Workshop Manual Octavia

Service
Service
Workshop
Workshop Manual Manual
OCTAVIA
OCTAVIA
1.9-Itr./66 kW (TDl) Engine,
1.9-ltr./66 kW (TDI) Engine,
Mechanical Components
Mechanical Components
ProCarManuals.com
ProCarManuals.com
Service Department. Technical Information

Service Department. Technical Information
S00.5110.52.20 Edition 03.98

S00.5110.52.20 Edition 03.98
ProCarManuals.com
ProCarManuals.com
The Service Manual is intended only for use within the Śkoda Organisation;
The Service Manual is intended only for use within the koda Organisation;
it is not permitted to pass it onto third persons.

it is not permitted to pass it onto third persons. Printed in CR
Printed in CR
© 1998
© 1998 KODA
SKODA AUTO a. s.s.
AUTO a.
2 3
Service
Service R
List of Supplements to
List of Supplements to
OCTAVIA Workshop
OCTAVIA Workshop Manual
Manual Edition: 04.04
Edition: 04.04
1.9 I/66 kW (TDI) Engine, Mechanical Components

1.9 l/66 kW (TDI) Engine, Mechanical Components
Replaces List of Supplements - Edition:

Replaces List of Supplements - Edition: 11.02
11.02
Supple-|
Supple- Edition
Edition Subject
|Subject Article Number
Article Number
ment
ment
08.96
08.96 Basic Edition
Basic Edition S00.5110.50.20
S00.5110.50.20
11 11.96
11.96 Supplement to Basic Edition
Supplement to Basic Edition S00.5110.51.20
S00.5110.51.20
22 03.98
03.98 Modifications to Engines from 08.97
Modifications to Engines from 08.97 S00.5110.52.20
S00.5110.52.20
33 06.99
06.99 Supplement for 4 x 4 Models
Supplement for 4 x 4 Models S00.5110.53.20
S00.5110.53.20
ProCarManuals.com
ProCarManuals.com
44 03.00
03.00 Modifications to Repair Groups 10, 13, 15, 19, 21, 26
Modifications to Repair Groups 10, 13, 15, 19, 21, 26 | S00.5110.54.20
S00.5110.54.20
55 05.01
05.01 Modifications to Vehicles MJ01
Modifications to Vehicles MJ01 S00.5110.55.20
S00.5110.55.20
66 11.02
11.02 Modifications to Repair Groups 00, 10, 13, 15, 17,
Modifications to Repair Groups 00, 10, 13, 15, 17, S00.5110.56.20
S00.5110.56.20
19, 20
19, 20
77 04.04
04.04 Modifications to Repair Groups 10, 13, 15, 17, 19,
Modifications to Repair Groups 10, 13, 15, 17, 19, S00.5110.57.20
S00.5110.57.20
21, 26
21, 26
88
99
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
Contents ⇒
Contents > next
next page.
page.
The Service Manual is intended only for use within the

The Service Manual is intended only for use within the
koda Organisation; it is not permitted to pass it on to
Skoda Organisation; it is not permitted to pass it on to
third
third persons.
persons. Printed in CR
Printed in CR
© KODA AUTO
2004 ŚKODA
© 2004 a. s.s.
AUTO a. S00.5110.57.20
S00.5110.57.20
WOO'SIEeNUEJNIEDOJd
ProCarManuals.com
OCTAVIA
OCTAVIA Service
Service
Contents
Contents
00
00 Technical Data
Technical Data Page
Page
Technical data ..............................................................................................................................
Technical data .......................-------eeeeeeeeeeee e ee wee e wee aww wawa aa aaa aaa aaa aaa aa aaa aaa aaa aaa aaa aaa aa aaa aaaaaaaaaaaaaa aaa 00-1
00-1
- )
! Engine number .............. eee eeee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa eaaaeeaaanaaaae
00-1
!
= )
! ofe] [ZE (ZZUU (CE
00-1
!
10
10 Removing and installing Engine
Removing and installing Engine Page
Page
Removing and installing engine ................................................................................................

Removing and installing engine .................-..--ssssse eee aaa aaa aaa aaa aa zaaaanaazaazaezaaaazazzzwazewa0a 10-1
10-1
LA
#
! ZJLOY[ate KJ ae | [PE 10-1
!
- *
! Attaching engine to repair stand
...................-eeeeeeeee aaa aaa aaa aa aaa aaa aa anawa aaa aaa aaa aaa aaaeeaaeeecece 10-12
!
LS]
! ae KV ofe! [EE
+ 10-12
!
-
! Tightening torquesS ................e
, eee eee eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaaeaaanaaaae
10-14
!-
- _ Aligning
! engine/gearbox mounting ...........
*./ eee eee eee eeeeee eee aaa aaa aaa aaa aaa aaa aaa aaa aaaaaaanaaaee
10-15
!
- )./
! Engine/gearbox mounting ..........- eee eee eeeeeeeeeeee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaaaaaeacece
10-16
!0
13
13 Crank Assembly
Crank Assembly Page
Page
Disassembling and assembling engine .......................---ssse

ssa e aaa aa aaa aa aaa aaa aaa aaaaazann0e
Disassembling and assembling engine .................................................................................... 13-1
13-1
-
! Removing and installing ribbed V-belt ...................- eee eeeeeee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaannaaeć

#1! 13-1
2!
-
! Removing and installing toothed belt

# ....................-eeeeeeeee eee aaa aaa aa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaaanaazacneć 13-4
2!-
ProCarManuals.com
-
! |nspecting semi-automaiic toothed belt tensioning pulley .........................-e-eaaaaaa
aaa aaa aaa aaa aaaaaaać
+! 13-11
2!
ProCarManuals.com
-
! Rotating crankshaft to TDC

$ when engine removed
( # ..........................e--eeaaaaaaaaa aaa aaa zana aaaaazaazznaneć 13-11
2!
Removing and installing crankshaft ..........................................................................................

Removing and installing crankshafft...................--ss-sss aaa aaa aaa aaa aaa eaaaaaanaaaznaannaza0e 13-12
13-12
-
$!!
! Replacing crankshaft seal -belt pulley side-
........................ee.eeaaaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaaanaeć 13-15
2!
-
#
! Removing and installing flywheel ...................... eee eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaanaaanaceć
13-16
2!0
-
##
! Removing and installing driven plate
....................--eeeeeeeeee aaa aaa aaa aa aaa aaa aaa aaa aaa aaa aaa zana aaaaznaanaaneć 13-16
2!0
-
#
! Removing and installing front sealing flange
.......................e.eeeaeea aaa aaa aaa aaa aaa aaa aaa aaa aaa anna aaannaaeć 13-18
2!3
Disassembling and assembling pistons and connecting rod ............---:--:ssssssssaseaaaaaaaaazanzennee

Disassembling and assembling pistons and connecting rod ................................................ 13-21
13-21
-
! |nspecting piston projection at TDC
+4 ( ................... eee eee ee eeee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaazaaannaaeć
13-24
2!-
15
15 Cylinder Head, Valve Gear
Cylinder Head, Valve Gear Page
Page
Removing and installing cylinder head .....................................................................................

Removing and installing cylinder head ................-----:ssssseeea aaa aa aaa aaa aa aaa aaa aaa aa aaa a aaa aaaaaaaaae 15-1
15-1
-
#
! Removing cylinder head .................- eee eeeeeeeee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa eeaeeeaeeeecaeć
15-4
!-
- _ +
! |nstalling cylinder head ...................-e eee eee eee aaa aaa aaa aaa aaa aaa aazaaaeaaanaaaae
15-6
!0
- Testing
! compreSSion .............
eee aaa aaa aaa aaa aaa aaa aaa eaaacnaaeć
15-8
!3
Servicing valve gear ....................................................................................................................

Servicing valve gear .................-:-eseeeee aaa naa e enea ea eee aaa e a zee a zee zaa waza waz waza waz wee ww ez we za wee awe e wwe waze aaa aaaazez zeza wa 15-10
15-10
- 5##
! _Grinding in valve seats ...................-. eee eee aaa
aaa aaaaznaaznaaa e 15-12
!
- _ +##
! |nspecting valve guides ......................- eee eee eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa waza aaa eaaccnaaae
15-14
!-
-
##
! Replacing valve stem seals .....................- eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa anawa aaa aaa aaaaa aaa aaaa aaa eaaecencee
15-14
!-
-
#
! Removing and installing camshafft .................- eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaazaaaznaceć
15-16
!0
- +$
! |nspecting hydraulic bucket tappetsS
................---....-.a eee eee aaa aaa a aaa aaa aaa aa aaa aaaaaaaaaaaa aaa aaaaaaaaaakaaaaaa na 15-18
!3
-
##
! Replacing valve guides ...................... eee eeeeee eee aaa aaa aaa aaa aaa aaa aaa aaa aaaaaaeaaacnaaae
15-19
!6
17
17 Lubrication System
Lubrication System Page
Page
Removing and installing parts of the lubrication system ..................-::-sssaseaaaaaaaaaanananaaznaznennce

Removing and installing parts of the lubrication system ....................................................... 17-1
17-1
- (
! Disassembling and assembling oil filter holder
....................-eee-eeeee aaa aaa aaa aaa aaa aaa aaa aaa aaaaaaaanaaaeć 17-2
!
-
! Removing and installing oil pan ................--eeeeeeeeeeee
aaa aaa aaa aaa aaa aa aaa aaa aaa aaa aaa aaa aaa aaa aaa eaaeseeceć

# 17-3
!2
-
! Testing oil pressure and oil pressure switch
....................eeeeesaaaa aaa aaa aaa aaa aaa aaa aaa aaa a aaaaaaaaaaaaaaaaa na 17-5
!
Edition 04.04
Edition 04.04 I
------------1 ------------
S00.5110.57.20
S00.5110.57.20
Service
OCTAVIA
<#484
19
Cooling System
# !: Page
>
!
Removing and installing parts of the cooling system .................--::sesssesaaea

aaa aaaaaaaazaaznnae
$ !
&
!
!: 19-1
/
-
! Parts of the cooling system fitted to body ............- eee eee eeeeeeaeae aaa aaa aa aaa aaa aaa aaa aaa aaa aaa aaaaaaaanaaeć
19-2
6!
-
! Parts of the cooling system attached to engine
...........................ee.eea aaa aaa aaa aaa aaa aaa aaa aaa aaaaaaaanaaae 19-2.2
6!
-
! Connection diagram for coolant hoses
....................--eeeeeeeeeeee aaa aaa aa aaa aaa aaa aaa aaa aaa aaa aaa aaaanaaananeć 19-2.4
6! -
-
! Draining and filling system with coolant
( ...............-eeeeeeeeeee aaa aaa aa aaa aaa aaa aaa aaa aaa aaa aaa aaa zaaaznaznnaneć 19-3
6!2
-
! Removing and installing coolant pump ..........--

# eee eeee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaaaaaaaznaanaaceć
19-5
6!
-
! Removing and installing coolant thermostat..........................eeeeeea

# aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa zaaaznaaeć
19-7
6!
-
! |nspecting cooling system for leaks ................
+$ eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaznaceć
19-8
6!3
-
! Removing and installing radiator ..............-.eee

# eee eeeeeeeeee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaaznaaanaceć
19-9
6!6
-
! Removing and installing fan

# .................-.eeeeeeeeeeaa
aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa eaaeeeeeeeeecceć 19-12
6!
20
*' Fuel Supply System
@ :: Page
>
!
Removing and installing parts of the fuel supply system .................-...-----ueueeeeeee

$ !
&
!
:: aaa aaaananezecnccce 20-1
*'/
-
#$
! Removing and installing fuel tank with attached parts
............................aaaaa aaa aaa aaa aaa wana azaaannacnć 20-1
!
-
#
! Removing and installing fuel cooler...........................-.-eeaaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa eeaeeeeececa
20-2
!
- $
! Safety precautions when working on fuel supply system
..........................--s-eeaaaaaaaa aaa aaa aaaaaaaaaać 20-3
!2
- _

! Rules for cleanlineSsS .................- eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaa aaa aaa eaaaeeeezanaaeć
20-3
!2
-
#
! Removing and installing fuel gauge sender
...........................e.-eeaeaa aaa aaa aaa aaa aaa aaa aaa aaaa anna zaaannaceć 20-4
!-
-
#$
! Removing and installing fuel tank......................eeeeeeeaeaa aaa aaa aaa aa aaa aaa aaa aaa aaa aaa aa aaa aaa aaa eee eeeeececa
20-4
!-
Removing and installing parts of the fuel supply system - 4 x 4 models ...............................
$ !
&
!
::/(7(& 20-6
*'/
-
! Removing and installing fuel tank with attached parts - 4 x 4 models ......................................

#$!-/- 20-6
!0
-
! Removing and installing fuel gauge sender - 4 x 4 models

#!-/- .................................aaaaaaaaaaaaanaannaae. 20-8
!3
ProCarManuals.com
-
! Removing and installing fuel tank - 4 x 4 models

#$!-/- ............................eeuaa aaa aaa aaa aaa aaa zeza aaaa aaa zaaannacć 20-9
!6
ProCarManualg.com
* Turbocharging
2
! ! Page
>
!
==h
Charge air system with turbocharger...................-----ese

aaa aa aa aaa aaa aaa aaa aa aaaaaaananzanane
#
!
:)2
! 21-1
*/
- _

! Rules for cleanlineSsS .................- eee eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaa aaa aaa eaaaeeeezanaaeć
21-1
!
-
#*5

! Removing and installing turbocharger for the engine AGR with attached parts ........................ 21-2
!
-
#*78
! Removing and installing turbocharger for the engine ALH with attached parts ....................... 21-3.1
!2
-
! Connection diagram of charge pressure control ...................-.::-ee-eeeeea aaa aaa aaa aaa aaa aaa aaa aaa aaa aaanaaae
21-4
!-
-
! Testing charge pressure control valve pressure unit
## ..............................--.-eaaaaa aaa aaa aaa aaa aaa zaaazacace 21-5
!
-
! Removing and installing turbocharger.................-e-eeeeeee eee aaa aaa aaa aaa aaa aaa aaa aaa aaaaaaaeć

# 21-6
!0
-
! Removing and installing parts of the charge air cooling system ..............................aaaaaaaaaanaaa.

# 21-9
!6
-
! Removing and installing charge air cooler

# .......................eeaaaeaaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaaaznazznacee 21-10
!
* Exhaust system
7
: Page
>
!
N
©
Removing and installing parts of the exhaust system ................-.--:essseeeeea

aaa aaa aaaaaaananzannce
$ !
&
!
7
: 26-1
*/
-
! Replacing centre silencer or rear silencer .................-eeeeeeee aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaanaaaeć

26-2
0!
-
! Aligning exhaust system free of streSs....................-
*/ eee aaa aaa aaa aaa aaa aaa aaa aaa aaa aiae 26-3
0!2
Removing and installing parts of the exhaust system - 4 x 4 models .................----:::222:111111.

$ !
&
!
7
:/(7(& 26-4.1
*/(
-
! Replacing centre silencer or rear silencer - 4 x 4 models ...........................uuaeaaa
aaa aaa aaa aa zaaannacać

!-/- 26-4.2
0!-
Exhaust gas recirculation system

7
!

: .....................-.-----ssee aaa aaa aaa aa aaa aaa aaa aaa aaa aaaaaaaaaa0e 26-5
*/-
- /
! Connection diagram of exhaust gas recirculation control
.......................--s--aaaaaaeaaa aaa aaaaazaazncccnć 26-5
0!
- Testing
! mechanical exhaust gas recirculation valve
/## .........................eeaaaaaaa aaa aaa aaa aaa aaa aaaaazaaanccneć 26-7
0!
-
! Removing and installing parts of the exhaust gas recirculation system ...................................

#/ 26-8
0!3
------------ II ------------ Edition 04.04

& '('(
S00.5110.57.20
S00.5110.57.20
OCTAVIA
OCTAVIA Technical Data
Technical Data 00
00
Technical
Technical data data
Engine number
Engine number
H <q The
K [he engine
engine number
number”) is
number)
number (engine
is located
(„engine code
located at
at the
code” and
the front
and serial
at the
front at
„serial
the connec-
connec-
tion of
tion of the
the engine/gearbox.
engine/gearbox.
o In addition, a sticker with „engine code" and „se-

In addition, a sticker with engine code and se-
o I) rial number" is affixed to the toothed belt guard.

rial number is affixed to the toothed belt guard.
ć The engine code is also indicated on the vehi-

The engine code is also indicated on the vehi-
cle data stickers.

cle data stickers.
< |4m
Engine features
Engine features
Engine code AGR ALH

ProCarManuals.com
Engine code AGR ALH

ProCarManuals.com
Manufactured
Manufactured 10.96 ä
10.96 > 08.00 ä
08.00 >
Displacement
Displacement l 1.896
1.896 1.896
1.896
Power output
Power output KW at rpm
kW at rpm 66/4000
66/4000 66/3750
66/3750
Torque
Torque Nm at rpm
Nm at rpm 210/1900
210/1900 210/1900
210/1900
Bore
Bore 5 mm
∅ mm 79.5
79.5 79.5
79.5
Stroke
Stroke mm
mm 95.5
95.5 95.5
95.5
Compression ratio
Compression ratio 19.5: 1
19.5 : 1 19.5: 1
19.5 : 1
min. CN
min. CN 49
49 49
49
Injection order
Injection order 1-3-4-2
1-3-4-2 1-3-4-2
1-3-4-2
Catalytic converter
Catalytic converter yes
yes yes
yes
Exhaust gas recirculation

Exhaust gas recirculation yes
yes yes
yes
Turbocharging
Turbocharging yes
yes yes
yes
Charge air cooling

Charge air cooling yes
yes yes
yes
Complies with emission limits

Complies with emission limits EU2
EU2 EU3
EU3
Edition 11.02
Edition 11.02 —— 00-1 ——
------------ 00-1 -------------
S00.5110.56.20
S00.5110.56.20
WOO'SIEeNUEJNIEDOJd
ProCarManuals.com
OCTAVIA
OCTAV1A Removing and Installing Engine
RemovingandInstallingEngine 10
10
Removing and installing engine

Removingandinstallingengine
Special tools, testers and aids required

Specialtools,testersandaidsreAuired
Workshop crane (e.g. V.A.G 1202 A)

+ "$9 1 * 5*'
♦
Catch pan (e.g. V.A.G 1306)

+ 9 1 * 520'
♦
+ Torque
♦ wrench
,
Pliers for spring strap clips

+
♦
Engine mount MP 1-202

♦ ):!
Engine mount T
♦ ) 10012
Bolt M10 x 25/8.8

♦ ;:/.3 3
Engine/gearbox jack (e.g. V.A.G 1383 A)

♦ )./4$9 1 * 5232*'
Double ladder (e.g. VAS 5085)

♦ (9 1*3'
Lifting device MP 9-201

♦ 7#:6!
Grease G 000 100

♦ 55
ProCarManuals.com
Cable strap
♦
ProCarManuals.com
Wire
+ "
♦
Adhesive tape
+ *#
♦
Removing
Removing
Notes:
Notes:
The engine
+ The
♦ engine is
is removed
removed downwards
downwards together
together
with the gearbox.
with the gearbox.
♦ AII cable straps

All cable straps that
that have
have to
to be
be loosened
loosened
when the
when the engine
engine was
was removed
removed must
must be
be fitted
fitted
again in
again in the
the same
same location.
location.
The hose
♦ The hose connections
connections are
are secured
secured with
with
screw-type clips, spring-type clips or clamp-
screw-type clips, spring-type clips or clamp-
type clips.
type clips.
♦ Always replace clamp-type

Always replace clamp-type clips
clips with
with spring-
spring-
type clips or screw -type clips.
type clips or screw -type clips.
Fuel lines
♦ Fuel lines at
at the
the engine
engine must
must only
only be
be secured
secured
with spring-type clips. The use of clamp-type
with spring-type clips. The use of clamp-type
or screw-type clips is not allowed.

or screw-type clips is not allowed.
Use pliers
♦ Use for spring
pliers for spring strap
strap clips
clips for
for installing
installing
the spring strap clips.
the spring strap clips.
Edition 04.04
Edition04.04 —— 10-1 —
------------ 10-1 ------------
S00.5110.57.20
S00.5110.57.20
10
10 Removing and Installing Engine
Removing and Installing Engine OCTAVIA
OCTAVIA
+ Pay
♦ Pay attention
attention to
to the
the correct
correct assignment
assignment of
of
the connectors;
the connectors; mark
mark ifif necessary.
necessary.
Procedure
Procedure
-
- Payattention to code of vehicles fitted with a
Pay attention to code of vehicles fitted with a
coded radio set; determine if necessary.

coded radio set; determine if necessary.
-
- Switch off ignition (if not already off) and dis-
Switch off ignition (if not already off) and dis-
connect earth strap at the battery.

connect earth strap at the battery.
<q --
K Remove engine trim panel:
Remove engine trim panel:
-
- Lift o
Lift out plug
ut p -1-
lug - and
1- a slacken
nd s nuts
lacken n uts
-arrowSs-.
-arrows-.
-
- Pull clip -2- off pin -3-.
Pull clip -2- off pin -3-.
-
- Ralse vehicle with lift platform; pay attention
Raise vehicle with lift platform; pay attention
to the following points:

to the following points:
A 6 5 z Dzi
<q The
[he arms
arms of
of the
the lift
lift platform
platform must
must be
be positioned
positioned
e. N zę [N(ękE K
only below
only below the
the side
side members.
members.
ProCarManuals.com
a SSZ5%
ProCarManuals.com
Warning!
Warning!
On no account may the arms of the lift platform be

On no account may the arms of the lift platform be
positioned below the sills, the front or rear sus-

positioned below the sills, the front or rear sus-
pension.
pension.
<q The
K [he two
two front
front jacking points are
jacking points are located
located at
at the
the
side members at the front at the level of the
side members at the front at the level of the
marking on the sill.

marking on the sill.
Warning!
Warning!
Never start the engine when the vehicle is raised

Never start the engine when the vehicle is raised
and engage a gear so long as only one driven gear

and engage a gear so long as only one driven gear
is making contact with the ground.

is making contact with the ground.
—— 10-2 —
------------ 10-2 ------------ Edition 03.98
Edition 03.98
S00.5110.52.20
S00.5110.52.20
OCTAVIA
OCTAVIA Removing and Installing
Removing and Installing 10
10
<q The
K [he two
two rear
rear jacking points are
jacking points are located
located at
at the
the
— rear longitudinal members at the level of the
rear longitudinal members at the level of the
marking at the sill.

marking at the sill.
<q|--
K Remove noise insulation panel in the middle
Remove noise insulation panel in the middle
and also on the left and right -arrows-.

and also on the left and right -arrows-.
ProCarManuals.com
ProCarManuals.com
-
- Open cap of coolant expansion reservolir.
Open cap of coolant expansion reservoir.
K- Turn drain plug -arrow- at the radiator to the

Turn drain plug -arrow- at the radiator to the
left or fit hose onto connection, as appropri-

left or fit hose onto connection, as appropri-
ate.
ate.
Edition 03.00
Edition 03.00 —- 10-3 —
------------ 10-3 ------------
S00.5110.54.20
S00.5110.54.20
10
10 Removing and Installing
Removing and Installing OCTAVIA
OCTAVIA
<q --
K |n addition, detach coolant hose
In addition, detach coolant hose at bottom at bottom
of oil cooler -arrow- and allow remaining cool-
of oil cooler -arrow- and allow remaining cool-
ant to flow out.

ant to flow out.
pu
——16 3 4
G
AŻ > <a --
K Detach air guide hose -1-.
Detach air guide hose -1-.
© (©)
| — -
- Detach vent hose -3- and connector for air
Detach vent hose -3- and connector for air
l mass meter -2-.

mass meter -2-.
ProCarManuals.com
ProCarManuals.com
2——4 | -
- _Slacken bolts -4- and -5- and remove air fil-
Slacken bolts -4- and -5- and remove air fil-
IB) ter housing.

ter housing.
——LI Jh
O LIBIAa
| |
| m <q|--
K Remove battery and battery
Remove battery and battery cradle -ar- cradle -ar-
Pe rows-.
rows-.
A10-0116
104 —— Edition 03.00

------------ ------------ Edition 03.00

S00.5110.54.20
S00.5110.54.20
OCTAVIA
OCTAVIA Removing and Installing Engine
Removing and Installing Engine 10
10
<a- Unbolt earth cable -1-.

K

ol - Detach cables -3- and -4- at the starter.

- Separate connector -2- and pull out of the

holder.

- Detach cables from the holder at the starter

and place to the side. Unbolt holder.

<a - Unbolt terminal 30/B+ cable -1- at the alter-

K
!

nator.

- Unplug connector -2- from terminal D+.

!
"

- _ Unscrew cable clamp -3-.

ProCarManuals.com

#

ProCarManuals.com
2 4 MŻ Models with air conditioning

Models with air conditioning
- Unplug connector at the AC compressor.

$ %

"

AII models
All models
Ą NA 2) <a - Disconnect/unplug the following cables/con-

K

"
# "

&
Ne Gi TEN rz N RZ p D nectors:
) Ja WG JAK 1 - Connector strip for glow plugs
%

" # "
>——A ) ę 2- Plug connection for needle lift sender

"

'
3 "LĄ (G80) (brown, black connector)

( ) * + ( - +

#

3 - Plug connection for engine speed sender

"

"

'
(G28) (black)
( ) * + ( - +
ŻW) 4 - Plug connection for injection pump

.

"

'
(A ć 5 - Connector for electronic tnermoswitch

%

-

#
7 (F14) (black; only with AC)

( / + ( - $ % +

0 1 #
- Unplug connector for coolant temperature

"

A sender (G62) (black) at flange of cylinder

( ) 2 + ( - +

"
1

head.

- Unplug connector for oil pressure switch (F 1)

( / +

"

#
at oil filter holder.

- Pull wiring loom out of the holders and run

# "

'
out to the side.

Edition 03.98 —— 10-5 -——

------------ -----------

Edition 03.98

S00.5110.52.20
S00.5110.52.20
10
OCTAVIA
Models fitted with manual gearbox

<q -
K Mark installation position of the shift cable

-B- relative to the gearbox shift lever.

-
Take off balancing weight -A- and shift cable

-B- at shift lever.

-
Pull selector cable off relay lever driver -C-;

raise lug in direction of arrow for this step.

-
Unclip hose line of slave cylinder at cable
!

support.

<q -
K [Take cable support of gearbox -arrow- and

place down to the side.

ProCarManuals.com
ProCarManuals.com
<q -
K Remove Slave cylinder -arrow- and place
"#
down to the side, secure with wire, do not

$
$
open line system.

#
Note:
Note:
Do not depress clutch pedal.

Do not depress clutch pedal.
ZA
gy [FEE
—-- 10-6 —
------------ 10-6 ------------ Edition 05.01
Edition 05.01
S00.5110.55.20
S00.5110.55.20
OCTAVIA
10
a - Unplug the following connectors:

K

1 - Speedometer sender (G22)

2 - Reversing lights switch (F4)

(EBS
Models fitted with automatic gearbox

A - Use a screwdriver to press off selector lever

K
!
cable -1- at gearbox selector lever -4- and

" "

! ! ! $ !
# # # #
pull locking clasp -3- off at cable support.

% & "

! ! !
# #
'
- Take off selector lever cable and place to

% "
&

! ! ! !
the side.

ProCarManuals.com
'
ProCarManuals.com
- Unbolt bracket for power steering pressure
Bć
" " %
!
line at gearbox support.

"

A>
! ! $
'
3
K - Unplug the following connectors:

1 - to solenoid valves

!
Una
2 - to speedometer sender -G22-

# #
3 - at multifunction switch -F 125-

&

(
!
# #
4 - at wheel speed sensor -G38-

& )

!
# #
cza
Edition 05.01 —-- 10-7 -—

Edition 05.01 ------------ -----------

S00.5110.55.20
S00.5110.55.20
10
OCTAVIA
Continued for all models

R — ——
<q - Detach fuel hoses -arrow- at the injection
"

K
! !

LNIUJGe7*%
_ I pump, seal with a clean plug and place to the
'

# $ # ! # & ! #
— side.
'

| ©) - Unplug connector -2- at the intake manifold

* + '

! # & ! ! ! $ !

, 4 | temperature sender (G72) with intake mani-

' , - * / +
.
$ # ! ! $ !
© JJ 05 fold pressure sender (G71).

' ' , - 0 /
.
17 -2
# !
Ą | 1 - Remove alr guide pipe -1-.

' 0

$ 2 & # #

<UNUE GM
— „Rss |
= W —
- _ Use pliers for spring strap clips to detach the

'

# # ! & # #
== — NN following coolant hoses:

! & ! 8
H <a _ |- Bottom coolant hose at coolant thermostat

0 9

K
$ ! ! $
Ek — | housing and at radiator (remove hose).

' ' , /

! & ! $ 2
(
ProCarManuals.com
(©) _ . .
dp (© SIO | > 2 - Coolant hose to expansion reservolr.
*

! 6 # ! ! 2
O O OKŃ
A J yo |
G ©_|l-968
c p
a R USE
= 7 —
U NA - 1
Q "NH n2
I
Ę
0 ———
—
=—————| NLS
s1 S10-0055 I
Ą
a — i ( a <q 1- Top coolant hose at branch
0 3 4

K
# ! !
A ! !
O| ( 2 - Coolant hose to expansion reservoir and
* '

! 6 # ! ! 2 !
— heat exchanger from cylinder head

' '

6 ! & $ 7 !
a 3 - Coolant hose to heat exchanger

(

2
! 6 ! &
4 - Coolant hose from heat exchanger at cool-

)

—= | ZA
! $ 6 ! &
W | ant pipe

! # #
LB [
t| —— a - _ Detach the following vacuum hoses:

! & 2 $ 8
|| _—_ /)
(il | vy. - at the vacuum pump

2 $ # $ #
AMIR" = Żowk | ae
X L - atthe mechanical exhaust
gas recirculation

$ ! 6 & !
2 2
——— 10-8 -—— Edition 05.01

------------ ----------- Edition 05.01

S00.5110.55.20
S00.5110.55.20
OCTAVIA
10
Unplug connector -1- at the exhaust gas

K

recirculation valve (N18).

Unplug connector from the charge pressure

control solenoid valve (N75) -2-.

!

Pull the charge pressure control solenoid

"
valve (N75) -2- off the bracket and place

! # $

down on the engine (hoses remain con-

%

nected, they have to be detached from the

#

'

&
fixtures).

| Unplug connector of intake manifold flap so-

$

Ó

lenoid valve (N239).

! ( )

Detach vacuum hose from the intake mani-

$

4

fold flap solenoid valve.

Remove air guide pipe between charge air

#

%

cooler and turbocharger ⇒

> page 21-39, item
# ! )

&
9.
)
Note:
Note:
Before removing the ribbed V-belt, mark direc-

Before removing the ribbed V-belt, mark direc-
tion of running. If an already used belt is fitted

ProCarManuals.com
tion of running. If an already used belt is fitted

ProCarManuals.com
on to run in the opposite direction, it may be

on to run in the opposite direction, it may be
destroyed. When installing the belt, ensure that

destroyed. When installing the belt, ensure that
it is correctly located in the belt pulleys.

it is correctly located in the belt pulleys.
Position flat ring wrench, waf 16, atthe hexa-

,
%
%
& &
"
gon of the tensioning pulley.

'
Swivel tensioning pulley in direction of arrow

K

% '
%
in order to slacken the ribbed V-belt.

$ # # . #

Take off ribbed V-belt.

$ # # . #
-

Unscrew 3 fixtures for power steering pres-

(
K

% %
sure line -arrows-.

