2 0 125 KW TDI PD Engine PDF

Service
Workshop Manual
OCTAVIA II 2004 ➤
2.0/125 kW TDI PD Engine
Engine ID BMN
Edition 08.06
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankgear
15 - Cylinder Head, Valve Gear
17 - Lubrication
19 - Cooling
20 - Fuel Supply
21 - Turbocharging
23 - Fuel Formation, Injection
26 - Exhaust System
28 - Glow Plug System
OCTAVIA II 2004 ➤
2.0/125 kW TDI PD Engine - Edition 08.06
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Safety precautions when working on the diesel direct injection system . . . . . . . . . . . . . . . . 3
1.5 Regulations concerning cleanliness when working on the fuel supply/fuel injection system
........................................................................ 4
1.6 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 4
1.7 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Tightening torques of the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Checking and adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1 Disassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.1 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Replacing gasket ring for crankshaft -on the belt pulley side- . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Removing and installing the sealing flange -on the belt pulley side- . . . . . . . . . . . . . . . . . . 36
2.3 Replace sealing flange -on the gearbox side- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Removing and installing drive chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.4 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.2 Checking the axial play of the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.3 Replacing camshaft gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.5 Removing and installing roller rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Contents i
OCTAVIA II 2004 ➤
2.6 Check hydraulic supporting elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.7 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.9 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.1 Disassembling and assembling oil filter holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1 Removing and installing parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1 Parts of cooling system, on the side next to the body - Summary of components . . . . . . . . 93
1.2 Parts of cooling system, engine side - Summary of components . . . . . . . . . . . . . . . . . . . . 94
1.3 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.4 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.5 Removing and installing fan shroud for radiator fan V7 and right radiator fan V35 . . . . . . 100
1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.8 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.9 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.1 Fuel tank with attached parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3 Drain the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.4 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.5 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.7 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 113
1.8 Removing and installing the tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.9 Inspecting a tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.10 Checking fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
21 - Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.3 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.5 Hose connections with push-fit couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.6 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Repairing the diesel direct injection system control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Intake manifold with component parts - Summary of components . . . . . . . . . . . . . . . . . . . . 137
1.3 Pre-wiring for unit injectors and for ceramic pencil type glow plugs - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.4 Removing and installing pre-wiring for unit injectors and ceramic pencil type glow plugs . . 138
ii Contents
OCTAVIA II 2004 ➤
1.5 Unit injectors - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

1.6 Removing and installing unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.7 Replacing O-rings of the unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.8 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.9 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.10 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.2 Removing and installing pre-exhaust pipe with diesel particle filter . . . . . . . . . . . . . . . . . . 155
1.3 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.5 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.1 Exhaust gas recirculation system - Summary of components . . . . . . . . . . . . . . . . . . . . . . 161
2.2 Radiator for exhaust gas recirculation - Summary of components . . . . . . . . . . . . . . . . . . . . 162
2.3 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.4 Check change-over for radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 163
2.5 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 164
28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.1 Removing and installing ceramic pencil type glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Contents iii
OCTAVIA II 2004 ➤
iv Contents
OCTAVIA II 2004 ➤
00 – Technical data
1 Technical data
1.1 Engine number

The engine number (“engine identification character” and “serial
number”) is located in the front at the engine/gearbox joint
-arrow-.
In addition, a sticker with the “engine identification character” and
“serial number” is affixed to the toothed belt guard.
The engine code is also indicated on the vehicle data sticker.
1.2 Engine characteristics

Engine identification character BMN
Manufactured 07.06 ? 05.08
Exhaust limit values conforming to EU4
Displacement l 1,968
Power output kW at rpm 125/4200
Torque Nm at rpm 350/1800
Bore ∅ mm 81,0
Stroke mm 95,5
Number of valves per cylinder 4
Compression ratio 18,5 : 1
Firing order 1-3-4-2
Catalytic converter yes
Exhaust gas recirculation with radiator yes
Turbocharging yes
Charge air cooler yes
Diesel particle filter yes
1. Technical data 1
OCTAVIA II 2004 ➤
01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations and direc‐
tions
1.1 Self-diagnosis
This repair group is no longer applicable.
For this use “Vehicle self-diagnosis”, “Measuring method” and
“Targeted fault finding” ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051.
1.2 Supplementary instructions and assem‐

bly work on vehicles with an air condi‐
tioning system
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Note
To avoid causing damage to the condenser and to the refrigerant

lines and hoses make sure the lines and hoses are not over-ex‐
tended, kinked or bent.
Steps which should be taken in order to remove and install the

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

OCTAVIA II 2004 ➤
1.3 Safety precautions when working on the

fuel supply system
WARNING
♦ On vehicles with pump injector engine, the temperature of

the fuel lines or of the fuel can be up to 100°C in an ex‐
treme case. Let the fuel cool down before opening the
lines, as otherwise there is a high risk of burning.
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
♦ The fuel pump is activated when the ignition is switched on

and by the door contact switch of the driver door. Before open‐
ing the fuel system and for reasons of safety, if the battery is
not disconnected, the connector -arrow- must be disconnected
from the fuel delivery unit.
WARNING
Please observe the following when undertaking all assembly

work, particularly in the engine compartment, due to its cram‐
ped construction.
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerent, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
Pay attention to the following points when removing and installing

the sender for fuel gauge display or the fuel pump (fuel delivery
unit) on a fuel tank that is filled or partially filled:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
1.4 Safety precautions when working on the

diesel direct injection system
If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
If the test and measuring devices are operated from the passen‐
ger seat, the passenger can be injured by the release of the
passenger airbag in the event of an accident.
1. Self diagnosis, safety measures, cleanliness regulations and directions 3

OCTAVIA II 2004 ➤
WARNING
Secure the diagnostic device to the rear seat and operate from
that position.
Observe the following points to prevent injury to persons and/or

damage to the injection and preheating system:
♦ Disconnect and connect wires of the preheating and injection
system as well as measuring device wires when the ignition is
switched off.
♦ If the engine should be run at the starter speed without it ac‐
tually igniting, then separate the central plug connection for
the unit injector at the cylinder head.
♦ Before disconnecting the battery determine the code of the
radio fitted with anti-theft coding.
♦ Switch off the ignition before connecting or disconnecting the
battery as this could otherwise damage the diesel direct injec‐
tion system control unit.
♦ If the battery is reconnected, carry out certain operations ⇒
Electrical System ⇒ Rep. Gr. 27 .
1.5 Regulations concerning cleanliness

when working on the fuel supply/fuel in‐
jection system
Carefully observe the following “6 rules” for cleanliness when
working on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately. Replace imme‐
diately any hoses which have suffered damage.
1.6 Regulations concerning cleanliness

when working on the exhaust gas turbo‐
charger
Carefully observe the following “5 rules” for cleanliness when
working on the exhaust gas turbocharger:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.

OCTAVIA II 2004 ➤
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
1.7 General instructions for charge air sys‐

tem
WARNING

ped construction.
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
Caution
In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter housing, air filter element and charge air
pipes as well as charge air hoses for soiling.
♦ Check all air guides and charge air cooler for foreign bod‐
ies.
If foreign bodies are detected in the charge air system, the
charge-air routing must be cleaned and the charge air cooler
must be replaced.
♦ The charge-air system must be tight, check ⇒ page 132 .

♦ Always replace self-locking nuts.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before being installed. The gasket ring
and the sealing surface must be slightly oiled only for push-fit
couplings ⇒ page 131 .
♦ Observe assembly markings on the hoses and components.
♦ All hose connections of the charge air system are secured with
spring strap clamps or push-fit couplings.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ Electronic Catalogue of Original Parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Assembly of hose connections with push-fit couplings
⇒ page 131 .
♦ Before screwing on the oil feed line, fill the exhaust gas tur‐
bocharger on the connection fitting with engine oil.
1. Self diagnosis, safety measures, cleanliness regulations and directions 5

OCTAVIA II 2004 ➤
♦ after installing the exhaust gas turbocharger run the engine

approx. 1 minute in idle and do not increase speed immedi‐
ately in order to ensure the supply of oil to the exhaust gas
turbocharger.

OCTAVIA II 2004 ➤
10 – Removing and installing engine

1 Removing and installing engine
1.1 Removing engine

Special tools and workshop equipment required
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Engine and gearbox jack , e.g. -V.A.G 1383 A-
♦ Engine mount -T10012-
♦ Workshop crane , e.g. -VAS 6100-
♦ Double ladder , e. g. -VAS 5085-
♦ Pliers for spring strap clamps
– Before removing the engine, interrogate the fault memory of
all control units ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
Note
♦ The engine is removed downwards together with the gearbox.

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

ped construction.
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.
Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .
– Before disconnecting the battery, if necessary remove the
adapter for the safety wheel bolts from the luggage compart‐
ment.
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐
trical System ⇒ Rep. Gr. 27 .
– Remove engine cover ⇒ page 13 .
1. Removing and installing engine 7

OCTAVIA II 2004 ➤
– Remove air filter with air mass meter -G70- and inlet hose
⇒ page 148 .
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .
– Unplug the following plug connections at the bulkhead plenum
chamber and expose lines:
1 - Plug (black) for charge pressure control solenoid valve -N75-
2 - Plug connection (orange) for exhaust gas temperature sender
3 -G495- ( temperature sender downstream particle filter -G527- )
3 - Plug connection (black) for exhaust gas temperature sender
1 -G235- ( temperature sender upstream turbocharger -G507- )
4 - Plug connection (black) for lambda probe -G39- with heating
for lambda probe -Z19-
5 - Plug connection (brown) for exhaust gas temperature sender
2 -G448- ( temperature sender upstream particle filter -G506- )
– Remove plenum chamber cover and bulkhead plenum cham‐
ber ⇒ Body Work ⇒ Rep. Gr. 66 .
– Slacken the screw for the front right drive shaft only by maxi‐
mum 90°, otherwise the wheel bearing may be damaged.
– Remove both front wheels ⇒ Chassis ⇒ Rep. Gr. 44 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Remove the right wheelhouse liner bottom part ⇒ Body Work
⇒ Rep. Gr. 66 .
– Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Remove the left drive shaft from the gearbox flange.
– Unscrew the nut from the left coupling rod -2- of the anti-roll
bar and press the coupling rod off the anti-roll bar.
– Unscrew the nuts from the left steering joint -3- and press the
steering joint out of the suspension arm.
– If present, remove coupling rod from front left vehicle level
sensor -G78- .
– Turn steering to full left lock.
– Swivel the steering joint outwards and secure the drive shaft
-1- with a band -A- in the wheel housing as shown in the illus‐
tration.
– Insert the steering joint to ensure stabilisation with a threaded
bore into the suspension arm.
– Remove the charge air hose on the right and left between the
charge air cooler and charge air pipe ⇒ page 130 .
8 Rep. Gr.10 - Removing and installing engine

OCTAVIA II 2004 ➤
– Disconnect plug -2- from charge pressure sender -G31- / in‐

take air temperature sender -G42- .
– Release screws -1- and -3-.
– Separate charge-air pipe from charge air hose -4- and remove
downwards.
Caution
Shut off the openings of the charge air cooler, e.g. with a clean
foam piece, so that no coolant can penetrate.
– Remove radiator ⇒ page 100 .
– Separate fuel feed line -2- and fuel return-flow line -1-, to do
so press securing ring.
– Detach coolant hose, fuel intake hose -2- and fuel return-flow
hose -1- from pipes at cylinder head.

OCTAVIA II 2004 ➤
– Release screw -1- by one turn.

– Release screw -2- and nut -3-.
– Take out fuel filter with connected hoses.
Note
Mark the direction of rotation with chalk or a felt-tip pen before

removing the V-ribbed belt. Reversing the rotation direction of an
already used belt may destroy it.

