft by means injection by way of the double cam on the drive
of a toothed belt. shaft offset by 180°.
The high-pressure fuel pump generates a fuel A roller ensures the power transmission of the
pressure up to a value of 180 MPa (1800 bar). drive cams on the piston.
suction valve
valve for fuel dosage N290
pump piston pressure valve
rail connection
piston spring fuel supply
fuel return line in the

fuel tank
roller
overflow valve
drive shaft
SP80_51
drive cams
You will find a detailed description of the 2.0 ltr. TDI engine of the first generation in
the Service Training manual No. 67.
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Valve for fuel dosage N290

The valve for fuel dosage is a component of the high-pressure fuel pump and ensures that the fuel
pressure in the high-pressure area is controlled in a way which fulfils the demand. The valve for fuel
dosage essentially controls the supplied fuel quantity which is needed to produce high pressure. This
has the advantage that the high-pressure fuel pump must only produce the pressure which is required
for the current operating mode. Thus the energy consumption of the pump is reduced and an unnec-
essary heating of the fuel is avoided.
Valve N290 is actuated by the engine control unit using the PWM signal.
Function
Not actuated Actuated
fuel supply to
the high pres-
spring sure pump control piston spring control piston
SP80_61 SP80_62
fuel supply electromagnetic fuel supply electromagnetic
coil coil
The valve for fuel dosage is not supplied. The Power is supplied to the valve for fuel dosage
control piston is pressed by the force of the and a magnetic field is generated by the electro-
spring and in turn the fuel supply passage to the magnetic coil. The position of the control piston
compression chamber of the high-pressure fuel changes according to the strength of the power
pump is opened. supply (PWM signal frequency) and in turn the
fuel quantity supplied to the high-pressure fuel
pump changes as well.
If the power supply to the valve reaches full
strength, the control piston is pressed against the
force of the spring and thus the fuel supply pas-
sage to the compression chamber of the high-
pressure fuel pump is closed.
Effects of function failure
In the event of signal failure of the valve for fuel dosage N290, the engine performance is reduced and
the engine control unit operates in emergency mode.
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Injection valves N30 - N33
2.0 ltr. TDI CR engine - 1st generation Technical data
On the 2.0 ltr. TDI engine of the first generation, Control voltage 110 - 148 V
piezoelectrically controlled injection valves are Number of openings of the injection
used for the fuel injection. 8
nozzle
Number of injections per operating
6
cycle
electrical connection
fuel return line
high pressure connection for the fuel supply

line of the rail
edge-type filter
piezoelectric control element
throttle valve
nozzle needle spring
nozzle needle
SP80_48
You will find a detailed description of the piezoelectrically controlled valve of the 2.0
ltr. TDI engine of the first generation in the Service Training manual No. 67.
You will find a detailed description of the function of the piezoelectric control ele-
ment in the Service Training manual No. 62.
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2.0 ltr. TDI CR engine - 2nd genera- Technical data

tion
Control voltage 12 V
On the 2.0 ltr. TDI engine of the second genera- Number of openings of the injection
8
tion, electromagnetic controlled injection valves nozzle
are used for the fuel injection. Number of injections per operating
7
cycle
fuel return line
high pressure connection for the fuel supply

line of the rail
electromagnetic coil
spring of the control valve
control valve
control piston
spring of the control piston
nozzle needle
SP80_70
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Compensating the injection quantity of the injection valves (INCA)
Compensating the injection quantity of the injection valves (INCA) is a function performed by the soft-
ware of the engine control unit.
The INCA code is determined for each injection valve during the manufacturing process and deter-
mines the difference from the nominal value and thus describes the injection parameters of each injec-
tion valve. In this way, the engine control unit can determine the exact duration of injection (injected
quantity).
On the 2.0 ltr. TDI engine, the injection valves are provided with a seven-digit INCA code.
After replacing the injection valve seat, the INCA code must be entered in the engine control unit using
the diagnostic unit in the mode "controlled functions".
2.0 ltr. TDI CR engine - 1st generation 2.0 ltr. TDI CR engine - 2nd generation
Data Matrix Code (code of Data Matrix Code (code of

the data matrix) the data matrix)
INCA code (7 digits) INCA code (7 digits)
SP80_50
SP80_49
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Fuel pressure regulator valve N276