%

Remove belt pulley of power steering hydrau-

#

' % '
lic pump.

Unbolt power steering hydraulic pump and

#

% '

tie up at the body. The lines remain con-

# /

'

nected.

| | S10-0057 |
LZ
Edition 05.01 —-- 10-35 -—

Edition 05.01 ------------ -----------

S00.5110.55.20
S00.5110.55.20
10
OCTAVIA
Models fitted with air conditioning

Warning!
Warning!
Refrigerant circuit of air conditioning system must

Refrigerant circuit of air conditioning system must
not be opened.
not be opened.
<q --
K Remove AC compressor and tie up with wire
Remove AC compressor and tie up with wire
at the towing eye -arrow- together with the

at the towing eye -arrow- together with the
connected hoses.
connected hoses.
Note:
Note:
Protect b
Protect bumper with
umper w adhesive
ith a d h e s i v e ttape
a p e ffrom
rom
scratches.
scratches.

<q --
K Remove pendulum support -arrow-.
Remove pendulum support -arrow-.
-
- Unbolt drive shafts from the flange of the
Unbolt drive shafts from the flange of the
gearbox and attach to body with wire.

gearbox and attach to body with wire.
ProCarManuals.com
ProCarManuals.com
4x4 models
4 x 4 models
-
- Detach propeller shaft from gearbox⇒
Detach propeller shaft from gearbox > Gear-
Gear-
box 02C, Repair Group 39.
box 02C, Repair Group 39.
Models with heavy-duty cooling system

Models with heavy-duty cooling system
-
- Remove right-hand electric fan (smaller fan
Remove right-hand electric fan (smaller fan
wheel diameter) ⇒
wheel diameter) > page
page 19-12.
19-12.

-
- Remove front part of exhaust system ⇒
Remove front part of exhaust system => page
page
26-1.
26-1.
<q --
K Attach engine holder 110012 to cylinder
Attach engine holder T10012 to cylinder
block with
block with nut
nut and
and M10
M10 bolt;
bolt; tighten
tighten to
to
40 Nm.
40 Nm.
ALI
-
- Raise engine and gearbox slightly with en-
Raise engine and gearbox slightly with en-
L/C
gine/gearbox lifter.
gine/gearbox lifter.
a<z 0012
VAG 1383A
—— 10-10 ——
------------ 10-10 ------------ Edition 05.01
Edition 05.01
S00.5110.55.20
S00.5110.55.20
OCTAVIA
10
Note:
Note:
Use a ladder, e.g. V.A.S 5085, to remove the

Use a ladder, e.g. V.A.S 5085, to remove the
bolts attaching the engine and gearbox brack-

bolts attaching the engine and gearbox brack-
ets.
ets.
<q- - Unscrew bolts from engine bracket -ar-

K

rOws-.

<q- - Unscrew bolts from gearbox bracket -ar-

K

rOow-.

- Carefully lower engine together with gear-

ProCarManuals.com
box.

ProCarManuals.com
Note:
Note:
It is essential to have a second person guide

It is essential to have a second person guide
the engine/gearbox assembly when lowering it

the engine/gearbox assembly when lowering it
in order to avoid any damage to the body be-

in order to avoid any damage to the body be-
cause of
cause of the
the tight
tight clearance.
clearance. At the same
At the same time,
time,
ensure that
ensure that the
the boots
boots of
of the
the joint shafts are
joint shafts are not
not
damaged.
damaged.

- Detach coolant hoses at the ATF cooler.

- Remove plug in the hole of the torque con-

verter panel.

<q- - Unscrew 3 nuts -arrow- from the torque con-

K

verter; rotate crankshaft 1/3 turn for each

" #

!
step.

- After separating engine and gearbox, secure

$

torque converter in the gearbox to prevent it

dropping out.
$


- Unscrew the bolts connecting engine/gear-

#

box.

A37-0201
- Separate gearbox from engine.

&
Edition 05.01
Edition 05.01 ——
------------ 10-11 ------------ 10-11 ———
$00.5110.55.20
S00.5110.55.20
10
OCTAVIA
Attaching engine
engine to
to repair stand
stand

The engine should be attached with the engine

The engine should be attached with the engine
holder MP 1-202 to the repair stand for carrying

holder MP 1-202 to the repair stand for carrying
out removal and installation operations.

out removal and installation operations.
Note:
Note:
The engine must not be attached to the repair

The engine must not be attached to the repair
stand for measuring the cylinder bore ⇒

stand for measuring the cylinder bore > page
page
————F7, 33
13-23.
~<q--
K Attach suspension device MP 9-201 to the
Attach suspension device MP 9-201 to the
plates at
plates at the
the engine
engine and
and take
take up
up weight of
weight of
engine with
engine with aa workshop crane, e.g.
workshop crane, e.g. V.A.G
V.A.G
1202 A:
1202 A:
¢ Belt
♦ Belt pulley
pulley side:
side:
2nd
2nd hole in rail - item 1 hole in rail - item 1
@ Flywheel
♦ Flywheel side:
side:
2nd
2nd hole in rail - item 7 hole in rail - item 7
KA .
Ry, SBS on ines ws (0 Warning!

Warning!
ProCarManuals.com
NS~DWV AS) OC NASSI Ne eth

ProCarManuals.com
AGES sy). \U/ 10-0042 Use locking pins at the hooks and at the rig pins
Use locking pins at the hooks and at the rig pins
PG <I VA to prevent them slipping out.

to prevent them slipping out.
- - Attach
Attach engine to repair stand with engine engine to repair stand with engine
holder MP 1-202.
holder MP 1-202.
Installing
Installing
Notes:
Notes:
¢ Always
♦ install new
Always install new seals
seals and
and gaskets
gaskets when
when
carrying out removal and installation work.
carrying out removal and installation work.
¢ Always
♦ install new
Always install new self-locking
self-locking nuts.
nuts.
Installation is carried out in the reverse order;

Installation is carried out in the reverse order;
pay attention to the following points:

pay attention to the following points:
- - Check whether dowel sleeves for centering

Check whether dowel sleeves for centering
engine/gearbox are inserted in the cylinder

engine/gearbox are inserted in the cylinder
block.
block.
<q- -
K Attach intermediate plate to sealing flange
Attach intermediate plate to sealing flange
and push
and push onto
onto the
the dowel
dowel sleeves
sleeves -arrows-.
-arrows-.

- - Check centering of the clutch driven plate.

Check centering of the clutch driven plate.
- - Check clutch release bearing for wear, re-

Check clutch release bearing for wear, re-
place if necessary.
place if necessary.
WW,
70
» - - Apply a thin film of grease G 000 100 to the
Apply a thin film of grease G 000 100 to the
splines of the input shaft.

splines of the input shaft.
—— 10-12 ———
------------ 10-12 ------------ Edition 05.01
Edition 05.01
$00.5110.55.20
S00.5110.55.20
OCTAVIA
OC6)81) Removing and Installing Engine
10
- Install slave cylinder of hydraulic clutch:

-
= 5-Speed Manual Gearbox 02J; Repair

"
!
⇒

Group 30; Clutch, Mechanism.

# $

! &
% '
- Align engine/gearbox mounting => page

*

) ) ) & ) )
- ( ⇒
10-15.
+ +
'
- Attach shift mechanism:

& &
- (

"
!
⇒

Group 34; Shift Mechanism, Housing.

# , -

! & )
% '
- Adjust shift mechanism, if necessary:

.

& &
- (
%

"
!
⇒

Group 34; Shift Mechanism, Housing.

# , -

! & )
% '

- Replace lock washer at support of selector

" /

0
lever cable.

'
- Use only nuts which are approved in the

0

- 1
Parts List for attaching the torque converter

2 3

) 4

at the driven plate.

'
-Install selector lever cable at gearbox, ad-

)
-
%
just if necessary:
.

= Automatic Gearbox; Repair Group 37; Serv-

" #
5
& ! !
ProCarManuals.com
⇒ (

icing shift mechanism.

ProCarManuals.com

) & &
'

- Install AC compressor:
$

&
- (
= Heating and Air Conditioning; Repair Group

- $ "

) ) !
⇒ (
87; Detaching and attaching compressor at

6 7
5
! ) ) &
bracket.
/

'

- Install power steering hydraulic pump:

0 ) &
-
= Running Gear; Repair Group 48; Remov-

" " , 6 "
) ! ! &
⇒
ing and installing power steering hydraulic

) ) 0 )
pump.
&
'
- Install ribbed V-belt ⇒

> page 13-3.
8 + # #

)

-
'
- Install drive shafts:

-
= Running Gear; Repair Group 40; Remov-

" " , "
) ! ! &
⇒
ing and installing drive shafts.

) )

'
- Align exhaust system free of stress ⇒

= page

) & )
- (
26-3.
9 #
'
- Fit on coolant hoses ⇒

= page 19-1, Parts of
+ ; + 2

)
- :
%
cooling system.

) &
'
Note:
Note:
Do not re-use drained coolant if the cylinder

Do not re-use drained coolant if the cylinder
block, cylinder head, cylinder head gasket, ra-

block, cylinder head, cylinder head gasket, ra-
diator, or
diator, or heat
heat exchanger,
exchanger, has
has been
been replaced.
replaced.
- Fill system with coolant ⇒

> page 19-3.
+ ; #

& 0 )
- :
'
Edition 05.01 — 10-13 -———

Edition 05.01 ------------ -----------

$00.5110.55.20
S00.5110.55.20
10
OCTAVIA
-
- Hoses and valves to mechanical exhaust gas
Hoses and valves to mechanical exhaust gas
recirculation valve, charge pressure control

recirculation valve, charge pressure control
and intake
and intake manifold
manifold flap valve (N239)
flap valve (N239)
= page
⇒ page 21-4,
21-4, Connection
Connection diagram
diagram for
for charge
charge
pressure control
pressure control
= page
⇒ page 26-5;
26-5; Connection
Connection diagram
diagram for exhaust
for exhaust
gas recirculation system.

gas recirculation system.
-
- Electrical connections and routing of cables:
Electrical connections and routing of cables:
= Current
⇒ Current Flow
Flow Diagrams,
Diagrams, Electrical
Electrical Fault
Fault
Finding, Fitting Locations.
Finding, Fitting Locations.
Note:
Note:
If the battery earth strap is disconnected and

If the battery earth strap is disconnected and
re-connected, it is then necessary to carry out

re-connected, it is then necessary to carry out
additional
additional Operations
Operations = Electrical
⇒ Electrical System:
System:
Repair Group 27.
Repair Group 27.
-
- Inspecting engine oil level:
Inspecting engine oil level:
= Inspection
⇒ Inspection and
and Maintenance
Maintenance
Tightening torques
Tightening torques
Notes:
Notes:
ProCarManuals.com
¢ Tightening
Tightening torques
torques apply
apply only
only to
to nuts
nuts and
and
ProCarManuals.com
♦
bolts
b which
olts w are
hich a r e llightly greased,
ightly g oiled,
reased, o iled,
phosphatized or blackened.
phosphatized or blackened.
¢ Additional
♦ lubricants such
Additional lubricants such as
as engine
engine or
or gear
gear
oils are permissible, but not Molykote.
oils are permissible, but not Molykote.
¢ Do
♦ Donotuse
not use parts which have
parts which have been
been degreased.
degreased.
¢ Tolerance
♦ Tolerance of
of tightening
tightening torques
torques ±+ 15
15 %
%
Component
Component Nm
Nm
Nuts/bolts
Nuts/bolts M6
M6 9
9
M7
M7 13
13
M8
M8 20
20
M10
M10 40
40
M12
M12 70
70
In variation of this:
In variation of this:
Driven plate to torque converter

Driven plate to torque converter 60
60
Engine/gearbox mounting, Pendulum

Engine/gearbox mounting, Pendulum = page
⇒ page
support
support 10-16
10-16
Bolts connecting engine to gearbox

Bolts connecting engine to gearbox
= 5-speed
⇒ 5-speed Manual
Manual Gearbox
Gearbox 02J;
02J; Repair
Repair Group
Group 34
34
= Automatic
⇒ Gearbox; Repair
Automatic Gearbox; Repair Group
Group 37
37
—— 10-14 ——
------------ 10-14 ------------ Edition 11.02
Edition 11.02
$00.5110.56.20
S00.5110.56.20
OCTAVIA
10
Aligning engine/gearbox mounting

Aligning engine/gearbox mounting
Warning!
Warning!
Before slackening the bolts, the engine/gearbox

Before slackening the bolts, the engine/gearbox
assembly must be secured with the supporting

assembly must be secured with the supporting
device MP
device MP 9-200.
9-200.
<@ Engine
K Engine mounting
mounting
a= 14.0 mm
a = 14.0 mm
b = at least 10.0 mm
b = at least 10.0 mm
Both bolt heads -1- must finish flush with the

Both bolt heads -1- must finish flush with the
edge -c-.
edge -c-.
Se
ProCarManuals.com
<——
ProCarManuals.com
[ n10-0191|
LT
<4 Gearbox
K Gearbox mounting
mounting
The edges -a- and -b- must be parallel to each

The edges -a- and -b- must be parallel to each
other.
other.
Edition 05.01
Edition 05.01 —— 10-15 --———
------------ 10-15 ----------
$00.5110.55.20
S00.5110.55.20
10
Removing and Installing Engine

OCTAVIA
OCTAV1A
Assembly bracket

Tightening torques
A
2 we a 1 ~<d

K Engine assembly bracket
1-
! 40Nm + 90° ('/, turn) - replace

-<=6>9 . '!
-
2-
! 25Nm
<
3-
2! 60 Nm + 45° (1/, '!

0<=->9 . turn) - replace

3
1 we aa 2 ~<@ Gearbox
K assembly bracket
!
ProCarManuals.com
ProCarManuals.com
c
/ 1-
! 40Nm + 90° (*/, turn) - replace

-<=6>9 . '!
-
3 2-
! 25Nm
<
3-
2! 60 Nm + 45° (1/, '!

0<=->9 . turn) - replace

3
<4 "

K Pendulum support
1-
! 40Nm + 90° ('/, turn) - replace

-<=6>9 . '!
-
2-
! 40Nm + 90° (‘/, turn) - replace

-<=6>9 . '!
-
3-
2! 20Nm+ 90° (‘/, turn) - replace

<=6>9 . '!
-
° 2—<
—— 10-16 ——
------------ 10-16 ------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
OCTAVIA Crank Assembly
Crank Assembly 13
13
Disassembling and assembling engine

Disassembling and assembling engine
Removing and installing ribbed V-belt

Removing and installing ribbed V-belt
3 - Belt pulley of hydraulic pump

3 - Belt pulley of hydraulic pump
4 - Hydraulic pump
4 - Hydraulic pump
# removing
♦ removing and
and installing
installing ⇒
= Running
Running
Gear; Repair
Gear; Repair Group
Group 4848
5-10 Nm + torque a further 1/,/ turn

5 - 10 Nm + torque a further turn (90°)
1
(90°)
4
¢ always
♦ always replace
replace
171615 \!
Weve
\.
6 - Belt pulley
6 - Belt pulley
_-|-7T] e ¢ can
♦ can be
be installed
installed only
only in
in one
one position
position --
holes are
holes are positioned
positioned opposite
opposite
7 - Tensioning element
7 - Tensioning element
@ up
♦ uptoto 07.97
07.97
8-Tensioning element with

8 - Tensioning element with vibration vibration
damper
damper
♦¢ from 08.97
from 08.97
9 - Bracket
9 - Bracket
¢ forinjection
♦ pump, alternator,
for injection pump, alternator, hydrau-
hydrau-
ProCarManuals.com
lic pump
lic pump and
and AC compressor
AC compressor
ProCarManuals.com
10-45 Nm
10 - 45 Nm
11 - Alternator
11 - Alternator
Notes:
Notes:
12 - Guide pulley
12 - Guide pulley
The illustration
¢ The
♦ illustration shows
shows the
the belt
belt drive
drive of
of mod-
mod- 13 - AC compressor
13 - AC compressor
els not
els not fitted
fitted with
with air
air conditioning.
conditioning. ¢ do
♦ donot open refrigerant
not open refrigerant circuit
circuit
Before removing
♦ Before removing the
the ribbed
ribbed V-belt,
V-belt, mark
mark the
the
direction of
direction of running.
running. If
If an
an already
already used
used belt
belt 14 - Cover
14 - Cover
is fitted on again to run in the opposite direc-

is fitted on again to run in the opposite direc-
tion, it may be destroyed. When installing the

tion, it may be destroyed. When installing the 15 - Banjo bolt, 30 Nm
15 - Banjo bolt, 30 Nm
belt, ensure
belt, ensure it
it is
is correctly
correctly located
located in
in the
the belt
belt
pulleys.
pulleys. 16 - Seal
16 - Seal
¢ replace
♦ replace
1 - Ribbed V-belt
1 - Ribbed V-belt
# removing
♦ removing and
and installing
installing ⇒
= page
page 13-3
13-3 17 - Pressure
17 - Pressure line line
2-25 Nm
2 - 25 Nm
Edition 11.02
Edition 11.02 ——._ 13-1 -———
------------ 13-1 -----------
$00.5110.56.20
S00.5110.56.20
13
13 Crank Assembly
Crank Assembly OCTAVIA
OCTAVIA
<Fig.1
K Fig. 1 Routing of ribbed V-belt on vehi-
Routing of ribbed V-belt on vehi-
cles without air conditioning

cles without air conditioning
<4Fig.2
K Fig. 2 Routing of ribbed V-belt on vehi-
Routing of ribbed V-belt on vehi-
cles with air conditioning

cles with air conditioning
ProCarManuals.com
ProCarManuals.com
<Fig.3
K Fig. 3 Attaching guide pulley
Attaching guide pulley of
of ribbed
ribbed V-
V-
1 belt
belt
Only on vehicles fitted with AC

Only on vehicles fitted with AC
1 - Cover
1 - Cover
2-25Nm
2 - 25 Nm
3 - Guide pulley
3 - Guide pulley
—— 15-8 ——
------------ 13-2 ------------ Edition 11.02
Edition 11.02
$00.5110.56.20
S00.5110.56.20
OCTAVIA
Crank Assembly 13
13
<Fig.4 Install AC
AC compressor

K

-
- To facilitate the positioning of the AC com-
To facilitate the positioning of the AC com-
pressor, drive the threaded bushings -B- for

pressor, drive the threaded bushings -B- for
fixing screws -A- slightly backwards in direc-

fixing screws -A- slightly backwards in direc-
tion of the arrow.

tion of the arrow.
-
- Tighten bolts to 45 Nm.
Tighten bolts to 45 Nm.
Remove ribbed V-belt

Note:
Note:
On vehicles fitted with AC remove guide pulley

On vehicles fitted with AC remove guide pulley
ProCarManuals.com
for ribbed V-belt with belt pulley ⇒

for ribbed V-belt with belt pulley > Fig.
Fig. 3
3 page
page
ProCarManuals.com
13-2.
13-2.
-
- Remove noise insulation on bottom right.
Remove noise insulation on bottom right.
-
- Remove air guide pipe between charge air
Remove air guide pipe between charge air
cooler and turbocharger ⇒

cooler and turbocharger => page
page 21-9,
21-9, item.
item.
9. 9.
-
- Position flat ring spanner SW
Position flat ring spanner SW 16 on hexa- 16 on hexa-
gon of tensioning pulley.
gon of tensioning pulley.
<@- -
K Swivel tensioning pulley in direction of arrow
Swivel tensioning pulley in direction of arrow

-
- Remove ribbed V-belt.
Remove ribbed V-belt.
Install ribbed V-belt

-
- Raise tensioning pulley for ribbed V-belt with
Raise tensioning pulley for ribbed V-belt with
flat ring spanner SW 16 and fit ribbed V-belt.

flat ring spanner SW 16 and fit ribbed V-belt.
Edition 11.02
Edition 11.02 ——. 13-3 ——_
------------ 13-3 ------------
$00.5110.56.20
S00.5110.56.20
13
, Crank Assembly
#
42: OCTAVIA
1
Removing and installing toothed belt

$ !
&
!&2
12 13 14 15 16 17 18 19 20
IM iw
TTI
ml NNN
ProCarManuals.com
ProCarManuals.com
| S13-0254 |
Note:
@ 7$226
♦ Locking pin 3359
Mark
the direction of running of the toothed belt
¢ Adjusting
♦ straightedge MP 1-312
*4:!2
before removing it. If an already used belt is fit-

!
ted on again to run in the opposite direction, it

@ "
♦ Wrench for toothed !
belt-tensioning
pulley
may be destroyed.

(e.g. Matra V159, Hazet 2587 or Stahlwille
9 :16?8@3
127-17)
!'

"
&
&#&
¢ #:6!
♦ Supporting device MP 9-200
¢ Torque
♦ wrench
,
¢ A
♦ Feeler gauges
¢ :!0
♦ Counterholder MP 1-216
@
♦ Puller T40001
- with hook T40001/2
$ and
-.
T40001/3
-.2
—— 13-4 ——
------------
------------ Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
Crank Assembly 13
13
1-120 Nm + torque a further % turn (90°)

1 - 120 Nm + torque a further ¼ turn (90°) 18 - Camshaft sprocket
18 - Camshaft sprocket
@ Use
♦ Use counterholder
counterholder MP
MP 1-310
1-310 or
or lever
lever ¢ Use
♦ Use special
special tool
tool T40001
T40001 for pulling off
for pulling off
T30004 for slackening and tightening
T30004 for slackening and tightening taper of camshaft
taper of camshaft
¢ Always
♦ Always replace
replace
¢ Thread
♦ Thread and
and contact
contact surface
surface must
must be
be 19 - Semi-automatic tensioning pulley
19 - Semi-automatic tensioning pulley
free of oil and grease

free of oil and grease ¢ Inspecting
♦ Inspecting semi-automatic
semi-automatic toothed
toothed
¢ T
♦ Torquing further by
orquing further by 90°
90° can
can be
be carried
carried belt tensioning
belt tensioning pulley
pulley ⇒> page
page 13-11
13-11
out in
out in several
several stages
stages ¢ Fitting
♦ Fitting location
location ⇒
= Fig.
Fig. 11

2 - 40 Nm + torque a further ¼ turn (90°) 20 - Guide pulley
20 - Guide pulley
¢ Always
♦ Always replace
replace
¢ T
90° can
can be
be carried
carried 21-30 Nm
21 - 30 Nm
out in
out in several
several stages
stages
22 - Rear toothed belt guard
22 - Rear toothed belt guard
3-15 Nm
3 - 15 Nm ¢ Insert
♦ Insert at
at lower
lower edge
edge behind
behind sealing
sealing
flange at front
flange at front
4-23 Nm
4 - 23 Nm
23 - Injection pump gear

5-22 Nm
5 - 22 Nm @ From
♦ From 08.97
08.97
6 - Bottom toothed belt guard

6 - Bottom toothed belt guard 24 - Injection pump gear
@ Up
♦ Uptoto 07.97
07.97
7-10 Nm
7 - 10 Nm
25 - Coolant pump
25 - Coolant pump
8 - Middle toothed belt guard

8 - Middle toothed belt guard ¢ Removing
♦ Removing and
and installing
installing
=> page
⇒ page 19-5
19-5
9-45 Nm
9 - 45 Nm
ProCarManuals.com
26 - Guide pulley
ProCarManuals.com
26 - Guide pulley
10 - Engine support
10 - Engine support @ Unbolt
♦ Unbolt in
in order
order to
to remove
remove coolant
coolant
pump
pump
11 - Top toothed belt guard
11 - Top toothed belt guard
27 - Crankshaft toothed belt sprocket

27 - Crankshaft toothed belt sprocket
12 - Toothed belt
12 - Toothed belt ¢ There
♦ There must
must not
not be
be any
any oil
oil on
on contact
contact
¢ Mark
♦ Mark direction
direction ofof running
running before
before re-
re- surface between
surface between toothed
toothed belt
belt sprocket
sprocket
moving
moving and crankshaft
and crankshaft
¢ Inspect
♦ Inspect for wear
for wear ¢ Fitting
♦ Fitting location:
location: flats on toothed
flats on toothed belt
belt
¢ Do
♦ Do not
not kink
kink sprocket
sprocket and
and crankshaft
crankshaft must
must be
be
¢ Removing
♦ Removing and
and installing
installing ⇒
= page
page 13-
13- aligned
aligned
6
6
28 - Bush
28 - Bush
13 - Guide pulley
13 - Guide pulley
@ From
♦ From 08.97
08.97 29 - Nut
29 - Nut
¢ Insert
♦ Insert into
into bush
bush -item
-item 28-
28-
14 - 20 Nm + torque a further ¼ turn (90°)
@ Replace
♦ Replace 30 - Injection pump
30 - Injection pump
¢ T
90° can
can be
be carried
carried ¢ On
♦ On nono account
account slacken
slacken central
central nut
nut
out in
out in several
several stages
stages -arrow-
-arrow-
¢ Removing
♦ Removing and
and installing
installing
15-20 Nm
15 - 20 Nm = 1.9-ltr./66
⇒ 1.9-ltr./66 kW
kW (TDI)
(TDI) Engine,
Engine, FuelFuel Injection
Injection
and Glow Plug System; Repair Group 23
16 - Bolt for guide pulley

16 - Bolt for guide pulley
¢ 17
♦ 17 Nm
Nm with mounting bracket
with mounting bracket -item
-item 31-45 Nm
31 - 45 Nm
31-; Part No. 038 903 143 E/F

31-; Part No. 038 903 143 E/F
@ 20
♦ 20 Nm
Nm with mounting bracket
with mounting bracket -item
-item 32 - Mounting bracket
32 - Mounting bracket
31-; Part
31-; Part No.
No. 038
038 903
903 143
143 A/B
A/B ¢ For
♦ For models
models without
without AC
AC
¢ For
♦ Forinjection pump, alternator
injection pump, alternator and
and hy-
hy-
17-45 Nm
17 - 45 Nm draulic pump
draulic pump
¢ Hold
♦ Hold camshaft
camshaft sprocket
sprocket with
with counter-
counter-
holder MP
holder MP 1-216
1-216 for slackening and
for slackening and
tightening
tightening
Edition 03.00 —— 13-5 -——

Edition 03.00 ------------ -----------

$00.5110.54.20
S00.5110.54.20
13
, Crank Assembly
#
42: OCTAVIA
1
<4 @!
K Fig. 1 Installation position of the semi-

/
automatic tensioning pulley

! :
The holding

claw !!
-arrow-
must
engage
in
the
recess on the rear toothed belt guard.

Removing toothed belt

$ !&2
Engine installed in the vehicle

!
&
-
! Remove right headlights ⇒
= )

# Electrical !
Sys-
tem; Repair Group 94, Removing and install-
B
56-?
#!
ing headlights.

-
! Remove engine cover ⇒

##=> !
page 10-2.
- Remove plug from the intake manifold pres-

ProCarManuals.com
!
#$!
ProCarManuals.com
sure sender (G71) and intake manifold tem-

95'$!
perature sender (G72).

95'
-
! Remove the air guide pipe between the

#
charge air cooler and the intake manifold.

$
-
! Unbolt coolant expansion reservoir and place
C/#
to the side.

-
! Unbolt power steering reservoir and place
C #
to the side.

-
! Unbolt washer fluid reservoir and place to
C #
the side.

-
! Unbolt fuel filter and place to the side.
C
-
! Remove the noise insulation.

#
-
! Remove the air guide pipe between the char-

#!
ge air cooler and the exhaust turbocharger

/
= !6
⇒ page 21-9.
For all vehicles

@

-
! Remove top toothed belt guard and cylinder

#
head cover.
#
-
! Remove vacuum pump for brake servo unit

##$#
=> !2
⇒ page 15-3.
-
! Remove the V-ribbed belt ⇒

#1!> 2!
page 13-1.
—— 13-6 ———
------------
------------ Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
Crank Assembly 13
13
Engine installed
Engine installed
- Rotate crankshaft to TDC of cylinder 1 -ar-
O_
- Rotate crankshaft to TDC of cylinder 1 -ar-
row-.
row-.
<@- -
K Check whether TDC marking on flywheel and
Check whether TDC marking on flywheel and
driven plate with reference mark are aligned

driven plate with reference mark are aligned
i |
-arrow-.
-arrow-.
| - Manual gearbox
I - Manual gearbox
My
Il - Automatic gearbox
II - Automatic gearbox
Note:
Note:
Rotating crankshaft to TDC of cylinder 1 with

Rotating crankshaft to TDC of cylinder 1 with
the engine removed ⇒

the engine removed => page 13-11.
page 13-11.

N <q- -
K Lock camshaft position with setting straight-
Lock camshaft position with setting straight-
edge MP 1-312.
edge MP 1-312.
Note:
Note:
ProCarManuals.com
The valves of cylinder 1 must be closed and the

The valves of cylinder 1 must be closed and the
ProCarManuals.com
valves of cylinder 4 at overlap -arrows-.

valves of cylinder 4 at overlap -arrows-.
-
- Centre setting straightedge as follows:
Centre setting straightedge as follows:
os Rotate locked camshaft until one end of the

@
Rotate locked camshaft until one end of the
straightedge strikes the cylinder head. Use

straightedge strikes the cylinder head. Use
a feeler gauge to measure the gap produced

a feeler gauge to measure the gap produced
. C/ at the other end of the straightedge. Insert a

at the other end of the straightedge. Insert a
fe =
oO feeler gauge
feeler gauge of of half
half this
this value
value between
between
MP 1-312 straightedge in
straightedge in cylinder
cylinder head.
head. Now,
Now, rotate
rotate
camshaft until
camshaft until the
the straightedge
straightedge is is resting
resting on
on
the feeler gauge. Insert the second feeler
the feeler gauge. Insert the second feeler
gauge with the same value between straight-

gauge with the same value between straight-
edge in cylinder head.

edge in cylinder head.
-
- Lock injection pump gear with locking
Lock injection pump gear with locking pin pin
3359.
3359.
Note:
Note:
Always moisten locking

Always moisten locking pin with oil.
pin with oil. It
It is
is recom-
recom-
mended to
mended to use
use a
a mirror
mirror for
for inserting
inserting the
the locking
locking
pin.
pin.
<@- -
K Slacken bolts -1- attaching injection pump
Slacken bolts -1- attaching injection pump
gear and replace with new bolts.

gear and replace with new bolts.
-
- Tighten bolts lightly so that it is still possible
Tighten bolts lightly so that it is still possible
to rotate the gear.

to rotate the gear.
Note:
Note:
On no account, slacken central nut -2- of the

On no account, slacken central nut -2- of the
injection pump gear otherwise this will alter the

injection pump gear otherwise this will alter the
basic setting
basic setting of
of the
the injection
injection pump
pump andand it
it can
can no
no
longer be
longer be set
set with
with workshop
workshop tools.
tools.

Edition 05.01
Edition 05.01 —— 13-7 ---———
------------ 13-7 ---------
$00.5110.55.20
S00.5110.55.20
13
13 Crank Assembly
OCTAVIA
VA ey // -

Slacken tensioning pulley.

l_ MP 9-200 - Remove vibration damper/belt pulley.

EG on <q- Insert supporting device MP 9-200 and take

! !

K

up weight of engine and gearbox in this po-

# $ #

"

%

\ sition.

@>
= <- Unbolt engine mounting bracket from engine

$

K $

(\n support and engine support from body -ar-

$

rows-.
"
y - Unbolt engine mounting bracket from engine.

$

$

=

a)
Note:
Note:
ProCarManuals.com
—_ To slacken the front bolt of the engine mounting

To slacken the front bolt of the engine mounting
ProCarManuals.com
— bracket, raise engine slightly with spindle of sup-

bracket, raise engine slightly with spindle of sup-
porting device MP
porting device MP 9-200.
9-200.
- Detach ribbed V-belt pulley from crankshaft.