– Remove alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
WARNING
Refrigerant circuit of the air conditioning system must not be

opened.
Note
To avoid causing damage to the AC compressor as well as to the

refrigerant lines and hoses make sure the lines and hoses are not
over-extended, kinked or bent.
– Remove AC compressor from the bracket for auxiliary units

⇒ page 22 .
– Attach AC compressor with connected refrigerant hoses to the
lock carrier.
– Remove bracket for the wiring harness of the oil level and oil
temperature sender -G266- from the assembly carrier.
– First release screw -1-, then release screws -2- and -3-.
– Remove pendulum support.
– Remove pre-exhaust pipe with diesel particle filter
⇒ page 155 .
– Unlatch the fuse and disconnect the front plug from the engine
control unit ⇒ page 152 .

OCTAVIA II 2004 ➤
– Release duct for engine wiring harness -arrow- and pull out
upwards.
– Open the cable guide -arrows-, remove the engine wiring har‐
ness and place down to the side.
– Release all remaining plugs at engine and gearbox and lay
aside the relevant lines.
Note
To release the plug of the engine speed sender, press the plug
together with a screwdriver and at the same time raise the release
button with a thin wire hook.
– Separate the quick couplings -arrows- at the heat exchanger.

– Disconnect bottom coolant hose at coolant expansion reser‐
voir.
Vehicles with auxiliary heating.
– Seperate coolant hoses on the auxiliary heating.
– Only remove long exhaust pipe of auxiliary heating ⇒ Heating,
Air Conditioning ⇒ Rep. Gr. 82 .
Continued for all vehicles
– Detach all connecting and vacuum hoses from the engine.
– Remove shift mechanism from gearbox ⇒ Manual Gearbox
⇒ Rep. Gr. 34 .
– Remove the tube-hose line to the slave cylinder of the clutch
control ⇒ Gearbox ⇒ Rep. Gr. 30 .
WARNING
After separating the hydraulic line, do not operate the clutch

pedal.

OCTAVIA II 2004 ➤
– Screw engine mount -T10012- to the cylinder block with nut

-2- and screw -1- to 20 Nm.
– Insert engine/gearbox jack -V.A.G 1383 A- in the engine
mount and slightly raise.
WARNING
Use double ladder to release the screws for the engine and
gearbox mounting.
– Successively release screws for engine mounting -arrows-.
– Successively release screws for gearbox mounting -arrows-.
Note
♦ Check whether all hose and line connections between engine,

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

– Remove the gearbox from the engine ⇒ Manual Gearbox ⇒
Rep. Gr. 34 .

OCTAVIA II 2004 ➤
1.1.1 Removing and installing engine trim

panel
Removing
– Pull oil dipstick -1- out of oil dipstick guide.
– Pull off the outer -2- and inner -3- engine cover evenly up‐
wards.
– Push the oil dipstick back into the oil dipstick guide.
Install
– Pull oil dipstick -1- out of oil dipstick guide.
Caution
Before installing the engine cover, check the correct position

of the fixing elements (ball sockets). If necessary they must be
put back into their correct position. Otherwise this can lead to
damage to the engine cover.
– If necessary, press the ball sockets of the engine cover into

the correct position.
– Place the engine cover onto the fixing points and press it into
the catch.
– Push the oil dipstick back into the oil dipstick guide.
1.2 Securing the engine to the assembly

stand
♦ Lifting device -MP 9-201 (2024A)-
♦ Engine mount -MP 1-202-
♦ Hook -MP 1-202/10-
♦ Bushing -T30010 (VW 540/1B)-
♦ Assembly stand -MP 9-101-
Procedure
• Separate engine from gearbox.

OCTAVIA II 2004 ➤
WARNING
Use securing pins on the hooks and rig pins to prevent release.
– Attach lifting device -MP 9-201- at engine and at workshop

crane e.g. -VAS 6100- .
Belt pulley side: 2nd hole of the attachment in Position 1.
Flywheel side: 4th hole of the attachment in Position 8.
– Lift off engine with installed engine mount -T10012- with work‐
shop crane from engine and gearbox jack.
– Remove engine mount -T10012 - .
– For carrying out assembly work, attach the engine with the
engine mount -MP 1-202- , the hook -MP 1-202/10- and the
sleeves -T30010- to the assembly stand -MP 9-101- (the figure
shows the 1.9 ltr./47kW SDI Engine; the fixing system is iden‐
tical).
1.3 Installing the engine

Installation occurs in reverse order to removal. Pay attention to
the following:
Note
♦ When performing installation work replace the self-locking

nuts.
♦ Replace screws which have been tightened to a turning angle
as well as gasket rings and seals.
♦ All cable straps should be fitted on again in the same place
when installing.
♦ Secure all hose connections with corresponding hose clips.

OCTAVIA II 2004 ➤
Caution

ped construction.
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.
Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .
– Clean the serration on the drive shaft and if the clutch disc has
been used clean the hub serration, remove corrosion and only
apply a very thin layer of grease -G 000 100- to the serration
on the drive shaft. Subsequently move the clutch disc up and
down on the drive shaft until the hub fits smoothly on the shaft.
Always remove all excess grease.
– After installing the coupling, check the centering of the clutch
disc ⇒ Manual Gearbox ⇒ Rep. Gr. 30 .
– Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ Manual Gearbox ⇒ Rep. Gr. 30 .
– Check whether the dowel sleeves for centering the engine/
gearbox are present in the cylinder block; insert if necessary.
– Ensure that the intermediate plate has been inserted on the
sealing flange and is pushed onto the dowel sleeves
-arrows-.
– Screw on gearbox to engine ⇒ Manual Gearbox ⇒ Rep. Gr.
34 .
– Insert engine with gearbox into the body.
– Successively screw in by hand the new screws for engine

mounting -arrows-.

OCTAVIA II 2004 ➤
– Successively screw in by hand the new screws for gearbox

mounting -arrows-.
– Adjust assembly bracket ⇒ page 19 and tighten screws
⇒ page 18 .
– Remove engine mount -T10012- from engine.

OCTAVIA II 2004 ➤
– First tighten pendulum support with new screws -2- and -3- at
gearbox and then tighten with new screw -1- at assembly car‐
rier.
Tightening torque: ⇒ page 18
– Install the right drive shaft and screw the left drive shaft onto
the gearbox flange ⇒ Chassis ⇒ Rep. Gr. 40 .
– Install pre-exhaust pipe with diesel particle filter
⇒ page 155 .
– Attach the tube-hose line to the slave cylinder of the clutch
control and bleed the clutch system ⇒ Gearbox ⇒ Rep. Gr.
30 .
– Attach shift mechanism to gearbox and adjust ⇒ Manual
Gearbox ⇒ Rep. Gr. 34 .
– Install radiator ⇒ page 100 .
– Attach the coolant hoses to the auxiliary heating.
– Install long exhaust pipe of auxiliary heating ⇒ Heating, Air
Conditioning ⇒ Rep. Gr. 82 .
– Install AC compressor ⇒ page 22 .
– Install alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install the V-ribbed belt ⇒ page 22 .
– Connect all connecting, fuel, coolant and vacuum hoses to the
engine.
– Observe the assembly instruction for hose connections with
push-fit couplings ⇒ page 131 .
– Connect electrical connections and attach cables ⇒ Current
flow diagrams and Fitting locations.
– Install battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install bulkhead plenum chamber and plenum chamber cover
⇒ Body Work ⇒ Rep. Gr. 66 .
– Install wiper arms ⇒ Electrical System ⇒ Rep. Gr. 92 .
– Top up coolant ⇒ page 97 .
– Checking the oil level ⇒ Maintenance ; Octavia II .
– Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Install the right wheelhouse liner bottom part ⇒ Body Work ⇒
Rep. Gr. 66 .
– Perform a test drive.
– Interrogate all fault memories, rectify any faults existing and
erase fault memory ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051.
Note
After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.

OCTAVIA II 2004 ➤
Tightening torques
Component Nm
Screws/nuts M6 9
M7 13
M8 20
M10 40
M12 70
Engine/gearbox connecting screws ⇒
Manual Gearbox ⇒ Rep. Gr. 34
1.4 Tightening torques of the unit mounting

Unit mounting for engine
A - 20 Nm + 90° (1/4 turn) - replace
B - 40 Nm + 90° (1/4 turn) - replace
C - 60 Nm + 90° (1/4 turn) - replace
Unit mounting for gearbox

1 - 40 Nm + 90° (1/4 turn) - replace
2 - 60 Nm + 90° (1/4 turn) - replace
Pendulum support
A (strength category 8.8) - 40 Nm + torque a further 90° (1/4 turn)
- replace
A (strength category 10.9 1)) - 50 Nm + 90° (1/4 turn) - replace
B - 100 Nm + 90° (1/4 turn) - replace

Remove: First release screw -B-, then screws -A-.
Install: First tighten screws -A-, then screw -B-.

OCTAVIA II 2004 ➤
1)On manual gearbox MQ350 (02Q), only use the screws with
the strength category 10.9 if bolt-holes have been installed (e.g.
Heli-Coil) -arrow-.
1.5 Checking and adjusting the unit mount‐

ing
1.5.1 Checking the unit mounting

Check dimensions on the right hanger for engine/gearbox unit:
• Between engine bracket and engine support there must be a
distance -a- of 10...13 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.
Note
The distance -a- can also be checked e.g. with corresponding

round bars.
Only if there is an acoustic complaint (engine or gearbox knock

on the frame side rail when cornering) and the dimension -a- is
outside 10…13 mm:
– Adjust the unit mounting ⇒ page 19 .
1.5.2 Adjusting the unit mounting

♦ Supporting device -T30099-
♦ Supporting plate -T30099/1-
♦ Hook -MP 9-200/10 (10-222A/10)-
Gr. 27 .
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
Gr. 66 .

OCTAVIA II 2004 ➤
– Position supporting device -T30099- and support plate -

T30099/1- and support the engine/gearbox unit in its installed
position.
– Uniformly pre-tension the engine/gearbox unit with both spin‐
dles, but do not raise.
– Release the screws -arrows- of the unit mounting at the en‐

gine.
– Slightly loosen the screws -2- of the unit mounting at the gear‐
box (less than 1 revolution).
– Successively replace all the screws of the unit mounting (as
long as it has not already been performed when installing the
engine) and screw them in loosely.

OCTAVIA II 2004 ➤
– Move the engine/gearbox unit with a tyre lever between engine

support -1- and supporting arm -3- for engine mount until the
following dimensions are set:
• Between engine bracket and engine support there must be a
distance -a- of 10 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.
Note
The distance -a- = 10 mm can be checked e.g. with suitable round

bars.
– Tighten the screws of the unit mounting for engine

⇒ page 18 .
– Make sure that on the gearbox side the edges of the support‐
ing arm -2- and gearbox support -1- are parallel.
• The dimension -x- must be the same on both mount sides.
– Tighten the screws of the unit mounting for gearbox
⇒ page 18 .
Further installation occurs in reverse order.