The fuel pressure regulator valve N276 is located at the high-pressure fuel tank (rail).
Setting the pressure in the rail to the desired value is performed by opening and closing the regulator
valve N276, which is actuated by the engine control unit using the PWM signal.
Structure
electromagnetic coil electrical connection
fuel rail
valve needle
valve armature
SP80_57
fuel return line in the fuel tank valve spring
Function
Not actuated
The pressure control valve is not supplied. The

valve needle is pressed by the action of the
spring, which enables the discharge of fuel from
the rail.
SP80_59
valve spring
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Actuated
engine control unit

In order to reach the operating pressure in the
rail, the engine control unit begins to supply
power to the electromagnetic coil of the valve us-
ing the PWM signal. The armature of the valve is
retracted by the coil against the spring force and
presses the valve needle into the seat.
The quantity of fuel discharged from the rail and
flowing into the tank is controlled depending on
the PWM signal frequency.
SP80_60
valve seat
Effects of signal failure
In the event of signal failure of the valve N276, the required fuel pressure cannot be produced and the
engine cannot be operated.
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1.6. ltr. TDI engine
1.6. ltr. TDI CR engine
The fundamental structural part of the 1.6 ltr. TDI engine is based on the 2.0 ltr./103 kW TDI engine
with Common Rail injection system.
The 1.6 ltr. TDI engine fitted to the models Octavia ll (model year 2009), Superb ll (model year 2010)
and Yeti (model year 2011) is offered in three versions with the power outputs of 55 kW, 66 kW and
77 kW.
Within the scope of continuous development of the proven design solution, these engines equipped
with the Common Rail injection system developed by the company Continental meet the EU5 emis-
sion standard.
SP80_01
• 4-valve technology • turbocharger with variable turbine geometry
• cylinder crankcase made out of cast iron and • exhaust gas recirculation module with integrat-
cylinder head made out of aluminium alloy ed valve of exhaust gas recirculation and an
• forged crankshaft with four balancing weights exhaust gas recirculation cooler
• Common Rail injection system developed by • particle filter with oxidation catalytic converter
the company Continental • injectors with INCA code
• piezo valve-controlled injectors • communication via the diagnostic transport
• injection pressure up to 160 MPa (1600 bar) protocol UDS
• metallic glow plugs
• plastic intake manifold
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Technical data

Engine code CAYA CAYB
3
Bore 79.5 mm 79.5 mm
max. power output 55 kW at 4000 min 66 kW at 4200 min
max. torque 195 Nm at 1500 - 2000 min 230 Nm at 1750 - 2500 rpm
Control unit Continental Simos PCR2 Continental Simos PCR2
filter filter
100 250 100 250
90 225 90 225
80 200 80 200
70 175 70 175
60 150 60 150
M (Nm)
M (Nm)
P (kW)
P (kW)
50 125 50 125
40 100 40 100
30 75 30 75
20 50 20 50
10 25 10 25
0 1000 2000 3000 4000 5000 6000 0 1000 2000 3000 4000 5000 6000
n (min-1) n (min-1)
SP80_74 SP80_30
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1.6. ltr. TDI engine
Technical data
1.6 ltr./77 kW TDI engine

Engine code CAYC
Structure Production engine
Number of cylinders 4
Valves per cylinder 4
Displacement 1598 cm3
Bore 79.5 mm
Stroke 80.5 mm
Compression ratio 16,5 : 1
max. power output 77 kW at 4400 min
max. torque 250 Nm at 1900 - 2500 rpm
Control unit Continental Simos PCR2
Fuel Diesel fuel according to DIN
Exhaust after treatment Exhaust gas recirculation; oxida-
tion catalytic converter; particle
filter
Emission standard EU5 + DPF
100 250
90 225
80 200
70 175
60 150
M (Nm)
P (kW)
50 125
40 100
30 75
20 50
10 25
0 1000 2000 3000 4000 5000 6000
n (min-1)
SP80_31
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Notes
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Fuel system
Ensures uninterrupted fuel supply to the fuel

pump for the predelivery.
9
2 - Fuel filter with preheating valve
The preheating valve prevents the filter from

clogging through paraffin crystals which form at
low outside temperatures.
4
3 - Fuel pump for predelivery 5
The fuel pump for predelivery is a component of

the high-pressure fuel pump.
It detects the current fuel temperature. 6
3
It produces a fuel pressure up to a value of

160 MPa (1600 bar).

2
on need.
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fuel tank (fuel rail).
8 7
8 - Fuel rail