# & $ # $

%

Remove toothed belt guard in middle and at

#

bottom.

- Mark direction of running of toothed belt.

$ $ #

- Take off toothed belt.

$ $ #

'

Installing toothed belt

Installing toothed belt
- Check whether TDC marking on flywheel and

# # # ( ) $ #

"

"
' '
reference mark are aligned.

$

- Slacken bolt attaching camshaft sprocket

# # $

1/2 turn. Counterhold camshaft sprocket with

* # # $ #

"
'
special tool MP 1-216 for this step.

* * + $ #

Warning!
Warning!
A—_AY When slackening and tightening camshaft sprock-

When slackening and tightening camshaft sprock-
et, never use adjusting straightedge as a counter-

et, never use adjusting straightedge as a counter-
Lakin holder. Counterhold

holder. Counterhold camshaft
camshaft sprocket
sprocket with
with spe-
spe-
T40001 _\e) cial tool
cial tool MP
MP 1-216.
1-216.
LEZ
Gd <4- = Insert puller T40001 and hook T40001/2 ,
K

-A-

( , ! ! ! *
#

( , ! ! ! *
B eo) \ and T40001/3 -B- into belt pulley. Use open-

( , ! ! ! * - . /

end wrench -C- as a counterholder and de-

# #

"

'
O tach belt pulley from the taper of the cam-

# $ # $ #

shaft.
# $

LZ S13-0253
AFUE A
—— 13-8 -——— Edition 03.00

03.00

------------ ----------- Edition

$00.5110.54.20
S00.5110.54.20
OCTAVIA
Crank Assembly 13
13
- Fix in position the bolt for attaching the cam-

Fix in position the bolt for attaching the cam-
shaft sprocket (camshaft sprocket can still

shaft sprocket (camshaft sprocket can still
be rotated).
be rotated).
- Align injection pump

Align injection pump gear
gear to
to centre
centre position
position
in the slots.
in the slots.
- Fit toothed belt onto crankshaft toothed belt

Fit toothed belt onto crankshaft toothed belt
sprocket, guide pulley, coolant pump, injec-

sprocket, guide pulley, coolant pump, injec-
tion pump gear and tensioning pulley (pay

tion pump gear and tensioning pulley (pay
attention to direction of running).

attention to direction of running).
K- Use nut turner (e.g. Matra V159) to turn

Use nut turner (e.g. Matra V159) to turn
tensioning pulley to the right until the notch

tensioning pulley to the right until the notch
and raised
and raised section
section -arrows-
-arrows- are
are opposite
opposite
each other.
each other.
- Tighten the clamping nut at the tensioning

Tighten the clamping nut at the tensioning
pulley to a final torque of 20 Nm.

pulley to a final torque of 20 Nm.
- Once again check whether TDC marking on

Once again check whether TDC marking on
the flywheel and reference mark are aligned.

the flywheel and reference mark are aligned.
- Tighten bolt for attaching camshaft sprocket

Tighten bolt for attaching camshaft sprocket
and torque finally to 45 Nm. Counterhold

and torque finally to 45 Nm. Counterhold
ProCarManuals.com
camshaft sprocket
camshaft sprocket with MP1-216.
with MP1-216.
ProCarManuals.com
K- Replace bolts for attaching injection pump

Replace bolts for attaching injection pump
gear -arrows- and tighten to a final torque of

gear -arrows- and tighten to a final torque of
20 Nm.
20 Nm.
- Remove adjusting straightedge.

Remove adjusting straightedge.
- Remove locking pin 3359.

Remove locking pin 3359.
- Rotate crankshaft a further two revolutions

Rotate crankshaft a further two revolutions
in direction of rotation of engine and position

in direction of rotation of engine and position
again at TDC of cylinder 1.

again at TDC of cylinder 1.
- Check whether
Check it is
whether it is possible
possible to
to block
block the
the in-
in-
jection pump gear
jection pump gear with
with locking
locking pin
pin 3359.
3359.
If it is not possible to block the injection pump

If it is not possible to block the injection pump
gear:
gear:
- Rotate crankshaft until it is possible to block

Rotate crankshaft until it is possible to block
the injection pump gear with locking pin 3359.

the injection pump gear with locking pin 3359.
- Block injection pump gear with locking pin

Block injection pump gear with locking pin
3359.
3359.
- Slacken bolts for attaching injection pump

Slacken bolts for attaching injection pump
gear.
gear.
- Rotate crankshaft until the help marking on

Rotate crankshaft until the help marking on
the flywheel is aligned with the edge of the

the flywheel is aligned with the edge of the
adjusting device.
adjusting device.
Edition 03.98
Edition 03.98 —— 13-9 ---——
------------ 13-9 ---------
$00.5110.52.20
S00.5110.52.20
13
13 Crank Assembly
Crank Assembly OCTAVIA OCTAVIA
- Tighten bolts attaching injection pump gear

to 20 Nm and then torque a further 1/4 turn

(90°).

- Remove locking pin 3359.

" # #
$
!

If itis possible to lock the injection pump gear:

% "

&
Tighten bolts attaching injection pump gear

1/4 turn (90°).

- Install centre part and top part of toothed belt

%

guard.

- Install engine mount ⇒

> page 13-4.
% #

'
- Install engine bracket, tightening torque

% "

(
=> page 10-16.

)

⇒ '
- Remove supporting device MP 9-200.

* +

!
!

'
- Install vacuum pump for brake servo unit

% "

!
!
= page 15-1, Removing and installing cylin-

$
!
,
⇒ '
(
'
der head.

ProCarManuals.com
- Install vibration damper/belt pulley.

%

! ,

ProCarManuals.com
- Install ribbed V-belt ⇒

> page 13-1.
% - #

' '
- Install air guide pipe between charge air

%

.
cooler and intake manifold.

"

- Plug in connector at intake manifold pres-

+ "

'
sure sender (G71) and at intake manifold

/ "
0

temperature sender (G72).

/
0

- Attach expansion reservoir

for coolant, power

2

! .
1
(
steering, 0
windshield washer system and fuel

.

,

filter.

- Install camshaft housing.

%

- Install top toothed belt guard.

%

- Install top engine trim panel ⇒

=> page 10-2,
%

'
Fig. A10-0115.
3
$
'

- Install air guide pipe between charge air

%

.
cooler and turbocharger ⇒=> page 21-9, item

'
9.

— 13-10 -——— Edition 05.01

05.01
5 7
------------ ----------- Edition

6
4 4
$00.5110.55.20
S00.5110.55.20
OCTAVIA
1 Crank Assembly
#
42: 13
,
-
! Install the noise insulation.
+
-
! Install right headlights ⇒
+= )B
Electrical System;
Repair Group 94, Removing and installing

5 6-?
#
headlights.

-
! Dynamically test and set commencement of
(
injection:
4%
= 6.00$"9
⇒ 1.91/66 kW (TDI) Engine, Fuel Injection and
(+')?A+4
Glow
5 Plug ?
System,

Repair 5
Group 2B
23; (!
Dy-
namically
test
and
set
commencement of
injection.
4
Inspecting semi-automatic toothed

!/

&
belt-tensioning pulley
2/ ! :
Test conditions
&
@
l Engine oil temperature not above 40 °C
)#->
Test procedure
&
! Position engine to top TDC

of cylinder 1.
(
ProCarManuals.com
ProCarManuals.com
~<q-!
K Use your thumbs to forcefully press on the
C
toothed belt. The

markings on the tensioning
$
pulley must move -arrows-.

#!!
-
! Relieve the toothed belt and turn the crank-

#$!
shaft two turns in the direction of rotation of

the engine, until the engine is again posi-

? !
tioned at TDC
of cylinder 1. When doing this,
( "?
it is important that the last 45° (1/, turn) are

->9 . '
3
rotated without any interruption.

-
! The tensioning pulley must return to its ini-
!
tial position. (Notch and lobe are again op-

9<!
posite one another).

'
Position crankshaft when engine is

>

) !
removed to TDC of cylinder 1

&#: &

"
&
&#&
¢ *4#
Adjusting device for TDC MP 1-313
OO),
♦ ( :!22
The engine is lying on the work surfaces (ve-

! : ! )
/
fr
2 fi hicles with manual gearbox):
)

!
271
=—wS
HY |S
LS For vehicles ä
@> '..
07.97
<@- !
K Screw in adjusting device for TDC
4# MP 1-313
( :!22
according to the illustration.

“MP 1-313
LR \\
Edition 04.04
& '('( ——_ 13-11 -———
------------
-----------
$00.5110.57.20
S00.5110.57.20
13
13 Crank Assembly
OCTAVIA
- Set adjusting device to 96 mm -arrow- (the

Set adjusting device to 96 mm -arrow- (the
left-hand notch of the vernier -arrow A- is the

reference point).
reference point).
- Rotate crankshaft until TDC marking -arrow

Rotate crankshaft until TDC marking -arrow
B- on the flywheel is aligned with the edge of

the adjusting device.

Models 08.97 ä
Models 08.97 >
<q --
K Screw in adjusting device for TDC MP 1-313,
Screw in adjusting device for TDC MP 1-313,
as shown in the illustration.

- Set adjusting device to 100.4 mm -arrow-

Set adjusting device to 100.4 mm -arrow-
(the left-hand notch of the vernier -arrow A-

(the left-hand notch of the vernier -arrow A-
is the
is the reference
reference point).
point).
[ s13-0162 | - Rotate crankshaft until TDC marking -arrow

Rotate crankshaft until TDC marking -arrow
VN \WEZ2I B- on the flywheel is aligned with the edge of


Engine attached to engine holder MP 1-202

Engine attached to engine holder MP 1-202
ProCarManuals.com
Models ä
Models > 07.97
07.97
ProCarManuals.com
<q --
K Place flexible steel rule (marking tool) on cir-
Place flexible steel rule (marking tool) on cir-
cumference of flywheel.
cumference of flywheel.
- Measure exactly 100 mm from the TDC

Measure exactly 100 mm from the TDC
marking -arrow A- and make a help marking

marking -arrow A- and make a help marking
-arrow B-
-arrow B- with
with the
the marking
marking tool.
tool.
9 10 17 12 13
ANAT ONUYOAYNY
eee onea recy ePOTO GOTTA ATTOA TATED
= <q --
K Screw in adjusting device for TDC MP 1-313,
Screw in adjusting device for TDC MP 1-313,

A -
- Set adjusting device to 91.4 mm -arrow- (the
Set adjusting device to 91.4 mm -arrow- (the

reference point).
reference point).
—— 13-11.1 ———
------------ 13-11.1 ------------ Edition 03.98
Edition 03.98
$00.5110.52.20
S00.5110.52.20
OCTAVIA
Crank Assembly 13
13
Rotate crankshaft until the

the TDC marking onon

- Rotate crankshaft

the flywheel is aligned with the

the edge of
of the
the

the

setting device -arrow B-.

Models 08.97 ä
>
! #
$

"
<@- - Place flexible marking steel straightedge

'
s

K
&

around circumference of
of flywheel.

Measure exactly 100 mm from the the TDC

) * *
-

&

marking -arrow A- and make an an auxiliary

+

&

Ms

SS
marking -arrow B- with the

the scribe point.
Y/|
'

,

PX
<@- - Screw in setting device MP 1-313, as

as shown
) . ) .

K

- ( %
in illustration.

Position setting device to 96 mm (left notch

0 1 2
-

of vernier -arrow A- is the reference point).

+ 3

,
/

ProCarManuals.com
ProCarManuals.com
Z Y 4 -
- Rotate crankshaft until the
Rotate crankshaft the TDC marking on on

0 the flywheel is aligned with the edge of set-

ting device -arrow B-.

’ L

4 5 5 8 5 ?
6 6 6 6 6
7 9 : ; 9 < = 9 > @
J
<- - Screw in setting device MP 1-313, as
as shown
) . ) .

K

- ( %
in illustration.

Position setting device to 30 mm (left notch

. * 2
-

of vernier -arrow A- is the reference point).

+ 3

,

Rotate crankshaft sufficiently until the

the TDC

- Rotate crankshaft

marking -arrow B- on on the

the driven plate is

,

aligned with the

the edge of
of setting device.

MP 1-313
Edition 05.01 — 13-11.2

---——
A C
Edition 05.01 ------------ 13-1 --------- B
$00.5110.55.20
S00.5110.55.20
13 Crank Assembly
OCTAVIA
With crankshaft ribbed

With crankshaft ribbed V-belt
V-belt pulley
pulley installed
installed
<q- - Align marking for TDC on ribbed belt pulley

K

of crankshaft with marking on bottom toothed

belt cover.

ProCarManuals.com
ProCarManuals.com
— 13-11.3
---—— Edition 05.01
05.01

------------ 13-1 ---------

Edition
$00.5110.55.20
S00.5110.55.20
OCTAVIA
Crank Assembly 13
13
ProCarManuals.com
ProCarManuals.com
Edition 05.01 — 13-11.4

---——_

Edition 05.01 ------------ 13-1 ---------

$00.5110.55.20
S00.5110.55.20
13
Crank Assembly

OCTAVIA
OCTAVIA
Removing
and installing crankshaft

6 - Crankshaft
( $ !
&

¢ axial
♦ axial play
play of
of new
new part:
part:
0.07....0.17 mm
0.07....0.17 mm
wear limit: 0.37
wear limit: 0.37 mm
mm
# main
♦ main bearing
bearing journal: @ 54.00
journal: ∅ 54.00 mm
mm
# conrod
♦ conrod bearing
bearing journal: @ 47.80
journal: ∅ 47.80 mm
mm
7 - Bearing shell
$
'

¢ for
♦ bearing cap
for bearing cap without lubricating
without lubricating
groove
groove
¢ do
♦ do not
not mix
mix up
up used
used bearing
bearing shells
shells
(mark)
(mark)
8 - Thrust washers
$ $
(

* +
¢ for
♦ bearing 3
for bearing 3
¢ pay
♦ pay attention
attention for
for different
different version
version for
for
cylinder block
cylinder block and
and bearing
bearing cap
cap
¢ pay
♦ pay attention
attention to
to locating
locating element
element of
of
washers
washers
9-65 Nm + torque a further '/,/ *0,12

turn (90°)
! $
,

. * *
# replace
♦ replace
10 - Bearing cap

'
=
ProCarManuals.com
# &
@ bearing
♦ bearing cap
cap 1:
1: belt
belt pulley
pulley side
side
g @ bearing
♦ bearing cap
cap 3:
3: with recesses for
with recesses for thrust
thrust
washers
washers
¢ installation
♦ installation position:
position: retaining
retaining lugs
lugs of
of
ie)
—Note
Note: bearing shells of cylinder block/bear-
bearing shells of cylinder block/bear-
ing cap must be positioned one above

ing cap must be positioned one above
Servicing clutch:
Servicing clutch:
the other
the other
—⇒ 5-speed
5-speed Manual
Manual Gearbox
Gearbox 02J;
02J; Repair
Repair Group
Group
© 30; Servicing
30; Servicing clutch
clutch 11 - Dowel pin
3+%
O ¢ inspecting
♦ inspecting projection
projection out
out of
of crankshaft
crankshaft
O 1-15Nm

=> Fig.
⇒ Fig. 1
1
O
2 - Seal

12 - Sensor
rotor

¢ pay
pay attention
attention to
to different
different versions
versions

♦ ¢ for
♦ wheel speed
for wheel speed sensor
sensor
=> Fig.
⇒ Fig. 33
¢ replacing
♦ replacing ⇒ =page 13-15
page 13-15
13-10 Nm + torque a further 1/,/ *0,12

0
turn (90°)

-

. *
!
*

$

/
# replace
♦ replace
3 - Front sealing flange
!

# removing
♦ removing and
and installing
installing ⇒
=> page
page 13-18
13-18 14 - Flywheel/driven %

"

plate
1 +
$

2 3

4
# removing
♦ removing andand installing
installing flywheel
flywheel
4 - Bearing shell
" $
=> page
page 13-16
13-16

⇒
¢ do
♦ do not
not mix
mix up
up used
used bearing
bearing shells
shells # removing
♦ removing andand installing
installing driven
driven plate
plate
(mark)
(mark)
=> page
⇒ page 13-16
13-16
¢ installation
♦ installation dimension
dimension for driven plate
for driven plate
5 - Chain
sprocket
$ (

=> page
page 13-17
13-17
'
% &
⇒
¢ for
♦ for oil
oil pump
pump chain
chain
——._ 13-12 ---———

------------ 13-12 --------- Edition 11.02

$00.5110.56.20
S00.5110.56.20
OCTAVIA

13

15-60 Nm + torque a further '/,* turn (90°)

18 -
Rear sealing flange with seal
! " #

¢ replace
♦ replace always replace
¢ always
♦ replace complete
complete
must be
¢ must
♦ be located
located on
on dowel
dowel sleeves
sleeves
16 - Intermediate !
plate take off
¢ take off oil
oil pan
pan for
for removing
removing ⇒ => page
page

♦
¢ is
♦ is attached
attached to to sealing
sealing flange
flange ⇒ = Fig.
Fig. 22 17-3
17-3
¢ must
♦ must be be located
located on on dowel
dowel sleeves
sleeves clean sealing
¢ clean
♦ sealing surface
surface before
before installing
installing
@ do
♦ do not
not damage
damage or or bend
bend when carry-
when carry- sealing flange
¢ sealing
♦ flange is
is supplied
supplied as
as replace-
replace-
ing out
ing out removal
removal and
and installation
installation work
work ment part with PTFE seal
ment part with PTFE seal
install seal
♦ install seal dry,
dry, crankshaft
crankshaft journal
journal must
must
17-15 Nm be free of grease
$
0 be free of grease

install new
♦ install new sealing
sealing flange with sleeve
flange with sleeve
(do not pull sleeve off seal before in-
(do not pull sleeve off seal before in-
stalling)
stalling)
<4 Fig. 1 Inspecting projection of dowel pin

K

out of crankshaft

Projection of dowel pin -3- out of crankshaft

Projection of dowel pin -3- out of crankshaft
¢
♦ a=2.5...3.0
a = 2.5...3.0 mm mm
ProCarManuals.com
ProCarManuals.com
<4 Fig.
2 Installing
!
intermediate plate

K

- Attach intermediate plate

Attach intermediate plate to
to the
the sealing
sealing flan-
flan-
ge and
ge and push
push itit onto
onto dowel
dowel sleeves
sleeves -arrows-.
-arrows-.
Nos
Edition 11.02
— 13-13 ——_
------------ 13-13 ------------
$00.5110.56.20
S00.5110.56.20
13 Crank Assembly
OCTAVIA
<4Fig.3 Seal versions

K Fig. 3

| Elastomer seal

Elastomer seal
Sealing lip -1-; with worm spring

Sealing lip -1-; with worm spring
ll PTFE seal
seal

Several sealing lips -2-; without worm spring

Several sealing lips -2-; without worm spring
Notes: Notes:
¢ Do
♦ Do not
not moisten
moisten PTFE
PTFE seal
seal with
with oil
oil before
before
installing. The shaft must also be free of oil
Sn
and grease.
and grease.
@ Never
♦ Never replace
replace aa PTFE
PTFE seal
seal (new
(new version)
version)
with an
with an elastomer
elastomer seal
seal (old
(old version).
version).
¢ APTFE
♦ seal can
A PTFE seal can be
be installed
installed in
in place of an
place of an
elastomer seal.
elastomer seal.
ProCarManuals.com
ProCarManuals.com
—— 13-14 —— Edition 11.02

11.02

------------ ------------ Edition

$00.5110.56.20
S00.5110.56.20
OCTAVIA
rank Assembly 13
13
Replace seal
seal for crankshaft/belt

pulley side
side

Special ttools, testers

testers and
and aids
aids required
#
! "
Torque
¢ T
♦ orque wrench
wrench
Gasket ring
¢ Gasket
♦ ring extractor
extractor MP
MP 1-226
1-226
Guide sleeve
¢ Guide
♦ sleeve MP
MP 1-231/1
1-231/1
Pressure sleeve
¢ Pressure
♦ sleeve MP
MP 1-314
1-314
Guide sleeve
♦ Guide sleeve T10053/1
T10053/1
Pressure sleeve
♦ Pressure sleeve T10053
T10053
Counterholder MP
¢ Counterholder
♦ MP 1-310
1-310 or
or Lever
Lever T
T 30004
30004
Pressure sleeve
¢ Pressure
♦ sleeve MP
MP 1-315
1-315
Removing
$
% & ' (
- Removing ribbed V-belt ⇒

Removing ribbed V-belt => page
page 13-3.
13-3.
ProCarManuals.com
ProCarManuals.com
- Removing toothed belt ⇒

Removing toothed belt > page
page 13-6.
13-6.
K- Removing toothed belt sprocket of crankshaft.

Removing toothed belt sprocket of crankshaft.
To this end lock toothed belt sprocket with

To this end lock toothed belt sprocket with
counterholder MP
counterholder MP 1-310
1-310 or
or lever
lever T 30004.
T 30004.
Note:
Note:
When screwing on the counterholder MP-310,

When screwing on the counterholder MP-310,
two washers are placed between the toothed

two washers are placed between the toothed
belt sprocket
belt sprocket and
and the
the counterholder.
counterholder.
- Screw
Screw in central screw of the toothed belt in central screw of the toothed belt
sprocket in the crankshaft.
MP 1-310 sprocket in the crankshaft.
- Unscrew inner part of the gasket ring extrac-

Unscrew inner part of the gasket ring extrac-
tor MP 1-226 two turns (approx. 3 mm) out

tor MP 1-226 two turns (approx. 3 mm) out
of the
of the outer
outer part
part and
and lock
lock with knurled screw.
with knurled screw.
\)\
Edition 11.02 —— 13-15 -———

------------ -----------

Edition 11.02

$00.5110.56.20
S00.5110.56.20
13
13 Crank Assembly
OCTAVIA
\
<q- - Oil threaded head of seal extractor MP

K

iO) 1-226, fit on and screw as far as possible

\ into the seal using considerable pressure.

O - Slacken knurled screw and turn inner part

" "

- !
against the crankshaft until the seal is pulled

"

2 out.

Installing
Installing
Notes:
Notes:
¢ Different
♦ Different seal
seal versions
versions ⇒
=> page 13-14, Fig.
page 13-14, Fig.
3.
3.
\
@ Never
♦ Never install
install an
an elastomer
elastomer seal
seal (old
(old version)
version)
if aa PTFE
if PTFE seal
seal (new
(new version)
version) was
was fitted.
fitted.
¢ APTFE
♦ seal can
A PTFE seal can be
be installed
installed if
if an
an elastomer
elastomer
seal was
seal was previously fitted.
previously fitted.
Installing elastomer seal

Installing elastomer seal
<@- - Inspect crankshaft for traces of wear from

"

K

$
seal.

ProCarManuals.com
- Lightly oil sealing lip of seal.

ProCarManuals.com

&
- %
- Fit guide sleeve with MP 1-314 onto the

) *

(
- '
crankshaft journal.
" +

- Push seal over guide sleeve.

(
(
<q- - Use thrust sleeve from MP 1-315 to press in

)
-
K

(
$

seal flush.

1 -- Central bolt of toothed belt sprocket

"

OX\\ SS Z
BS
eZ MP 1-315
—_ 13-15.1 -——_ Edition 03.00

03.00

------------ ----------- Edition

$00.5110.54.20
S00.5110.54.20
OCTAVIA
1 Crank Assembly
#
42: 13
,
Installing PTFE

!>@ seal
\ Note:

The sealing lips of the seal must not be oiled or

greased.

) Cf -
! Use aclean cloth to remove oil residues on
C#
\ the crankshaft journal.

$4
K! Fit guide sleeve T10053/1

A # onto
2. the $!
crank-
shaft journal.
4
ZA ! Push seal over guide sleeve onto the crank-

##$!
shaft journal.
4
Zo
(Ue
K! Use thrust sleeve T10053

C # to
2 press
in
seal
as far as the stop. Use old central bolt of
C
crankshaft toothed belt sprocket for this step.

$$
ProCarManuals.com
ProCarManuals.com
ZZ.
Continued for both versions

# &2
<- !
K Install crankshaft toothed belt sprocket and
+$$
lock with counterholder T30004

$ or MP 1-310.
2-:!2
Note:

@ " #$%

♦ When screwing on the counterholder MP 1-
310 place 2 washers between the toothed
&%' (
belt sprocket
and the counterholder.

@ )

♦ Replace central bolt for toothed belt-tension-
ing pulley.

@ "

♦ When tightening the central bolt, the crank-
shaft must not turn.

-
! Tighten the new central bolt for toothed belt

sprocket to 120 Nm + torque a further

$ < = , ‘/,.

-
turn (90°).
96>'
-
! Install toothed belt ⇒
+> 2!-
page 13-4.
-
! Install ribbed V-belt ⇒
+1!> 2!2
page 13-3.
Edition 04.04
& '('( —— 13-15.2 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
13
, Crank Assembly
#
42: OCTAVIA
1
Removing and installing flywheel

$ !
&
!:)

"
&
&#&
¢ Torque
♦ wrench
,
¢ :!2
<@- !
K Insert counterholder MP 1-223 into the hole
+:!2
in the cylinder block and lock the flywheel.

$$
Note:

Fitting position of counterholder:

*
A
- for tightening
B - for slackening
+
-
! Release bolts for flywheel.

Note:

Replace flywheel bolts.

)
-
! Tighten the bolt to 60 Nm + torque a further
0<=,
1/,. 96>'

-
turn (90°).
ProCarManuals.com
Removing and installing drive plate

ProCarManuals com
=
$ !
&
!&

O

"
&
&#&
MP 1-223 ¢ Torque
♦ wrench
,
¢ :!
¢ (
♦ Depth gauge
Removing
$ !
<q- !
K Attach counterholder MP 1-221 with bolt
* : !
M8 x -
:3D/ 45
to
the #
drive
plate. +
Insert
two :
M10
nuts between the counterholder and the drive
#
plate.

Note:

Fitting position of counterholder:

*
A
- for tightening
B - for slackening
+
-
! Release bolts for drive plate.

#
——— 13-16 ---———

------------
--------- Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
Crank Assembly 13
13
Installing
Installing
<@- -
K Position driven plate using the washer with
Position driven plate using the washer with
recesses -1-.
recesses -1-.
-
- Insert new bolts -3- and tighten to 30 Nm.
Insert new bolts -3- and tighten to 30 Nm.
<@- -
K Check installed dimension at three points of
Check installed dimension at three points of
driven plate and calculate average value.

driven plate and calculate average value.
ProCarManuals.com
@ Specification
Specification -a-:
-a-: 19.5...21.1
19.5...21.1 mm
mm
ProCarManuals.com
Note:
Note:
The measurement is made through the hole of

The measurement is made through the hole of
the driven plate as far as the cylinder block.

the driven plate as far as the cylinder block.
If the measurement obtained is less than the

If the measurement obtained is less than the
specification:
specification:
<@- -
K Once again remove driven plate and fit shim
Once again remove driven plate and fit shim
-2-. Re-tighten bolts -3- to 30 Nm.

-2-. Re-tighten bolts -3- to 30 Nm.
Note:
Note:
Replace bolts of driven plate.

Replace bolts of driven plate.
-
- Tighten bolts -3- to 60 Nm and torque a fur-
Tighten bolts -3- to 60 Nm and torque a fur-
ther 1/4 turn (90°).

ther 1/4 turn (90°).
Edition 06.99
Edition 06.99 —— 13-17 ———
------------ 13-17 ------------
$00.5110.53.20
S00.5110.53.20
13
, Crank Assembly
#
42: OCTAVIA
1
Removing and installing front seal-

$ !
&
!
/
ing flange
!
!

"
&
&#&
¢ :!2
♦ Counterholder MP 1-310 or T 2-
30004
¢ 5#:!2-
♦ Guide sleeve from MP 1-314
¢ (0--*
♦ Silicone sealant D176 404 A2
Removing
$ !
! Remove ribbed V-belt ⇒

#1!= 2!
page 13-1.
! Remove toothed belt ⇒

#= 2!-
page 13-4.
K! Remove crankshaft toothed belt sprocket.

# $ $
Lock toothed belt sprocket with counterhol-

7$$!
der MP 1-310 or T30004.

:!2 2-
Note:

When screwing on the counterholder MP 1-310

" #%&%'
place 2
( washers
between
the
toothed
belt
ProCarManuals.com
sprocket
and the counterholder.

anuals.com
© ! Drain engine oil.

(
! Remove oil pan ⇒

#=> !2
page 17-3
\
! Unscrew front sealing flange.

C
ProCar
! Remove sealing flange, if necessary release

#?
by applying slight blows with arubber-headed

!
hammer.

! Remove sealant residues on cylinder block

#$
with a flat scraper.

K! Use a rotating plastic brush to remove seal-

C#!
ant residues on the front sealing flange (wear

9
protective goggles).
#'
! Clean sealing surfaces, they must be free of

?
oil and grease.

— 13-18 ———
------------
------------ Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
Crank Assembly 13
13
Installing

Note:
Note:
The sealing flange must be installed within 5

The sealing flange must be installed within 5
minutes after applying the silicone sealant.

minutes after applying the silicone sealant.
<@- - Cut off tube nozzle at the front marking

K

(©∅ of tube approx. 3 mm).

¢ Thickness of sealant bead -arrows-:

"
! ! ! $ ! %
# #
2...3mm
&

Note:
Note:
The sealant bead must not be thicker than 3

cA mm otherwise excess sealant may get into the

mm otherwise excess sealant may get into the
oil pan and clog the oil intake pipe.

oil pan and clog the oil intake pipe.
ProCarManuals.com
ProCarManuals.com
<4- - Apply the silicone sealant to the clean seal-

K
( ! ! !
'
ing surface of tthe sealing flange, as shown

! ! ! ! $
in the illustration.

!
- Fiton sealing flange immediately and tighten

" "

-
! (
all the bolts slightly.

! ! (
Notes:
Notes:
¢ If/IfaPTFE
♦ seal is
a PTFE seal is fitted,
fitted, the
the crankshaft
crankshaft jour-
jour-
nals must be free of oil and grease and the

nals must be free of oil and grease and the
seal must not be oiled.

seal must not be oiled.
¢ Use
♦ Use the
the following
following devices
devices for
for fitting
fitting on
on the
the
sealing flange
sealing flange with
with seal
seal installed:
installed:
- Elastomer seal - MP 1-314
- Elastomer seal - MP 1-314
- PTFE seal - T10053/1

- PTFE seal - T10053/1
- Tighten bolts to 15 Nm.