OCTAVIA II 2004 ➤
13 – Crankgear
1 Disassembling and assembling en‐
gine
1.1 Removing and installing V-ribbed belt
1 - 90 Nm + torque a further 90°

(1/4 turn)
❑ replace
❑ Attachment
⇒ page 23
2 - Guide pulley
❑ for toothed belt
3 - Bracket for auxiliary units
❑ order of tightening
⇒ page 23
4 - Bushing
5 - 23 Nm
6 - AC generator
❑ removing and installing
⇒ Electrical System ⇒
Rep. Gr. 27
❑ to facilitate positioning,
drive the threaded bush‐
ings for fixing screws at
the generator slightly
backwards
7 - 45 Nm
❑ observe the order of
tightening up
⇒ page 23
8 - Bushing
❑ 2 pieces
❑ must be inserted into the
support (Pos. 3)
9 - 25 Nm
10 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning ⇒ Rep. Gr. 87
11 - V-ribbed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
❑ do not kink
❑ removing ⇒ page 23
❑ installing ⇒ page 23
12 - Belt pulley
❑ with vibration damper
❑ can be installed only in one position
22 Rep. Gr.13 - Crankgear

OCTAVIA II 2004 ➤
13 - 10 Nm + torque a further 90° (1/4 turn)

❑ replace
14 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with open-end wrench to slacken the V-ribbed belt
❑ after removal of the fuel filter, can be interlocked with locking pin -T10060A- or Allan key
15 - 23 Nm
Attachment - toothed belt camshaft drive

Screw -arrow- with inside thread for engine support fixture
Bolts at bracket for auxiliary units - tightening sequence

Removing
Caution

removing the V-ribbed belt. Reversing the rotation direction of
an already used belt may destroy it.
– Swing the the tensioning device in

-the direction of the arrow- detension the V-ribbed belt.
– Hold the tensioning device and remove the slackened V-rib‐
bed belt.
Install
the following:
Note
Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.
1. Disassembling and assembling engine 23

OCTAVIA II 2004 ➤
– First position the ribbed V-belt on the belt pulleys of the crank‐
shaft and AC compressor and on the belt pulley of the gener‐
ator last; then release the tensioning device.
– Check correct positioning of the ribbed V-belt on the belt pul‐
leys.
– Start engine and check ribbed V-belt run.
1.2 Removing and installing toothed belt
1.2.1 Summary of components - part 1

(1/4 turn)
❑ replace
2 - Belt pulley of the crankshaft
❑ with vibration damper
❑ can be installed only in
one position
3 - 10 Nm
❑ insert using locking
agent -D 000 600 A2-
4 - 40 Nm + torque a further
180° (1/2 turn)
❑ replace
❑ observe tightening tor‐
que and tightening se‐
quence ⇒ page 25
5 - Engine support bracket
6 - Top toothed belt guard
❑ when installing, correct‐
ly insert into the middle
part of the toothed belt
guard
7 - Middle toothed belt guard
❑ to remove, remove top
toothed belt guard and
unscrew tensioning de‐
vice for ribbed V-belt.
8 - Bottom toothed belt guard

OCTAVIA II 2004 ➤
Tightening torque and tightening sequence for engine support
Caution
The tightening sequence and the tightening torque of the fixing

screws for the engine support must definitely be respected.
Otherwise stress of the engine support occurs, which results
in the breaking of the engine support.
– First screw in new screws -1…3- by hand.

– Then tighten screws -1…3- to 40 Nm.
– Then torque screws -1…3- a further 180° (1/2 turn.)
Note
♦ Raise or lower engine with the supporting device -T30099- .

♦ Before the engine mount is installed, all the screws of the en‐
gine support must be tightened to the specified tightening
torque.
1.2.2 Summary of components - part 2
Note

removing the toothed belt. Reversing the rotation direction of an
already used belt may destroy it.

OCTAVIA II 2004 ➤
1 - 120 Nm + torque a further

90° (1/4 turn)
❑ replace
❑ do not oil
❑ to release and tighten
use counterholder -
T30004- or counterhold‐
er -MP 1-310 (3099)-
2 - 20 Nm
❑ self-locking, replace
3 - small guide pulley
(1/8 turn)
5 - Tensioning pulley
6 - Toothed belt
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ install (set the timing)
⇒ page 30
7 - 25 Nm
8 - Toothed belt sprocket of ex‐
haust camshaft
❑ Check fitting position
9 - 25 Nm
10 - Toothed belt sprocket of
inlet camshaft
11 - 100 Nm
❑ to release and tighten use counterholder -T10051-
12 - 100 Nm
❑ to release and tighten use counterholder -T10051- ⇒ page 72
13 - Hub
❑ for exhaust camshaft
❑ to remove use extractor -T10052-
14 - Hub
❑ for inlet camshaft with rotor for hall sender -G40-
❑ to remove use extractor -T10052- ⇒ page 72
15 - Rear toothed belt guard
16 - Rubber grommet
❑ for the removal of the hall sender -G40- (rear toothed belt guard must not be removed)
❑ replace if damaged
17 - 10 Nm
❑ insert using locking agent -D 000 600 A2-

OCTAVIA II 2004 ➤
18 - O-ring
❑ replace
19 - Coolant pump
❑ removing and installing ⇒ page 101
20 - 15 Nm
21 - Toothed belt sprocket of crankshaft
❑ there must not be any oil present on the contact surface between the toothed belt sprocket and the
crankshaft
❑ can be installed only in one position
22 - large guide pulley
❑ replace
❑ Attachment ⇒ page 23
Adjust TDC for cylinder 1 with the belt pulley of the crankshaft
fitted
– Turn the crankshaft at the central bolt in direction of rotation
of engine in such a way that the notch on the belt pulley of the
crankshaft (TDC marking for cylinder 1) -large arrow- and the
engraved arrow -small arrow- are positioned opposite each
other on the middle toothed belt guard, as shown.
Use a mirror.
1.2.3 Removing toothed belt

♦ Rig pin -3359- or -MP 1-301- (2x)
♦ Locking pin -T10060A-
♦ Crankshaft arrester -T10100-
♦ Counterholder -T10172 - with bolts -T10172/4-
♦ Offset screwdriver -T10264-
♦ Rig tool -T10265-
– Detach coolant hose -1- from coolant expansion reservoir.

OCTAVIA II 2004 ➤

– Place fuel filter with connected hoses to the side.
– Lock tensioning device for ribbed V-belt with locking pin or

hexagon socket wrench.
⇒ Rep. Gr. 66 .
– Remove ribbed V-belt tensioning device -arrows-.
– Remove top toothed belt guard; to do so release retaining clips

-arrows-.
Caution
Spin the engine at the crankshaft only in direction of rotation of

engine (in clockwise direction).
– Rotate the crankshaft in direction of rotation of engine on TDC

for cylinder 1.

OCTAVIA II 2004 ➤
• Both tooth segments -arrows- of the toothed belt sprockets

must be facing up.
– Lock hubs with the locking pins -3359- .
– Remove the belt pulley of the crankshaft. To do so, counter‐

hold with a ring spanner at the central bolt.
– Remove middle and bottom toothed belt guard.
– Lock the toothed belt sprocket of the crankshaft with the crank‐
shaft arrester -T10100- (bottom illustration “B”).
Note
♦ The markings on the toothed belt sprocket and on the crank‐

shaft arrester must be in line with each other -arrow-.
♦ The stud of the crankshaft arrester -arrow- must engage at the
same time in the hole of the sealing flange.
♦ The crankshaft arrester can only be fitted onto the toothed belt
sprocket from the front side of the serration.
– Mark the direction of rotation of the toothed belt with chalk or

a felt-tip pen.

OCTAVIA II 2004 ➤
– Loosen screws of toothed belt sprockets -arrows- by approx.

one turn.
– Loosen the fixing nut -1- of the tensioning pulley.

– Turn the eccentric of the tensioning pulley with offset screw‐
driver -T10264- in anti-clockwise direction -arrow- until the
tensioning pulley can be interlocked with the rig tool -T10265- .
– Now turn the eccentric of the tensioning pulley clockwise

-arrow- as far as the stop and tighten the fixing nut -1- by hand.
– First of all take toothed belt off toothed belt sprocket of coolant
pump and then from the other toothed belt sprockets.
1.2.4 Installing (set the timing)
Caution
The work procedure which is described here must be precisely

respected.
♦ If, for example, the final check is not carried out and the
rig tools are not inserted again, there is a risk that the tim‐
ing is not correctly set and the vehicle shows signs of poor
vehicle handling and idle jerking occurs.
• Interlock camshafts with locking pins -3359- or -MP 1-301- .

• Interlock crankshaft with crankshaft arrester -T10100- .
• Tensioning pulley interlocked with rig tool -T10265- and fixed
with fixing nut up to right stop.

OCTAVIA II 2004 ➤
Note
♦ Always perform adjusting work on the toothed belt only on a

cold engine.
♦ When rotating the camshafts, the crankshaft must not be posi‐
tioned at TDC for any one piston. Risk of damaging valves and
pistons.
– Slightly screw in screws -arrows-.

• It must still be possible to turn the toothed belt sprockets of the
camshafts on the hubs, however they must not hang loose.
– Turn the toothed belt sprockets of the camshafts clockwise in
the elongated holes as far as the stop.
– Fit toothed belt onto toothed belt sprocket of crankshaft, ten‐
sioning pulley, toothed belt sprockets of camshafts, large and
small guide pulley and, last of all, onto toothed belt sprocket
of coolant pump.
– Loosen the fixing nut of the tensioning pully and pull the rig
tool -T10265- out of the tensioning pulley.
– Pay attention to the correct fitting of the tensioning pulley in

the opening in the rear toothed belt guard -arrow-.
– Turn the eccentric of the tensioning pulley with the offset

screwdriver -T10264- clockwise -arrow- in such a way until the
pointer -2- stands in the centre of the base plate in the gap.
Note
♦ Ensure that the fixing nut of the tensioning pulley does not turn.
♦ Use mirror.
– Hold the eccentric of the tensioning pulley in this position and

tighten fixing nut of tensioning pulley to 20 Nm and torque a
further 45° (1/8 turn).
Note
When tightening the fixing nut, the pointer -2- turns maximum 5
mm to the right from the gap of the base plate. This position must
not be corrected, because the toothed belt settles when running-
in.

OCTAVIA II 2004 ➤
– Insert counterholder -T10172- with bolts -T10172/4- , as

shown, and press in -direction of arrow-.
– Keep toothed belt sprockets with counterholder -T10172- un‐
der tension and tighten screws -arrows- of both toothed belt
sprockets to 25 Nm.
– Remove locking pins -3359- and crankshaft arrester -
T10100- .
Test timing:
– Turn crankshaft 2 turns in the direction of running of the engine
until the crankshaft is positioned shortly before TDC for cylin‐
der 1.
– Interlock during this motion the hub -A- in the direction of run‐
ning of the engine with locking pin -3359- .
– Check whether:
♦ the hub -B- can be interlocked with the locating pin -3359- ;
♦ the crankshaft can be interlocked with the crankshaft arrester
-T10100- ;
♦ the pointer -2- of the tensioning pulley must be in the area
-a- of the base plate -1-.
If the hub -B- cannot be arrested:

– Loosen screws -2- of toothed belt sprocket of inlet camshaft
-B-.
– Fit ring spanner onto the central screw for the inlet camshaft.
– Turn the hub until the locking pin -3359- can be inserted.
– Tighten screws -2- of toothed belt sprocket of inlet camshaft
-B- to 25 Nm.
T10100- .
– Rotate the crankshaft 2 turns in the direction of running of the
engine until the crankshaft is positioned again on TDC for cyl‐
inder 1.
– Repeat timing test ⇒ page 32 .

OCTAVIA II 2004 ➤
If the crankshaft cannot be arrested:

– Loosen screws -1- and -2- of toothed belt sprockets -A- and
-B-.
– Rotate crankshaft in direction of rotation of engine until it can

be arrested with the crankshaft arrester -T10100- .
Note
♦ The stud -arrow- must engage into the hole in the sealing
flange.
♦ If the crankshaft was turned behind the TDC for cylinder 1, turn
crankshaft back slightly and once again set to the TDC for cyl‐
inder 1 by turning in direction of rotation of engine.
– Insert counterholder -T10172- with bolts -T10172/4- , as

shown, and press in -direction of arrow-.
– Keep toothed belt sprockets with counterholder -T10172- un‐

der tension and tighten screws -1- and -2- of toothed belt
sprockets -A- and -B- to 25 Nm.
T10100- .
– Rotate the crankshaft 2 turns in the direction of running of the
engine until the crankshaft is positioned again on TDC for cyl‐
inder 1.
– Repeat timing test ⇒ page 32 .
Further installation
Further installation occurs in reverse order to removal.