G247

high-pressure area.
10 - Non-return delivery valve

11 11 11 11
It maintains the pressure in the return line de-
livered by the injectors at the value of 0.1 MPa
(1 bar). This pressure is required for the proper
function of the piezoelectric injection valves.
10
11 - Injection valves N30, N31, N32, N33

bers.
SP80_11
1
Legend
High pressure (23 up to 160 MPa); (230 up to 1600 bar)
Injector return line (0.1 MPa); (1 bar)
Supply line / return line
GB 25
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The Common Rail injection system was devel- A good mixture formation coupled with a per-
oped for the 1.6 TDI engine by the company fect process of the fuel spraying is obtained with
Continental. the high injection pressure of up to 160 MPa
(1600 bar).
System components: In the spirit of essential characteristics, the
injection pressure in the Common Rail injection
• engine control unit J623 system is independent of the engine speed and
• injection valves N30 - N33 the quantity of fuel injected.
• fuel rail
• fuel pressure sender G247
• fuel pressure regulator valve N276
• high-pressure line
• high-pressure fuel pump
injection valves N30-N33
fuel pressure regulator valve

N276
fuel rail
SP80_13
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On the 1.6 ltr. TDI engine, the high-pressure fuel The high-pressure injection unit has the task of
pump consists of several parts: producing a high fuel pressure of up to 160 MPa
(1600 bar) for the injection valves.
• high-pressure pump unit The pump consists of two radial pistons offset by
• upstream delivery pump 180° which are driven by an eccentric and a fuel
• valve for fuel dosage N290 pressure regulator to control the pressure of fuel
as needed.
All the parts are combined in a single body.
upstream delivery pump high-pressure pump unit
fuel return line in the fuel tank
valve for fuel dosage N290
fuel supply from the fuel tank
high pressure connection to rail
SP80_29
high-pressure pump unit
fuel discharge
fuel supply
fuel supply to the

valve for fuel dosage
N290
upstream delivery
pump
SP80_17
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Upstream delivery pump

It is a mechanical toothed gear pump which is
driven by the crankshaft via a toothed belt. Its
housing is part of the high-pressure fuel pump.
It is the task of the pump to increase the pres-
sure of the fuel delivered from the fuel tank to
approx. 0.5 MPa (5 bar) and to supply the fuel to
the high-pressure pump unit via the valve for fuel
dosage N290. Thus, a regular fuel supply of the
high-pressure pump unit is ensured in all operat-
ing conditions.
SP80_55
fuel supply from the fuel

tank
fuel supply to the valve for

fuel dosage N290
SP80_17 upstream delivery pump
Effects of failure
As a result of a malfunction of the upstream delivery pump or if damage occurs, the high-pressure
pump unit is not sufficiently supplied with fuel and in turn the engine cannot be started.
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The valve for fuel dosage N290 controls the fuel
supply to the high-pressure pump unit and thus
ensures its fuel supply. Therefore the quantity of
fuel to be delivered by the high-pressure pump
unit can already be adapted to the current need
of the engine in the low pressure branch. Then
the high-pressure pump unit condenses only the
necessary quantity of fuel for the current operat-
ing mode.
Valve N290 is actuated by the engine control unit
using the PWM signal.
SP80_56
Function
Piston electromagnetic coil Piston electromagnetic coil

Spring Spring
Fuel supply to high-pres- Fuel supply to high-pres-

sure pump unit SP80_22 sure pump unit SP80_23
Fuel supply of the up- Armature Fuel supply of the up- Armature
stream delivery pump stream delivery pump
The valve for fuel dosage is not supplied. The Power is supplied to the valve for fuel dosage
piston shuts off the fuel supply to the high-pres- and a magnetic field is generated by the electro-
sure pump unit by means of the spring force. magnetic coil. The piston is pressed against the
spring force via the armature of the valve where-
by the piston opens the passage for the fuel sup-
ply to the high-pressure pump unit.
In the event of signal failure of the valve N290, the valve closes the supply line to the high-pressure
pump unit and the engine stops. A restarting of the engine is not possible.
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On the 1.6 ltr. TDI engine, piezoelectrically Technical data
controlled injection valves are used for the fuel
injection. Control voltage 80 - 150 V
Number of openings of the injection
7
nozzle
7
cycle
piezoelectric control element
valve piston
high pressure connection for the fuel supply line of the