+ -

,
-
!
- Install oil pan ⇒

> page 17-3.
+

/
-
!
Note:
Note:
After installing, allow

After installing, allow the
the sealant
sealant to
to dry
dry for
for about
about
30 minutes. Do not pour in engine oil until after
30 minutes. Do not pour in engine oil until after
this waiting period.

this waiting period.
- Install toothed belt ⇒

> page 13-4.
" + 0

-
!
Edition 05.01 — 13-19 -——_

1 2 1 4
Edition 05.01 ------------ -----------

3
$00.5110.55.20
S00.5110.55.20
13
13 Crank Assembly
OCTAVIA
ProCarManuals.com
ProCarManuals.com
— 13-20 -——— Edition 03.00

03.00

------------ ----------- Edition

$00.5110.54.20
S00.5110.54.20
OCTAVIA
Crank Assembly 13
13
Disassembling and assembling pistons and

and connecting rod
rod

Disassembling and assembling

2-Piston

¢ with
♦ combustion chamber
with combustion chamber
mark installation
¢ mark
♦ installation position
position and
and match-
match-
ing cylinder
ing cylinder
installation position
¢ installation
♦ position and
and assignment
assignment of
of
piston/cylinder ⇒
piston/cylinder = Fig.
Fig. 4
4
arrow on
♦ arrow on piston
piston crown
crown points
points toward
toward
belt pulley side
belt pulley side
use piston
♦ use piston ring
ring tensioning
tensioning strap
strap for
for
installing
installing
♦ if cracks
if cracks present on piston stem, re- present on piston stem, re-
place piston place piston
inspecting piston
♦ inspecting piston projection
projection at
at TDC
TDC
=> page
⇒ page 13-24
13-24
© of
♦ ∅ of piston
piston =
= 79.47
79.47 mm
mm
3 - Piston pin

heat piston
¢ heat
♦ piston to
to 60
60 °C
°C ifif stiff
stiff
use MP
¢ use
♦ MP 3-400
3-400 for removing and
for removing and install-
install-
ing
ing
4 -Circlip

5 - Conrod
Conrod

ProCarManuals.com
,
always replace
¢ always
♦ replace asas aa set
set
ProCarManuals.com
mark relevant
♦ mark relevant cylinder
cylinder -A-
-A-
installation position:
¢ installation
♦ position:
markings -B-
markings -B- point
point toward
toward belt
belt pulley
pulley
1 - Piston rings
rings side
side

offset joints
¢ offset
♦ 120°
joints 120°
use piston
piston ring
ring pliers
pliers for removing and
and 6 - Bearing shell

¢ use
♦ for removing

installing
installing ¢ pay
♦ pay attention
attention to to correct
correct installation
installation
@ marking
♦ marking TOP
,TOP* faces
faces piston
piston crown
crown position
position
¢ inspecting
♦ inspecting gap
gap clearance
clearance ⇒ = Fig.
Fig. 11 ¢ do
♦ do not
not mix
mix up
up used
used bearing
bearing shells
shells
@ inspecting
♦ inspecting end
end clearance
clearance ⇒ => Fig.
Fig. 2
2 # ensure tightly seated in
♦ ensure tightly seated in retaining
retaining lugs
lugs
¢ axial
♦ axial play
play
wear limit: 0.37
wear limit: 0.37 mm
mm
7 - Cylinder
Cylinder block

¢ inspecting
♦ inspecting cylinder
cylinder bore
bore ⇒
= Fig.
Fig. 3
3
¢ ∅ piston
♦ piston =
= 79.51
79.51 mmmm
Edition 11.02
Edition 11.02 ———_. 13-21 ——_-
------------ 13-21 ------------
$00.5110.56.20
S00.5110.56.20
13
Crank Assembly

OCTAVIA
OCTAVIA
8 -
Conrod cap

@ mark
♦ mark matching
matching cylinder
cylinder -A-
-A-
¢ installation
♦ installation position:
position:
marking -B-
marking -B- points
points toward
toward belt
belt pulley
pulley
side
side
9 - Oil spray nozzle

¢ for
♦ cooling system
for cooling system
10-25 Nm

¢ with
♦ pressure relief
with pressure relief valve
valve
¢ insert
♦ insert without sealant
without sealant
11-30 Nm + torque a further ‘/, turn (90°)

! "

# replace
♦ replace
¢ oil
♦ oil thread
thread and
and bolt
bolt contact
contact surface
surface
ProCarManuals.com
a)
ProCarManuals.com
O <4 .
Fig.1 Inspecting piston ring gap clear-

K
$ $
ance

©
Special tools,

testers and aids required
%

'

2
&
¢ Feeler
♦ Feeler gauge
gauge
ay
Inspection procedure
NG
'

YE

#
e
ej} -
- Insertring at right angles to cylinder wall, from
Insert ring at right angles to cylinder wall, from
a above as far as the lower cylinder opening,

above as far as the lower cylinder opening,
\\ about 15
about 15 mm
mm away
away from edge of
from edge of cylinder.
cylinder.
\ @)' Piston ring new wear limit

Dims.
Dims. In mm In mm
1stcompression ring |
1st compression ring 0.25...0.40
0.25...0.40 1.0
1.0
2nd compression ring}

2nd compression ring 0.25...0.40
0.25...0.40 1.0
1.0
Oil scraper ring

Oil scraper ring 0.25...0.50
0.25...0.50 1.0
1.0
—— 13-22 ———
------------ 13-22 ------------ Edition 11.02

$00.5110.56.20
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OCTAVIA
Crank Assembly 13
13
<4Fig.2
K Fig. 2 Inspecting piston
Inspecting piston ring
ring end
end clearan-
clearan-
ce
ce
Special tools,
Special testers and
tools, testers and aids
aids required
required
¢ Feeler
♦ Feeler gauge
gauge
7, -- Clean annular
Clean annular groove
groove before
o
before inspecting
inspecting
Piston ring
Piston ring New
New Wear limit
Wear limit
Dimensions in
Dimensions in mm
mm
1st compression
1st compression ring
ring 0.06 ..
0.06 .. 0.09
0.09 0.25
0.25
2nd compression
2nd compression ring
ring 0.05 ..
0.05 .. 0.08
0.08 0.25
0.25
oil scraper
oil scraper ring
ring 0.03 ..
0.03 .. 0.06
0.06 0.15
0.15
<4 Fig.
K Fig. 3
3 Inspecting cylinder
Inspecting cylinder bore
bore
Special tools,
Special testers and
tools, testers and aids
aids required
required
ProCarManuals.com
el
ProCarManuals.com
¢ Internal
♦ Internal precision
precision measuring
measuring instrument
instrument
50...100 mm
50...100 mm
-- Measure at
Measure at 33 points
points diagonally
diagonally opposite
opposite in
in
transverse direction
transverse direction -A-
-A- and
and in
in longitudinal
longitudinal
direction -B-.
direction -B-.
!
¢ Differences
♦ Differences compared
compared to
to nominal
nominal size
size
max. 0.10
max. 0.10 mm
mm
ips ae
een, =,
~ ~
Note:
Note:
The measurement
The measurement of of the
the cylinder
cylinder bore
bore must
must not
not
be carried
be carried outout when
when thethe cylinder
cylinder block
block isis
attached to
attached to the
the repair
repair stand
stand with
with the
the engine
engine
holder MP
holder MP 1-202
1-202 as
as incorrect
incorrect measurements
measurements
may result.
may result.
Edition 08.96
Edition 08.96 — 13-23 ———
------------ 13-23 ------------
$00.5110.50.20
S00.5110.50.20
13
13 Crank Assembly
OCTAVIA
<4 Fig.
K Fig. 44 Installation position of pistons and
Installation position of pistons and
matching piston/cylinder
matching piston/cylinder

¢ Electric
♦ Electric pen
pen
Procedure
Procedure
-
- Mark installation position and matching
Mark installation position and matching
) —~—_— piston on the inside of piston (not on piston

piston on the inside of piston (not on piston
I to oN crown) with
crown) with electric
electric pen
pen or
or felt
felt pen.
pen.
= heal ==
|
Pistons in cylinders 1 and 2:

a L\\\
Large valve pocket for inlet valve facing flywheel
Large valve pocket for inlet valve facing flywheel
side -arrows-
side -arrows-

Large valve pocket for inlet valve facing

Large valve pocket for inlet valve facing belt belt
pulley side -arrows-
pulley side -arrows-
Note:
Note:
ProCarManuals.com
ProCarManuals.com
If the pistons are new, the assignment to the

If the pistons are new, the assignment to the
cylinder is stamped with ink on the piston crown.

cylinder is stamped with ink on the piston crown.
¢ Pistons
♦ Pistons for
for cylinders
cylinders 11 and
and 2:
2:
marking ½
marking “%
¢ Pistons
♦ Pistons for
for cylinders
cylinders 3
3 and
and 4:
4:
marking ¾
marking ¥%
Inspecting piston projection at TDC

Inspecting piston projection at TDC

¢ Measuring
♦ Measuring instrument
instrument for
for piston
piston projection
projection
MP 1-107
MP 1-107
Procedure
Procedure
MP 1-107
<@ When
K When installing
installing new
new pistons
pistons or
or a
a short
short engine,
engine,
inspect piston projection at TDC. Install the
inspect piston projection at TDC. Install the
appropriate cylinder head gasket as shown in

appropriate cylinder head gasket as shown in
the table
the table below
below depending
depending on
on the
the piston
piston pro-
pro-
jection.
jection.
Piston projection beyond

Piston projection beyond Identification holes
Identification holes
top edge of cylinder block

top edge of cylinder block
0.91 mm... 1.00 mm

0.91 mm ... 1.00 mm 1
1
1.01 mm... 1.10 mm

1.01 mm ... 1.10 mm 2
1.11 mm... 1.20 mm

1.11 mm ... 1.20 mm 3
—— 13-24 ——
------------ 13-24 ------------ Edition 08.96
Edition 08.96
$00.5110.50.20
S00.5110.50.20
OCTAVIA

13

<q Marking

of cylinder head gasket

K

¢ Part
♦ Part No.
No. =
= arrow
arrow 11
¢ Control
♦ Control code
code =
= arrow
arrow 22 (ignore!)
(ignore!)
@ Openings
♦ Openings =
= arrow
arrow 3
3
Vv ° O >) Note:
Note:
O
C
If different measurements are obtained when

If different measurements are obtained when
measuring the piston projection, the highest

measuring the piston projection, the highest
measurement applies
measurement applies for
for assigning
assigning the
the gasket.
gasket.
23
ProCarManuals.com
ProCarManuals.com
Edition 05.01 —— 13-25 -——_

------------ -----------

$00.5110.55.20
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OCTAVIA
OCTAVIA Cylinder Head/Valve Gear

15

Removing and installing cylinder head

ProCarManuals.com
ProCarManuals.com
in
NG a
[ S15—0242 |
Removing and installing toothed belt
Removing and installing toothed belt ¢ IfIf the
♦ the cylinder
cylinder head
head is
is replaced,
replaced, the
the entire
entire
= page
⇒ page 13-4
13-4 coolant system must be replaced.
coolant system must be replaced.
¢ It
♦ Itisis not
not allowed
allowed to
to rework
rework the
the cylinder
cylinder heads
heads
Testing compression pressure ⇒
Testing compression pressure => page
page 15-8
15-8
of the diesel engines.
of the diesel engines.
Notes:
Notes:
1 - Cylinder head gasket

@ When
♦ When installing
installing an
an exchange
exchange cylinder
cylinder head
head ¢ replace
♦ replace
with the camshaft installed, it is necessary
with the camshaft installed, it is necessary ¢ pay
♦ pay attention
attention to
to marking
marking ⇒
= Fig.
Fig. 2
2
to oil the contact
to oil the contact surfaces
surfaces between
between thethe
bucket tappets
bucket tappets and
and the
the cam
cam track.
track. 2-20 Nm

¢ Do
♦ Donot remove the
not remove the plastic washers supplied
plastic washers supplied
as a protection for the open valves until just
as a protection for the open valves until just
before fitting on the cylinder head.

before fitting on the cylinder head.
Edition 11.02
—— 15-1 ——
------------ 15-1 ------------
$00.5110.56.20
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1515 Cylinder Head/Valve Gear
Cylinder Head/Valve Gear OCTAVIA
OCTAVIA
ProCarManuals.com
ProCarManuals.com
| S15—0242 |
3 - Cylinder head
3 - Cylinder head 6 - Oil deflector
6 - Oil deflector
¢
♦ inspecting for distortion ⇒
inspecting for distortion = Fig.
Fig. 11 @ from
♦ 07.97
from 07.97
#
♦ removing cylinder
removing cylinder hear
hear ⇒> page
page 15-4
15-4
¢
♦ installing cylinder
installing cylinder head
head ⇒> page
page 15-6
15-6 7 - Cylinder head cover
7 - Cylinder head cover
¢
♦ after replacing, fill entire system with
after replacing, fill entire system with ¢ with
♦ vulcanized gasket
with vulcanized gasket
coolant
coolant ¢ ifif gasket
♦ gasket has
has been
been damaged
damaged replace
replace
cylinder head
cylinder head cover
cover
4 - Lifting eye
4 - Lifting eye
8 - Collar
8 - Collar
5 - Cylinder head bolt

5 - Cylinder head bolt
¢ replace
♦ replace 9-Cap
9 - Cap
¢ pay
♦ pay attention
attention to
to order
order for loosening
for loosening ♦¢ replace
replace seal
seal ifif damaged
damaged
=> page
⇒ page 15-4
15-4
@ pay
♦ pay attention
attention to
to order
order for tightening
for tightening 10 - Ventilation tube
10 - Ventilation tube
=> page
⇒ page 15-6
15-6 ¢ to
♦ to air
air guide
guide pipe
pipe
en
------------ 15-2 ------------ Edition 11.02
Edition 11.02
$00.5110.56.20
S00.5110.56.20
OCTAVIA
OCTAVIA Cylinder Head/Valve Gear

15

11 - Retaining clip 17 - &

Sealing cone

*

12-Pressure control

valve 18 - ,Injection lines

+

¢ for
♦ for crankcase
crankcase ventilation
ventilation ♦¢ tighten
tighten with
with 25
25 Nm
Nm
@ use
♦ use wrench (e.g. 3035)
wrench (e.g. 3035) for
for removing
removing
13 -
Gasket ¢ replace
replace complete
complete wiring
wiring harness
harness ifif

♦

¢ replace
♦ replace ifif damaged
damaged damaged
damaged
¢ do
♦ donot change bending
not change bending shape
shape
14-Collar nut, 10 Nm

"

19 - Vacuum
. pump

15 - &
Seal ¢ for
♦ brake booster
for brake booster
¢ replace
damaged
20-20
Nm
$%
16 - Oil deflector

'

¢ from
from 08.97
08.97 21 -
Gasket

♦

¢ replace
♦ replace
<4 /
Fig. 1 Inspecting cylinder 0 )
head for distor-

K

tion

Special tools, testers

and aids required

¢ Feeler
♦ Feeler gauge
gauge
ProCarManuals.com
ProCarManuals.com
@ Knife-edge
♦ Knife-edge straightedge
straightedge
Maximum
Maximum permissible distortion: 0.1 mm permissible distortion: 0.1 mm
Note:
Note:
Reworking of cylinder heads on diesel engines

Reworking of cylinder heads on diesel engines
is not allowed.
is not allowed.
<4Fig.2 Identification )
of cylinder 0
head gas-

/ ,

K

ket
!
@ Spare
♦ Spare Parts
Parts no.
no. =
= arrow
arrow 1
1
¢ Control
♦ Control code
code =
= arrow
arrow 2
2 (disregard!)
(disregard!)
¢ Bores
♦ Bores =
= arrow
arrow 3
3
C
Oo O- Note:
Note:
ra
Differing thickness of cylinder head gaskets are
Differing thickness of cylinder head gaskets are
inserted according to the piston projection

inserted according to the piston projection
=> page
⇒ page 13-24.
13-24. When
When replacing
replacing a
a gasket
gasket use
use aa
23 new gasket with the same designation.
new gasket with the same designation.
Edition 11.02 —— 15-3 -——

#
------------ -----------

!
"
$00.5110.56.20
S00.5110.56.20
15
- Cylinder Head, Valve Gear
#: &?
&"8
+
OCTAVIA
1
Remove cylinder head

$: &
&
Note:
Note:
All cable straps that have been loosened or cut

open when removed must be fitted again in the

same location when installed.


"
&
&#&
@ "$9 1 * 5*'

♦ Workshop crane (e.g. V.A.G 1202 A)
@ 9 1 * 520'

♦ Catch pan (e.g. V.A.G 1306)
¢
♦ Pliers for spring strap clips
¢ 7#:6!
♦ Lifting device MP 9-201
@ "49 22'
♦ Wrench for injection lines (e.g. 3035)
Work procedure
&
Note:
Note:
If the battery is disconnected and reconnected,

!
carry out certain additional operations ⇒

=> ,
Elec-
ProCarManuals.com
trical System; Repair Group 27.

-
.) / (0
! Disconnect the earth strap from the battery

(
with the ignition off.

K! Remove engine cover ⇒

##=> !
page 10-2.
K! Remove noise insulation in the middle as well

#
as on left -arrows-.
!!
! Remove the air guide pipe between the

#
charge air cooler and the intake manifold.

$
! Unscrew the oil return-flow line from the tur-

C!!
bocharger at the cylinder block.

$
! Unscrew the oil feed line from the turbo-

C !
charger.

! Unscrew bracket for oil feed line to turbo-

C $ !
charger from intake manifold.

$
! Remove exhaust pipe from turbocharger.

#/

#1!= 2!
page 13-1.
! Drain coolant ⇒
(> 6!2
page 19-3.
Pam
——_ 15-4 —_
------------
------------ Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
#: &?
&"8
+
15
-
Tals g
4
WS 2 <@- !
K Remove air guide hose -1-.

#!!
= f°} -
! Detach vent hose -3- and unplug connector
(#!2!
| 7 for air mass meter -2-.

!!
o's r -
! Release screws -4- and -5-. Remove air fil-

!-!!!
#!
3) ter housing.

! Unscrew and remove air guide hose for air

C#
filter/turbocharger at induction pipe.

.
! Remove injection lines with wrench 3035.

#422
$10-0048 ! Remove return flow lines from injection noz-

#4@!
© | /I@Taa zles to the injection pump.
@4
! Unplug glow plug edge connector.

C
! Detach line at needle lift sender and pull the

(
plug from the holder.

! Detach coolant hose at cylinder head

( and
unscrew coolant flange.

ProCarManuals.com
! Unscrew oil feed line for turbocharger at the

C
ProCarManuals.com
brackets and unscrew from turbocharger.

$
! Remove coolant pipe at the brackets and

# $
detach to the left.

K! Remove fuel hoses from the injection pump,

#4?
close with plugs and lay aside.

! Remove plug -2- at the intake manifold tem-

#!!$!
perature sender (G72) with intake manifold

95'$
pressure sender (G71) and remove air guide

95'#
pipe -1-.
\ es]
!!
! Take off top toothed belt guard.

$
! Position engine on TDC

of cylinder 1, remove
( ?#
toothed belt from camshaft sprocket and re-

$!
move camshaft sprocket ⇒

#$ = 2!-
page 13-4.
! Unscrew 2 screws for the rear toothed belt

C
guard (on both sides of the cylinder head).

9'
|©
1 7 9 }
! Unscrew nut for tensioning pulley.
C
¢
a K! Release the cylinder head bolts in the order

@ 1...10.

! Unscrew bolts in the given sequence

C # , and
I
take out of the holes.
$
v7
10 8 2
Edition 04.04
& '('( —— 15-5 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
15
#: &?
&"8
+
OCTAVIA
1
—_
<q -!
K Hang the lifting device MP 9-201 at the cyl-
8#:6!!
inder head.

Note:
Note:
Attach the induction pipe with a wire to the car-

rier lug of the lifting device in order to achieve a

stable centre of gravity for the cylinder head.

Ti -
! Slightly raise the cylinder head with the work-
$!
(Nee shop crane.

Ss we
aN
AS
\ S a
U f
(ms bs x a $10-0042 -
! Swivel the cylinder head to the left out of the
#
rear toothed belt guard and simultaneously

I RD) VayI iv cal remove the tensioning pulley.

#
Installing cylinder head

!: &
&
Notes:
Notes:
¢ Always
♦ replace cylinder head bolts.

¢ 1
♦ Carefully

remove
residual
sealant

from
the
cylinder head and cylinder block
using a
chemical cleaner. Make

sure
this
does
not
cause any extended scoring or scratching.
ProCarManuals.com

ProCarManuals.com
¢ 1

♦ Carefully remove all abrasive residue.
@¢ )

♦ Remove the new cylinder head seal from its
wrapping immediately before fitting.

¢
♦ Treat the new gasket with the utmost care.

Damage to the silicone layer and in the area

2

of the bead results in leakages.

¢

♦ There must be no oil or coolant in the blind
holes of the cylinder head bolts in the cylin-

der block.


"
&
&#&
@ "$9 1 * 5*'

♦ Workshop crane (e.g. V.A.G 1202 A)
¢ Torque
♦ wrench
,
¢
@ 5:!3
♦ Guide bolts MP 1-208
¢ Adjusting
*4:!2
¢ 7#:6!
♦ Lifting device MP 9-201
@ "49 22'
♦ Wrench for injection lines (e.g. 3035)
¢
♦ Wire
"
@ "9 2-'
♦ Wrench for cylinder head bolts (e.g. 3452)
—— 15-6 ---———
------------
--------- Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
#: &?
&"8
+
15
-
Work procedure
&
! Before fitting the cylinder head position the

;
crankshaft on TDC
$ marking
( $ of
cylinder 1
=> D2!
⇒ page 13-7. The adjusting straightedge MP
4:
1-312 must allow itself to be used in the cam-

!2!
shaft.

! Fit on the cylinder head gasket.

A$
! To?:!
centre it, screw in the guide bolts MP 1-
208 into the outer holes on the suction side.
3
| $15-0082 |
_- <q
K! -
Hang the lifting device MP 9-201 at the cyl-
8#:6!!
inder head.

ProCarManuals.com
MP 9-201—>
ProCarManuals.com
Note:
Note:
Attach the induction pipe with a wire to the car-

rier lug of the lifting device in order to achieve a

stable centre of gravity for the cylinder head.

! Swivel cylinder head into rear toothed belt

#
guard.

) -
! While swivelling the cylinder head into the
"#
Tr rear toothed belt guard, simultaneously

?
‘) ~y|_S10-0042 push the tensioning pulley.

SNS Z fol
-
! When inserting the cylinder head, pay at-
"?!
tention to the position of the rear lugs on

the cylinder head gasket. When insert-

$ " !
ing they must not be buckled up by the

$
heat shield of the exhaust manifold.

/
! Insert 8 new cylinder head bolts and tighten

+3
manually.

! Remove the guide bolts by screwing out with

#
2 6 8 a bolt tightener from MP 1-208 and screw in

:!3
Ne.
the cylinder head bolts by hand.

K! Tighten cylinder head bolts in the order shown:

%
! 1st pre-tighten with the torque wrench to:

!,%
Stage | = 40 Nm
+E-<
AY
Stage II = 60 Nm
++E0<
7 3) 3 9
Edition 04.04
& '('( —— 15-7 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
15
#: &?
&"8
+
OCTAVIA
1
-
! 2nd torque further with a rigid wrench:
,%
Stage III = 90° (1/, turn)

+++E6>9 . '
-
Stage IV = 90° (1/,. '

+1E6>9

turn)
-
Note:
Note:
Tightening up the cylinder head bolts after do-

ing repair work

is not necessary.
-
+> 2!-
page 13-4.
Testing compression
! pressure
Test conditions
&
@
l Engine oil temperature at least 30 °C
)2>

"
&
&#&
¢ Torque
♦ wrench
,
¢ 9 1 * 523
♦ Compression tester (e.g. V.A.G 1381 or
V.A.G 1763)
1 * 502'
¢ Adapter
♦ (e.g. V.A.G 1381/12)
*9 1 * 523.'
ProCarManuals.com
ProCarManuals.com
¢ A/!
♦ Flexible-head wrench for glow plugs
Test procedure
&
-
! Remove engine cover ⇒

##=> !
page 10-2.
-
! Disconnect the 10-pin connector from the
( !
=) V.A.G 1763 injection pump.

4
a -
! Remove all the glow plugs with the flexible-

#/!
head wrench.

Zylinder |
@&) <@- !
K Screw in adapter (e.g. V.A.G 1381/12) in-
9 1 * 5 23.' !
stead of the glow plugs into the respective

#
V.A.G 1783 aN < cylinder.

oN
A72 AG 1381/1271 ~ [est compression pressure with compres-
! !
: f
il 1wN i]
sion tester (e.g. V.A.G 1381 or V.A.G 1763).
9 1 * 5231 * 502'
} 15-0319 4
———. 15-8 —_—_

------------
------------ Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
#: &?
&"8
+
15
-
Note:

Use of tester ⇒
=>
operating instructions
-
! Operate starter until the tester no longer in-
F!
dicates a pressure rise.

Compression readings:
#
& !1
New engine
5) ! Wear limit

Pressure
>
difference
&
between indivi-
2) &/
dual cylinders
&
: &
2.5...3.1 MPa
2 : 1.9 MPa
6: max. 0.5 MPa
/ :
(25...31 bar)
9 2' (19 bar)
96' (max. 5 bar)
9/ '
-
! Screwin glow plugs with flexible-head wrench.
/!
Tightening torque: 15 Nm
,%<
! Interrogating fault memory:

+%
=> 6.00$"9
⇒ 1.91/66 kW (TDI) Engine - Fuel Injection and
(+')!A+4
Glow Plug System; Repair Group 01.

5B
5
Note:

ProCarManuals.com
Faults are stored when disconnecting the 10-pin

ProCarManuals.com
%'
plug connection at the injection pump. After

3
the

measurement interrogate the fault memory and

erase if necessary.

Edition 04.04
& '('( —— 15-9 ---——_
------------
---------
$00.5110.57.20
S00.5110.57.20
15
Cylinder Head/Valve Gear

OCTAVIA
OCTAVIA
Servicing
valve gear

4 - Bucket tappet

¢ do
♦ donot mix up
not mix up
¢ with
♦ hydraulic valve
with hydraulic valve clearance
clearance com-
com-
pensation
pensation
@ inspecting
♦ inspecting ⇒
=page 15-18
page 15-18
@ place
♦ place down
down with
with contact
contact surface
surface fac-
fac-
ing down
ing down
¢ before
♦ before installing,
installing, inspect
inspect axial
axial play
play of
of
camshaft ⇒
camshaft => Fig.
Fig. 11
¢ oil
♦ oil contact
contact surface
surface
5 -
Valve collets
! !

6 -
Valve spring

retainer
"

7 -
Valve spring

(

@ removing
♦ removing and
and installing:
installing:
cylinder head removed: use
cylinder head removed: use
MP 1-218, MP 1-211, MP 1-213

MP 1-218, MP 1-211, MP 1-213
cylinder head installed:

cylinder head installed:
=> page
⇒ page 15-14
15-14
8 -
Valve stem seal
!
)

¢ replacing
♦ replacing ⇒
= page
page 15-14
15-14
ProCarManuals.com
9 -
Valve guide
#
*

¢ inspecting
♦ inspecting ⇒= page
page 15-14
15-14
ov ¢ replacing
♦ replacing ⇒ = page
page 15-19
15-19
Note:
Note:
a 10 - Seal
$ !

“Cylinder heads with

with cracks
cracks between
between the
the valve
valve ¢ pay
pay attention
attention to
to different
different versions
versions

Cylinder heads
♦
eats may be re-used without any reduction in
seats may be re-used without any reduction in — Fig.
⇒ Fig. 44
cife
life provided these are
provided these are only
only slight incipient cracks
slight incipient cracks ¢ for
♦ removing and installing, take off
for removing and installing, take off
Owhich are not more than 0.5 mm wide.

which are not more than 0.5 mm wide.
bearing cap and toothed belt sprocket
bearing cap and toothed belt sprocket
— ¢ before
♦ before fitting on, fix
fitting on, fix in
in place
place the
the groove
groove
QO. 1-Bearing cap at the camshaft cone with adhesive

at the camshaft cone with adhesive

¢ installation
♦ installation position
position ⇒=> Fig.
Fig. 2
2 tape (e.g. with Sellotape)
tape (e.g. with Sellotape)
¢ installation sequence= page 15-16

♦ installation sequence ⇒ page 15-16
¢ removing
♦ removing and
and installing
installing toothed
toothed belt
belt
¢ lightly
♦ lightly coat
coat contact
contact surface
surface of
of bearing
bearing sprocket > page 13-4
sprocket ⇒ page 13-4
cap 1 and 5 with sealant AMV 174 004
cap 1 and 5 with sealant AMV 174 004
01
01
11 - Cylinder

¢ pay
♦ pay attention
attention to
to Note
Note ⇒> page
page 15-10
15-10

2-20 Nm ¢ reworking
reworking valve
valve seats
seats ⇒= page
page 15-12
15-12

♦

3 - Camshaft 12 -Valve

¢ inspecting
♦ inspecting axial
axial play
play ⇒= Fig.
Fig. 11 ¢ valve
♦ valve dimensions
dimensions ⇒
=> Fig.
Fig. 33
removing and
¢ removing
♦ and installing
installing
=> page
⇒ page 15-16
15-16
runout: max.
¢ runout:
♦ max. 0.01
0.01 mmmm
camshaft marking
¢ camshaft
♦ marking ⇒ => Fig.
Fig. 55
—— 15-10 -——— Edition 11.02

(
------------ -----------

&
'
% %
$00.5110.56.20
S00.5110.56.20
OCTAVIA
OCTAVIA Cylinder Head, Valve Gear
Cylinder Head, Valve Gear 15
15
<4Fig.1
K Fig. 1 Inspecting axial play of camshaft
Inspecting axial play of camshaft

¢ Universal
♦ Universal dial
dial gauge
gauge holder
holder MP
MP 3-447
3-447
¢ Dial
♦ Dial gauge
gauge
(Cot
Wear limit: max.
Wear limit: max. 0.15 mm 0.15 mm
Carry out measurements with bucket tappets

Carry out measurements with bucket tappets
removed and first and last bearing caps installed.

removed and first and last bearing caps installed.
<4Fig.2
K Fig. 2 Installation position of camshaft
Installation position of camshaft
bearing caps
bearing caps
ProCarManuals.com
Note:
Note:
ProCarManuals.com
Pay attention to off-centre position. Before in-

Pay attention to off-centre position. Before in-
stalling the camshaft, fit on bearing caps and

stalling the camshaft, fit on bearing caps and
determine installation
determine installation position.
position.
<Fig.3
K Fig. 3 Valve dimensions
Valve dimensions
Note:
Note:
Valves must not be reworked. Only grinding-in

Valves must not be reworked. Only grinding-in
is permissible.
is permissible.
h Dimension
Dimension Inlet valve
Inlet valve Exhaust
Exhaust
valve
valve
Oaa mm 35.95 31.45

'
mm 35.95 31.45
Obb mm 6.963 6.943

'
mm 6.963 6.943
C
c mm
mm 96.85
96.85 96.85
96.85
(os Ze° 45
45 45
45
"
Edition 03.00
Edition 03.00 ——. 15-11 ———
------------ 15-11 ------------
$00.5110.54.20
S00.5110.54.20
Cylinder Head/Valve Gear

OCTAVIA
OCTAVIA
<iFig.4 Seal versions

K

Elastomer seal

Sealing lip
Sealing lip -1-;
-1-; with worm spring
with worm spring
PTFE seal

Several sealing
Several sealing lips
lips -2-;
-2-; without
without worm
worm spring
spring
Notes: Notes:
¢
♦ Do
Do not moisten PTFE seal with oil before not moisten PTFE seal with oil before
Sn
and grease.
and grease.
Never replace
♦ Never replace a
a PTFE
PTFE seal
seal (new
(new version)
version)
with an elastomer seal (old version).
with an elastomer seal (old version).
¢ APTFE
♦ seal can
A PTFE seal can be
be installed
installed in
in place of an
place of an
elastomer seal.
elastomer seal.
<Fig.5 Camshaft marking

K

¢
♦ Base circle of cam:
Base circle of cam: a = a = @ 38
38 mm
mm '
¢ Marking
♦ Marking by
by means
means of
of stamped
stamped numbers
numbers and
and
letters between
letters between inlet cam and exhaust cam inlet cam and exhaust cam
ProCarManuals.com
ProCarManuals.com
Cylinder 1 -arrow A-
Cylinder 1 -arrow A- 38A
38A
Cylinder 2 -arrow B-
Cylinder 2 -arrow B- DE
DE
Grinding
in valve seats

"
!


and aids required
& &

# $

' (

¢ Grinding
♦ Grinding paste
paste
Notes: Notes:
@ When
♦ When repairing
repairing engines
engines with
with leaking
leaking valves,
valves,
it is not adequate to only machine or replace
it is not adequate to only machine or replace
the valve seats and valves. It is also neces-

the valve seats and valves. It is also neces-
sary to inspect the valve guides for wear,

sary to inspect the valve guides for wear,
particularly on engines
particularly on engines with
with high
high mileage
mileage
= page
page 15-14.
15-14.
ó
Rework valve
♦ Rework valve seats
seats only
only sufficiently
sufficiently to
to obtain
obtain
a proper contact pattern. Before commenc-
a proper contact pattern. Before commenc-
ing reworking, calculate the maximum permis-

ing reworking, calculate the maximum permis-
sible reworking
sible reworking dimension
dimension => page 15-13. If
page 15-13. If
ó
the reworking
the reworking dimension
dimension isis exceeded,
exceeded, proper
proper
operation of
operation of the
the hydraulic
hydraulic clearance
clearance compen-
compen-
sation is
sation is no
no longer
longer assured.
assured. InIn this
this case,
case, a
a
new cylinder head should be installed.
new cylinder head should be installed.
——_ 15-12 ---———

------------ 15-12 --------- Edition 11.02

$00.5110.56.20
S00.5110.56.20
OCTAVIA
15
Calculating maximum permissible reworking

dimension
dimension
-
- Insert valve and press firmly against the valve
Insert valve and press firmly against the valve
seat.
seat.
Note:
Note:
If the valve is replaced as part of repair work,

If the valve is replaced as part of repair work,
use a new valve for the measurement.