OCTAVIA II 2004 ➤
2 Removing and installing sealing

flange and flywheel
Note
Repairing the clutch ⇒ Manual Gearbox ⇒ Rep. Gr. 30 .
1 - Gasket ring
❑ replace ⇒ page 35
❑ do not oil or grease
2 - Sealing flange -on the belt
pulley side-
❑ must be positioned on
dowel sleeves
⇒ page 36
3 - Cylinder block
4 - The two-mass flywheel
⇒ page 44
❑ Assembly is only possi‐
ble in one position
through offset holes.
(1/4 turn)
❑ replace
6 - Intermediate plate
❑ must be positioned on
dowel sleeves
❑ do not damage/bend
during assembly work
❑ inserted on sealing
flange ⇒ page 35
7 - 15 Nm
❑ replace
8 - Sealing flange -on the gear‐
box side-
❑ can only be replaced
complete with gasket ring and with rotor of engine speed sender -G28-
9 - Engine speed sender -G28-
10 - 5 Nm

OCTAVIA II 2004 ➤
Installing intermediate plate

– Insert intermediate plate on sealing flange and push onto the
dowel sleeves -arrows-.
2.1 Replacing gasket ring for crankshaft -on

the belt pulley side-
♦ Counterholder -T30004 (3415)- or counterholder for toothed
belt sprocket -MP 1-310 (3099)-
♦ Gasket ring extractor -MP 1-226 (3203)-
♦ Assembly device -T10053-
Removing
• Engine installed.
– Removing toothed belt ⇒ page 24 .
– Remove toothed belt sprocket of crankshaft, to this end lock
the toothed belt sprocket with counterholder -T30004 - or with
counterholder for toothed belt sprocket -MP 1-310- .
– To guide the gasket ring extractor screw in central screw for

toothed belt sprocket of crankshaft in the crankshaft up to the
stop.
2. Removing and installing sealing flange and flywheel 35

OCTAVIA II 2004 ➤
– Turn inner part of gasket ring extractor -MP 1-226- two turns
(approx. 3 mm) out of the outer part and lock with knurled
screw.
– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Release knurled screw and turn the inner side against the
crankshaft until the gasket ring is pulled out.
– Clamp gasket ring extractor into the vice and remove gasket
ring with pliers.
– Clean the contact and sealing surface.
Install
Note
Do not oil the sealing lip and the outer surface of the gasket before
the pressing in procedure.
– Remove oil residue on the crankshaft stub with a clean cloth.
– Insert guide bushing -T10053/1- on the crankshaft stub.

– Slide gasket ring over the guide bushing.
– Press in the gasket ring flush with the central screw for the
toothed belt sprocket of crankshaft and with the pressure
bushing of the assembly device -T10053- .
Note
♦ There must not be any oil present on contact surface between

toothed belt sprocket and crankshaft.
♦ Replace central screw for toothed belt sprocket of crankshaft.
♦ Do not oil central screw for toothed belt sprocket of crankshaft.
– Install toothed belt sprocket of crankshaft, to this end lock the

toothed belt sprocket with counterholder -T30004 - or with
counterholder for toothed belt sprocket -MP 1-310 (3099)- .
– install (set the timing) ⇒ page 24 .
2.2 Removing and installing the sealing

flange -on the belt pulley side-
♦ Counterholder -T30004 (3415)- or counterholder for toothed
belt sprocket -MP 1-310 (3099)-

OCTAVIA II 2004 ➤
♦ Protective goggles and gloves

♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning agent and grease remover e.g. -D 000 401 04-
♦ Silicone sealant -D 176 404 A2-
Removing
• Engine installed.
– Remove toothed belt sprocket of crankshaft, to this end lock
the toothed belt sprocket with counterholder -T30004- or with
counterholder for toothed belt sprocket -MP 1-310 - .
– Drain engine oil ⇒ Maintenance ; Octavia II .
– Removing the oil pan ⇒ page 88 .
– Unscrew the fixing screws of the sealing flange and remove
sealing flange, if necessary release by applying slight blows
with a rubber-headed hammer.
– Drive out the gasket ring from the removed sealing flange.
Install
the following:
WARNING
Wear protective gloves when working with sealant and grease

remover!
– Remove residual sealant from the sealing surfaces on sealing

flange, cylinder block and on the oil pan with chemical sealant
remover.
– Degrease the sealing surfaces.
Note
Pay attention to the use by date on the silicone sealant.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).

OCTAVIA II 2004 ➤
– Apply silicone sealant bead -arrow- to the clean sealing sur‐

face of the upper part of the sealing flange, as shown.
• Thickness of sealant bead -arrow-: 2...3 mm.
Note
♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clogg the strainer
in the oil suction pipe.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ When installing the sealing flange with the gasket ring fitted
place a guide sleeve -T10053/1- on the crankshaft journal.
– Carefully push the sealing flange onto the dowel sleeves at the
cylinder block and tighten new fixing bolts by hand.
– Tighten the screws of the sealing flange alternately and cross‐
wise to 15 Nm.
– Install new gasket ring ⇒ page 35 .
– Installing the oil pan ⇒ page 88 .
– Install toothed belt sprocket of crankshaft, to this end lock the
toothed belt sprocket with counterholder -T30004 - or with
counterholder for toothed belt sprocket -MP 1-310- .
– Top up with engine oil and check the oil level ⇒ Maintenance ;
Octavia II .
2.3 Replace sealing flange -on the gearbox

side-
♦ Screw M6 x 35 (3x)
♦ Screw M7 x 35 (2x)
♦ Feeler gauges
♦ Steel straightedge
2.3.1 Removing
• Gearbox removed.
– Remove the two-mass flywheel ⇒ page 44 .
– Remove the intermediate plate from the dowel sleeves and
unhook from sealing flange -arrows-.
– Position crankshaft on TDC for cylinder 1 ⇒ page 27 .

OCTAVIA II 2004 ➤
– Remove engine speed sender -G28- -1-.

– Release the fixing screws of the rear sealing flange.
– Screw 3 screws M6 x 35 mm into the threaded bores of the

sealing flange -arrows-.
– Press out sealing flange together with rotor from the crank‐
shaft by alternately screwing the screws into the sealing
flange.
2.3.2 Install
Note
♦ The sealing flange with PTFE gasket ring is provided with

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

OCTAVIA II 2004 ➤
A - Mounting sealing flange with rotor on the assembly device -

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

surface -B- of the threaded spindle in a vice.
– Remove the securing clip -arrow- from the new sealing flange.
Note
Do not remove or turn the rotor from the sealing flange.
– Lay the front side of the sealing flange on a clean and level
surface.
– Press the sealing lip supporting ring -A- -arrows-, until it rests
on the level surface.
• The top side of the rotor and the front side of the sealing flange
must be flush.

OCTAVIA II 2004 ➤
Locating hole -B- on the rotor -C- must be flush with the marking
-A- on the sealing flange.
– Lay the sealing flange with the front side on the assembly de‐
vice -T10134- in such a way that the positioning pin -A- en‐
gages in the hole -B- of the rotor.
Note
Make sure the sealing flange lies flat on the assembly device.
– When tightening the knurled screws -B- press the sealing lip
supporting ring -A- on the surface of the assembly device -
T10134- in such a way that the positioning pin can no longer
slide out of the rotor hole.
B - Mounting the assembly device -T10134- with sealing flange
on the crankshaft flange
• The crankshaft flange must be free of grease and oil
• Crankshaft is at TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.
– Screw assembly device -T10134- with Allan screws -A- up to

the stop onto the crankshaft flange.

OCTAVIA II 2004 ➤
– Screw in two screws M7 x 35 mm -A- by about 3 thread turns

for the sealing flange guide into the cylinder block.
– Move the assembly cup -C- by hand in the

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

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

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

dle.
– Release both screws -A- to the guide from the cylinder block.
– Unscrew three knurled screws -B- from the sealing flange.
– Unscrew two Allan screws and remove assembly device.
– Remove sealing lips supporting ring.

OCTAVIA II 2004 ➤
The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- of 0.5 mm between the crankshaft flange
-A- and the rotor -B-.
– Position the steel striaghtedge onto the crankshaft flange.

– Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
– Press down rotor ⇒ page 43 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing flange crosswise.
Tightening torque: 15 Nm
– Install engine speed sender -G28- -1-. Tightening torque: 5

Nm.
– Fit intermediate plate.
– Install flywheel with new screws. Tighten fixing bolts to 60 Nm
and torque a further 1/4 turn (90°).
E - Pressing down the rotor
– Screw assembly device -T 10134- with Allan screws up to the

stop onto the crankshaft flange.
– Screw in three knurled screws -B- into the flange.
– Subsequently insert the guide bolt with black handle -D- fully
into the threaded bore of the crankshaft. If the guide bolt is
correctly positioned, then the handle has a distance of approx.
10 mm from the assembly cup -C-.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup.

OCTAVIA II 2004 ➤
– Tighten the hexagon nut of the assembly device using a torque

wrench with adapter.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 42 .
If the dimension -a- is again too small:
– Tighten the hexagon nut of the assembly device to 45 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 42 .
2.4 Removing and installing the two-mass

flywheel
♦ Counterholder -MP1-223 (3067)-
or
♦ Engine mount -MP 1-202 (VW 540)-

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

OCTAVIA II 2004 ➤
Continued for all

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

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

Install
the following:
Note
Use new screws for attaching.
– Rotate the secondary side -A- of the two-mass flywheel in such

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

OCTAVIA II 2004 ➤
3 Crankshaft, Piston and Conrod
3.1 Removing and installing crankshaft
Note
The engine should be attached to the engine repair stand with the
engine holder -MP 1-202- for carrying out removal and installation
work.
1 - Bearing shell
❑ for cylinder block with lu‐
bricating groove
❑ do not mix up used bear‐
ing shells (mark)
2 - Drive chain sprocket
❑ for oil pump
⇒ page 47
3 - Bearing shell
❑ for bearing cap without
lubricating groove
❑ do not mix up used bear‐
ing shells (mark)
4 - Thrust washers
❑ for bearing 3
❑ different version for cyl‐
inder block and bearing
cap
❑ pay attention to locating
element
(1/4 turn)
❑ replace
6 - Bearing caps
❑ Bearing cap 1: belt pul‐
ley side
❑ bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ retaining lugs of the
bearing shells of the cyl‐
inder block/bearing cap must be on top of one another
7 - Crankshaft
❑ with chain sprocket for oil pump drive
❑ Axial play when new: 0.07...0.17 mm; Wear limit: 0.37 mm
❑ Crankshaft bearing pins: ∅ 54.00 mm
❑ Conrod bearing: ∅ 50.90 mm

OCTAVIA II 2004 ➤
3.2 Removing and installing drive chain

sprocket
♦ Drive bushing -MP1-316 (30 - 100)-
♦ Two-arm extractor, standard commercially available
♦ Protective gloves
Removing
– Remove sealing flange - on the belt pulley side ⇒ page 36 .
– Remove chain tensioner, chain sprocket for oil pump and oil
pump chain.
– Remove drive chain sprocket of crankshaft with two-arm ex‐
tractor -2-. At the same time protect the crankshaft journal with
a suitable washer -1-.
Install
the following:
WARNING
Wear protective gloves!
– Heat up the drive chain sprocket in an oven for about 15 mi‐

nutes to 220 °C.
– Place the drive chain sprocket on the shaft end using pliers
and with drive bushing -30 - 100- slide on until the stop on the
crankshaft is reached.
• Fitting location: the broad collar of the drive chain sprocket
(45° chamfer in the hole) points to the engine.
3. Crankshaft, Piston and Conrod 47

OCTAVIA II 2004 ➤
3.3 Disassembling and assembling pistons and conrods
1 - Piston rings
❑ Offset joint 120°
❑ use piston ring pliers for
removing and installing
❑ marking “TOP” faces
piston crown
❑ Inspect gap clearance
⇒ page 49
❑ Inspect end clearance
⇒ page 49
2 - Piston
❑ with combustion cham‐
ber
❑ mark installation posi‐
tion and matching cylin‐
der
❑ Installation position and
assignment of piston/
cylinder ⇒ page 50
❑ arrow on piston crown
faces towards the belt
pulley side
❑ replace piston if there is
any sign of crack forma‐
tion on the piston body
❑ Inspecting piston
⇒ page 50
❑ Piston dimension: ∅
80.96 mm
❑ use piston ring tension‐
ing strap for installing
❑ inspect piston projection
at TDC ⇒ page 51
3 - Piston pin
❑ if stiff, heat piston to 60°C
❑ use drift -VW 222A- for removing and installing
4 - Circlip
5 - Conrod
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Markings -B- point towards the belt pulley side
❑ with a split bearing cap
❑ separate new conrod ⇒ page 51
6 - Bearing shell
❑ Fitting position ⇒ page 51
❑ do not mix up already used bearing shells (mark)
❑ Observe version: top bearing shell (towards the piston) must be made from a long lasting material, rec‐
ognition feature for new bearing shells: black marking on the contact surface near the separation point
❑ insert in middle ⇒ page 51
❑ check for firm seating
❑ Axial play wear limit: 0.37 mm

OCTAVIA II 2004 ➤
7 - Cylinder block
❑ Inspect cylinder ⇒ page 50
❑ Cylinder dimension: ∅ 81.01 mm
8 - Conrod bearing cap
❑ cracked cover fits only in one position at the relevant conrod
9 - Oil injection nozzle
❑ for piston cooling
10 - 25 Nm
❑ replace without sealant
11 - Conrod bolt - 30 Nm + torque a further + 90° (1/4 turn)
❑ replace
❑ Oil thread and contact surface
Inspecting piston ring gap clearance

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

♦ Feeler gauges

OCTAVIA II 2004 ➤
– Clean before inspecting the annular grooves of the piston.