rail
valve piston spring
fuel supply in the valve nozzle
control piston
spring of the control piston
control pin for the lifting of the nozzle needle
pressure disc
fixing nut of the nozzle
nozzle needle
SP80_44
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Compensating the injection quantity of the valves llC
On the 1.6 ltr. TDI engine with the Common Rail injection system developed by the company Conti-
nental, the compensation operation for adjusting the injection quantity of the valves is identified with
the code llC.
Compensating the injection quantity of the valves llC is a function performed by the software of the
engine control unit.
The llC code is determined for each injection valve during the manufacturing process and determines
the difference from the nominal value and thus describes the injection parameters of each injection
valve. In this way, the engine control unit can determine the exact duration of injection (injected quan-
tity).
Each injector of the 1.6 ltr. TDI engine is marked with a six digit llC code, comprised of letters and
numbers.
After replacing the injection valve seat, the llC code must be entered in the engine control unit using
the diagnostic unit in the mode "controlled functions". The digit zero, which is the seventh digit, is auto-
matically added to the six digit llC code by the diagnostic unit VAS.
Data Matrix Code (code of
the data matrix)
part number
INCA code
(6 digits)
SP80_47
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Fuel pressure regulator valve N276

The fuel pressure regulator valve N276 is located
at the high-pressure fuel tank (rail) and regulates
the fuel pressure. Valve is actuated by the engine
control unit using the PWM signal. If the sup-
ply line is not supplied with power, the valve is
opened.
valve needle electromagnetic coil
fuel pressure in the

high-pressure reservoir
valve seat SP80_27
valve ball
valve spring
fuel discharge in the fuel tank valve armature
Function
Not actuated
If the valve N276 is not supplied with power, the

ball at the end of the valve needle is pressed into
the valve seat by means of the spring force. In
this way the very low fuel pressure is maintained
in the rail.
If the fuel pressure in the rail is higher than the
force of the spring acting on the valve needle, the SP80_32
valve opens and the fuel is led back to the fuel
tank via the outlet tube.
to fuel tank
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Actuated
In order to reach the operating pressure in the

rail, the engine control unit begins to supply the
electromagnetic coil of the valve. The armature of
the valve is retracted by the coil and presses the
valve needle into the seat. The valve closes.
The quantity of fuel discharged from the rail and
flowing into the tank is controlled depending on SP80_33
the PWM signal frequency.
In the event of signal failure of the valve N276, the required fuel pressure cannot be produced and the
engine cannot be operated.
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1.2 ltr. TDI engine
1.2 ltr. TDI CR engine

The smallest and latest representative of the diesel engine family with the Common Rail injection sys-
tem is the turbocharged 1.2 ltr. three-cylinder TDI engine with a small displacement.
The 1.2 ltr. TDI engine has a power output of 55 kW and is fitted to the models Fabia and Roomster
(model year 2011).
The 1.2 ltr. TDI engine meets the EU5 emission standard just as both previous engine assemblies
with a larger displacement.
SP80_64
• 4-valve technology • metallic glow plugs

• cylinder crankcase made out of cast iron and • plastic intake manifold with regulating flaps
cylinder head made out of aluminium alloy • turbocharger with variable turbine geometry
• forged crankshaft with four balancing weights • exhaust gas recirculation module with integrat-
• a balance shaft in the crankcase ed valve of exhaust gas recirculation and an
• Common Rail injection system developed by exhaust gas recirculation cooler
the company Delphi • electric fuel pump in the tank (0.6 MPa); (6 bar)
• electromagnetic valve-controlled injectors • particle filter with oxidation catalytic converter
• injection pressure up to 180 MPa (1800 bar) • injectors with INCA code
• knock sensor • communication via the diagnostic transport
protocol UDS
GB
34
SP_80_GB.indd 34 5.5.2010 10:53:21

Technical data

Engine code CFWA/CLMA*
Structure Production engine
Number of cylinders 3
Valves per cylinder 4
Displacement 1199 cm3
Bore 79.5 mm
Stroke 80.5 mm
Compression ratio 16,5 : 1
max. power output 55 kW at 4200 min
max. torque 180 Nm at 2000 rpm
control unit DELPHI DCM 3.7
fuel Diesel fuel according to DIN
Exhaust after treatment Exhaust gas recirculation; oxida-
tion catalytic converter; particle
filter
Emission standard EU5 + DPF / EU4*
100 250
90 225
80 200
70 175
60 150
M (Nm)
P (kW)
50 125
40 100
30 75
20 50
10 25
0 1000 2000 3000 4000 5000 6000
n (min-1)
SP80_45
* for countries outside the EU
GB 35
SP_80_GB.indd 35 5.5.2010 10:53:22