~<@--
K Measure the distance -a- between end of
Measure the distance -a- between end of
valve stem and top edge of cylinder head.

valve stem and top edge of cylinder head.
-
- Calculate maximum permissible reworking
Calculate maximum permissible reworking
dimension from the distance -a- measured

dimension from the distance -a- measured
LC C@
and the
and the minimum
minimum dimension.
dimension.
§)\
Minimum dimensions:
Minimum dimensions:
Inlet valve
Inlet valve 35.8 mm
35.8 mm
Exhaust valve
Exhaust valve 36.1 mm
36.1 mm
Distance measured less minimum dimension

Distance measured less minimum dimension
= maximum permissible reworking dimension.

= maximum permissible reworking dimension.
Example:
ProCarManuals.com
Example:
ProCarManuals.com
Distance measured
Distance measured 36.5
36.5 mm
mm
-
- Minimum dimension
Minimum dimension 35.8
35.8 mm
mm
= Max.
= Max. perm.
perm. reworking
reworking dimension
dimension 0.7
0.7 mm
mm
Note:
Note:
If the maximum permissible reworking dimen-

If the maximum permissible reworking dimen-
sion is 0 mm, repeat measurement with a new

sion is 0 mm, repeat measurement with a new
valve. If
valve. If the
the maximum
maximum permissible reworking
permissible reworking
dimension is
dimension is still
still 00 mm,
mm, replace
replace cylinder
cylinder head.
head.
\o ee da _ |< Reworking
K Reworking inlet
inlet valve
valve seat
seat
|
A
|
Dimension
Dimension Valve seats
Valve seats
|
| Oaa
∅ 35.7 mm
35.7 mm Valve seat diameter
Valve seat diameter
\* | b b max. perm. reworking dimension

max. perm. reworking dimension
\N N '
a \ | Ccc 1.6 mm
1.6 mm Valve
Valve seat width
seat width
| Z
Z Cylinder head bottom edge
Cylinder head bottom edge
| 45°
45° Valve seat angle
Valve seat angle
30° 30 Bottom correction angle

Bottom correction angle
Edition 03.98
Edition 03.98 —— 15-12.1 ———
------------ 15-12.1 ------------
$00.5110.52.20
S00.5110.52.20
15
Cylinder Head, Valve Gear OCTAVIA
OCTAVIA
a ~ va << Reworking
K Reworking exhaust
exhaust valve
valve seat
seat
Z | Dimension
Dimension Valve seats
Valve seats
Lo ~~ : Oaa
∅ 31.4 mm
31.4 mm Valve seat diameter
Valve seat diameter
b
b max. perm. reworking dimension
max. perm. reworking dimension
Y | Ccc 2.7 mm
2.7 mm Valve seat width
Valve seat width
b : Z
Z Cylinder head bottom edge
Cylinder head bottom edge
45°
45° Valve seat angle
Valve seat angle
$15-0121 Procedure
Procedure
Reworking can be carried out with a machine or

Reworking can be carried out with a machine or
by hand. It is essential that the following condi-

by hand. It is essential that the following condi-
tions are
tions are met:
met:
l@ Wear limit of the valve guides must not ex-

Wear limit of the valve guides must not ex-
ceed the permissible dimension

ceed the permissible dimension
= page
page 15-14.
15-14.
ó
l@ Use NAC milling tool with carbide metal tips

Use NAC milling tool with carbide metal tips
ProCarManuals.com
(min. 90 HRC).
(min. 90 HRC).
ProCarManuals.com
<4 Reworking
K Reworking valve
valve seats
seats with NAC hand
with NAC hand mill-
mill-
ing tool
ing tool
-
- Place cylinder head down on a felt base and
Place cylinder head down on a felt base and
secure against turning.

secure against turning.
-
- Adapt diameter of guide drift to diameter of
Adapt diameter of guide drift to diameter of
valve guide.
valve guide.
Valve guide
Valve guide Guide drift ∅@ mm
Guide drift mm
- Inlet valve
Inlet valve
700.04
7.0 -0.01
L Exhaust valve
Exhaust valve
-
- Match diameter of milling tool to diameter of
Match diameter of milling tool to diameter of
valve seat.
valve seat.
Valve seat
Valve seat Milling tool ∅@ mm
Milling tool mm
90°
90° 60°
60°
Inlet valve
Inlet valve 37
37 34
34
Exhaust valve
Exhaust valve 32
32 -
-
—— 15-12.2 ———_
------------ 15-12.2 ------------ Edition 03.98
Edition 03.98
$00.5110.52.20
S00.5110.52.20
OCTAVIA
#: &?
&"8
+
15
-

#

!
7 2) !
dimension
&
-
! Insert valve and press firmly against the valve
+####
seat.

Note:
Note:
lf the valve is replaced when carrying out repair

!
work,

~<@-!
K Measure distance -a- between the valve stem
:!!##
end and the upper face of the cylinder head.

-
! Calculate max. permissible reworking dimen-
/ $!
sion from the distance -a- and measure the

!!
minimum dimension.

Minimum dimension:
:%
Inlet valve
+## 35.8 mm
2 3
Outlet valve
F## 36.1
20 mm
Minimum dimensions less distance measured

:
= max. permissible reworking.

E/ $
ProCarManuals.com
ProCarManuals.com
Example:
7
1
distance measured -a-

!! 36.5
20 mm

S———
oe a -
! Minimum dimension
: 35.8
2 3 mm

=
E max. permissible reworking
/ $ 0.7
mm

dimension

Wp
Note:
Note:
If the max. permissible reworking

!

dimension is

0mm, repeat measurement with a new valve. If

'

!
the

max. permissible reworking

dimension

is
again 0 mm, replace cylinder head.
'

Yo “Ee eo
~<@ $) !

K Reworking inlet valve seat
a= 35.7 mm
E2
b= 1.6 mm
E 0
45° = Valve seat angle

->E1#
Note:
Note:
The 30° rear milled section on the valve seat is

&'4

absolutely essential due to the flow character-

istics in the inlet canal.

~<@ $) !

K Reworking outlet valve seat
a= 31.4 mm
E2 -
b=2.7mm
E
\ 45° = Valve seat angle

->E1#
Edition 04.04
& '('( —— 15-13 ---——_
------------
---------
$00.5110.57.20
S00.5110.57.20
15
#: &?
&"8
+
OCTAVIA
1
<@- !
K Grind in valve/valve seat with fine grinding
5 ##.##
paste so as to achieve a perfect contact pat-

#!
tern -arrows-.
!!
-
! Inspect valve for leaks.
+##$
The inspection

can
be
carried
out with
water

colour (perfect contact pattern over entire cir-

9 # !
cumference) or by filling fuel into the combus-

' !
tion chamber (no fuel must flow out at the valve

9##
seat).
'
Note:
Note:
After installing the cylinder head, check

the hy-
draulic bucket
tappets ⇒
> %5%6
page 15-18.
Inspecting valve guides

!
!&

"
&
&#&
@ C#:2!--
♦ Universal dial gauge holder MP 3-447
MP 3-447 ¢ (
♦ Dial gauge
ProCarManuals.com
ProCarManuals.com
Test procedure
&
<@- !
K Insert valve into valve guide. End of valve
+ ## ## ) ##
stem must be flush with guide.

Valve rock: max. 1.3 mm

1#$%/ 2
©
Notes:
Notes:
¢ !

♦ Ifthe wear limit is exceeded, repeat measure-
ment with new valves. Ifthe wear limit is again

!

exceeded, replace valve guides ⇒

=> $
page
15-19.
%5%7
¢ !
♦ If
the
valve
is
replaced
when
carrying
out
repair work,

use a new valve for the meas-
urement.

Replacing valve stem seals

$
!

(cylinder head installed)

9'

"
&
&#&
@ Assembly
♦ lever with pressure plate MP 1-211
*#:!
¢ Assembly
♦ device MP 1-213
*#:!2
Gasket ring extractor MP 1-206

♦ 5$/:!0
Sd
¢ +:!20
♦ Insertion tool MP 1-306
——. 15-14 —__

------------
------------ Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
OCTAVIA Cylinder Head,
Cylinder Head, Valve
Valve Gear
Gear 15
Removing
Removing
-- Remove camshaft
Remove camshaft ⇒
=> page
page 15-16.
15-16.
-- Remove bucket
Remove bucket tappets
tappets (do
(do not
not mix
mix up)
up) and
and
place down
place down with
with running
running surface
surface facing
facing down.
down.
-- Move piston
Move piston of
of the
the relevant
relevant cylinder
cylinder into
into top
top
MP 1-213 dead centre
dead centre (TDC).
(TDC).
~<q--
K Insert assembly
Insert assembly device
device MPMP 1-213
1-213 and
and set
set
mounting at
mounting at height
height of
of stud
stud bolt.
bolt.
-- Use assembly
Use assembly lever
lever and
and thrust
thrust piece
piece MP
MP
1-211 to
1-211 to remove
remove valve
valve springs.
springs.
Note:
Note:
MP 1-211 The valves

The valves are
are supported
supported on on the
the piston
piston crown
crown
LAS
when carrying
when carrying out
out this
this step.
step.
ProCarManuals.com
ProCarManuals.com
~<q--
K Use MP
Use MP 1-206
1-206 to
to pull
pull off
off valve
valve stem
stem seals.
seals.
MP 1-206
Installing
Installing
~<q--
K Fit plastic
Fit plastic sleeve
sleeve -A-
-A- onto
onto the
the valve
valve stem
stem in
in
order to
order to avoid
avoid damaging
damaging the
the new
new valve
valve stem
stem
1 __ MP 1-306 seals.
seals.
-- Oil valve
Oil valve stem
stem seal
seal -B-,
-B-, insert
insert into
into the
the fitting
fitting
tool MP
tool MP 1-306
1-306 and
and carefully
carefully push
push onto
onto the
the
valve guide.
valve guide.
) CXC)
Notes:
Notes:
a
ecg
(Ga
¢ Wait
♦ Wait about
about 3030 minutes
minutes before
before starting
starting the
the
U
engine after
engine after installing
installing the
the camshaft.
camshaft. The The
Q
hydraulic compensating
hydraulic compensating elements
elements have have to to
(
settle (otherwise
settle (otherwise valves
valves will
will strike
strike the
the piston).
piston).
Edition 08.96
Edition 08.96 ——_ 15-15 ---———
------------ 15-15 ---------
$00.5110.50.20
S00.5110.50.20
15
#: &?
&"8
+
OCTAVIA
1
¢ After
♦ carrying
out
work
on
the
valve
gear,
carefully crank (
engine at least 2 revolutions
to ensure that no valve touches the piston

when the engine is started.

Removing and installing camshaft

$ !
&
!


"
&
&#&
¢ Torque
♦ wrench
,
¢ :!0
¢ Adjusting
*4:!2
¢
♦ Puller T40001 with hook T40001/2
-$ and
-.
T40001/3
-.2
Removing
$ !
-
! Remove top toothed belt guard, cylinder head

#?
cover and vacuum pump.

##
<@- !
K Position crankshaft on TDC
$ of cylinder 1 (ve-
( 9#!
hicles with manual gearbox).

/'
ProCarManuals.com
ProCarManuals.com
Note:
Note:
Position crankshaft
# on TDC of cylinder 1 when
21 %
engine was removed ⇒

=> %&%%
page 13-11.
<@- !
K Position crankshaft on TDC
$ of cylinder 1 -ar-
( !!
rows- (vehicles with automatic gearbox).

!9#/'
LS [ereoaee]
——— 15-16 ---———

------------
--------- Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
#: &?
&"8
+
15
-
LS
vyal
NS O
<q -!
K At
:
the same time the adjusting straightedge
*4
MP !2
1-312
must
be
inserted
easily
into
slot at the rear of the camshaft (without the
9
the
illustrated gauges).
'
Notes:
Notes:
If
¢ !
♦ the 3
adjusting
straightedge
cannot
be
in-
serted, rotate the crankshaft
1
% further
turn
(360°).
8&9'4:
The valves of cylinder 1 must be closed and

♦ %

the valves of cylinder 4 must overlap -arrows-.
;

DEE
| sis-0207
Oe $13-0207
] ! Loosen tensioning pulley.
7
! Remove toothed belt.

#
Notes:
Notes:
To loosen and tighten the fixing bolt for the cam-

shaft sprocket 3

never use the adjusting straight-
edge as counterholder ! Counterhold with coun-
<1
terholder MP 1-216.
#%(%9
! Loosen the fixing bolt on the camshaft

7 /
ProCarManuals.com
sprocket by 1 turn.
ProCarManuals.com
$
K! Place puller T40001

with hook T40001/2
-$ -A-
-.!*!
and T40001/3
-B- on the camshaft. Use open-
-.2!;! C!
end wrench as counterholder and loosen the

camshaft sprocket from the cone of the cam-

$!
shaft.

! Remove camshaft sprocket.

#$
ph -
! First of all remove bearing caps 5, 1 and 3.

A#?2
$13-0253
a Loosen bearing caps 2 and 4 alternately di-
7-!
AF-S A
agonally across.

Installing

!
Notes:
Notes:
When fitting the camshaft the cams of cylin-

♦ "

der 1 must point upwards.
%

When installing the bearing caps, pay atten-

K ♦ "
tion to the centre displacement of the bore,

before installing insert bearing cap and de-

termine fitting position.

! Oil contact surfaces of camshaft.

F
! Tighten bearing

caps
2
and 4-
alternately
crosswise to 20 Nm.
<
“7 X
! Install bearing caps 5, 1 and 3 and likewise
+?2$
tighten to 20 Nm.
<
! Fit on the camshaft sprocket and tighten by

A$
hand.

! Installing toothed belt ⇒

+> 2!-
page 13-4.
Edition 04.04
& '('( —— 15-17 ---———
------------
---------
$00.5110.57.20
S00.5110.57.20
15
Cylinder Head, Valve Gear OCTAVIA
OCTAVIA
Notes:
Notes:
¢ After
♦ installing the
After installing the camshaft,
camshaft, the
the engine
engine must
must
not be
not be started
started for
for about
about 30
30 minutes.
minutes. The
The hy-
hy-
draulic valve
draulic valve clearance
clearance compensating
compensating ele-
ele-
ments have to settle (otherwise valves will
strike the pistons).

¢ After
♦ carrying out
After carrying out work
work on
on the
the valve
valve gear,
gear,
carefully crank engine at least 2 revolutions
to ensure that no valve strikes the piston

when the
when the engine
engine is
is started.
started.
Inspecting hydraulic bucket tap-

Inspecting hydraulic bucket tap-
pets
pets
Notes:
Notes:
¢ Always
♦ replace the
Always replace the bucket
bucket tappets
tappets complete
complete
(cannot be adjusted or repaired).
(cannot be adjusted or repaired).
¢ Irregular
♦ Irregular valve
valve noises
noises when
when starting
starting are
are nor-
nor-
mal.
mal.

ProCarManuals.com
ProCarManuals.com
¢ Feeler
♦ Feeler gauge
gauge
¢ Wooden
♦ Wooden or
or plastic
plastic wedge
wedge
-
- Start engine and continue running until the
Start engine and continue running until the
radiator fan has cut in once.

radiator fan has cut in once.
-
- Increase engine speed to about 2500 rpm
Increase engine speed to about 2500 rpm
for 2 minutes;
for 2 minutes; carry
carry out
out a
a road
road test
test ifif neces-
neces-
sary.
sary.
If the hydraulic bucket tappets are still loud, de-

If the hydraulic bucket tappets are still loud, de-
termine the faulty tappet as follows:

termine the faulty tappet as follows:
- Remove cylinder head cover.

Remove cylinder head cover.
-
- Rotate crankshaft clockwise until the cams
Rotate crankshaft clockwise until the cams
of the bucket tappets to be inspected are

of the bucket tappets to be inspected are
facing up.
facing up.
-
- Determine clearance between
Determine clearance between cam and cam and
bucket tappet.
bucket tappet.
~<q--
K Use a wooden or plastic wedge to press
Use a wooden or plastic wedge to press
bucket tappet down. If it is possible to insert

bucket tappet down. If it is possible to insert
a 0.20
a 0.20 mm
mm feeler
feeler gauge
gauge between
between camshaft
camshaft
and bucket
and bucket tappet,
tappet, replace
replace tappet.
tappet.
—— 15-18 ——_
------------ 15-18 ------------ Edition 03.98
Edition 03.98
$00.5110.52.20
S00.5110.52.20
OCTAVIA
15
Notes:
Notes:
¢ After
♦ After installing the camshaft,
installing the camshaft, the
the engine
engine must
must
not be
not be started
started for
for about
about 30
30 minutes.
minutes. The
The hy-
hy-
draulic valve
draulic valve clearance
clearance compensating
compensating ele-
ele-

¢ After
♦ carrying out
After carrying out work
work on
on the
the valve
valve gear,
gear,

when the
when the engine
engine is
is started.
started.
Replacing valve guides

Replacing valve guides

@ Driver
♦ Driver MP1-205
MP1-205
¢ Hand
♦ Hand reamer
reamer MP1-204
MP1-204 and
and diluted
diluted soluble
soluble
oil
oil
Removing
Removing
-
- Clean cylinder head and inspect. Cylinder
Clean cylinder head and inspect. Cylinder
ProCarManuals.com
heads which have valve seat rings which can

ProCarManuals.com
heads which have valve seat rings which can
no longer
no longer be
be reworked,
reworked, or
or cylinder
cylinder heads
heads
which have already been machined to their
which have already been machined to their
minimum dimension, are not suitable for re-

minimum dimension, are not suitable for re-
placing the valve guides.

placing the valve guides.
-
- Use MP1-205 to press out worn valve guides
Use MP1-205 to press out worn valve guides
from the camshaft side (valve guide with

from the camshaft side (valve guide with
shoulder, repair
shoulder, repair versions
versions -- from
from the
the combus-
combus-
tion chamber
tion chamber side).
side).
Installing
Installing
-
- Moisten new valve guides with oil and press
Moisten new valve guides with oil and press
into the cold cylinder head with MP

into the cold cylinder head with MP 1-205 1-205
from the camshaft side as far as the shoul-
from the camshaft side as far as the shoul-
der.
der.
Note:
Note:
After the guide

After the guide makes
makes contact
contact with
with the
the shoul-
shoul-
der, the pressure applied must not be increased
der, the pressure applied must not be increased
beyond 10 kN otherwise
otherwise the
the shoulder
shoulder may
may shear
shear

beyond
Off.
off.
-
- Use hand reamer MP1-204
Use hand reamer MP1-204 to ream open to ream open
valve guide. It is essential to use diluted solu-
valve guide. It is essential to use diluted solu-
ble oil for this step.

ble oil for this step.
-
- Rework valve seats ⇒
Rework valve seats => page
page 15-12.
15-12.
Edition 03.98 —— 15-19 -———

Edition 03.98 ------------ -----------

$00.5110.52.20
S00.5110.52.20
WoOo'sjenueIIeDOId
ProCarManuals.com
OCTAVIA
OCTAVIA Lubrication system
Lubrication system 17
17
Removing and installing parts of the lubrication system

Removing and installing parts of the lubrication system
2 - Chain sprocket for oil pump

2 - Chain sprocket for oil pump
¢ pay
♦ pay attention
attention toto installation
installation position
position
¢ can
♦ can be
be fitted
fitted onto
onto oil
oil pump
pump shaft
shaft only
only
in one
in one position
position
3-25 Nm
3 - 25 Nm
4 - Chain for oil pump

4 - Chain for oil pump
@ before
♦ before removing,
removing, mark
mark running
running direc-
direc-
tion
tion
5 - Sealing flange
5 - Sealing flange
# removing
♦ removing and
and installing
installing ⇒=> page
page 13-18
13-18
@ replacing
♦ replacing crankshaft
crankshaft seal
seal
=> page
⇒ page 13-15
13-15
6-15 Nm
6 - 15 Nm
7 - Collar bolt, 15 Nm
7 - Collar bolt, 15 Nm
8 - Bush
8 - Bush
9 - Chain tensioner
9 - Chain tensioner
ProCarManuals.com
10 - Spring
10 - Spring
ProCarManuals.com
11 - Washer
11 - Washer
Notes:
Notes:
12 - Chain sprocket
12 - Chain sprocket
If considerable
¢ If
♦ considerable quantities
quantities of
of metal
metal swarf
swarf or
or 13 - O-ring
13 - O-ring
abrasion are
abrasion are found
found in
in the
the engine
engine oil
oil when
when ¢ replace
♦ replace
carrying out repair work in the engine, it is
carrying out repair work in the engine, it is
then necessary to carefully clean the oil gal-

then necessary to carefully clean the oil gal- 14 - Suction line
14 - Suction line
leries and
leries and inin addition
addition to
to replace
replace the
the oil
oil cooler
cooler ¢ clean
♦ clean strainer
strainer if
if soiled
soiled
in order
in ordertoto avoid
avoid any
any consequential
consequential damage.
damage.
The oil
♦ The oil level
level must
must not
not extend
extend beyond
beyond the
the 15 - Splash plate
15 - Splash plate
max. marking - risk of damage to catalytic

max. marking - risk of damage to catalytic
converter!
converter!
16 - Oil pan
16 - Oil pan
# removing
♦ removing and
and installing
installing ⇒
= page
page 17-3
17-3
To extract
♦ To extract oil,
oil, remove
remove filler
filler funnel
funnel on
on dipstick
dipstick
guide tube.
guide tube. 17-10 Nm
17 - 10 Nm
Testing compression
¢ Testing
♦ compression ⇒
=> page 17-5.
page 17-5.
18
- Oil level and oil temperature
18 - Oil level and oil temperature sender sender
Inspecting oil level, oil quantity, oil specification
Inspecting oil level, oil quantity, oil specification
-G266
-G266
= Inspection
⇒ Inspection and
and Maintenance
Maintenance ¢ only
♦ only for models with
for models with extended
extended serv-
serv-
ice interval
ice interval
1 - Oil pump
1 - Oil pump
¢ testing
♦ testing ⇒
= Electrical
Electrical system;
system; Repair
Repair
¢ Duocentric
♦ Duocentric pump
pump Group 90
Group 90
¢ with
♦ with 1.2
1.2 MPa
MPa pressure
pressure relief
relief valve
valve
¢ before
♦ before installing,
installing, check
check whether
whether thethe 19 - Gasket
19 - Gasket
two dowel
two dowel sleeves
sleeves for centering oil
for centering oil ¢ replace
damaged
pump/cylinder block are fitted
pump/cylinder block are fitted
¢ ifif scores
♦ scores present
present on
on running
running surfaces
surfaces 20 - Seal
20 - Seal
and gears, replace

and gears, replace
¢ replace
♦ replace
¢ torque
♦ torque for attaching oil
for attaching oil pump
pump cover
cover to
to
oil pump housing: 10 Nm
oil pump housing: 10 Nm
21 - Oil drain plug, 30 Nm
21 - Oil drain plug, 30 Nm
Edition 11.02
Edition 11.02 —— 17-1 -——
------------ 17-1 -----------
$00.5110.56.20
S00.5110.56.20
17 Lubrication system
Lubrication system OCTAVIA
OCTAVIA
Disassembling and assembling oil filter holder

Disassembling and assembling oil filter holder
10 5 111213 14 15 14 16
pv 6 - Screw plug, 10 Nm
6 - Screw plug, 10 Nm
¢ up
♦ uptoto 03.01
03.01
7 - Screw plug
7 - Screw plug
¢ up
♦ uptoto 03.01
03.01
¢ must
♦ must not
not be
be opened
opened
©
8 - Spring
8 - Spring
©
¢ up
♦ uptoto 03.01
03.01
¢ for
♦ pressure relief
for pressure relief valve
valve 0.5
0.5 MPa
MPa
N
(5 bar)
(5 bar)
9 - Piston
9 - Piston
¢ up
♦ uptoto 03.01
03.01
O
¢ for
♦ pressure relief
for pressure relief valve
valve 0.5
0.5 MPa
MPa
(5 bar)
(5 bar)
WLHAOO
\Y49 10 - 0.09 MPa (0.9 bar) Oil pressure switch

10 - 0.09 MPa (0.9 bar) Oil pressure switch
F1, 25 Nm
F1, 25 Nm
# grey
♦ grey
¢ inspecting
inspecting ⇒
= page
page 17-5
17-5
ProCarManuals.com
♦
Is com
=D
11 - Gasket
11 - Gasket
# replace
♦ replace
12-15 Nm + torque a further 1/,/ turn

1
(90°)
4
# replace
replace
ProCarMan
13 - Oil filter holder

13 - Oil filter holder
14 - Seal
14 - Seal
2 - Gasket
2 - Gasket
# replace
♦ replace
¢ replace
♦ replace
15 - Oil feed line
15 - Oil feed line
3 - Oil cooler
3 - Oil cooler
¢ to
♦ to turbocharger
turbocharger
@ ensure
♦ ensure clearance
clearance to
to surrounding
surrounding com-
com-
ponents
ponents
@ pay
♦ pay attention
attention to
to Note
Note ⇒
= page
page 17-1
17-1
17 - Cap, 25 Nm
17 - Cap, 25 Nm
4 - Gasket
4 - Gasket
¢ slacken
♦ slacken and
and tighten
tighten with
with oil
oil filter wrench
filter wrench
¢ replace
♦ replace
3417
3417
¢ fit
♦ fit into
into the
the grooves
grooves on
on the
the oil
oil cooler
cooler
18 - O-ring
18 - O-ring
5 - Seal
5 - Seal
# replace
♦ replace
@ up
♦ uptoto 03.01
03.01
¢ cut
♦ cut open
open and
and replace
replace ifif leaking
leaking
19 - Oil filter element
19 - Oil filter element
@ pull
♦ pull off
off from cap -item.
from cap -item. 17-
17-
@ when
♦ changing oil
when changing oil filter replace
filter replace
O-rings -item. 18-.

O-rings -item. 18-.
—— 17-2 ——
------------ 17-2 ------------ Edition 11.02
Edition 11.02
$00.5110.56.20
S00.5110.56.20
OCTAVIA
OCTAVIA Lubrication System
Lubrication System 17
17
Removing and installing oil pan

Removing and installing oil pan

¢ T
♦ Torque
orque wrench
wrench
¢ Silicone
♦ Silicone sealant
sealant D176
D176 404
404 A2
A2
¢ Hand
♦ Hand drill
drill with
with rotating
rotating plastic
plastic brush
brush attach-
attach-
ment
ment
¢ Flat
♦ Flat scraper
scraper
Removing
Removing
<@- -
K Remove noise insulation panel in middle as
Remove noise insulation panel in middle as
well as on left and right -arrows-.

well as on left and right -arrows-.
ProCarManuals.com
ProCarManuals.com
-
- Drain engine oil.
Drain engine oil.
-
- Unbolt oil pan.
Unbolt oil pan.
Notes:
Notes:
¢ Use
♦ Use wrench
wrench to
to slacken
slacken and
and tighten
tighten oil
oil pan
pan
bolts.
bolts.
¢ On
♦ On models
models with
with extended
extended service
service interval,
interval,
unplug connector
unplug connector from
from oil
oil level
level and
and oil
oil tem-
tem-
perature sender -G266.
perature sender -G266.
-
- Take off oil pan; detach with light blows from
Take off oil pan; detach with light blows from
a rubber-headed hammer if necessary.

a rubber-headed hammer if necessary.
- Use a flat scraper to remove sealant residues

Use a flat scraper to remove sealant residues
on cylinder block.
on cylinder block.
K- Use rotating plastic brush to remove sealant

Use rotating plastic brush to remove sealant
residues on oil pan (wear eye protection).

residues on oil pan (wear eye protection).
- Clean sealing surfaces; they must be free of

Clean sealing surfaces; they must be free of
oil and grease.

oil and grease.
Edition 05.01
Edition 05.01 ——. 17-3 ———
------------ 17-3 ------------
$00.5110.55.20
S00.5110.55.20
17
Lubrication System OCTAVIA
OCTAVIA
Installing
Installing
Note:
Note:
The oil pan must be installed within 5 minutes

The oil pan must be installed within 5 minutes
after applying the silicone sealant.

after applying the silicone sealant.
<4- -
K Cut off tube nozzle at the front marking
Cut off tube nozzle at the front marking
(©∅ of
( of tube
tube about
about 3 mm).
3 mm).
@ Thickness
♦ Thickness of
of sealant
sealant bead:
bead:
2...3mm
2 ... 3 mm
Note:
Note:


oil pan
oil and block
pan and block the
the strainer
strainer in
in the
the oil
oil intake
intake
pipe.
pipe.
ProCarManuals.com
& for —_— —— <q- -

K Apply silicone sealant to the clean sealing
Apply silicone sealant to the clean sealing
. I | surface of the oil pan, as shown in the illus-

surface of the oil pan, as shown in the illus-
¥) tration.
tration.
ae (
w 4] Note:
Note:
md /; Apply sealant bead

Apply sealant bead with
with particular care in
particular care in the
the
> \ area of the rear sealing flange -arrows-.
area of the rear sealing flange -arrows-.
ram i)
s \¥) -
- Fit onoil pan immediately and slightly tighten
Fit on oil pan immediately and slightly tighten
lo CI
\
\ \
all the bolts of oil pan/cylinder block.
all the bolts of oil pan/cylinder block.
O +4 y)
?] 7 -
- Tighten 3 bolts of oil pan/gearbox to 45 Nm.
Tighten 3 bolts of oil pan/gearbox to 45 Nm.
A -
- Tighten bolts of oil pan/cylinder block diago-
Tighten bolts of oil pan/cylinder block diago-
nally across in 2 stages, the last stage to

nally across in 2 stages, the last stage to
ZS
15 Nm.
15 Nm.
Notes:
Notes:
@ When
♦ When attaching
attaching the
the oil
oil pan
pan toto the
the removed
removed
engine, ensure
engine, ensure that
that the
the oil
oil pan finishes flush
pan finishes flush
with the
with the cylinder
cylinder block
block atat the
the flywheel
flywheel side.
side.
¢ After
♦ installing the
After installing the oil
oil pan, allow the
pan, allow the sealant
sealant
to dry for about 30 minutes. Do not pour in
to dry for about 30 minutes. Do not pour in
engine oil until after this waiting period.

engine oil until after this waiting period.
¢ On
♦ On models
models fitted
fitted with
with extended
extended service
service in-
in-
terval, unplug connector of oil level and oil
terval, unplug connector of oil level and oil
temperature sender -G266 and erase fault

temperature sender -G266 and erase fault
memory ⇒
memory => 1.9
1.9 l/66
I/66 kW
kW (TDI)
(TDI) Engine
Engine -- Fuel
Fuel
Injection and
Injection and Glow
Glow Plug
Plug System;
System; Repair
Repair
Group 01;
Group 01; Interrogating
Interrogating and
and erasing
erasing fault
fault
memory.
memory.
—— 17-4 —_ Edition 05.01

------------ ------------ Edition 05.01

$00.5110.55.20
S00.5110.55.20
OCTAVIA
17
Testing oil pressure and oil pres-

Testing oil pressure and oil pres-
sure switch
sure switch

Oil pressure
¢ Oil
♦ pressure tester
tester (e.g.
(e.g. V.A.G 1342)
V.A.G 1342)
Diode test
¢ Diode
♦ test lamp
lamp (e.g.
(e.g. V.A.G
V.A.G 1527)
1527)
Adapter cable
¢ Adapter
♦ cable set
set (e.g.
(e.g. V.A.G 1594)
V.A.G 1594)
Current flow
¢ Current
♦ flow diagram
diagram
Operation of dynamic oil pressure warning

Operation of dynamic oil pressure warning
system
system
Testing warning lamp

Testing warning lamp
The oil pressure warning lamp flashes after ig-

The oil pressure warning lamp flashes after ig-
nition on (,terminal 15 on“) and engine not run-

nition on (terminal 15 on) and engine not run-
ning.
ning.
Warning criteria
Warning criteria
Engine not running and oil pressure switch

ProCarManuals.com
l Engine not running and oil pressure switch

ProCarManuals.com
closed
closed
l Coolant temperature higher than 60 °C, en-

Coolant temperature higher than 60 °C, en-
gine speed greater than 1500 rpm and oil

gine speed greater than 1500 rpm and oil
pressure switch
pressure switch open
open
l Coolant temperature less than 60 °C, engine

Coolant temperature less than 60 °C, engine
speed greater than 300 rpm and oil pressure

speed greater than 300 rpm and oil pressure
switch open
switch open
l At engine speed greater than 5000 rpm, an

At engine speed greater than 5000 rpm, an
active oil warning is not cancelled, irrespec-

active oil warning is not cancelled, irrespec-
tive of
tive of the
the status
status of
of the
the oil
oil pressure
pressure switch.
switch.
l If the voltage supply of the control unit is o.k.