Piston ring new Wear limit
(dimensions in mm)
Oil scraper ring 0,03 … 0,06 0,15
Inspecting pistons

♦ External micrometer
– Measure about 10 mm from the lower edge, offset at right an‐
gles to the piston pin shaft.
• Max. deviation from specified dimension: 0.04 mm
Installation position and assignment of piston/cylinder
Pistons in cylinders 1 … 4:
• The arrow on the piston crown -arrows- faces towards the belt
pulley side.
Inspecting cylinder bore

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

OCTAVIA II 2004 ➤
• Max. deviation from specified dimension: 0.10 mm

Fitting position of the bearing shells in the conrods
– Insert bearing shell in the conrod or in the center of the conrod
bearing cap.
• Dimension -a-: 2.5 mm
3.4 Checking piston projection in TDC

♦ Measuring tool for piston projection -MP 1-107-
Test sequence
When fitting new pistons or a partial engine, check the piston pro‐
jection in TDC on all pistons.
Depending on the piston projection fit the relevant cylinder head
seal in accordance with the table below.
Piston projection over cylinder Bore marking
block - top side mm
0,91 … 1,00 1
1,01 … 1,10 2
1,11 … 1,20 3
Identification of the cylinder head seal

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

according to the piston projection. When replacing a gasket
use a new gasket with the same identification -arrow 3-.
♦ If different values are measured during the projection meas‐
urement of the piston, the greatest dimension applies for the
seal assignment.
3.5 Separating new conrod

It can happen that the predetermined breaking point on the new
conrod is not completely pierced. If the conrod bearing cap cannot
be lifted by hand, proceed in the following manner:
– Mark the mark assignment to cylinder of the conrod.

OCTAVIA II 2004 ➤
– Slightly tension the conrod, as shown in the illustration, in a

vice provided with aluminium protective jaws.
Note
♦ The conrod must only be slightly tensioned in order to avoid

damage on the conrod.
♦ The conrod is clamped below the broken line.
– Screw out both screws -arrows- approximately 5 turns.
– Carefully knock with a plastic hammer in -direction of arrow -

against the conrod bearing cap until it is loose.

OCTAVIA II 2004 ➤
15 – Cylinder Head, Valve Gear

1 Removing and installing cylinder
head
Note
♦ Cylinder heads with cracks between the valve seats may con‐
tinue to be used without any reduction in the life time, provided
the cracks are slight and maximum 0.5 mm wide.
♦ It is not permissible to rework the cylinder heads of diesel en‐
gines.
♦ Replace O-rings and gaskets.
♦ Replace cylinder head bolts and screws which have been
tightened to a turning angle.
♦ When installing an exchange cylinder head with the camshafts
installed, it is necessary to oil the contact surfaces between
the roller arms and the cams after installing the head.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ When replacing the cylinder head, replace all the coolant
⇒ page 97 .
♦ If engine damage occurs and it is suspected that the cause of
this is oil/fuel mixing (olfactory test of the engine oil), the tan‐
dem pump must absolutely be checked for internal tightness
⇒ page 117 .
♦ Change contaminated engine oil ⇒ Maintenance ; Octavia II .
1. Removing and installing cylinder head 53

OCTAVIA II 2004 ➤
1.1 Summary of components
1 - Rear toothed belt guard

2 - Rubber grommet
3 - Pin screw - 10 Nm
4 - Hub
❑ for inlet camshaft with
rotor for hall sender -
G40-
❑ to remove use extractor
-T10052-
5 - 100 Nm
❑ to release and tighten
use counterholder -
T10051-
6 - Hub
❑ for exhaust camshaft
❑ to remove use extractor
-T10052-
7 - 10 Nm
❑ insert using locking
agent -D 000 600 A2-
8 - Valve-lever shaft
❑ Mark the installation po‐
sition of the valve lever
❑ do not interchange
⇒ page 58
❑ before inserting, check
whether all the ball
studs and O-rings are
inserted in the unit injec‐
tors
❑ replace
❑ pay attention to order for slackening ⇒ page 58
❑ pay attention to order and procedure for tightening ⇒ page 64
10 - Gasket for cylinder head cover
❑ replace if damaged or leaking
❑ press onto the spacer sleeves (Pos. 15)
11 - Cylinder head cover
12 - Screw cap
13 - Gasket
❑ replace if damaged or leaking
14 - Sealing sleeve
15 - Screw with spacer sleeve, 10 Nm
❑ pay attention to sequence for loosening and tightening ⇒ page 56
54 Rep. Gr.15 - Cylinder Head, Valve Gear

OCTAVIA II 2004 ➤
16 - 20 Nm
17 - Cylinder head bolt
❑ replace
❑ pay attention to order for slackening ⇒ page 58
❑ pay attention to order and procedure for tightening ⇒ page 66
18 - Multipin plug connection
❑ central for pump-nozzle units
❑ when removing, disconnect plug connection from bushing by turning to the left
19 - Gasket
❑ replace
20 - Tandem pump
❑ check ⇒ page 116
21 - 20 Nm
22 - Cylinder head
❑ check for distortion ⇒ page 56
❑ after replacing fill entire system with fresh coolant ⇒ page 97
23 - Mixing tube
❑ inserted into cylinder head
❑ pull out with hook
❑ Fitting position mixing tube ⇒ page 55
24 - Cylinder head gasket
❑ Pay attention to the marking ⇒ page 56
25 - Hall sender -G40-
❑ for camshaft position
Fitting position mixing tube

The recess of the mixing tube points to the top -arrow-.

OCTAVIA II 2004 ➤
Inspecting the cylinder head for distortion

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

Note
Differing thicknesses of cylinder head gaskets are inserted ac‐

cording to the piston projection. If only the gasket is replaced, then
it must be replaced with a new gasket with the same marking.
1.2 Removing and installing cylinder head

cover
Removing
– Unclip changeover valve for radiator of exhaust gas recircu‐
lation -N345- -2- from the bracket.
– Release plug -1- and -3- and expose electrical cables.
– Release vacuum lines -4, 5, 6- and expose lines.
– Release screws -arrows-.

OCTAVIA II 2004 ➤
– Detach the hose -1- of the crankcase ventilation from the cyl‐
inder head cover.
– Remove the vacuum hose -1- from the cylinder head cover.
– Release screws -arrows- and remove holder.
Note
The coolant hoses and fuel lines remain connected.
– Remove top toothed belt guard; to do so release retaining clips

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

-11 … 1-.
– Remove cylinder head cover with gasket.
Install
the following:
Note
Replace cylinder head cover gasket and cylinder head cover bolts
if damaged.

OCTAVIA II 2004 ➤
– First tighten the cylinder head bolts in the order -1...11-, then
to 10 Nm.
1.3 Removing and installing cylinder head

♦ Lifting device -MP9-201 (2024 A)-
♦ Rig pin -3359- or -MP 1-301- (2x)
♦ Counterholder -T10051 -
♦ Extractor -T10052-
♦ Locking pin -T10060A-
♦ Crankshaft arrester -T10100-
♦ Wrench socket -T10264-
♦ Rig pin -T10265-
♦ Locking agent -D 000 600 A2-
♦ Protective goggles
1.3.1 Removing cylinder head

– Switch off the ignition and pull out the ignition key.
⇒ page 148 .
– Drain coolant ⇒ page 97 .
– Remove cylinder head cover ⇒ page 56 .
– Unbolt heat shield for right drive shaft.

OCTAVIA II 2004 ➤
– Release nuts -2- and screws -3- and remove the connection
pipe for exhaust gas recirculation.
– Release screw -2- and hollow screw -3-.

– Turn the support for exhaust gas turbocharger by 90° and pull
it towards the bottom out of the oil return-flow line.
– Release screws -arrows- at holder for diesel particle filter.

– Observe the safety instructions when working on the fuel sup‐
ply ⇒ page 3 .
– Disconnect the fuel intake hose -2- (white marking) and the
fuel return-flow hose -1- (blue marking) from the tandem
pump.

OCTAVIA II 2004 ➤
– Disconnect coolant hoses -1 … 4-.
– Release plug -arrow- at fuel temperature sender -G81- and

expose the electrical cables.
– Expose vacuum hose at retaining clip -arrow-.

– Release screw -1-.
– Disconnect vacuum hose -2- to the vacuum setting element
for air flow control.
– Unclip intake manifold flap valve -N316- -arrow- from bracket.

– Remove exhaust gas recirculation valve -N18- ⇒ page 161 .

OCTAVIA II 2004 ➤
– Disconnect plug connection -3- for exhaust gas temperature

sender 1 -G235- ( temperature sender upstream turbocharger
-G507- ) and expose cable.
– Remove oil intake hose -3- from exhaust gas turbocharger.

– Pull retaining clips -Pfeile- out slightly and remove the charge
air hose.
– Remove nut -2-.
– Swivel the vacuum line slightly to the left.
– Expose electrical cable to exhaust gas temperature sender 1

-G235- ( temperature sender upstream turbocharger -G507- )
-1-.

OCTAVIA II 2004 ➤
– Slacken retaining clip -1- for diesel particle filter and remove
it.
– Press the diesel particle filter slightly backwards.
– Disconnect plug -arrow- at coolant temperature sender -G62- .
– Pull release pin in -direction of arrow 1- and open the knurled

nut in -direction of arrow 2-.
– Disconnect central plug for unit injectors and ceramic pencil
type glow plugs and expose wiring loom.
– Remove vacuum hose -1- on the tandem pump.

– Remove vacuum hose -4- at non-return valve.
– Disconnect vacuum hose -2-.
– Press rubber grommet -3- out of the engine lifting eye.

OCTAVIA II 2004 ➤
– Unscrew the coolant fitting -arrows-.

– Remove toothed belt sprockets of camshafts and pull off hubs
for camshafts ⇒ page 25 .
– Release screws -2...4-.

– Unscrew screw -5- and remove the Hall sender -G40- from
cylinder head.
– Unscrew nut -1- for tensioning pulley.
– Release screws -1- -3- and -5-.

– Loosen screws -2- and -4- and release alternately in several
stages.
Note
Do not pull out screws of the valve-lever shaft, so that the indi‐
vidual parts on the valve-lever shaft remain attached. If necessary
mark assignment of the individual parts.
– Remove valve-lever shaft.
– Unscrew screws -6...10- of bearing frame.

OCTAVIA II 2004 ➤
– Slacken cylinder head bolts in the order shown.
– Hook on lifting device -2024 A- at cylinder head.
WARNING
Lifting hooks and pegging pins on the supporting device must

be secured using insertion locking mechansims -arrows-.
– Slightly raise the cylinder head with workshop crane .