Fuel system
The electric fuel pump ensures uninterrupted fuel

supply to the fuel supply line below a pressure of 8
0.5 - 0.6 MPa (5 - 6 bar).
2 - Fuel filter
3
It detects the current fuel temperature. 5
It produces a fuel pressure up to a value of

180 MPa (1800 bar).

4
on need.

fuel tank (fuel rail). The function principle is the
same as for the 2.0 ltr. TDI engine.
2
GB
36
SP_80_GB.indd 36 5.5.2010 10:53:22

7 - Fuel rail
7 6
10
G247

high-pressure area.
9 - Injection valves N30, N31, N32

9 9 9
bers.
10 - Throttle valve
The throttle valve compensates for the shock

waves in the high pressure branch which occur
when opening and closing the injectiors during
the injection phase.
11 - Pressure regulator of fuel supply line

11 The pressure regulator maintains the pressure in
the fuel supply line at a value of approx. 0.5 MPa
(5 bar) and ensures that the excess fuel is re-
1 SP80_68 turned to the fuel tank.
Legend
high pressure (23 up to 180 MPa); (230 up to 1800 bar)
injector return line (vacuum 0.1 to 0.5 MPa); (1 to 5 bar)
supply line / return line
GB 37
SP_80_GB.indd 37 5.5.2010 10:53:23

Pressure regulator of fuel supply line
fuel tank
SP80_77
to fuel filter and to

line of excess fuel in the high-pressure pump
tank
return line from the

pressure regulator of fuel high-pressure pump
diaphragm valve
pressure regulator of fuel

flow direction
fuel return line to fuel

tank
SP80_75
blank flange
GB
38
SP_80_GB.indd 38 5.5.2010 10:53:24

The Common Rail injection system was developed for the 1.2 TDI engine by the company Delphi.
System components:
• engine control unit J623

• injection valves N30 - N32 • fuel pressure regulator valve N276
• fuel rail • high-pressure line
• fuel pressure sender G247 • high-pressure fuel pump
injection valves N30 - N32 fuel pressure regulator valve N276
fuel rail
SP80_66
GB 39
SP_80_GB.indd 39 5.5.2010 10:53:38


On the 1.2 ltr. TDI engine, the high-pressure fuel A small Venturi tube, integrated in the high-pres-
pump has a piston. The pump piston is driven by sure fuel pump, generates vacuum in the injector
a double cam which in turn is driven by the crank- return fuel line.
shaft via a toothed belt.
The high-pressure fuel pump generates a fuel
pressure up to a value of 180 MPa (1800 bar).
rail connection hydraulic head of the

fuel supply
fuel return line in the

fuel tank
valve for fuel dosage

N290
injector return fuel line
SP80_67
drive shaft
GB
40
SP_80_GB.indd 40 5.5.2010 10:53:42

On the 1.2 ltr. TDI engine, the valve for fuel dos- The valve ensures the quantity of fuel supplied
age N290 accomplishes the same task as an to the high-pressure pump and thereby the fuel
electromagnetically controlled valve on the 1.6 ltr. pressure control in the rail needed according to
and 2.0 ltr. TDI engines described above. the current operating conditions of the engine.
SP80_71
Function
If the valve is not supplied with a PWM signal If the valve is supplied with a PWM signal, this
sent by the control unit, the valve is opened and results in the valve closing and thus the fuel sup-
fuel is directed into the high-pressure pump. ply to the high-pressure pump is interrupted.
In the event of signal failure of the valve for fuel dosage N290, the engine performance is reduced and
the engine control unit operates in emergency mode.
GB 41
SP_80_GB.indd 41 5.5.2010 10:53:46


On the 1.2 ltr. TDI engine, electromagnetic Technical data
controlled injection valves are used for the fuel
injection.
Control voltage 12 V
Number of openings of the injection
7
nozzle
6
cycle
high pressure connection for the fuel supply line of

the rail
fuel return line
electromagnetic coil
spring of the control valve
control valves
nozzle needle spring
nozzle needle
SP80_76
GB
42
SP_80_GB.indd 42 5.5.2010 10:53:49