If the voltage supply of the control unit is o.k.
(terminal 15) and the oil pressure switch is

(terminal 15) and the oil pressure switch is
open for more than 0.5 seconds and engine

open for more than 0.5 seconds and engine
speed greater than 1500 rpm, this is stored.

speed greater than 1500 rpm, this is stored.
If this condition occurs 3 times during ,,ter-

If this condition occurs 3 times during ter-
minal 15 on“, the warning becomes or re-

minal 15 on, the warning becomes or re-
mains activate
mains activate even
even at
at engine
engine speeds
speeds lower
lower
than 1300
than 1300 rpm.
rpm.
Edition 03.98
Edition 03.98 —— 17-5 ---——
------------ 17-5 ---------
$00.5110.52.20
S00.5110.52.20
17
. Lubrication System
%2
: OCTAVIA
1
Test conditions
&
@
l Inspect engine oil level to ensure that it is
+ #
OK ⇒
FG => +:
Inspection and Maintenance.
@
l Warning light for oil pressure (K3) must light
"9G2'
up briefly when switching on the ignition.

@
l Engine oil temperature must be at least 80 °C
)3D>
(radiator fan must run once).

9'
LZ V.A.G 1342Ny Testing oil pressure switch

! )
-
! Detach cable from oil pressure switch.
(
T <@- !
K Unscrew oil pressure switch and screw in oil
C
ive pressure tester (e.g. V.A.G 1342)

9 1 * 52-'
WS)
(eXexexeFeoXe) -
! Screw oil pressure switch into the tester

of 9 €o0 V.A.G 1342.

1 * 52-
-
! Connect brown cable of tester to earth (-).
9!'
-
! Connect diode test lamp (e.g. V.A.G 1527)
9 1 * 5'
TA) 0 to oil pressure switch -2- and to the battery

!!
ProCarManuals.com
positive (+).
#9='
ProCarManuals.cem
-
! Start engine and slowly increase
engine
speed.

-
! Atapressure of 0.075...0.105 MPa (0.75...1.05
* :9
bar) the LED must come on. If it does not come

'7)( +
on, replace oil pressure switch.

?
Testing oil pressure

!
-
! Unscrew oil pressure switch and screw in
C
V.A.G 1342.
1 * 52-
-
! Screw oil pressure switch into V.A.G 1342.
1 * 52-
-
! Start engine (engine oil temperature at least
9
80 °C).
3> '
¢ F%
♦ Oil pressure when engine idling: min. 0.1
MPa (1.0 bar)
:9 '
¢ F% :

♦ Oil pressure at 2000 rpm: min. 0.2 MPa
(2.0 bar)
9 '
At a higher engine speed the oil pressure must

*
not
be
greater
than
0.7 :
MPa 9
(7.0 '
bar). F!
Other-
wise replace oil pump cover with pressure relief
#
valve.
##
—— 17-6 ——_
------------
------------ Edition 04.04
& '('(
$00.5110.57.20
S00.5110.57.20
OCTAVIA
17
Engine oil
Engine oil
The engine is factory-filled with a branded

The engine is factory-filled with a branded
multigrade oil which can also be used as an all-

multigrade oil which can also be used as an all-
seasons oil - except in extremely cold climatic

seasons oil - except in extremely cold climatic
zones.
zones.
The specifications stated below must be indi-

The specifications stated below must be indi-
cated individually or together with other specifi-

cated individually or together with other specifi-
cations on
cations on the
the can.
can.
AA -- Multigrade
Multigrade high-lubricity
high-lubricity oils,
oils, specification
specification
VW 500 00
VW 500 00 1) (only
(only in
1)
in combination
combination with
with
specification VW
specification 505 00
VW 505 00 1)))
1)
B-Multigrade oils, specification VW

B - Multigrade oils, specification VW 505 505
00 1)
00
1)
- Multigrade oils, specification

- Multigrade oils, specification VW 501VW 501
01 1) (only
01 (only in
1)
in combination
combination with
with specifica-
specifica-
tion VW
tion VW 505
505 00
00 1))
1)
- Multigrade oils, specification ACEA

- Multigrade oils, specification ACEA B3- B3-
96 2) (only
96 (only exceptionally
2)
exceptionally for topping up)
for topping up)
- Multigrade oils, specification
- Multigrade oils, specification VW 502VW 502
00 3) (only
00 (only in
3)
in combination
combination with
with specifica-
specifica-
ProCarManuals.com
tion VW
tion VW 505
505 00
00 1)))
1)
ProCarManuals.com
1)
1)
A date not earlier than 11.92 must be indi-
cated after this VW Standard.

2)
2)
This oil must only be used once for top-
This oil must only be used once for top-
ping up within the specified oil change in-

ping up within the specified oil change in-
terval if no approved engine oil is available.

terval if no approved engine oil is available.
3)
3)

The oils may also be intermixed when topping

The oils may also be intermixed when topping
up.
up.
Inspecting engine oil level

Inspecting engine oil level
l@ Carry out measurement of oil level only when

Carry out measurement of oil level only when
engine at normal operating temperature (oil

engine at normal operating temperature (oil
temperature higher
temperature higher than
than 60°C).
60°C).
l@ The vehicle must be standing on level ground

The vehicle must be standing on level ground
when measuring the oil level. Wait a few

when measuring the oil level. Wait a few
minutes after
minutes after switching
switching off
off the
the engine
engine toto al-
al-
low the
low the oil
oil to
to flow back into
flow back into the
the oil
oil pan.
pan.
-- Withdraw dipstick, wipe off with a clean cloth

Withdraw dipstick, wipe off with a clean cloth
and re-insert the dipstick fully.

and re-insert the dipstick fully.
Edition 06.99
Edition 06.99 ——
------------ 17-7 -——
-----------

$00.5110.53.20
S00.5110.53.20
17
Lubrication System OCTAVIA
OCTAVIA
- Then, remove dipstick again and read off oil

-

level.

<q Markings on dipstick:

K

The engine oil should be maintained at the level

within the range between the *min” and *max”

markings. The “max” marking corresponds to

an engine oil quantity of about 5.2 Itr.

#
"
!

Note: Note:
The oil level must not A
extend beyond the max.
% & & & / 0 / 2
6DA
, , , ,
' ( ' ) * + - . ' - ' 1 - ' ) 3 .
$ $ $
marking of the
DA dipstick.
6 % 8 / % % 6
, ,
) 3 5 - 7 9 + :
$
ProCarManuals.com
ProCarManuals.com
—— 17-8 -—— Edition 06.99

06.99

------------ ----------- Edition

$00.5110.53.20
S00.5110.53.20
OCTAVIA
1 Cooling System
$ 19
%
Removing and installing parts

of the cooling system

&
Notes:
Notes:
@ "
♦ When
the
engine
is

warm
the
cooling
sys-
tem is under pressure. If necessary reduce

!
pressure before repairs.

¢
♦ The
hose
connections
are
secured
with
spring strap clips. In the event of repairs only
!
use spring strap Clips.

¢
♦ Use pliers for
spring
strap
clips
to
fit
the
spring strap Clips.

¢ Always
♦ replace seals and gasket
rings.
¢
♦ The arrows which are on the coolant pipes
and the coolant hoses must stand opposite

to each other.

Draining and filling up coolant ⇒

( > 6!2
page 19-3.
Coolant mixing ratio ⇒

/ => 6!-
page 19-4.
Inspect cooling system for leaks ⇒

+$ => 6!3
page 19-8.
ProCarManuals.com
ProCarManuals.com
Edition 04.04

—— 19-1 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
19
% Cooling System
$ OCTAVIA
1
Parts of the cooling system fitted to body

" & &

=S
18
ProCarManuals.com
c?
1 17
dq 9
=
<|a 16
15
O
q 14
14 9g
8 [si9-0175 |
1 - Radiator
'
4-Fan shroud
' +
¢
♦ after
replacing fill entire
system
with
fresh coolant
5-10 Nm
, ' -
# #
♦ removing and installing ⇒= 6!6
page 19-9
6 - Auxiliary fan
. ' ! &
2-O-ring
( ' )' @ #?!
♦ onvehicles with air conditioning, or ad-
¢
♦ replace ditional equipment
,
3 - Top coolant hose

* ' 7 - Fan holder
/ ' +

#
♦ secured using a retaining clip
#
♦ connection diagram for coolant hoses
=> 6! -
⇒ page 19-2.4
——. 19-2 ———_

------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Cooling System
$ 19
%
8 - Retaining clips
0 ' 15 - Bottom coolant hose
, ' 2
¢
♦ for fan cable ¢
♦ attached to radiator using a retaining
¢ $
♦ check tightness clip

#
9 - Connector
% ' $ => 6! -
⇒ page 19-2.4
10 - Radiator fan
'
& 16 - O-ring
. ' )'
¢
♦ replace
11 - To coolant pipe
'
#
♦ connection diagram for coolant hoses 17 - Thermoswitch (-F18-), 35 Nm
/ ' 3 4'+0'5*,-
= 6! -
⇒ page 19-2.4 ¢ for
♦ radiator fan

¢ %
♦ switching temperatures:
12 - Expansion reservoir
( ' ! 1st stage

¢ $
♦ inspect cooling system for leaks with on: 92...97 °C
%6 6>
the tester V.A.G 1274 and adapter

1 * 5 - off: 84...91 °C
%3- 6>
V.A.G 1274/8
1 * 5-.3 2nd stage

on: 99...105 °C
%66 >
13 -Cap
* ' $ off: 91...98 °C
%6 63>
¢ 1
♦ inspect with the tester V.A.G 1274 and
* 5-
adapter V.A:G 1274/9

1 *%5-.6 18 - Holder
0 ' 1

@ F# - 0
♦ Overpressure from 1.4...1.6 bar ¢ for
♦ radiator

¢
♦ pay attention to fitting position
14 - Holder
' 1
¢ #
♦ pay attention to different version
¢
♦ for connector of fan
19-10 Nm
% ' -
ProCarManuals.com
ProCarManuals.com
Edition 04.04

——— 19-2.1 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
19
% Cooling System
$ OCTAVIA
1
Parts of the cooling system attached to engine

" &

12 131415 3 16 17
ProCarManuals.com
WD SJenuecyIe7)Old
vr
26 253 24 [ S19-0176 |
T=
1-15 Nm
' ,- 4 - To top radiator
'

#
2 - Coolant pipe
( ' $ => 6! -
⇒ page 19-2.4
¢
♦ inspect for smooth operation
¢
♦ pay attention to fitting position 5 - To cylinder head
, '

# #
♦ removing and installing ⇒= 6!
page 19-5 #
=> 6! -
⇒ page 19-2.4
3 - O-ring
* ' )'
¢
♦ replace 6 - To top expansion reservoir
. ' !
#
=> 6! -
⇒ page 19-2.4
>a
=
o
Y
N
------------
------------

Ww S
= &
—
oc
CoN
be)
ow
2)
S00.5110.57.20
”
OCTAVIA
1 Cooling System
$ 19
%
7 - To heat exchanger for heating

/ ' ! & 17 - From heat exchanger for heating
/ ' + ! &
#
♦ connection diagram for coolant hoses #
= 6! -
⇒ page 19-2.4 => 6! -
⇒ page 19-2.4
8 - Radiator for exhaust gas recirculation

0 '
&! 18-10 Nm
0 ' -
@
♦ only
on
engines ALH with
*78 automatic
gearbox
/ 19 - Connection fitting
% ' $ &
9 - From connection fitting

% ' + & 20 - Coolant pipe
( ' $
#
♦ connection diagram for coolant hoses #
= 6! -
⇒ page 19-2.4 => 6! -
⇒ page 19-2.4
10-10 Nm
' - 21 - To top radiator
( '

#
11 - To expansion reservoir
' ! => 6! -
⇒ page 19-2.4
#
= 6! -
⇒ page 19-2.4 22 - To bottom expansion reservoir
(( ' !
#
12 - Top coolant hose
( ' => 6! -
⇒ page 19-2.4
@ $
♦ attached to bulkhead
#
♦ connection diagram for coolant hoses 23 - To bottom radiator
(* '

= 6! -
⇒ page 19-2.4 #
=> 6! -
⇒ page 19-2.4
13 - O-ring
* ' )'
¢ $
♦ check tightness 24 - Connection fitting
( ' $ &
ProCarManuals.com
¢
replace ¢ for coolant regulator

ProCarManuals.com
♦ ♦
14 - Coolant temperature sender -G62-

' $
' .(' 25 - Coolant regulator
(, ' $
¢
♦ with
sender for coolant
temperature # #
♦ removing and installing ⇒ = 6!
page 19-7
display -G2-
!5! ¢
¢ %
♦ inspecting: 8
Heat
thermostat in
water
15 - Retaining clips
, ' bath

¢ $
♦ check tightness @ / 3>
♦ opening start approx. 85 °C
@ )/ >
♦ End approx. 105 °C
16 - To heat exchanger for heating
. ' ! & @ F$
♦ Opening stroke at least 7 mm
#
= 6! -
⇒ page 19-2.4 26 - Oil cooler
(. ' )
# #
♦ removing and installing ⇒
= !
page 17-2
Edition 04.04

——— 19-2.3 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
19
% Cooling System
$ OCTAVIA
1
Connection diagram for coolant hoses

$
&
4—"
ProCarManuals.com
ProCarManuals.com
—_ | Jol
I
Go
| S19-0172 |
1 - Radiator
'
3 - Coolant pump, coolant regulator
* ' $
¢
♦ after
replacing fill entire
system
with # #
♦ removing
and
installing
coolant
pipe
fresh coolant
=> 6!
⇒ page 19-5
# #
♦ removing and installing ⇒ = 6!6
page 19-9 ¢
♦ inspect for smooth operation
@ #
♦ removing
and
installing
coolant
pipe
2 - Oil cooler
( ' ) = 6!
⇒ page 19-7
# #
♦ removing and installing ⇒
= !
page 17-2
—— 15-2.44 ——_
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Cooling System
$ 19
%
4 - Cylinder block
' $
8 - Heat exchanger for heating
0 ' 1 ! &
5 - Expansion reservoir
, ' ! 9 - ATF radiator
% ' +

¢ #!
♦ only on vehicles with automatic gear-
6 - Intake manifold
. ' &
box
/
7 - Radiator for exhaust gas recirculation

/ '
&! 10 - Heater for coolant
' 1 &
@
♦ only
on *78
engines ALH with
automatic @
♦ only
on #
vehicles
with
special ,!
equip-
gearbox
/ ment

Draining and filling up coolant

6
&
Special tools, testers and aids required:

A
7
@ 9 1 * 520'

♦ Catch pan (e.g. V.A.G 1306)
¢
Draining
6
-
! Open cap of coolant expansion reservoir
F/#
Caution!
C

Hot steam may escape when the expansion reser-

ProCarManuals.com
ProCarManuals.com
voir is opened; cover the cap with a cloth and open

carefully.

~< !-
K
##=> !
Remove engine cover ⇒ page 10-2.
~< !-
K
#
Remove the left noise insulation and in the
!!
middle -arrows-.
oY Cems)
Edition 04.04

—— 19-3 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
19
% Cooling System
$ OCTAVIA
1
<@- !
K Turn drain plug -arrow- on the radiator to the
!!
left, if necessary fit auxiliary hose onto con-

?/!
nection.

<q- !
K + #
In addition remove coolant hose at bottom
!!
on the oil cooler -arrow- and drain residual

coolant.
Filling up
+
ProCarManuals.com
Select the appropriate coolant additive from the

#
ProCarManuals.com
H$
original spare parts catalogue Skoda or from the

list
of
allowed
coolant #
additives ⇒= +
Inspection
and Maintenance; change coolant.
:B
Recommended mixture ratios:

/%
Antifreeze
&B Antifreeze
&B Drinking
6
protection
concentration‘)2)

5(5
water?)
3
(5
down to

3
-25°C
!> 40 % (2.7 1)
-I9 ' 60 % (4.1 1)
0I9- '
-35° C
!2> 50 % (3.4 1)
I92 -' 50 % (3.4 I)
I92 -'
1) ;,!
Because of inadequate corrosion protec-
'
tion, the antifreeze concentration must not

?@
2I
be under 30 % /0DI?
and must not exceed 60 %,
the antifreeze protection and cooling effi-
@!
ciency
are
reduced
as
the
concentration
increases.

2)
'
The coolant amount may differ according

to the version of the vehicle.

##
— 19-4 ——_
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
OCTAVIA Cooling System
Cooling System 19
19
♦ IfIf the
the two
two coolants
coolants are
are mixed,
mixed, the
the coolant
coolant
turns brown in colour. Brown coolant should
turns brown in colour. Brown coolant should
be drained immediately, the cooling system

be drained immediately, the cooling system
flushed out with drinking water and filled with

flushed out with drinking water and filled with
fresh coolant. If this is not done, there is a

fresh coolant. If this is not done, there is a
risk of
risk of damage
damage to
to the
the engine
engine and
and the
the cooling
cooling
system.
system.
♦ IfIf bluish-green
bluish-green coolant
coolant (G11)
(G11) is
is replaced
replaced with
with
the red coolant (G12), the entire cooling sys-
the red coolant (G12), the entire cooling sys-
tem should be flushed out with drinking wa-

tem should be flushed out with drinking wa-
ter.
ter.
Coolant which
♦ Coolant which complies
complies with
with the
the standard
standard TL
TL
VW 774
VW 774 CC (G11)
(G11) -bluish-green
-bluish-green inin colour-
colour-
should not be added to a cooling system of
should not be added to a cooling system of
the vehicle unless this system Is already filled

the vehicle unless this system is already filled
with this
with this coolant.
coolant.
♦ IfIf the
the cooling
cooling system
system of
of the
the vehicle
vehicle is
is filled
filled
with red coolant (G12), only red coolant
with red coolant (G12), only red coolant
(G12) may be used for refilling or topping up

(G12) may be used for refilling or topping up
the cooling
the cooling system.
system.
Coolant additives from the koda Genuine Parts

Coolant additives from the Skoda Genuine Parts
Catalogue which comply with the standard TL
Catalogue which comply with the standard TL
VW 774
VW 774 D:
D:
ProCarManuals.com
ProCarManuals.com
Coolant additives
Coolant additives Manufacturer
Manufacturer
Glysantin G 30-72
Glysantin G 30-72 BASF AG
BASF AG
XT 4030
XT 4030 ELF OIL AG
ELF OIL AG
Coolant ETX 6280

Coolant ETX 6280 TEXACO
TEXACO
FROSTOX SF-D 12
FROSTOX SF-D 12 HENKEL HEARTOL GmbH
HENKEL HEARTOL GmbH
Note:
Note:
The coolant additives stated can also be inter-

The coolant additives stated can also be inter-
mixed.
mixed.
Recommended mixing ratios:

Recommended mixing ratios:
Antifreeze
Antifreeze Antifreeze
Antifreeze Water?)
Water
2)
protection
protection concentration‘)2)
concentration
1)2)
down to
down to
-25 °C
-25 °C 40 % (2.0 ltr.)
40 % (2.0 ltr.) 60 % (3.0 ltr.)
60 % (3.0 ltr.)
-35 °C
-35 °C 50 % (2.5 ltr.)
50 % (2.5 ltr.) 50 % (2.5 Itr.)
50 % (2.5 ltr.)
1)
1)
Do not exceed an antifreeze concentration
Do not exceed an antifreeze concentration
of 60 %; the antifreeze protection and cool-

of 60 %; the antifreeze protection and cool-
ing efficiency
ing efficiency are
are reduced
reduced atat higher
higher con-
con-
centrations.
centrations.
2)
2)
Quantity of coolant may differ according
Quantity of coolant may differ according
to equipment of vehicle.
to equipment of vehicle.
Edition 06.99 —— 19-4.1 -———

Edition 06.99 ------------ -----------

$00.5110.53.20
S00.5110.53.20
19
19 Cooling System
Cooling System OCTAVIA
OCTAVIA
ProCarManuals.com
ProCarManuals.com
—— 19-4.2 ———
------------ 19-4.2 ------------ Edition 03.98
Edition 03.98
$00.5110.52.20
S00.5110.52.20
OCTAVIA
1 Cooling System
$ 19
%
! Fill with coolant gradually up to ,max*“ mark-

AJ/K$!
ing on the expansion reservoir.

/#
! Start engine and run for max. 2 minutes at

/
approx. 1500 rpm; fill up coolant to overflow

/ B#
opening of expansion reservoir.

/#
! Close expansion reservoir.

/#
! Run engine until the fan starts.

! Inspect coolant level. If the engine is warm

+# +
the coolant level must be on the ,max“ mark-

#J/K$!
ing,
? if
the
engine
is
cold
the #
level
must
lie
between the ,,min* and ,,max“ marking.
JKJ/K$
Removing and installing coolant

pump


A
¢ Torque
♦ wrench
,
Removing

ProCarManuals.com
ProCarManuals.com
! Drain coolant ⇒
(> 6!2
page 19-3.
! Remove right noise insulation.

#
K! Detach fuel hoses -arrows- to the injection

( !! 4
pump, seal with a clean plug and place to

?
the side.

! Disconnect plug -2- at intake manifold tem-

(!!$!
perature sender -G72 wit intake manifold

!5 $
pressure sender -G71.

!5
! Remove air guide pipe -1-.

#!!
\ ewe]
Edition 04.04

—— 19-5 ——_
------------
------------
$00.5110.57.20
S00.5110.57.20
19
% Cooling System
$ OCTAVIA
1
K! Unbolt fixing nut -3- for air guide pipe -2-.

C/!2!!!
! Remove air guide pipe -2-.

#!!

#1!> 2!
page 13-1.
! Remove tensioning pulley ⇒

#> 2!
page 13-1.
! Remove top and middle toothed belt guard

#
=> 2!-
⇒ page 13-4.
! Remove toothed belt from camshaft sprocket

#$
and from injection pump gear ⇒

4=> 2!-
page 13-4.
Notes:

¢

♦ The vibration damper and the bottom toothed
belt guard can remain installed.

The timing belt remains fitted onto the crank-

♦

shaft timing belt sprocket.

Pay attention to all the notes for removal and

♦ #

installation of the toothed belt ⇒
> %&;
page 13-4.
ProCarManuals.com
ProCarManuals.com
K! Unscrew screw -1- for guide pulley and press

C!!
down the guide pulley -2- approx. 30 mm.

!!/ 2
! Unscrew coolant pump -4- and carefully re-

C!-!!
move engine support and toothed belt guard.

#
Installing

! Clean sealing surface for O-ring or smoothen.

F!
! Replace O-ring -5- and moisten with cool-

F! !! !
ant.

! Insert coolant pump. Fitting position: Plug in

+ A%
[| housing points down.

! Tighten screws -3- of coolant pump to 15 Nm.

!2!<
! Replace screw -1- for guide pulley, tighten

!! ?
to 40 Nm and turn a further 90° (1/, turn).

-<6>9 . '
-
—— 19-6 ——
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Cooling System
$ 19
%

+> 2!-
page 13-4.
! Install the V-ribbed belt ⇒

+1!> 2!
page 13-1.
! Fill coolant ⇒
A> 6!2
page 19-3.
Removing and installing coolant

regulator


A
¢ Torque
♦ wrench
,
¢
Removing

! Drain coolant ⇒
(> 6!2
page 19-3.
K! Remove coolant hose from connection

# ! fit-
ting -2-.
!!
! Unscrew screws -1- and remove connection

C!!#
fitting -2- together with O-ring -3- and cool-

!!F!!2!!
ant regulator -4-.

ProCarManuals.com
!-!
ProCarManuals.com
! Turn the

coolant
regulator 6>
90° 9(1/,. '

turn)
-
to
the left and detach from connection fitting.

Installing

! Clean sealing surface for O-ring.

F!
! Replace O-ring and moisten with coolant.

F!
! Insert coolant pump into the connection fit-

+!
ting and turn 90° (1/, turn) to the right. In-

6> 9 . ' +!
-
specting: The
% clamp of the coolant thermo-
!
stat must be positioned vertically.

#
! Tighten screws -1- to 15 Nm.

!!<
! Filling system with coolant ⇒

A> 6!2
page 19-3.
Test coolant regulator

! Heat thermostat in water bath.

8
Opening start
) Opening start
) | )
Opening stroke
approx. 87 °C
/ 3> | / >
approx. 102 °C’) |
at least 7 mm
'
1)
'
cannot be tested

Edition 04.04

—— 19-7 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
19
19 Cooling System
OCTAVIA
Installing coolant
Installing coolant pipe
pipe
- Before installing,
Before installing, clean
clean or
or smooth
smooth sealing
sealing
surface for
surface for O-ring.
O-ring.
K- Moisten O-ring
Moisten O-ring -1--1- with
with coolant
coolant and
and fit
fit onto
onto
coolant pipe
coolant pipe -2-.
-2-.
- Insert coolant
Insert coolant pipe
pipe into
into the
the hole
hole on
on the
the
cylinder block.
cylinder block.
- Bolt bracket
Bolt bracket for
for coolant
coolant pipe
pipe tight
tight to
to 10
10 Nm-
Nm-
Testing cooling
Testing cooling system
system for
for leaks
leaks
Special tools,
testers and
and aids
aids required
required
¢ Cooling
♦ Cooling system
system tester
tester (e.g.
(e.g. V.A.G
V.A.G 1274)
1274)
¢ Adapter
♦ Adapter (e.g.
(e.g. V.A.G
V.A.G 1274/8)
1274/8)
¢ Adapter
♦ Adapter (e.g.
(e.g. V.A.G
V.A.G 1274/9)
1274/9)
Test condition
Test condition
ProCarManuals.com
@ Engine
Engine at
at operating
operating temperature
temperature
ProCarManuals.com
Test procedure
Test procedure
Important!
Important!
Hot vapours
Hot vapours may
may escape
escape when
when the
the expansion
expansion
reservoir is
reservoir is opened.
opened. Cover
Cover over
over cap
cap with
with cleaning
cleaning
rags and
rags and open
open carefully.
carefully.
- Mount tester
Mount tester V.A.G
V.A.G 1274
1274 with
with adapter
adapter V.A.G
V.A.G
1274/8 onto
1274/8 onto the
the expansion
expansion reservoir.
reservoir.
- Use the
Use the priming
priming pump
pump of of the
the tester
tester to
to
produce a
produce a pressure
pressure of
of about
about 0.1
0.1 MPa.
MPa.
- IfIf the
the pressure
pressure drops,
drops, locate
locate the
the leakage
leakage
point and
point and rectify
rectify fault.
fault.
Testing pressure
Testing pressure relief
relief valve
valve in
in cap
cap
- Screw cap
Screw cap onto
onto the
the tester
tester using
using adapter
adapter
V.A.G 1274/9.
V.A.G 1274/9.
- Operate the
Operate the priming
priming pump
pump of
of the
the tester
tester to
to
produce a
produce a pressure
pressure of
of about
about 0.15
0.15 MPa.
MPa.
- The pressure
The pressure relief
relief valve
valve should
should open
open at
at a
a
pressure of
pressure of 0.12
0.12 ...
... 0.15
0.15 MPa.
MPa.
—— 19-8 ———-
------------ 19-8 ------------ Edition 08.96
Edition 08.96
$00.5110.50.20
S00.5110.50.20
OCTAVIA
1 Cooling System
$ 19
%
Removing and installing the radia-

'
tor

Notes:

¢ Always
♦ replace gasket
rings and seals.

¢ )

♦ Raise vehicle with lift platform ⇒
=> %'%
page 10-1.

A
¢ Torque
♦ wrench
,
¢ "
♦ Wire
Removing

-
! Drain coolant ⇒
(> 6!2
page 19-3.
<q- !
K Disconnect connector -1- from thermoswitch
(!!
(-F18-) and separate plug connections

9!A3!' !! -2-
and -3- at fan shroud (press catches).
!2!9'
-
! Disconnect coolant hoses at connection fit-
(!
tings of radiator (pull off retaining clips).

9'
ProCarManuals.com
ProCarManuals.com
SS
ZO
Vehicles with air conditioning

83

~<q-!
K Unscrew the 4 fixing bolts -arrows- attach-
C - / !! !
ing the condenser.

Caution!

Do not open the refrigerant circuit of the air condi-

tioning system.

Note:

The refrigerant lines/hoses must not be over-

=

stretched, kinked
or bent in order to avoid dam-

age to the condenser.