– Swivel the cylinder head to the left out of the rear toothed belt
guard and simultaneously remove the tensioning pulley.
– Place the cylinder head down on a soft surface with the sealing
surface to the top.
– Due to the high sensitivity to fracture of the installed ceramic
pencil type glow plugs, the cylinder head must never be placed
down with the installed ceramic pencil type glow plugs on the
sealing surface as the ceramic pencil type glow plugs protrude
slightly beyond the sealing surface. Handling the ceramic pen‐
cil type glow plugs ⇒ page 167 .
1.3.2 Installing cylinder head
Note
♦ There must not be any oil or coolant present in the blind holes
for the cylinder head bolts.
♦ Replace cylinder head bolts.
♦ When performing installation work replace the self-locking
nuts.
♦ Replace screws which have been tightened to a turning angle
as well as gasket rings and seals.
♦ Remove the new cylinder head seal from its wrapping imme‐
diately before fitting.
♦ Treat the seal with the utmost care. Damage to the silicone
layer and in the area of the bead results in leakages.
♦ When installing an exchange cylinder head with the camshafts
installed, it is necessary to oil the contact surfaces between
the roller arms and the cams after installing the cylinder head.
♦ The plastic base for protecting the open valves should only be
removed immediately before attaching the cylinder head.

OCTAVIA II 2004 ➤
WARNING

remover!
– Make sure that when cleaning the cylinder head and cylinder
block no impurities can get into the cylinder or into the oil and
coolant galleries.
– Carefully remove old residual sealant from the cylinder head/
cylinder block using a chemical sealant remover.
– Before fitting the cylinder head rotate the crankshaft so that all
the pistons are almost evenly at TDC.
– Pay attention to the identification of the cylinder head seal.
Note
♦ If the cylinder head gasket or cylinder head are replaced, then

install a new cylinder head gasket with the same identification
marking.
♦ If parts of the crankshaft drive were replaced then the new
cylinder head gasket must be defined by measuring the pro‐
trusion of the pistons in TDC .
– Position the new cylinder heads.

• Pay attention to dowel sleeves -arrows- in cylinder block.
• Observe the installed position of the cylinder head gasket, the
marking “above” or the part number must point to the cylinder
head.

OCTAVIA II 2004 ➤
– Hook on lifting device -2024 A- at cylinder head.
WARNING
Lifting hooks and pegging pins on the supporting device must

be secured using insertion locking mechansims -arrows-.
– Slightly raise the cylinder head with workshop crane .

– Swivel the cylinder head with the pin screw for the timing belt
tensioning pulley into the recess in the rear toothed belt guard
and simultaneously fit on the tensioning pulley.
– Fit cylinder head onto cylinder block.
– Insert new cylinder head bolts and tighten by hand.

– Tighten the cylinder head in four stages in the indicated tight‐
ening sequence:
Stage Tighten
I – Pre-tighten with the torque wrench to 40 Nm.
II – Pre-tighten with the torque wrench to 60 Nm.
III – Using a rigid wrench torque a further 90° (1/4
turn).
IV – Using a rigid wrench torque a further 90° (1/4
turn).
Note
Tightening up the cylinder head bolts after doing repair work is

not necessary.
– Before inserting the valve-lever shaft, check whether all the

ball studs -1- and O-rings -2- are inserted in the unit injectors.

OCTAVIA II 2004 ➤
– Screw on valve-lever shaft and bearing frame as follows:

– Replace screws -1 … 5-.
Se‐ Tighten
quence
I – Tighten screws -2- and -4- alternately in stages,
until the valve-lever shaft is positioned on the
bearing frame.
II – Tighten screws -1-, -3- and -5- to 20 Nm and tor‐
que a further 90° (1/4 turn).
III – Tighten screws -2- and -4- to 20 Nm and torque
a further 90° (1/4 turn).
IV – Tighten bearing frame screws -6…10- to 20 Nm.
– Insert screws -2 … 5- with spread on locking agent -D 000 600

A2- and tighten to 10 Nm.
– Turn nut -1- for timing belt tensioning pulley onto the pin screw.
– Position hub onto exhaust camshaft.

– Tighten screw -1- to 100 Nm, use counterholder -T10051- to
hold.
– Fit the hub onto the inlet camshaft in the same way and tighten.
– Push toothed belt sprockets of camshafts onto hubs.

• Both tooth segments -arrows- of the toothed belt sprockets
must be facing up.
– Slightly screw in plug -1-.
• It must still be possible to turn the toothed belt sprockets of the
camshafts on the hubs, however they must not hang loose.
– Lock hubs with locking pins -3359- .
– Rotate crankshaft to TDC for cylinder 1.

OCTAVIA II 2004 ➤
– Lock the toothed belt sprocket of the crankshaft with the crank‐
shaft arrester -T10100- (bottom illustration “B”).
Note

– install (set and check the timing) ⇒ page 24 .

– Install cylinder head cover ⇒ page 56 .
Further installation occurs in reverse order to removal. Pay at‐
tention to the following:
– Always replace gasket rings and seals.
– Install diesel particle filter ⇒ page 155 .
Note
Change contaminated engine oil ⇒ Maintenance ; Octavia II .
– Top up or replace coolant ⇒ page 97 .
1.4 Testing the compression

The compression pressure is tested in the “Targeted fault finding”
using the vehicle diagnosis system, measurement and informa‐
tion system -VAS 5051- under “Repair Group 15; Cylinder head/
valve gear; Subsystem, Boundary conditions; Diagnostic Object:
poor compression pressure”.

OCTAVIA II 2004 ➤
2 Repairing valve gear
Note
♦ After installing the camshafts, the engine must not be cranked

or started for about 30 minutes. The hydraulic tappets must
settle (otherwise valves would strike the pistons).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.
♦ Always replace gasket rings and seals.
♦ Removing and installing the tandem pump ⇒ page 114 .
1 - Bracket for cable rail - 10

Nm
2 - 20 Nm
❑ pay attention to se‐
quence for loosening
and tightening
⇒ page 72
❑ for pump-nozzle unit
(1/4 turn)
❑ replace
and tightening
⇒ page 72
5 - Cylinder head bolt
❑ replace
and tightening
⇒ page 64
6 - Washer
❑ for cylinder head screws
❑ before installing the
bearing frame, insert in‐
to the cylinder head
7 - Valve collets
8 - Valve spring retainer
9 - Valve spring
10 - Valve stem seal
11 - Valve guide
❑ not to be replaced
2. Repairing valve gear 69

OCTAVIA II 2004 ➤
12 - Roller rocker arm for inlet valve
❑ do not mix up used roller rocker arms (mark)
❑ with hydraulic valve clearance compensation; check ⇒ page 80
❑ inspect roller bearings of roller for smooth operation and play
13 - Roller rocker arm for outlet valve
❑ do not mix up used roller rocker arms (mark)
❑ with pressed in hydraulic tappet; check ⇒ page 80
❑ inspect roller bearings of roller for smooth operation and play
14 - Gasket rings
❑ do not oil and grease sealing lip
❑ before installing, remove oil on the camshaft journal
❑ before installing, cover the groove for the spring on the camshaft cone with suitable adhesive tape
15 - Cylinder head
❑ Valve seats must not be reworked.
16 - Inlet valves
❑ Valve dimensions ⇒ page 84
17 - Exhaust valves
❑ Valve dimensions ⇒ page 84
18 - O-ring
❑ replace
19 - Shaft with retaining plate for roller rocker arm
❑ Outlet side
20 - 10 Nm
21 - Screw plug - 10 Nm
❑ replace
22 - Shaft for roller rocker arm
❑ Inlet side
23 - Bearing shell
❑ do not mix up used bearing shells (mark)
❑ ensure the retaining lugs are correctly located in the bearing frame and in the cylinder head
24 - Exhaust camshaft
❑ Inspecting axial play ⇒ page 71
25 - Inlet camshaft
❑ Inspecting axial play ⇒ page 71
26 - Bearing frame
❑ pay attention to sequence for loosening and tightening ⇒ page 72
❑ install with silicone sealant -D 176 501 A1-

OCTAVIA II 2004 ➤
2.2 Checking the axial play of the camshafts

♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge
Test sequence
– Perform measurement with roller rocker arms removed and
bearing frame installed
• Wear limit: 0.15 mm
2.3 Replacing camshaft gasket rings

♦ Inserting device -MP 1-214 (10-203)-
♦ Gasket ring extractor -T30003 (3240)-
♦ Counterholder -T10051 -
♦ Screw M12 x 1.5 x 65 or screw M12 x 1.5 x 75 from inserting
device -MP 1-214 (10-203)- with 10 mm spacer washer.
Removing
• Cylinder head fitted.
– Remove toothed belt sprockets of camshafts and pull off hubs
⇒ page 25 .

OCTAVIA II 2004 ➤
– Set the inner part of the sealing ring extractor -T30003- flush
with the outer part and interlock with the knurled screw.
– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring for exhaust camshaft as far
as possible.
– Release knurled screw and turn the inner side against the
camshaft until the gasket ring is pulled out.
– Clamp gasket ring extractor into the vice and remove gasket
ring with pliers.
– Clean the contact and sealing surface.
– Remove the gasket ring for inlet camshaft in the same way.
Install
the following:
Note
Sealing lips of the gasket rings must not be oiled or greased ad‐
ditionally.
– Remove oil residue from the camshaft stud with a clean cloth.
– Cover groove on the exhaust camshaft cone with adhesive
tape and carefully push the sealing ring onto the camshaft.
– Press in gasket ring with inserting device -MP 1-214- and

screw M12 x 1.5 x 65 (or screw M12 x 1.5 x 75 from inserting
device -MP 1-214- with 10 mm spacer washer) up to the stop.
– Install the gasket ring for inlet camshaft in the same way.
– Install hubs and toothed belt sprockets of camshafts
⇒ page 25 .
2.4 Removing and installing camshafts

♦ Counterholder -T10051-
♦ Rig pin -3359- or rig pin -MP 1-301-
♦ Surround -T10262-
♦ Dial gauge

OCTAVIA II 2004 ➤
Removing
• Cylinder head fitted.
– Remove the toothed belts from the toothed belt sprockets of
camshafts ⇒ page 24 .
– Remove locking pins -3359- .
– Screw out screws -1- and -2- of toothed belt sprockets of cam‐
shafts.
– Remove the toothed belt sprockets of camshafts from the
hubs.
– Loosen fixing screw -1- of the hub. Use counterholder -

T10051- for this purpose.
– Unscrew the fixing bolt of the hub by approx. 2 turns.
– Position the extractor -T10052- and align it with the hub bores.
– Tighten fixing screws -1-.
– Put the hub under tension by uniformly tightening the screw
-2- until the hub is released from the camshaft cone.
Note
To do so, counterhold on the hexagon of the extractor using a

wrench SW 30.
– Remove hub from cone of camshaft.

– Remove the hub of the outlet camshaft in the same way.
– Remove tandem pump ⇒ page 114 .
Note
The hoses can remain connected to the tandem pump.

OCTAVIA II 2004 ➤
– Release the counternuts -2- of the adjusting screws -1- on all

unit injectors and unscrew the adjusting screws until the rele‐
vant roller rocker arm rests against the tappet spring of the unit
injector.
Note
Do not pull out screws of valve-lever shaft, so that the individual

parts on the valve-lever shaft remain attached. If necessary mark
assignment of the valve lever.

– Loosen screws -2- and -4- and release alternately in several
stages. Then remove the valve-lever shaft with the valve lev‐
ers.
– Pull release pin in -direction of arrow 1- and open the knurled

– Disconnect central plug for unit injectors and ceramic pencil
type glow plugs and expose wiring loom.
– Push the extractor -T10312- from the side onto the plugs of
the unit injectors and pull them off in -direction of arrow-.