Compensating the injection quantity of the valves C2I
On the 1.2 ltr. TDI engine with the Common Rail injection system developed by the company Delphi,
the compensation operation for adjusting the injection quantity of the valves is identified with the code
C2I.
Compensating the injection quantity of the valves C2I is a function performed by the software of the
engine control unit.
The C2I code is determined for each injection valve during the manufacturing process and determines
the difference from the nominal value and thus describes the injection parameters of each injection
valve. In this way, the engine control unit can determine the exact duration of injection (injected quan-
tity).
On the 1.2 ltr. TDI engine, the injection valves are provided with a twenty digit C2l code.
After replacing the injection valve seat, the C2I code must be entered in the engine control unit using
the diagnostic unit in the mode "controlled functions".
Data Matrix Code (code

of the data matrix)
Code C2I
(20 digits)
SP80_69
GB 43
SP_80_GB.indd 43 5.5.2010 10:53:59

80
Overview of the previously edited service training resources
No.Designation No.Designation
1 Mono-Motronic 51 2.0 ltr./85 kW petrol engine with balancing shafts
2 Central locking and two-stage intake manifold
3 Vehicle alarm 52 ŠkodaFabia; 1.4 ltr. TDI engine with unit injection
4 Working with wiring diagrams system
5 ŠKODA FELICIA 53 ŠkodaOctavia; Presentation of the vehicle
6 Safety of the ŠKODA vehicles 54 ŠkodaOctavia; Electrical Components
7 Principles of ABS - were not published 55 FSI petrol engines; 2.0 ltr./110 kW and 1.6 ltr./85
8 ABS - FELICIA kW
9 System for safe start-up with transponder 56 Automatic gearbox DSG-02E
10 Air conditioning in the vehicle 57 Diesel engine; 2.0 ltr./103 kW TDI with pump-nozzle
11 Air conditioning FELICIA units, 2.0 ltr./100 kW TDI with pump-nozzle units
12 1.6 engine - MPI 1AV 58 ŠkodaOctavia, Chassis and electromechanical
13 Four-cylinder diesel engine power-assisted steering
14 Power-assisted steering 59 ŠkodaOctavia RS, 2.0 ltr./147 kW FSI turbo engine
15 ŠKODA OCTAVIA 60 2.0 ltr./103 kW 2V TDI diesel engine; particle filter
16 1.9 ltr. TDI diesel engine with additive
17 ŠKODA OCTAVIA Convenience electronic system 61 Radio navigation systems in the Škoda
18 ŠKODA OCTAVIA Manual gearbox 02K, 02J 62 ŠkodaRoomster; Vehicle presentation part l
19 1.6 ltr. and 1.8 ltr. petrol engines 63 ŠkodaRoomster; Vehicle presentation part lI ll
20 Automatic gearbox - fundamentals 64 ŠkodaFabia II; Vehicle presentation
21 Automatic gearbox 01M 65 ŠkodaSuperb II; Vehicle presentation part l
22 1.9 ltr./50 kW SDI diesel engines, 1.9 ltr./81 kW TDI 66 ŠkodaSuperb II; Vehicle presentation part lI
23 1.8 ltr./110 kW and 1.8 ltr./92 kW petrol engines 67 2.0 ltr./125 kW TDI diesel engine with Common Rail
24 OCTAVIA, CAN BUS injection system
25 OCTAVIA - CLIMATRONIC 68 1.4 ltr./92 kW TSI petrol engine with turbocharger
26 OCTAVIA - safety of the vehicle 69 3.6 ltr./191 kW FSI petrol engine
27 OCTAVIA - 1.4 ltr./44 kW engine and gearbox 002 70 All-wheel drive with Haldex coupling of the lV.
28 OCTAVIA - ESP - fundamentals, design, function generation
29 OCTAVIA 4 x 4 - all-wheel drive 71 ŠkodaYeti; Vehicle presentation part l
30 2.0 ltr. 85 kW and 88 kW petrol engines 72 ŠkodaYeti; Vehicle presentation, part ll
31 Radio navigation system - design and functions 73 LPG system in Škoda vehicles
32 ŠKODA FABIA - technical information 74 1.2 ltr./77 kW TSI petrol engine with turbocharger
33 ŠKODA FABIA - electrical systems 75 7-speed dual-clutch automatic gearbox 0AM
34 ŠKODA FABIA - electro-hydraulic power-assisted 76 Greenline vehicles
steering 77 Geometry
35 1.4 ltr. - 16 V 55/74 kW petrol engines 78 Passive safety
36 ŠKODA FABIA - 1.9 ltr. TDI Unit injection 79 Additional heating
37 Manual gearbox 02T and 002 80 2.0 ltr., 1.6 ltr., 1.2 ltr. diesel engines with Common
38 ŠkodaOctavia; model 2001 Rail injection system
39 Euro-On-Board-Diagnosis
40 Automatic gearbox 001
41 Six-speed gearbox 02M
42 ŠkodaFabia - ESP
43 Exhaust emissions
44 Extended service intervals
45 Three-cylinder petrol engines 1.2 ltr.
46 ŠkodaSuperb; Presentation of the vehicle; part I
47 ŠkodaSuperb; Presentation of the vehicle; part Il
48 ŠkodaSuperb; 2.8 ltr./142 kW V6 petrol engine
49 ŠkodaSuperb; 2.5 ltr./114 kW TDI V6 petrol engine
50 ŠkodaSuperb; Automatic gearbox 01V
Only for the internal use in the service network ŠKODA.