Edition 04.04

—— 19-9 ———-
------------
------------
$00.5110.57.20
S00.5110.57.20
19
19 Cooling System
OCTAVIA
<@- -
K Detach bracket
Detach bracket -arrow-
-arrow- for
for refrigerant
refrigerant pipe.
pipe.
VI Continued for
Continued models
all models
for all
-- Remove
Remove both both headlights:
headlights:
⇒= Electrical
Electrical System;
System; Repair
Repair Group
Group 94;
94; Remov-
Remov-
ing and
ing and installing
installing headlights
headlights
K -- Remove the
Remove the 44 bolts
bolts -arrows-
-arrows- for
for attaching
attaching
the top
the top radiator
radiator mount.
mount.
ProCarManuals.com
ProCarManuals.com
~<@--
K Remove the
Remove the 44 bolts
bolts -arrows-
-arrows- for
for attaching
attaching
the bottom
the bottom radiator
radiator mount.
mount.
Z.
——— 19-10 ———

------------ 19-10 ------------ Edition 11.96
Edition 11.96
$00.5110.51.20
S00.5110.51.20
OCTAVIA
OCTAVIA Cooling System
Cooling System 19
19
Models with
Models with air
air conditioning
conditioning
-- Pull out
Pull out radiator
radiator slightly
slightly together
together with
with con-
con-
denser.
denser.
<q- -
K Detach clip
Detach clip -arrow-
-arrow- for
for attaching
attaching refrigerant
refrigerant
pipe.
pipe.
Continued for
Continued for all
all models
models
-- Remove fan
Remove fan shroud
shroud (4
(4 bolts).
bolts).
Note:
Note:
When removing
When removing and
and installing
installing the
the fan
fan shroud,
shroud,
ensure that
ensure that the
the radiator
radiator ribs
ribs are
are not
not damaged.
damaged.
-- Carefully take
Carefully take out
out the
the radiator
radiator downward.
downward.
Installing
Installing
ProCarManuals.com
ProCarManuals.com
Installation is
Installation is performed
performed in in the
the reverse
reverse order;
order;
pay attention
pay attention toto the
the following
following points:
points:
K -- Tighten thermostatic
Tighten thermostatic switch
switch -1-
-1- to
to
35 Nm.
35 Nm.
<3} -- Fiton
Fit the brackets
on the brackets -2-
-2- and
and -3-
-3- at
at the
the radiator,
radiator,
CO) as illustrated.
as illustrated.
> th) |e p> -- Tighten the

Tighten the bolts
and radiator
and
bolts for
for attaching
radiator mounts
attaching the
mounts toto
the fan
fan shroud
shroud
10 Nm.
10 Nm.
aye
\ Z EX
4
ba ~( @G
-- On models
On models with
bolts for
bolts
with air
for attaching
air conditioning,
conditioning, tighten
attaching condenser
condenser and
tighten the
and brackets
the
brackets
=
3 2 for refrigerant
for refrigerant pipes
pipes to
to
10 Nm.
10 Nm.
-- Replace O-rings
Replace O-rings in
in the
the connection
connection fittings
fittings of
of
the coolant
the coolant hoses.
hoses.
-- Insert drain
Insert drain plug
plug for
for coolant.
coolant.
-- Fill system
Fill system with
with coolant
coolant ⇒
> page
page 19-3.
19-3.
-- Install
Install headlights:
headlights:
⇒= Electrical
Electrical System;
System; Repair
Repair Group
Group 94;
94; Remov-
Remov-
ing and
ing and installing
installing headlights
headlights
-- Electrical
Electrical connections
connections andand routing:
routing:
⇒= Current
Current Flow
Flow Diagrams,
Diagrams, Electrical
Electrical Fault
Fault
Finding and
Finding and Fitting
Fitting Locations
Locations binder
binder
Edition 11.96
Edition 11.96 —— 19-11 ———
------------ 19-11 ------------
$00.5110.51.20
S00.5110.51.20
19
19 Cooling System
OCTAVIA
Removing and installing fan

Removing and installing fan
Note:
Note:
@ Raise
♦ Raise vehicle
vehicle with
with lift
lift platform => page
platform ⇒ 10-17,
page 10-1,
Removing and installing engine.

Removing and installing engine.

<@- -
K Separate plug connections -2- and -3- at the
Separate plug connections -2- and -3- at the
fan ring (press

fan ring (press catches)
catches) and
and detach
detach plug
plug
connections from
connections the holder.
from the holder.
-
- Detach wiring harness from the holder at the
Detach wiring harness from the holder at the
fan ring.
fan ring.
Only for fan V7 (large ∅

Only for fan V7 (large @) )
-
- Remove right headlight
Remove right headlight
= Electrical
⇒ Electrical System;
System; Repair
Repair Group
Group 94;
94; Remov-
Remov-
ing and installing headlights.
ing and installing headlights.
SVE
ProCarManuals.com
-
- Unscrew bolts (3 in total) for attaching air
Unscrew bolts (3 in total) for attaching air
ZO
ProCarManuals.com
guide pipe (below right headlight). Detach air

guide pipe (below right headlight). Detach air
guide pipe
guide pipe so
so that
that the
the fan bolt can
fan bolt can be
be un-
un-
screwed.
screwed.
Both fans
Both fans
-
- Unscrew bolts (3 in total) attaching the fan
Unscrew bolts (3 in total) attaching the fan
and lift out fan (fan V7 up, fan V35

and lift out fan (fan V7 up, fan V35 with with
smaller ∅
smaller @ down).
down).
Installation
Installation
Install in the reverse order.

Install in the reverse order.
—— 19-12 ——— Edition 03.98

03.98

------------ ------------ Edition

$00.5110.52.20
S00.5110.52.20
OCTAVIA
OCTAVIA Fuel Supply System
Fuel Supply System 20
Removing and installing parts of the fuel supply system

Removing and installing parts of the fuel supply system
Removing and installing fuel tank with attached parts

Removing and installing fuel tank with attached parts
3 - Fuel gauge sender

3 - Fuel gauge sender
789 10. 111213 141516 ¢ with

♦ closing flange
with closing flange
=" # removing
♦ removing and
¢ position
♦ position of
and installing
installing ⇒
of sender
sender with
= page
page 20-4
with strainer
20-4
strainer can
can be
be
moved relative to top part
4-Union nut, 80 Nm
4 - Union nut, 80 Nm
¢ use
♦ use wrench
wrench MP
MP 1-227
1-227 for
for removing
removing
and installing
and installing
5 - Feed line
5 - Feed line
¢ black
♦ black
¢ is
♦ is attached
attached to
to connection
connection marked
marked V
,V“
at closing
at closing flange
flange
¢ to
♦ to detach
detach from
from closing
closing flange,
flange, press
press
unlocking button
unlocking button atat connector
connector
6 - Return-flow line
¢ blue
♦ blue
¢ is
♦ is attached
attached to
to connection
connection marked
marked R
,,R“
at closing
at closing flange
flange
¢ to
♦ to detach
detach from
from closing
closing flange,
flange, press
press
ProCarManuals.com
unlocking button
connector
ProCarManuals.com
7 - Overflow hose
7 - Overflow hose
8 - O-ring
8 - O-ring
Notes:
Notes: 9 - Gravity valve
9 - Gravity valve
¢ for
♦ removing, unclip
for removing, unclip valve
valve and
and lift
lift up
up
¢ Pay
♦ Pay attention
attention to
to safety
safety precautions > page
precautions ⇒ page
and out of filler neck
and out of filler neck
20-3.
20-3.
¢ inspecting
♦ inspecting valve
valve for clearance
for clearance
Pay attention
♦ Pay attention to
to rules
rules for
for cleanliness
cleanliness ⇒
> page
page valve vertical: open
valve vertical: open
Sd
20-3.
20-3. valve tilted 45°: closed
valve tilted 45°: closed
¢ Always
♦ replace collar-type
Always replace collar-type clamps
clamps with
with 10 -Cap
10 - Cap
screw-type clamps.
screw-type clamps.
¢ Always
♦ replace all
Always replace all gaskets
gaskets and
and seals.
seals. 11 - Rubber bowl
11 - Rubber bowl
¢ attached
♦ attached with tensioning ring
with tensioning ring
@ Servicing
♦ Servicing throttle
throttle mechanism:
mechanism:
= 1.9
⇒ 1.9 l/66
1/66 kW
kW (TDI)
(TDI) Engine
Engine -- Fuel
Fuel Injection
Injection 12 - Earth connection
12 - Earth connection
@ Servicing
♦ Servicing fuel
fuel filter
filter 13 - O-rings
13 - O-rings
= 1.9
⇒ 1.9 l/66
1/66 kW
kW (TDI)
(TDI) Engine
Engine -- Fuel
Fuel Injection
Injection
and Glow Plug System; Repair Group 23 14 - Vent valve
14 - Vent valve
¢ inspecting
♦ inspecting ⇒
= Fig.
Fig. 11
1 - Fuel tank
1 - Fuel tank
15-10 Nm
15 - 10 Nm
2 - Seal
2 - Seal
¢ moisten
♦ moisten with fuel for
with fuel for installing
installing 16 - Vent hoses
16 - Vent hoses
¢ carefully
♦ carefully insert
insert seal
seal into
into the
the fuel tank
fuel tank
before installing fuel gauge sender

Edition 11.02
Edition 11.02 —— 20-1 ———
------------ 20-1 ------------
$00.5110.56.20
S00.5110.56.20
20
20 Fuel Supply System
Fuel Supply System OCTAVIA
OCTAVIA
17 - Clamping washer
789 10~_ 111213 141516 ¢ removing:

♦ removing: turn
turn to
to left
left
———, ¢ installing:
♦ installing: tighten
tighten toto 22 Nm
Nm
18 - Heat shield
18 - Heat shield
¢ for
♦ fuel tank
for fuel tank
19 - Cover
19 - Cover
¢ for
♦ fuel tank
for fuel tank
¢ not
♦ not fitted to all
fitted to all models
models
20 - 20 Nm + torque a further ‘/,/ turn

1
(90°)
4
# replace
♦ replace
21 - Tensioning straps
¢ pay
♦ pay attention
attention to
to different
different lengths
lengths
22 - Fuel cooler
22 - Fuel cooler
¢ only
♦ only for
for models
models fitted
fitted with automatic
with automatic
gearbox
gearbox
# removing
♦ removing and
and installing
installing ⇒ = page
page 20-2
20-2
23 - To fuel filter
23 - To fuel filter
24-20 Nm
24 - 20 Nm
ProCarManuals.com
ProCarManuals.co
<4 Fig.
K Fig. 1
1 Inspecting vent valve
Inspecting vent valve
Lever in off position: closed

Lever in off position: closed
Lever pressed in -direction of arrow-: open

Lever pressed in -direction of arrow-: open
Removing and installing fuel cooler

Removing and installing fuel cooler

¢ Tightening
♦ Tightening torque
torque
Removing
Removing
Pay attention to rules for cleanliness

Pay attention to rules for cleanliness
= page
⇒ page 20-3.
20-3.
Note:
Note:
The fuel cooler is located on the return-flow line

The fuel cooler is located on the return-flow line
to the fuel tank. It is fitted on the underbody of

to the fuel tank. It is fitted on the underbody of
the vehicle.
the vehicle.
-
- Remove cover -A-
Remove cover -A-
-
- Disconnect fuel line on the fuel cooler.
Disconnect fuel line on the fuel cooler.
-
- Unscrew the fixing nuts -arrows-.
Unscrew the fixing nuts -arrows-.
Installing
Installing
Installation occurs in reverse order while pay-

Installation occurs in reverse order while pay-
ing attention to the following:

ing attention to the following:
¢ Tighten
♦ Tighten fixing
fixing nuts
nuts for
for fuel
fuel cooler
cooler to
to 20
20 Nm.
Nm.
—— 20-2 ———_
------------ 20-2 ------------ Edition 11.02
Edition 11.02
$00.5110.56.20
S00.5110.56.20
OCTAVIA
OCTAVIA Fuel Supply
Fuel Supply System
System 20
20
Safety precautions
Safety precautions when
when carrying
carrying
out work
out work on
on fuel
fuel supply
supply system
system
Pay attention
Pay attention to
to the
the following
following points
points when
when
removing and
removing and installing
installing the
the fuel
fuel gauge
gauge sender
sender
or the
or the fuel
fuel pump
pump (fuel
(fuel delivery
delivery unit)
unit) from
from the
the fuel
fuel
tank:
tank:
The extraction
¢ The
♦ extraction hose
hose of of an
an exhaust
exhaust extraction
extraction
system should
system should be be placed
placed closeclose to to the
the
assembly opening
assembly opening of of the
the fuel
fuel tank
tank and
and the
the
extraction system
extraction system switched switched on on before
before
commencing work
commencing work in in order
order toto extract
extract thethe fuel
fuel
vapours which
vapours which are are released.
released.
IfIf no
no exhaust
exhaust extraction
extraction system system is is available,
available,
itit is
is possible
possible toto use
use a a radial
radial fan
fan with
with a a delivery
delivery
volume of
volume of more
more than than 15 15 mm%/h (motor not
3/h (motor not
positioned in
positioned in the
the air
air flow).
flow).
Avoid skin
♦ Avoid skin contact
contact with
with fuel!
fuel! Wear
Wear fuel-
fuel-
resistant gloves!
resistant gloves!
Rules for
Rules for cleanliness
cleanliness
ProCarManuals.com
Pay careful
Pay careful attention
attention toto the
the following
following rules
rules for
for
ProCarManuals.com
cleanliness when
cleanliness when carrying
carrying out
out work
work onon the
the fuel
fuel
supply/fuel injection
supply/fuel injection system:
system:
Thoroughly clean
¢ Thoroughly
♦ clean connection
connection points
points and
and the
the
surrounding area
surrounding area before
before disconnecting.
disconnecting.
Place removed
♦ Place removed parts
parts down
down on
on aa clean
clean sur-
sur-
face and
face and cover
cover over.
over. Do
Do not
not use
use fluffing
fluffing
cloths!
cloths!
Carefully cover
♦ Carefully cover over
over or
or seal
seal opened
opened compo-
compo-
nents ifif repairs
nents repairs are
are not
not carried
carried out
out imme-
imme-
diately.
diately.
Install only
♦ Install only clean
clean parts:
parts:
Do not
Do not remove
remove replacement
replacement partsparts from
from their
their
wrapping until
wrapping until just before installing.
just before installing.
Do not
Do not use
use parts
parts which
which have
have been
been stored
stored
unwrapped (e.g.
unwrapped (e.g. in
in tool
tool boxes
boxes etc.).
etc.).
♦ IfIf the
the system
system is
is open:
open:
Avoid working
Avoid working with
with compressed
compressed air, air, ifif
possible.
possible.
Avoid moving
Avoid moving the
the vehicle,
vehicle, ifif possible.
possible.
In addition,
♦ In addition, ensure
ensure that
that no
no diesel
diesel fuel
fuel flows
flows
onto the
onto the coolant
coolant hoses.
hoses. IfIf this
this happens,
happens, thethe
hoses should
hoses should bebe cleaned
cleaned again
again immediately.
immediately.
Replace any
Replace any hoses
hoses which
which have
have suffered
suffered da-
da-
mage.
mage.
Edition 08.96
Edition 08.96 —— 20-3 ——-
------------ 20-3 ------------
$00.5110.50.20
S00.5110.50.20
20
OCTAVIA
Removing and installing fuel gauge

Removing and installing fuel gauge
sender
sender

@ Wrench
♦ Wrench for union nut
for union nut MP
MP 1-227
1-227
Removing
Removing
-
- Unscrew cover (below rear seat).
Unscrew cover (below rear seat).
-
- Slacken fuel feed line and fuel return-flow
Slacken fuel feed line and fuel return-flow
line and detach.

line and detach.
-
- Separate multipin connector for fuel gauge.
Separate multipin connector for fuel gauge.
<q- -
K Use MP 1-227 to slacken union nut and pull
Use MP 1-227 to slacken union nut and pull
closing flange and sender out of the fuel tank.

Installing
Installing
<q- -
K Pay attention to installation position:
Pay attention to installation position:
ProCarManuals.com
ProCarManuals.com
¢ Marking
♦ Marking on
on closing
closing flange must be
flange must be aligned
aligned
with marking on fuel tank -arrows-.
¢
♦ Blue return-flow line -1- to connection
Blue return-flow line -1- to connection
marked with ”’R”.

marked with R.
¢ Black
♦ Black feed
feed line
line -2-
-2- to
to connection
connection marked
marked
with ”V”.
with V.
Removing and installing fuel tank


¢ Fuel
♦ Fuel extractor
extractor (e.g.
(e.g. V.A.G 1433 A)
V.A.G 1433 A)
¢ Engine/gearbox
♦ Engine/gearbox lifter
lifter (e.g.
(e.g. V.A.G 1383 A)
V.A.G 1383 A)
Removing
Removing
-
- Use fuel extractor (e.g. V.A.G 1433 A) to
Use fuel extractor (e.g. V.A.G 1433 A) to
empty fuel tank.

empty fuel tank.
-
- Remove rear axle:
Remove rear axle:
=
⇒ Running Gear; Repair Group
Running Gear; Repair Group 42; Remov-42; Remov-
ing and installing rear axle
ing and installing rear axle
—_— 20-4 ——
------------ 20-4 ------------ Edition 06.99
Edition 06.99
$00.5110.53.20
S00.5110.53.20
OCTAVIA
OCTAVIA Fuel Supply
Fuel Supply System
System 20
20
- Unbolt cover
Unbolt cover (below
(below rear
rear seat).
seat).
- Unplug multi-pin
Unplug multi-pin connector
connector for
for fuel
fuel gauge.
gauge.
- Open fuel
Open fuel filler
filler cap
cap and
and lever
lever out
out tensioning
tensioning
ring in
ring in rubber
rubber bowl
bowl (around
(around filler
filler neck).
neck).
- Push rubber
Push rubber bowl
bowl through
through to
to the
the inside.
inside.
- Remove rear
Remove rear right
right wheelhouse
wheelhouse liner.
liner.
- Slacken 2
Slacken 2 screws
screws for
for fuel
fuel filler
filler neck
neck working
working
from the
from the wheelhouse.
wheelhouse.
K- Remove cover
Remove cover below
below the
the fuel
fuel tank
tank -arrows-
-arrows-
(not fitted
(not fitted to
to all
all models).
models).
-- Separate 2
Separate 2 fuel
fuel pipes
pipes at
at the
the front
front right
right of
of the
the
fuel tank:
fuel tank:
K -- Press buttons
Press buttons on
on the
the hose
hose connections
connections
ProCarManuals.com
for this
for this purpose
purpose -arrows-.
-arrows-.
ProCarManuals.com
¢ black
♦ black =
= feed
feed pipe
pipe
¢ blue
♦ blue =
= return
return flow
flow pipe
pipe
-- Position engine/gearbox
Position engine/gearbox jack (e.g. V.A.G
jack (e.g. V.A.G
1383 A)
1383 A) below
below the
the fuel
fuel tank
tank for
for supporting
supporting it.
it.
<@- -
K Slacken the
Slacken the bolted
bolted connections
connections -arrows-
-arrows- at
at
the front
the front left
left and
and at
at the
the retaining
retaining straps.
straps.
-- Lower fuel
Lower fuel tank.
tank.
Installing
Installing
-- Take heat
Take heat shield
shield from
from the
the old
old fuel
fuel tank
tank and
and
fit onto
fit onto the
the new
new one.
one.
Edition 08.96
Edition 08.96 ——. 20-5 ——_
------------ 20-5 ------------
$00.5110.50.20
S00.5110.50.20
20
OCTAVIA
Removing and installing parts of fuel supply system for 4 x 4 models

Removing and installing parts of fuel supply system for 4 x 4 models
Removing and installing fuel tank with attached parts for 4 x 4 models
Removing and installing fuel tank with attached parts for 4 x 4 models
8 9 10 11 12 18
=
ProCarManuals.com
‘e
O
oY
qe
-_
Cc
qe
= Say
a
OC
ie
—
al
|_S20-0080_|
Notes:
Notes: @ Servicing
♦ Servicing fuel
fuel filter:
filter:
¢
Pay attention to safety precautions= page = 1.9-ltr./66
⇒ 1.9-ltr./66 kW
kW (TDI)
(TDI) Engine,
Engine, Fuel
Fuel Injection
Injection
♦ Pay attention to safety precautions ⇒ page
30-3 yp pag and Glow Plug System; Repair Group 23;
and Glow Plug System; Repair Group 23;
20-3.
‘ Servicing diesel direct injection system;
Servicing diesel direct injection system;
¢ Pay
♦ Pay attention
attention to
to rules
rules for
for cleanliness
cleanliness > page
⇒ page Servicing fuel
Servicing fuel filter
filter
20-3.
20-3.
1 - Fuel tank
1 - Fuel tank
¢ Always
♦ replace seals
Always replace seals and
and gaskets.
gaskets. ¢ Removing and installing
♦ Removing and installing
@ Servicing
♦ Servicing throttle
throttle mechanism:
mechanism: = page
⇒ page 20-9
20-9
= 1.9-ltr./66
⇒ 1.9-ltr./66 kW
kW (TDI)
(TDI) Engine,
Engine, Fuel
Fuel Injection
Injection

Servicing throttle
Servicing throttle mechanism
mechanism
—— 20-6 ———
------------ 20-6 ------------ Edition 06.99
Edition 06.99
$00.5110.53.20
S00.5110.53.20
OCTAVIA
20
2 - Seal
2 - Seal 14 -Vent valve
14 - Vent valve
moisten with
¢ moisten
♦ fuel for
with fuel for installing
installing
carefully insert
¢ carefully
♦ insert seal
seal into
into the
the fuel tank
fuel tank 15-10 Nm
15 - 10 Nm
before installing
fuel gauge sender
16 - Vent hoses
16 - Vent hoses
3 - Right fuel gauge sender

3 - Right fuel gauge sender
with pump
¢ with
♦ pump for
for pumping
pumping over
over fuel
fuel 17 - Left fuel gauge sender
17 - Left fuel gauge sender
with closing
¢ with
♦ closing flange
flange ¢ with
♦ closing flange
with closing flange
removing and
¢ removing
♦ and installing
installing ⇒=> page
page 20-8
20-8 # removing
♦ removing and
and installing
installing ⇒ = page
page 20-8
20-8
position of
¢ position
♦ of sender
sender with strainer can
with strainer can be
be ¢ position
♦ position of
of sender
sender can
can be
be moved
moved rela-
rela-
moved relative to top part tive to top part
tive to top part
4- Union nut, 80 Nm
4 - Union nut, 80 Nm 18 - Heat shield
18 - Heat shield
use wrench
¢ use
♦ MP 1-227
wrench MP 1-227 for removing
for removing ¢ for
♦ for fuel tank
fuel tank
and installing
and installing
19 - 20 Nm + torque a further 1/4 turn (90°)

19 - 20 Nm + torque a further 1/4 turn (90°)
5 - Feed line
5 - Feed line ¢ replace
♦ replace
black
¢ black
♦
is attached
¢ is
♦ attached to
to connection
connection marked
marked V
,V“ 20 - Clamping washer
at closing
at closing flange
flange
to detach
¢ to
♦ detach from closing flange,
from closing press
flange, press 21 - Tensioning straps
unlocking button
connector ¢ pay
♦ pay attention
attention to
to different
different lengths
lengths
blue
¢ blue
♦
is attached
¢ is
♦ attached to
to connection
connection marked
marked R
,,R“
at closing
at closing flange
flange
ProCarManuals.com
to detach
detach from closing flange, press
ProCarManuals.com
¢ to
♦ from closing flange, press
unlocking button
connector
7 - Overflow hose
7 - Overflow hose
8 - O-ring
8 - O-ring
9 - Gravity valve
9 - Gravity valve
for removing,
¢ for
♦ removing, unclip
unclip valve
valve and
and lift
lift up
up
and out
and out of
of filler
filler neck
neck
inspecting valve
¢ inspecting
♦ valve forfor clearance
clearance

10
- Cap
10 - Cap
11 - Rubber bowl
11 - Rubber bowl
13 - O-rings
13 - O-rings
Edition 05.01
Edition 05.01 —— 20-7 ———
------------ 20-7 ------------
$00.5110.55.20
S00.5110.55.20
20
Fuel Supply System

OCTAVIA
OCTAVIA
Removing and installing fuel

gauge

sender for

4 x 4 models


and aids required

@ Wrench
♦ Wrench for union nut
for union nut MP
MP 1-227
1-227
Removing fuel gauge sender (on right)

! " # $

- - Unscrew cover (below rear seat).

- - Slacken fuel feed line and fuel return-flow

Slacken fuel feed line and fuel return-flow
line and detach.

line and detach.
- - Separate multipin connector for fuel gauge.

Separate multipin connector for fuel gauge.
<q- -
K Use MP 1-227 to slacken union nut and pull

Removing fuel gauge sender (on left)

! " ! $

- - Unscrew cover (below rear seat).

- - Use MP 1-227 to slacken union nut and pull


ProCarManuals.com

ProCarManuals.com
Installing fuel gauge sender (on right)

% ! " # $

<q- -
K Pay attention to installation position:
¢ Marking
♦ Marking on
on closing
aligned
NO

¢ Blue
♦ Blue return-flow
return-flow line
line -1-
-1- to
to connection
connection
marked
marked with -R-. with -R-.
¢ Black
♦ Black feed
feed line
line -2-
-2- to
to connection
connection marked
marked
with -V-.
with -V-.
1 Installing fuel gauge sender (on left)

% ! " ! $

- - Pay attention to installation position:

¢ Marking
♦ Marking on
on closing
aligned
—— 20-8 -——— Edition 06.99

------------ -----------

$00.5110.53.20
S00.5110.53.20
OCTAVIA
20

for 4 x 4 models
for 4 x 4 models

@ Engine/gearbox
♦ Engine/gearbox lifter
lifter (e.g.
(e.g. V.A.G
V.A.G 1383
1383 A)
A)
¢ Fuel
♦ Fuel extractor
extractor (e.g.
(e.g. V.A.G
V.A.G 1433
1433 A)
A)
Removing
Removing
-
- Use fuel extractor (e.g. V.A.G 1433 A) to
Use fuel extractor (e.g. V.A.G 1433 A) to
empty fuel tank.

empty fuel tank.
-
- Unscrew cover (below right rear seat).
Unscrew cover (below right rear seat).
-
- Unplug multipin connector for fuel gauge.
Unplug multipin connector for fuel gauge.
-
- Open fuel filler flap and remove rubber bowl.
Open fuel filler flap and remove rubber bowl.
- Take off rear right wheel.

Take off rear right wheel.
- Remove rear right wheelhouse liner.

Remove rear right wheelhouse liner.
Slacken 2 bolts for fuel filler neck from work-

ProCarManuals.com
- Slacken 2 bolts for fuel filler neck from work-

ProCarManuals.com
ing from wheelhouse.

ing from wheelhouse.
- Separate 2 fuel lines on front right at fuel tank:

Separate 2 fuel lines on front right at fuel tank:
K -
- Press down buttons on hose connectors
Press down buttons on hose connectors
-arrows- for this step.

-arrows- for this step.
¢ black
♦ black =
= feed
feed line
line
¢
♦ blue = return-flow line
blue = return-flow line
- Remove exhaust (without front exhaust pipe)

Remove exhaust (without front exhaust pipe)
=> page
⇒ page 26-4.1.
26-4.1.
- Remove rear part of propshaft.

Remove rear part of propshaft.
5-Speed Manual
⇒ 5-Speed Manual Gearbox
Gearbox 02C;
02C; Repair
Repair
Group 39; Removing and installing propel-
Group 39; Removing and installing propel-
ler shaft.
ler shaft.
K- Unscrew the bottom bolts -arrow- attaching

Unscrew the bottom bolts -arrow- attaching
the left and right shock absorbers.

the left and right shock absorbers.
Edition 06.99 —— 20-9 -———

Edition 06.99 ------------ -----------

$00.5110.53.20
S00.5110.53.20
20
Fuel Supply System

OCTAVIA
OCTAVIA
- Separate connector at ABS and Haldex cou-

Separate connector at ABS and Haldex cou-
pling.
pling.
- Detach vent hoses of Haldex coupling.

Detach vent hoses of Haldex coupling.
- Support the rear final drive with the engine/

Support the rear final drive with the engine/
gearbox lifter (e.g. V.A.G 1383 A).

gearbox lifter (e.g. V.A.G 1383 A).
K- Unscrew bolts at rear axle -arrows-.

Unscrew bolts at rear axle -arrows-.
- Swivel out rear axle by lowering the lifter.

Swivel out rear axle by lowering the lifter.
- Remove guard plate.

Remove guard plate.
- Unscrew 2 bolts of fuel tank mount.

Unscrew 2 bolts of fuel tank mount.
ProCarManuals.com
ProCarManuals.com
<q --
K Slacken bolts -arrows- at tensioning straps.
Slacken bolts -arrows- at tensioning straps.
- Lower fuel tank.

Lower fuel tank.
Installing

- Installation is carried out in the reverse

Installation is carried out in the reverse or- or-
der.der.
— 20-10 -——— Edition 06.99

------------ -----------

$00.5110.53.20
S00.5110.53.20
OCTAVIA
1 Turbocharging
21
(
Charge air system with turbo-

$ 3 '
charger

Notes:

Observe the cleanliness regulations ⇒

¢ >
♦ >
page
21-1.
(%%
Connection

♦ 1 diagram
for
charge pressure

control ⇒
> (%;
page 21-4.
♦ The hose connections are secured
with
clamps.

The charge air system must be tight.

¢

♦
¢ Always
♦ replace self-locking
nuts.

Inspecting turbocharger
¢ !
♦
=> 6.00$"9
(+')!A+4
Glow Plug System; Repair Group 23.

5B
52
Rules for cleanliness

&
Carefully observe the following rules for cleanli-

#!
ness when working on the exhaust turbocharger:

$/%
ProCarManuals.com
¢ Thoroughly clean the connection points and

ProCarManuals.com
♦
their surroundings before releasing.

Place removed parts on a clean surface and

♦ #
cover. Do not use fuzzy cloths!
# (@@L
Carefully cover or close opened components

♦ #
if the repair is not completed immediately.

Only install clean parts:

♦ F%
Remove spare parts from their wrapping im-

#!
mediately before fitting.

Do not use any parts which have been stored

(#
unwrapped (e.g. in tool boxes etc.).

9 / '
When the system is open:

♦ "%
Avoid using compressed air.
*#
Avoid moving the vehicle.