OCTAVIA II 2004 ➤
– Disconnect plug -1- from the ceramic pencil type glow plugs.
Caution
The disassembly/assembly of the pre-wiring must only be per‐

formed by unscrewing/screwing the clamps. Slackening the
cable duct from the clamps causes them to bend up and it can
lead to cable fracture due to high play.
– Unscrew fixing screws -2- of the stainless steel clamps (10

Nm) and lay pre-wiring aside.
– Release the upper fixing screws of the rear toothed belt guard.
– Slacken and unscrew the remaining 15 screws for the bearing
frame evenly from the outside to the inside.
– Release press-off screws SW 15 of the frame -T10262- by

turning anti-clockwise upwards up to the stop.
– Position frame -T10262- , as shown, on the bearing frame and
tighten fixing screws SW 10 to 10 Nm.
– Screw in press-off screws by hand, until these touch the cyl‐
inder head screws.
– Screw in press-off screws evenly in the order -1...4-, which is
type-punched on the screw heads, until the bearing frame is
being released from the cylinder head.
– Remove bearing frame.
Note
♦ Ensure that the bearing shells of the camshafts are not mixed
up.
♦ Mark assignment of the bearing shells for the camshafts with
waterproof marker on the reverse side.
– Take out camshafts.

Install
the following:
WARNING

remover!
– Remove residual sealant on the bearing frame and cylinder

head using a chemical sealant remover.
– Clean sealing surfaces, they must be free of oil and grease.

OCTAVIA II 2004 ➤
– Check if the crankshaft is on TDC for cylinder 1.

• Interlock toothed belt sprocket of crankshaft with crankshaft
arrester -T10100- (bottom illustration “B”) at TDC for cylinder
1.
Note

♦ Ensure that the used bearing shells of the camshafts are not
mixed up (pay attention to marking).
♦ When installing the camshafts pay attention to a correct fit of
the retaining lugs of the bearing shells in the bearing frame
and cylinder head.
– Oil contact surfaces of camshafts and bearing shells.
– Insert camshafts into the TDC position for cylinder 1:

• The cams -1- and -2- for cylinder 1 must point upwards on both
camshafts.
• The grooves -arrows- in the camshafts also point upwards.

OCTAVIA II 2004 ➤
– Cut off nozzle tube at the front marking (∅ nozzle approx. 2

mm) and apply silicone sealant -D 176 501 A1- to the clean
sealing surface of the bearing frame -arrows-.
• Thickness of sealant bead: 2 mm
Note
The bearing frame must be installed within 5 minutes after apply‐

ing the silicone sealant.
– Position bearing frame with inserted bearing shells on the

dowel pins of the cylinder head.
– Replace screws -1, 3, 5, 7, 9-.

– Tighten the screws -1...20- evenly in the following order from
inside to outside.
– Insert valve-lever shaft.
– Tighten the screws -1...5- of the valve-lever shaft in the fol‐

lowing order + torque a further 90° (1/4 turn).
– Insert the cable rail in the brackets, connect plug for unit in‐
jectors, plug for ceramic pencil type glow plugs and the central
plug connection for unit injectors and for ceramic pencil type
glow plugs.
– Install camshaft gasket rings ⇒ page 71 .
– Install tandem pump ⇒ page 114 .
– Install hubs and toothed belt sprockets of camshafts
⇒ page 25 .
– install toothed belt and set the timing ⇒ page 24 .

OCTAVIA II 2004 ➤
– Place a dial gauge as shown onto the adjusting screw of the

unit injector.
Caution

– Turn the crankshaft in the running direction of the engine until

the roller of the roller rocker arm is on the drive cam tip.
• Roller side of roller rocker arm -arrow A- is on the highest point.
• Dial gauge -arrow B- is on the lowest point.
– Remove the dial gauge.
– Turn the adjusting screw in the roller rocker arm until one feels
a significant resistance (the unit injector is against the stop).
– Turn the adjusting screw in the opposite direction from the stop
by about 180°.
– Hold the adjusting screw in this position and tighten up the lock
nut using a torque of 30 Nm
Note

or started for about 30 minutes. The hydraulic tappets must
settle (otherwise valves would strike the pistons).
2.5 Removing and installing roller rocker

arm
♦ Extractor -T10133/3-
Note
♦ Replace O-rings.
♦ Do not mix up used roller rocker arms.
Remove roller rocker arm for exhaust valves

Gr. 27 .
– Remove the camshafts ⇒ page 72 .
– Remove connection pipe for exhaust gas recirculation be‐
tween mechanical valve for exhaust gas recirculation and
radiator for exhaust gas recirculation ⇒ page 162 .
– Remove connection fittings for coolant from cylinder head
⇒ page 94 .

OCTAVIA II 2004 ➤
– Mark assignment of the roller rocker arms and the shafts for
re-installation.
– Release screws -4- and -5-.
– Pull shaft for roller rocker arm -3- on the outlet side out of the
cylinder head with the extractor -T10133/3- and remove roller
rocker arm.
Caution
If the screw plug -5- is loosened, the shaft for the roller rocker
arms may rotate against the retaining plate. If a misshaping in
the shaft is detected during a visual inspection of the thread,
the shaft must no longer be installed, because the oil supply
holes for the roller rocker arms do no longer fit in size. This can
result in rubbing damage.
Install roller rocker arm for exhaust valves

the following:
– Lubricate roller rocker arm bearing with clean engine oil before
installing.
– Slide new O-ring onto the shaft for roller rocker arm.
– Insert shaft for roller rocker arm into the cylinder head and in‐
sert roller rocker arm simultaneously and consecutively.
– Tighten fixing screw -4- to 10 Nm.
– Replace the screw plug -5- and tighten to 10 Nm.
– Attach connection fittings for coolant to cylinder head
⇒ page 94 .
– Attach connection pipe for exhaust gas recirculation between
mechanical valve for exhaust gas recirculation and radiator for
exhaust gas recirculation ⇒ page 162 .
– Install camshafts ⇒ page 72 .
Remove roller rocker arm for inlet valves
Gr. 27 .
– Mark the assignment of the roller rocker arm when installing
again.

OCTAVIA II 2004 ➤
– Pull shaft for roller rocker arm on the inlet side out of the cyl‐
inder head with the extractor -T10133/3- and remove roller
rocker arm.
Install roller rocker arm for inlet valves
the following:
– Lubricate roller rocker arm bearing with clean engine oil before
installing.
– Insert shaft for roller rocker arm into the cylinder head and in‐
sert roller rocker arm simultaneously and consecutively.
• The shaft for roller rocker arm must be flush with the cylinder
head.
2.6 Check hydraulic supporting elements

♦ Feeler gauges
Note
♦ The hydraulic supporting elements pressed into the roller rock‐

er arms cannot be repaired.
♦ Irregular valve noises when starting engine are normal.
Test sequence
– Start engine and allow to run until the radiator fan starts. In‐
crease engine speed to about 2500 rpm for 2 minutes and
undertake a test drive if necessary.
Note
If there are irregular valve noises which disappear after a long

drive but keep reappearing on short journeys then the oil retaining
valve is is defective. Fitting location: in the oil filter holder
⇒ page 85 . The oil retaining valve cannot be replaced individ‐
ually.
If the valves are still loud, determine which is the faulty hydraulic
supporting element as follows:
– Turn the crankshaft until the cam of the hydraulic tappet to be
tested is positioned on top, while doing so push the vehicle
forward in 4th gear when ignition is switched off.

OCTAVIA II 2004 ➤
– Press the roller rocker arm down with a screwdriver -arrows-

and measure the play between the cams and the roller of the
roller rocker arm.
If a 0.20 mm feeler gauge can be slipped between the camshafts
and the roller of the roller rocker arm:
– Replace roller rocker arm with hydaulic valve clearance com‐
pensation; to do so remove the roller rocker arm ⇒ page 72 .
Note
♦ After installing the camshafts, the engine must not be started

for about 30 minutes. Roller rocker arm with hydraulic valve
clearance compensation must settle (otherwise valves would
strike the piston).
2.7 Replacing valve stem seals

• Cylinder head fitted
♦ Valve stem seal extractor -MP 1-230 (3364)-
♦ Valve stem seal insertion tool -MP 1-233 (3365)-
♦ Disassembly and assembly device for valve keys -VAS 5161-
♦ Guide plate for 2.0 TDI engine -VAS 5161/21-
Note
♦ With cylinder head removed:

♦ Remove the ceramic pencil type glow plugs from the cylinder
head ⇒ page 167 .
♦ Remove unit injectors from the cylinder head ⇒ page 142 .
♦ Position cylinder head on a suitable valve supporting plate.
Removing
Note
♦ Ensure that the bearing shells of the camshafts are not mixed
up.
♦ Mark assignment of the bearing shells for the camshafts with
waterproof marker on the reverse side.
– Remove bearing shells of camshafts from the cylinder head.

– Remove unit injectors ⇒ page 142 .

OCTAVIA II 2004 ➤
– Put the piston of the relevant cylinder at “bottom dead centre”.

– Position the guide plate -VAS 5161/21-1- onto the cylinder
head.
– Attach the guide plate -VAS 5161/21-1- with the knurled
screws -VAS 5161/21-4- .
– Insert the impact drift -VAS 5161/3- into the guide plate and
knock off the tightly fitted valve keys using a plastic hammer.
– Screw the adapter -VAS 5161/21-2- into the guide plate by

hand.
– Fix the detent part -VAS 5161/6- with the suspension forks -
VAS 5161/5- at the cylinder head.
– Slide the knurled spacer ring -VAS 5161/21-5- onto the as‐
sembly cartridge -VAS 5161/8- .
– Insert the assembly cartridge -VAS 5161/8- into the guide
plate -VAS 5161/21-1- .
– Connect the adapter -VAS 5161/21-2- to the compressed air
with a commercially available intermediate piece and apply
constant pressure.
• Minimum pressure: 0.6 MPa (6 bar) overpressure
– Hook the pressure fork -VAS 5161/2- onto the detent part -
VAS 5161/6- .
– Press the assembly cartridge -VAS 5161/8- downwards and
turn simultaneously the knurled screw of the assembly car‐
tridge to the right, until the tips click into the valve keys.
– Slightly move the knurled screw of the assembly cartridge
back and forward. This presses the valve keys apart and in‐
stalls them into the assembly cartridge.
– Release the pressure fork -VAS 5161/2- .
– Remove assembly cartridge -VAS 5161/8- with knurled spacer
ring -VAS 5161/21-5- , valve spring retainer and valve spring.
– Pull off valve stem seals with extractor for valve stem seal
-3364- .
Install

OCTAVIA II 2004 ➤
– Insert the supplied plastic bushings -B- on the relevant valve

stem. This will prevent any damage to the new valve stem
seals -A-.
– Insert the new valve stem seal in the insertion tool for valve
stem seal -MP 1-233- .
– Oil the sealing lip of the valve stem seal and carefully slide it
onto the plastic sleeve -B-.
– Carefully press the valve stem seal with the valve stem seal
insertion tool -MP 1-233- onto the valve guide.
– Take off plastic sleeve again -B-.
– Insert the valve spring and the valve spring retainer.
– If the valve keys were removed from the assembly cartridge -

VAS 5161/8- , first of all they must be inserted into the insertion
device for valve keys -VAS 5161/18- .
Note
The large diameter of the valve keys points to the top.
– Press the assembly cartridge from the top onto the insertion
device for valve keys -VAS 5161/18- and raise the valve keys.
– Insert the assembly cartridge -VAS 5161/8- into the guide

plate.
– Press down the pressure fork -VAS 5161/2- , turn the knurled
screw of the assembly cartridge back and forward and while
doing so pull it towards the top. Thereby the valve keys are
replaced.
– Release the pressure fork -VAS 5161/2- on tightened knurled
screw.
The valve stem seal is removed and installed on the other valves
in the same way.
– Install unit injectors ⇒ page 142 .
Note

or started for about 30 minutes. Roller rocker arm with hy‐
draulic valve clearance compensation must settle (otherwise
valves would strike the piston).