All rights reserved. Subject to technical modifications.
This paper was made out of
S00.2002.80.20 E GB Technical status 01/2010 chlorine-free bleached cellulose.
© ŠKODA AUTO a.s. http://portal.skoda-auto.com
SP_80_GB.indd 44 5.5.2010 10:54:00

Service: 2.0, 1.6, 1.2 - Litre Diesel Engines

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Service 80

2.0, 1.6, 1.2 - litre diesel engines

SP_80_GB.indd 1 5.5.2010 10:52:42

The 2.0 ltr. TDI engine is produced in two gen-

The range of diesel engines also includes the

The 1.2 ltr. TDI CR engine is offered exclusively

SP_80_GB.indd 2 5.5.2010 10:52:46

2.0 ltr. TDI engine 4

The fuel system of the 2.0 ltr. TDI engine 10

1.6. ltr. TDI engine 20

The fuel system of the 1.6 ltr. TDI engine 24

1.2 ltr. TDI engine 34

The fuel system of the 1.2 ltr. TDI engine 36

You will find the notes for the assembly and

The time for going to press was on the 01/2010.

SP_80_GB.indd 3 5.5.2010 10:52:52

2.0 ltr. TDI CR engine - 1st generation

• 4-valve technology • metallic glow plugs

SP_80_GB.indd 4 5.5.2010 10:52:52

2.0 ltr./103 kW TDI engine 2.0 ltr./125 kW TDI engine

Power output and torque diagram

2.0 ltr./103 kW TDI engine 2.0 ltr./125 kW TDI engine

110 325 120 375

100 300 110 350

90 275 100 325

SP_80_GB.indd 5 5.5.2010 10:52:53

2.0 ltr. TDI CR - 2nd Generation

SP_80_GB.indd 6 5.5.2010 10:52:53

2.0 ltr./81 kW TDI engine 2.0 ltr./81 kW TDI engine for

Power output and torque diagram

100 300 100 300

SP_80_GB.indd 7 5.5.2010 10:52:56

2.0 ltr./103 kW TDI engine 2.0 ltr./125 kW TDI engine

Power output and torque diagram

2.0 ltr./103 kW TDI engine 2.0 ltr./125 kW TDI engine

100 300 110 350

90 275 100 325

SP_80_GB.indd 8 5.5.2010 10:52:56

SP_80_GB.indd 9 5.5.2010 10:52:56

1 - Electric fuel pump G6

Ensures uninterrupted fuel supply to the fuel sup-

2 - Fuel filter with preheating valve

The preheating valve prevents the filter from

3 - Additional fuel pump V393

It delivers the fuel from the fuel supply line to the

It prevents harmful dirt particles from penetrating

5 - Fuel temperature sender G81

It detects the current fuel temperature.

6 - High-pressure fuel pump

It creates a high fuel pressure up to a value of

7 - Valve for fuel dosage N290

It controls the quantity of compressed fuel, based

SP_80_GB.indd 10 5.5.2010 10:52:57

It regulates the fuel pressure in the high-pressure

It accumulates high-pressure fuel, which is re-

10 - Fuel pressure sender - high pressure

It detects the current fuel pressure in the high-

11 - Non-return delivery valve

It maintains the pressure in the return line deliv-