*###
Edition 04.04

—— 21-1 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
21
( Turbocharging
OCTAVIA
1
Removing and installing turbocharger for the engine AGR3

& with attached parts
1 <= D 3 4 56
ProCarManuals.com
ProCarManuals.com
9 NG
27 . \
% 2425 24 9991 | S21-0019 |
1 - Intake manifold
' &
4- Vacuum setting element
' 8
@
♦ onengines ä > 6
07.97 @ 3 6
♦ onengines 08.97 ä >
¢ with
♦ mechanical exhaust gas recircu-
/! ¢ for
♦ intake manifold flap
$
lation valve
##
5 - Induction pipe
, '

2 -Intake manifold
( ' &
# 3 6
♦ onengines 08.97 ä>
@ 3 6
♦ onengines 08.97 ä > ¢ with
♦ mechanical /
exhaust
gas !
recircu-
lation valve
##
3 - O-ring
* ' )' ¢ for
♦ intake manifold flap
$
@ 3 6
♦ onengines 08.97 ä>
¢
♦ replace
21-2 —__
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Turbocharging
21
(
6-10 Nm
. ' - 24 - O-ring
( ' )'
¢
♦ replace
7 - From charge air cooler
/ ' +
25 - Oil return-flow line

(, ' ) '&3
8 - Gasket
0' ¢ for
♦ vehicles ä
# > - 66
04.99
¢
♦ fitting %
position: ;
Bead
points
towards @ $
♦ tocylinder block
intake manifold
$
(. ' 2 : -
9 - Gasket
%'
¢

♦ Replace 27-15 Nm
(/ ' ,-
10-20 Nm
' (- 28 - Front exhaust pipe
(0 ' + !
11 - Exhaust gas recirculation pipe

' ! 29 - Turbocharger
(% '
# #
♦ removing and installing ⇒= !0
page 21-6
12 - Gasket
( '
¢
♦ pay attention to fitting position 30 - Screwed socket
* ' 3

¢ 2<#
♦ 30 Nm for vehicles ä
> 66
02.99
13 - Exhaust manifold
* ' ! &
¢ <#2 66
♦ 20 Nm for vehicles 03.99 ä>
14 - Bracket
' 2 31 - Oil feed line
* ' )&

¢ from
♦ oil filter holder

15 - Shield
, '
= ?!
⇒ pos. 15, page 17-2.
16 - Washer
. ' 9 32-30 Nm
*( ' *-
¢
♦ 1.6 mm thick
0$ ¢
♦ replace
¢
coat thread and head contact surface
ProCarManuals.com
♦
17-25 Nm of bolt with hot bolt paste G 052 112
ProCarManuals.com
/ ' (,- 5
A3
*2
18 - O-ring
0 ' )'
¢
♦ replace 33 - Intake manifold flap change-over valve
** ' &
& '
(-N239-)
4'-(*%'5
19 - Connecting piece
% ' $
¢
♦ for charge pressure control 34 - Washer
* ' 9
¢
♦ 4mm thick
-$

( ' 2 : ,-
35-25 Nm
*, ' (,-
21 - Screwed socket, 40 Nm
( ' 3
- ¢
♦ replace
¢
♦ coat thread and contact surface of bolt
22 - Oil return- flow line
(( ' ) '&3 with hot bolt paste G 052 112 A3
5*2
¢ # 66
♦ for vehicles 05.99 ä>
@ $
♦ tocylinder block
23 - From air filter

(* ' + &
Edition 04.04

—— 21-3 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
21
( Turbocharging
OCTAVIA
1
Removing and installing turbocharger for the engine ALH with attached parts

& ;13

an) <A\
ProCarManuals.com
ProCarManuals.com
|_S21-0068 |
' ! &
5-25 Nm
, ' (,-
¢
♦ with turbocharger
¢
♦ must be replaced completely 6 - Gasket
. '
@
2 -Intake manifold
( ' &
7 - Washer
/ ' 9
3 - From charge air cooler

* ' +
8-25 Nm
0 ' (,-
4 - Gasket
' #
♦ replace
¢
♦ replace ¢
♦ coat stud bolts with hot bolt paste
-G 052 112 A3-
!5D*2!
——__ 21-3.1 ——
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Turbocharging
21
(
9 - From air filter

% ' + & 20 - O-ring
( ' )'
¢
♦ replace ¢ for
♦ oil return-flow line
!
¢
♦ replace
10 - To charge air cooler
'
21 - Turbocharger
( '
11 - Vacuum setting element

' 8 #
♦ can
only
be
replaced
complete
with
¢
♦ charge pressure control exhaust manifold
/
# /!
♦ component part of the exhaust turbo- # #
♦ removing and installing ⇒= !3
page 21-8
charger cannot be replaced separately
¢ +
♦ Inspect #
vacuum
setting
element of
charge pressure control ⇒
> !
page 21-5
12 - Shield
( '
¢ ##
♦ charge pressure regulating valve and
vacuum setting element are compo-
# !
13 - Support
* ' nent parts of the exhaust turbocharger
/
¢ !$
♦ turbocharger - cylinder block and must not be replaced individually.
#
¢ After
♦ installing
* the ?
turbocharger,
run
14-40 Nm
' - engine at idling speed for about 1

minute to ensure that oil is supplied to

15-25 Nm
, ' (,- the turbocharger.

16 - O-ring
. ' )' 22 - O-ring
(( ' )'
¢
♦ replace ¢
♦ replace
17 - Connection fitting, 40 Nm
/ ' $ & - 23 - Front exhaust pipe with catalytic con-
(* ' + ! 3 '
verter

18-17 Nm
0 ' /-
24 - Connection fitting, 30 Nm
( ' $ & *-
19 - Oil return-flow line

% ' ) '&3
ProCarManuals.com
@ $
tocylinder block 25 - Oil feed line
ProCarManuals.com
♦ (, ' )&

¢ 2<
♦ tighten to 35 Nm ¢ <
♦ tighten to 25 Nm
26-10 Nm
(. ' -
Edition 04.04

——__ 21-3.2 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
21
( Turbocharging
OCTAVIA
1
Connection diagram for charge

$
&
pressure control

Engines AGR:
7
~<
K 1 - Charge pressure control solenoid valve
! ##
Vy (-N75-)
9!<!'
2 - Air guide pipe

! *
¢ from
♦ air filter

3 - Turbocharger
2!
¢ with
♦ pressure
connection for charge

, \— 2 pressure control


- ! 1
¢ for
♦ charge pressure control valve
##
3
ProCarManuals.com
ProCarManuals.com
BY aa 4
Ss
Engines ALH:
;17
7 8 ~<
K 1 - Charge pressure control solenoid valve
! ##
| (-N75-)
9!<!'
<« te sop 2 - To/##9!<3!'

! exhaust gas recirculation valve (-N18-)
3 - To
2! air filter
4 - Vacuum reservoir
- ! 1#
5 - Vacuum setting element of charge pres-

! 1!
sure control

6 - Turbocharger
0!
7 - To$!###
! intake manifold flap change-over valve
(-N239-)
9!<26!'
8 - Non-return valve, white connection points

3 ! <!##?
to charge pressure control solenoid valve

##
(-N75-)
9!<!'
—— 21-4 —__
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Turbocharging
21
(
Inspecting vacuum setting element

of charge pressure control

&
Test conditions:

@
l Engine oil temperature at least 80 °C
,
6'41
Engines AGR:
7
Test procedure

~<@-!
K Remove plug from charge pressure control

#
solenoid valve -N75 (pos. 2).

##!<9 '
-
! Start the engine and bring the engine up to

high revolutions by pressing rapidly on the

#
accelerator pedal.

<@- !
K Actuator rod -2- of charge pressure control
*!!
valve must move.

###
If the actuator rod does not move:

+#%
- Inspect lever of charge pressure control valve

ProCarManuals.com
! +###
ProCarManuals.com
-1- for smooth operation. In case of rust, re-

!! +?!
Si place turbocharger.

Y) If the actuator rod does not move despite hav-

+##!
ing an easily moving lever:

##%
|
-
! Replace vacuum setting element of charge

#
pressure control valve -3-.

##!2!
Engines ALH:
;17

A
@ 8#9 1 * 526'

Hand vacuum pump (e.g. V.A.G 1390)
Y-6)
♦
Test procedure

@
ar wT
I
<4- !
K Connect hand vacuum pump to the vacuum
##
setting element for charge pressure control

valve
## and $
check
actuator
rod for smooth

operation.

- If the actuator rod only moves with difficulty or

+#
does not move at all:

#%
-
! Replace turbocharger.

Edition 04.04

—— 21-5 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
21
( Turbocharging
OCTAVIA
1
Removing and installing turbo-

'
charger


A
¢ Torque
♦ wrench
,
¢
¢ 85*2
♦ Hot bolt paste G 052 112 A3
Engines AGR:
7
Removing

<q -!
K Unbolt fixing nut -3- and air guide pipe -2-
C / !2! !!
together with hose to turbocharger.

! Detach hose to charge pressure control so-

(!
lenoid valve -N75 at turbocharger, and un-

## !< ? !
screw banjo bolt, as appropriate.

4?
! Detach hose at vacuum setting element for

(#
charge pressure control valve.

##
ProCarManuals.com
ProCarManuals. com
For 4x4 vehicles

+!
! Remove intake manifold and exhaust mani-

#$/!
fold > !

⇒ page 21-2.
For all vehicles

+
! Unbolt front exhaust pipe from turbocharger

C/
and tie up at body (max. deflection of de-

9/ !
coupling element 10°).

>'
! Unbolt oil feed line from turbocharger and

C
remove clamp securing intake manifold.

#$
! Unbolt oil return-flow line from turbocharger.

C!
! Remove air guide pipe from air filter to tur-

#!
bocharger.

K! Unscrew fixing nut -2- from below and bolts

C/!!
-1- from above.

!!#
—— 21-6 ——
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Turbocharging
21
(
For 4x4 vehicles

+!
! Lift turbocharger up and out.

7
For other vehicles

+
! Take turbocharger down and out.

$
Installing

! Fit hose onto vacuum setting element for

A #
charge pressure control valve and secure

##
with collar clamp.

K! Coat thread and head contact surface of fix-

/!
ing bolts -1- with hot bolt paste G 052 112

!! 5
A3.
*2
! Fit turbocharger onto exhaust manifold and

A/
tighten securing bolt -1- by hand.

!!
! Coat nut -2- with hot bolt paste G 052 112

!! 5
A3 and tighten to 25 Nm.

*2<
! Tighten fixing bolts -1- to 30 Nm.

/!!2<
ProCarManuals.com
ProCarManuals.com
For 4x4 vehicles

+!
! Install intake manifold and exhaust manifold

+$/
= !
⇒ page 21-2.
For all vehicles

+
! Fit on oil return-flow line with new gasket and

A!$
tighten to 15 Nm.
<
! Attach
* front exhaust
/ pipe with new $
gasket
and tighten to 25 Nm.
<
Note:

Fill the turbocharger with engine oil at connec-

tion fitting of oil feed line.

! Fit on oil feed line and tighten to 25 Nm.

A<
! Tighten clamps for oil feed line to 10 Nm.

<
! Fit hose onto charge pressure control valve

A##
and secure with collar clamp.

! Connect hose to charge pressure control

solenoid valve -N75 to turbocharger and se-

##!<!
cure with collar clamp, or screwin4

? banjo bolt
with new gasket rings and tighten to 15 Nm
$<
as appropriate.

Edition 04.04

—— 21-7 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
21
( Turbocharging
OCTAVIA
1
-
! Install air guide pipe from charge air cooler
+
with hose to turbocharger.

-
! Install air guide pipe from air filter to turbo-
+!
charger.

Note:

After installing the turbocharger, run engine at

idling
speed
for
about %
1

minute
but
do
no
yet
rev
up
to
ensure proper supply
of
oil
to
turbo-
charger.

Engines ALH:
;17
Removing

! Remove top connection pipe and charge air

#
connection hose.

-
! Removing intake manifold.

#$
<@- !
K Detach connecting hoses -1- and -2-.
(!!!!
-
! Remove oil return-flow line -5-.

#!!!
ProCarManuals.com
ProCarManuals.com
-
! Unscrew bolts -3- and -4- and remove sup-
C!2!!-!#!
port.

-
! Detach vacuum hose -7- from vacuum
(#!!#! set-
ting element for charge pressure control.

&
} -
! Remove exhaust pipe -6- from turbocharger

#/!0!
$21-0022 and lay aside.

VY WT
-
! Remove oil feed line from turbocharger.

#
-
! Unbolt exhaust manifold from cylinder head.
C/
-
! Lift turbocharger up and out.
7
Installing

Further installation is carried out in reverse or-

A#!
der. Pay attention to the following:

%
Note:

After installing the turbocharger, run engine at

idling speed for about 1 minute to ensure that

%

oil is supplied to the turbocharger.

—— 21-8 ———
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
OCTAVIA Turbocharging system
Turbocharging system 21
21
Removing and installing parts of the charge air cooling system

Removing and installing parts of the charge air cooling system
4 5 6 7 8 4
Notes:
Notes:
¢ Hose
♦ Hose connections
connections are
are secured
secured with
with spring
spring
strap clips. Only spring strap clips may be
strap clips. Only spring strap clips may be
used when carrying out repairs.

used when carrying out repairs.
¢ It
♦ It is
is recommended
recommended to
to use
use the
the pliers for re-
pliers for re-
moving and installing the spring strap Clips.
moving and installing the spring strap clips.
@ There
♦ There must
must not
not be
be any
any leak
leak in
in the
the charge
charge air
air
system.
system.
1 - Charge air cooler

1 - Charge air cooler
@ Removing
♦ Removing and
and installing
installing
= page
⇒ page 21-10
21-10
2-10 Nm
2 - 10 Nm
3 - Bracket
3 - Bracket
4-Hose
4 - Hose
ProCarManuals.com
ProCarManuals.com
5 - Air guide pipe

5 - Air guide pipe
@ Charge
♦ Charge air
air cooler/intake
cooler/intake manifold
manifold
6 - O-ring
6 - O-ring
@ Replace
♦ Replace ifif damaged
damaged
7-Intake manifold temperature sender

7 - Intake manifold temperature sender
-G72
-G72
¢ With
♦ With intake
intake manifold
manifold pressure
pressure sender
sender
-G71
-G71
8-5Nm
8 - 5 Nm
9 - Air guide pipe

9 - Air guide pipe
@ For
♦ For models
models 08.97
08.97 ä>
¢ Charge
♦ Charge air
air cooler/turbocharger
cooler/turbocharger
10 - Air guide pipe

10 - Air guide pipe
¢ For
♦ For models
models ä > 07.97
07.97
¢ Charge
♦ Charge air
air cooler/turbocharger
cooler/turbocharger
Edition 06.99 —— 21-9 -——

Edition 06.99 ------------ -----------

$00.5110.53.20
S00.5110.53.20
21 Turbocharging
Turbocharging OCTAVIA
OCTAVIA
Removing and installing charge air

Removing and installing charge air
cooler
cooler

Torque
♦ T wrench
orque wrench
Pliers for
♦ Pliers spring strap
for spring strap clips
clips
K- Remove noise insulation in middle

Remove noise insulation in middle and on and on
right -arrows-.
right -arrows-.
ProCarManuals.com
Is co
K- Detach fuel lines -arrows- to injection pump,

Detach fuel lines -arrows- to injection pump,
seal with plugs and place to the side.

seal with plugs and place to the side.
ProCarManu
- Unplug connector -2- at intake manifold tem-

Unplug connector -2- at intake manifold tem-
perature sender -G72 together with intake

perature sender -G72 together with intake
manifold pressure sender -G71.

manifold pressure sender -G71.
- Remove air guide pipe -1-.

Remove air guide pipe -1-.
- Remove windshield washer fluid reservoir.

Remove windshield washer fluid reservoir.
K- Unscrew 2 bolts -arrows- for charge air

Unscrew 2 bolts -arrows- for charge air
cooler.
cooler.
Note:
Note:
If the vehicle is equipped with xenon headlights,

If the vehicle is equipped with xenon headlights,
the right headlight must be removed ⇒

the right headlight must be removed => Electri-
Electri-
cal System; Repair Group 94.
cal System; Repair Group 94.
A21-0012
Edition 05.01
05.01

------------ ------------ Edition

$00.5110.55.20
S00.5110.55.20
OCTAVIA Turbocharging
Turbocharging 21
21
t K -- Unscrew nut
Unscrew nut -3-
-3- securing
securing air
air guide
guide pipe
pipe -2-.
-2-.
-- Take off
Take off air
air guide
guide pipe.
pipe.
-- Detach right
Detach right wheelhouse
wheelhouse liner
liner at
at the
the front
front
edge.
edge.
-- Turn down
Turn down nut
nut -1-
-1- at
at bracket
bracket for
for intercooler.
intercooler.
-- Remove intercooler
Remove intercooler downward.
downward.
—
A21-0013
ProCarManuals.com
ProCarManuals.com
Edition 08.96
Edition 08.96 —— 21-11 -——
------------ 21-11 -----------
$00.5110.50.20
S00.5110.50.20
WoOo'sjenueIIeDOId
ProCarManuals.com
OCTAVIA
1 Exhaust System
! 26
(.
Removing and installing parts of the exhaust system

& !
7 - Gasket
/'
¢
♦ replace
8 - Front exhaust pipe

0 ' + !
¢ with
♦ oxidation catalytic converter
/#
¢
♦ protect
catalytic #
converter
against
shocks and blows
$
¢ #?/ !
♦ avoid a large deflection, max. deflec-
tion 10°
>
9 - Double clamp
% ' 6
¢
♦ align /
exhaust
system
pipe
free
of
stress before tightening ⇒
> 0!2
page 26-3
¢ fitting
♦ position:
% bolted
connection
pointing to left

¢ #
♦ tighten bolted connections evenly
10-40 Nm
' -
11 - Hanger
' 1
¢
12 - Hanger
( ' 1
ProCarManuals.com
13 - Rear silencer
* '
ProCarManuals.com
¢
♦ the front and rear silencer are installed
as standard as a single part, in the
?
event of repairs the front and rear si-

#!
lencer are delivered separately; to be

#B
connected together with a double

Notes:
Notes:
clamp.

@ )

♦ Removing
and
installing
exhaust

manifold ¢ /
♦ align exhaust system free of stress
=> $(%( (%&%
⇒ page 21- 2 or page 21-3.1 => D0!2
⇒ page 26-3
¢
♦ replace middle or rear silencer⇒ =>
page
¢ Always
♦ replace
gaskets and
self-locking

26-2
0!
nuts.

1-20 Nm
' (-
2 - Tunnel bridge
( '

¢ /
♦ with hole for aligning exhaust system
=> 0!2
⇒ page 26-3
3 - Hanger
* ' 1
¢
♦ fitting position ⇒
=> A
Fig. 2
4-25Nm
' (,-
5 - Hanger
, ' 1
6-25 Nm
. ' (,-
¢
♦ replace
¢
G 052 112 A3
5D*2
Edition 04.04

——— 26-1 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
26
(. Exhaust System
! OCTAVIA
1
<4 +
K Fig. 1 Separation point

@ "
♦ When
replacing
middle
silencer
or
rear !
si-
lencer

¢ :$
♦ Marked
by
three
recesses
around !
circum-
ference of exhaust pipe
/
<{Fig.2
K +( Fitting position of the hangers
+ &
The angled

side !!
-arrow-
at
the
base
of
the
hanger points in direction of travel.
#
can / U
=
ProCarManuals.com
AEH
ProCarManuals.com
S Let ag
(an) Replacing middle silencer or rear

on) silencer

[s2sci78 | Special tools, testers and aids required

A
¢ Torque
♦ wrench
,
¢ ;9 1 * 52'
♦ Body saw (e.g. V.A.G 1523)
Work procedure
9

-
! Separate exhaust pipe at the separation point
/
-arrow 2- at right angles with a body saw (e.g.

!!9
V.A.G 1523).
1 * 52'
-
! When installing double clamp -4- position on
"!-!
the side markings -arrows 1 and 3-.

$!2!
-
! Align exhaust system free of stress ⇒
*/=>
page
26-3.
0!2
-
! Align rear silencer horizontally.
*@
-
! Tighten bolted connections of double clamp

evenly to 40 Nm.
#-<
-
! Fitting position of double clamp: parallel to
A %
vehicle floor, bolted connections point toward

#?
left.

——— 26-2 ———

------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Exhaust System
! 26
(.
Align exhaust system free of stress

! &&

A
< —>
<—
¢ Torque
♦ wrench
,
@
l The exhaust system is aligned when cold
/
Work procedure
9

<q- !
K Shop-made tool from an M10 bolt to the di-
!:!
mensions stated for aligning the exhaust

/
system.

¢
♦ Dimension x = 4mm
(/E-
S26-0179
¢ (E
♦ Dimension y = 25 mm
Note:
Note:
ProCarManuals.com
ProCarManuals.com
A
second person is ?
required
for
aligning
the
exhaust system.

! Loosen bolted connections of double clamp

7
= 0!?! 6
⇒ page 26-1, -pos. 9.
K! Insert shop-made tool through the rear hole

+!
-arrow- of the tunnel bridge, the flat side

!! ?
points toward the hanger pin of the exhaust

/
system.

Note:
Note:
The exhaust system is pretensioned in the di-

rection of travel when the shop-made tool is in-

serted.

-
*@
~<q-!
K The hanger pin at the exhaust pipe must be
/
parallel to the tunnel bridge (dimension -x-

9 !/!
on left and right identical).

'
Note:
Note:
ll On vehicles with separation point ⇒

> > (9(
page 26-2
inspect horizontal position of rear silencer addi-
@
tionally at tail pipes.

Edition 04.04

—— 26-3 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
26
(. Exhaust System
! OCTAVIA
1
<q- !
K Position double clamp with a distance of

about 5 mm to the line of the marking -A ar-

$!*!
row !
1-
and
tighten #
evenly
to -
40 <
Nm
in
the
horizontal position.
@
Notes:
Notes:
@
♦ The

marking -A-
applies
to
vehicles
with
manual gearbox and automatic gearbox.

¢

♦ The bolted connection of the double clamp
points toward left.

ProCarManuals.com
ProCarManuals.com
—— 26-4 ——
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Exhaust System
! 26
(.
Removing and installing parts of the exhaust system for 4x4 vehicles

& ! &!
3 - Front exhaust pipe

* ' + !
1 3 4 5
4 - Gasket
'
¢
♦ replace
5 - Oxidation catalytic converter

, ' )!

¢ $
♦ protect against shocks and blows
6-25 Nm
. ' (,-
¢
♦ replace
7 - Bolt
/ ' 2
8 - Retaining strap
0 '
9-25 Nm
% ' (,-
10 - Rear silencer
'
¢ !!?
♦ installed as standard with part -11-, in
the event of repairs it is delivered se-
##!
parately

¢ )/
♦ Exhaust
pipe with separation
point
=> D0!-
⇒ page 26-4.2
ProCarManuals.com
11 - Front silencer
10
' +
ProCarManuals.com
¢ !!?
♦ installed as standard with part -10-, in
the event of repairs it is delivered se-
##!
parately

¢ /
♦ exhaust pipe with separation point
=> D0!-
⇒ page 26-4.2
Notes:
Notes:
¢
♦ align free of stress
@ )

♦ Removing
and
installing
exhaust

manifold
=> $(%( (%&%
⇒ page 21- 2 or page 21-3.1 12 - Double clamp
( ' 6
¢ fitting
♦ position:
% bolted
connection
¢ Always
♦ replace
gaskets and
self-locking

pointing to left; fitting position is mar-
B!
nuts.

ked by tree lugs on the front silencer
$
¢ #
♦ tighten bolted connections evenly
1 - Gasket
'
¢
♦ replace
13-40 Nm
* ' -
2-25 Nm
( ' (,-
14 - Bracket
' 2
¢
♦ replace
¢
G 052 112 A3
5D*2
Edition 04.04

—— 26-4.1 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
26
(. Exhaust System
! OCTAVIA
1
<4 +
K Fig. 1 Separation point

@ "
♦ When
replacing
middle
silencer
or
rear !
si-
lencer

¢ :$
♦ Marked
by
three
recesses
around !
circum-
ference of exhaust pipe
/
Replacing middle silencer or rear

silencer for 4x4 vehicles

&!
ProCarManuals.com
ProCarManuals.com

A
¢ Torque
♦ wrench
,
¢ ;9 1 * 52'
♦ Body saw (e.g. V.A.G 1523)
Work procedure
9

-
! Separate exhaust pipe at the separation point
/
-arrow- at right angles with a body saw (e.g.

!!9
V.A.G 1523).
1 * 52'
-
! Mark on both sides 50 mm from the separa-
:$!
tion point.

-
! Position double clamp on both sides of the

markings.
$
-
! Align exhaust system free of stress.
*/
-
*@
-
! Tighten bolted connections of double clamp

evenly to 40 Nm.
#-<
-
! Fitting position of double clamp: Bolted con-
A%;!
nection points toward left.

—— 26-4.2 ———
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Exhaust System
! 26
(.
Exhaust gas recirculation system

!
Notes:
Notes:
¢

♦ The exhaust gas recirculation system is ac- ¢
♦ The

mechanical
exhaust
gas
recirculation
tuated by the diesel direct injection system
3
valve
with
conically
shaped
valve
tappets
control unit -J248 through the EGR valve
A(;6 ,/) permits different

opening
cross-sections
at
-N18 to the mechanical exhaust gas recircu-
B%6
different valve lift.

lation valve. @ Any
♦ desired valve position is possible as a

¢ 1

♦ Components marked with * are tested by the
C result of the pulsed actuation.

final control diagnosis

¢ Always
♦ replace self-locking
diagrams.

= 6.00$"9
(+')!A+4
Glow Plug System; Repair Group 01; Final

5B
5BA
control diagnosis.

Connection diagram for control of exhaust gas recirculation system

$
& &!
For vehicles ä
+> /
07.00
1 2 1 - Mechanical exhaust gas recirculation

' < !
——____|- valve

| J 3 ¢
♦ testing ⇒= 0!
page 26-7
ProCarManuals.com
=———
ProCarManuals.com
2-EGR
4'-0'5C
(' solenoid valve (-N18-)*
Ss. 3-To air filter

* ' &
4-To brake servo unit

'
ra 4 5 -Non-return valve
, ' -'
6 - Vacuum
. ' 8 pump
8 k
C7] A 7-Vacuum setting element for intake
/ ' 8 &
es — ee 5s) manifold flap

&
&
¢ 3 6
♦ only for models 08.97 ä
>
| 8 - Intake manifold flap change-over valve

0 ' &
& '
(-N239-)
4'-(*%'5
7 —— 6 ¢ 3 6
♦ only for models 08.97 ä
>
Edition 04.04

—— 26-5 ——_
------------
------------
$00.5110.57.20
S00.5110.57.20
26
(. Exhaust System
! OCTAVIA
1
For vehicles 08.00 ä

+0 >
is)
Ol
1-Vacuum setting element for intake
' 8 &
manifold flap
&
&
2 - Intake manifold flap change-over valve

( ' &
& '
(-N239-)
4'-(*%'5
3 - Distributor
* ' 6
4- Non-return valve
' -'
@ white
♦ connection points to charge pres-
!
sure control solenoid valve -N75-).

##!<!'
5 - Vacuum
, ' 8 unit
6 - To air filter
. ' &
7 - Charge pressure control solenoid val-

/ ' $
'
ve (-N75-)*
4'-/,'5C

8 0 ' 8
¢ for
♦ charge pressure control valve
##
ProCarManuals.com
¢
part
of ?
turbocharger,
cannot
be !
re-
ProCarManuals.com
♦
placed separately

9 - EGR
4'-0'5C
% ' solenoid valve (-N18-)*
10 - Mechanical exhaust gas recirculation

' < !
valve

¢
♦ testing ⇒= 0!
page 26-7
11 - Vacuum
' 8 pump
12 - Brake servo unit

( ' 2
13 - Non-return
* ' -' valve
—— 26-6 ———
------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Exhaust System
! 26
(.
Testing mechanical exhaust gas

!
recirculation valve


A
@ 8#9 1 * 526'

♦ Hand vacuum pump (e.g. V.A.G 1390)
Test procedure

-
! Remove engine trim panel.

#
-
! Separate air guide pipe between inlet con-
!
nection and charge air cooler at inlet con-

!
nection.

V.A.G 1390
5,
-
! Detach vacuum hose from mechanical
( # /! ex-
haust gas recirculation valve.
##
<@- !
K Connect hand vacuum pump
#
(e.g. V.A.G 1390) to valve.

9 1 * 526'##
-
! Operate pump and observe diaphragm rod.
F#
¢ The
♦ diaphragm rod must move in direc-
#!
tion of -arrow-.
ProCarManuals.com
!!
ProCarManuals.com
-
! Detach hose of hand vacuum pump
( # from
exhaust gas recirculation valve.
/##
¢ The
♦ diaphragm rod must move back into
#$
the initial position in the opposite direc-

!
tion of the arrow.

Edition 04.04

——— 26-7 ———
------------
------------
$00.5110.57.20
S00.5110.57.20
26
(. Exhaust System
! OCTAVIA
1
Removing and installing parts of the exhaust gas recirculation

& !
ProCarManuals.com
ProCarManuals.com
| S26-0174 |
1 - Intake manifold
' &
4 - Mechanical exhaust gas recirculation
' < !
valve

2-O-ring
( ' )' # !
♦ component of the induction pipe can-
¢
♦ replace not be replace separately

¢
♦ testing ⇒= 0!
page 26-7
3 - Induction pipe
* '

¢ /!
♦ with mechanical exhaust gas recircu- 5-10 Nm
, ' -
lation valve
##
6 - From Turbocharger
. ' +
——_ 26-8 ———

------------
------------ Edition 04.04

$00.5110.57.20
S00.5110.57.20
OCTAVIA
1 Exhaust System
! 26
(.
7 - Gasket
/' 13 - Connecting tube
* ' $
¢
♦ replace ¢ from
♦ exhaust manifold to radiator
/
@
♦ only
on
engines ALH
*78 with automatic

8-25 Nm
0 ' (,- gearbox
/
9 - Connecting tube
% ' $ 14 - To heat exchanger for heating
' ! &
¢
♦ from radiator to induction pipe
@
♦ only
on
engines ALH with
*78 automatic 15 - Radiator for exhaust gas recirculation
, '
&!
gearbox
/ @
♦ only
on
engines ALH
*78 with automatic

gearbox
/
10 - Connecting tube
' $
¢
♦ from exhaust manifold to induction
/ 16 - From connection fitting
. ' + &
pipe
@
♦ connection of heating
' ! &
17 - To expansion reservoir
/ ' !
12-25 Nm
( ' (,-
¢
♦ replace
ProCarManuals.com
ProCarManuals.com
Edition 04.04

—— 26-9 ——
------------
------------
$00.5110.57.20
S00.5110.57.20
WoOo'sjenueIIeDOId
ProCarManuals.com

Workshop Manual Octavia

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Service

Service Department. Technical Information

S00.5110.52.20 Edition 03.98

it is not permitted to pass it onto third persons.

1.9 I/66 kW (TDI) Engine, Mechanical Components

Replaces List of Supplements - Edition:

The Service Manual is intended only for use within the

Removing and installing engine ................................................................................................

Disassembling and assembling engine .......................---ssse

Removing and installing crankshaft ..........................................................................................

Disassembling and assembling pistons and connecting rod ............---:--:ssssssssaseaaaaaaaaazanzennee

Removing and installing cylinder head .....................................................................................

Servicing valve gear ....................................................................................................................

Removing and installing parts of the lubrication system ..................-::-sssaseaaaaaaaaaanananaaznaznennce

Removing and installing parts of the cooling system .................--::sesssesaaea

Removing and installing parts of the fuel supply system .................-...-----ueueeeeeee

Charge air system with turbocharger...................-----ese

Removing and installing parts of the exhaust system ................-.--:essseeeeea

Removing and installing parts of the exhaust system - 4 x 4 models .................----:::222:111111.

Exhaust gas recirculation system 

------------ II ------------ Edition 04.04

o In addition, a sticker with „engine code" and „se-

o I) rial number" is affixed to the toothed belt guard.

ć The engine code is also indicated on the vehi-

cle data stickers.

Engine code AGR ALH

Engine code AGR ALH

Exhaust gas recirculation

Charge air cooling

Complies with emission limits

Removing and installing engine

Special tools, testers and aids required

Workshop crane (e.g. V.A.G 1202 A)

Catch pan (e.g. V.A.G 1306)

Pliers for spring strap clips

Engine mount MP 1-202

Bolt M10 x 25/8.8

Engine/gearbox jack (e.g. V.A.G 1383 A)

Double ladder (e.g. VAS 5085)

Lifting device MP 9-201

Grease G 000 100

♦ AII cable straps

♦ Always replace clamp-type

or screw-type clips is not allowed.

coded radio set; determine if necessary.

connect earth strap at the battery.

to the following points:

On no account may the arms of the lift platform be

positioned below the sills, the front or rear sus-

marking on the sill.

Never start the engine when the vehicle is raised

and engage a gear so long as only one driven gear

is making contact with the ground.

marking at the sill.

and also on the left and right -arrows-.

K- Turn drain plug -arrow- at the radiator to the

left or fit hose onto connection, as appropri-

ant to flow out.

l mass meter -2-.

IB) ter housing.

104 —— Edition 03.00

------------ ------------ Edition 03.00

<a- Unbolt earth cable -1-.

Exhaust gas recirculation system