OCTAVIA II 2004 ➤
2.8 Valve dimensions

Dimension Inlet valve Exhaust valve
∅a mm 29,20 25,50
∅b mm 5,975 5,965
c mm 87,80 87,50
α ∠° 45 45
Note
Valves must not be reworked. Only grinding in is permissible.
2.9 Inspect valve guides

♦ Dial gauge
Test sequence
Note
If the valves are replaced when carrying out repair work, use new
valves for the measurement.
– Insert valve into valve guide. End of valve stem must be flush
with guide.
Valve rock: maximum 1.3 mm
Note
If the wear limit is exceeded, repeat measurement with new

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

OCTAVIA II 2004 ➤
17 – Lubrication
1 Removing and installing parts of the
lubrication system
Note
♦ If engine damage occurs and it is suspected that the cause of

this is oil/fuel mixing (olfactory test of the engine oil), the tan‐
dem pump must absolutely be checked for internal tightness
⇒ page 117 .
♦ If considerable quantities of metal swarf as well as abrasion is
found in the engine oil when carrying out engine repairs, care‐
fully clean the oil galleries in order to avoid consequential
damage and additionally replace the engine oil cooler as well
as the oil filter element.
♦ The oil level must not be above the MAX. marking on the oil
dipstick - risk of damage to catalytic converter!
Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Octavia II .
1 - 15 Nm
2 - Drive chain sprocket
❑ for oil pump
⇒ page 47
3 - Dipstick
❑ oil level must not exceed
max. marking
4 - Hopper
❑ Remove for extracting
oil
5 - Guide tube
6 - Oil injection nozzle
❑ for piston cooling
❑ Pay attention to part
number (right-angle
bend)
7 - Pressure relief valve, 27 Nm
❑ opens at an overpres‐
sure of 0.25 to 0.32 MPa
(2.5 to 3.2 bar)
❑ replace without sealant
8 - O-ring
❑ replace
9 - Intake manifold
❑ Clean strainer if dirty
10 - Baffle
11 - Charge air pipe
❑ suction side
1. Removing and installing parts of the lubrication system 85

OCTAVIA II 2004 ➤
⇒ page 130
12 - 8 Nm
13 - Oil pan
❑ install with silicone sealant -D 176 600 A1-
14 - Drain plug, 30 Nm
❑ with gasket
❑ replace
15 - 10 Nm
❑ replace
16 - Oil level and oil temperature sender -G266-
❑ check ⇒ Vehicle diagnosis, testing and information system VAS 5051
17 - O-ring
❑ replace
18 - Oil pump
❑ with pressure relief valve 1.2 MPa (12 bar)
❑ before installing, check whether both dowel sleeves are present
❑ if there is any scoring on the contact surfaces of the gears, replace
❑ Tighening torque of oil pump cover at oil pump housing: 10 Nm
19 - Oil pump sprocket
❑ Fits onto oil pump shaft in one position only
❑ pressure side ⇒ page 130
❑ replace
22 - Oil pump chain
❑ before removing mark running direction
❑ check for wear
23 - Chain tensioner
❑ do not disassemble
❑ Replace chain tensioner if spring is broken.
❑ When installing, hook on the spring and pretension
❑ tighten to 16 Nm
24 - Sealing flange -on the belt pulley side-
❑ must be positioned on dowel sleeves
❑ replace the gasket ring for the crankshaft - on the belt pulley side ⇒ page 35
86 Rep. Gr.17 - Lubrication

OCTAVIA II 2004 ➤
1.1 Disassembling and assembling oil filter holder
1 - Screw plug - 25 Nm
2 - Gasket
❑ replace
3 - Engine oil cooler
❑ pay attention to the in‐
formation regarding a
necessary replacement
❑ connection diagram for
coolant hoses
⇒ page 96
4 - Gasket
❑ replace
❑ Fitting position
⇒ page 88
(1/4 turn)
❑ replace
❑ tighten crosswise
6 - Oil filter holder
❑ with oil retaining valve
❑ the oil retaining valve
cannot be replaced indi‐
vidually
7 - Gasket ring
❑ replace
8 - Oil pressure switch -F1- - 20
Nm
❑ 0.07 MPa (0.7 bar)
switch
9 - Screw cap - 25 Nm
❑ slacken and tighten with oil filter wrench -3417-
10 - O-ring
❑ replace
11 - Oil filter element
❑ pull off cap (Pos. 9)
❑ when replacing oil filter element replace O-rings (Pos. 10)
❑ pay attention to change intervals ⇒ Maintenance ; Octavia II
12 - Oil feed line
❑ to exhaust gas turbocharger
❑ Observe the mounting sequence:
– Screw on the union nuts first of all by hand.
– Then tighten the union nuts to 22 Nm.
– Subsequently secure the oil feed line in the brackets.
13 - Connection fittings - 35 Nm

OCTAVIA II 2004 ➤
Fitting position of gasket for engine oil cooler

– Place the gasket -2- in such a way that it can be pressed onto
all the lugs of the engine oil cooler -1-.
• The oil duct -arrow- must not be covered from the gasket.
1.2 Removing and installing oil pan

♦ Socket insert -T10058-
Removing
⇒ Rep. Gr. 66 .
– Slightly pull out the retaining clip -2- and detach the charge air
hose -1-.
– Release screw -4- and screw at cylinder block
( ⇒ page 130 ) and press off charge air pipe -3- to the front
from the oil pan.
– Release screw -1- and press off charge air pipe -2- to the rear
from the oil pan.
– Disconnect plug at oil level and oil temperature sender -
G266- .
– Drain engine oil ⇒ Maintenance ; Octavia II .

OCTAVIA II 2004 ➤
– Unscrew the bolts of oil pan/gearbox -arrows-.

– Loosen bolts -1...20- crosswise and release.
– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.
Install
the following:
WARNING

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

inder block and on the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).
– Apply silicone sealant bead -arrow- to the clean sealing sur‐

face of the oil pan, as shown.
• Thickness of sealant bead: 2…3 mm
Note
♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clogg the strainer
in the oil suction pipe.
♦ Take particular care when applying the sealant bead in the
area of the sealing flange -gearbox side- -arrows-.
♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant -D 176 600 A1- .
– Fit on oil pan immediately and tighten the bolts as follows:

– First of all tighten bolts -1 … 20- crosswise to 5 Nm.
– Tighten the bolts of the oil pan/gearbox -arrows- to a torque of
40 Nm.
– Tighten screws -1...20- crosswise to 15 Nm.
Note
♦ When installing the oil pan with the engine removed, ensure
that the oil pan is flush with the cylinder block at the flywheel
side.
♦ After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
– Fill with engine oil and check the oil level ⇒ Maintenance ;
Octavia II .

OCTAVIA II 2004 ➤
1.3 Removing and installing oil pump

Removing
– Remove baffle ⇒ page 85 .
– Pull the chain sprocket off the oil pump shaft.
– Release screws -1- and -3- and remove oil pump.
Install
the following:
– Insert top dowel sleeves into the oil pump.
• Installed position of the oil pump shaft/chain sprocket: Chain
sprocket fits onto the shaft in one position only.
• Replace the sprocket screw for the oil pump.
1.4 Testing oil pressure and oil pressure

switch
♦ Oil pressure tester , e. g. -V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
Test conditions
• Oil level o.k.
• Engine oil temperature approx. 80°C.
Test preparations
– Remove air intake pipe at lock carrier and air intake hose
⇒ page 148 .
– Disconnect plug -arrow- at oil pressure switch -F1- and un‐
screw oil pressure switch -F1- .

OCTAVIA II 2004 ➤
– Screw the connection of the oil pressure tester -V.A.G 1342-

into the hole for the oil pressure switch.
– Screw oil pressure switch -2- into the oil pressure tester.
Testing oil pressure switch
– Connect brown cable -1- of oil pressure tester to earth (-).
– Unclamp the voltage tester with its auxiliary cables out of the
measuring tool set on the oil pressure switch and plus (+) ter‐
minal on the battery.
• The LED should not light up.
If the LED lights up:
– Replace oil pressure switch.
If the LED does not light up:
– Start engine.
Note
Observe the testing equipment and the LED while actuating the
starter since the switching point of the oil pressure switch can
already be exceeded when starting up.
• At 0.055...0.085 MPa (0.55...0.85 bar) the LED should light up.

If the LED does not light up:
– Replace oil pressure switch.
Testing oil pressure
– Start engine.
• Oil pressure when engine idling: at least 0.08 MPa (0.8 bar)
• Oil pressure at a speed of 2000 rpm: at least 0.2 MPa (2.0 bar)
If the specified values are not reached: Oil pump defective.
– Replace oil pump ⇒ page 90 .
• Oil pressure at a higher engine speed: maximum 0.7 MPa (7.0
bar)
If the specified value is exceeded: Pressure relief valve defective.
– Replace oil filter holder ⇒ page 87 .

OCTAVIA II 2004 ➤
19 – Cooling
cooling system
WARNING
Hot steam may escape when the coolant expansion reservoir

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

sure. If necessary reduce pressure before repairs.
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ The arrows affixed to the coolant pipes and the coolant hoses
must stand opposite to each other.
92 Rep. Gr.19 - Cooling

OCTAVIA II 2004 ➤
1.1 Parts of cooling system, on the side next to the body - Summary of com‐
ponents
1 - Top coolant hose

❑ to connection fitting lat‐
erally at cylinder head
coolant hoses
⇒ page 96
2 - O-ring
3 - Radiator
⇒ page 100
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 97
4 - Screw cap
❑ Test pressure
0.14 … 0.16 MPa
(1.4 … 1.6 bar)
5 - Connector
6 - 3 Nm
7 - Coolant expansion reser‐
voir
8 - 5 Nm
9 - 5 Nm
10 - Bottom coolant hose
❑ to connection fitting for
coolant regulator at cyl‐
inder block
coolant hoses
⇒ page 96
11 - Right radiator fan -V35-
12 - Plug connection
13 - Connector
14 - Radiator fan -V7-
❑ with radiator fan control unit -J293-
15 - Fan shroud
1. Removing and installing parts of the cooling system 93

OCTAVIA II 2004 ➤
1.2 Parts of cooling system, engine side - Summary of components
1 - O-ring
❑ replace
2 - Retaining clip
❑ check tightness
3 - Coolant temperature send‐
er -G62-
4 - Hose
❑ to radiator for exhaust
gas recirculation
coolant hoses
⇒ page 96
5 - Connection fittings
❑ at cylinder head
❑ with coolant tempera‐
ture sender -G62-
6 - 10 Nm
7 - from heat exchanger
❑ Return-flow line
coolant hoses
⇒ page 96
8 - 40 Nm
9 - Hose
❑ to cylinder head
10 - Hose
❑ to the upper coolant
pipe
11 - Distributor part
12 - Hose
❑ to the distributor parts
13 - Hose
❑ To connection fitting at cylinder head
14 - Hose
❑ towards top radiator
15 - Distributor part
16 - 15 Nm
17 - Hose
❑ from engine oil cooler
18 - from bottom of coolant expansion reservoir
❑ connection diagram for coolant hoses ⇒ page 96
19 - Coolant pipe
20 - Hose
❑ from bottom of radiator

OCTAVIA II 2004 ➤
21 - Coolant temperature sender at radiator outlet -G83-

❑ with coolant regulator
❑ with coolant temperature sender at radiator outlet -G83-
23 - Coolant regulator
❑ check: heat up regulator in a water bath
Start of opening:approx. 87°C
Full opening: approx. 102°C
Stroke: minimum 7 mm
24 - Hose
❑ from cylinder block connection
26 - Coolant pump
❑ check smooth operation
27 - to top of coolant expansion reservoir
❑ connection diagram for coolant hoses ⇒ page 96
28 - Top coolant pipe
❑ bolted to intake manifold

OCTAVIA II 2004 ➤
1.3 Connection diagram for coolant hoses

For vehicles without auxiliary heating.

voir
❑ with cap
❑ Testing the pressure re‐
lief valve in the cap
⇒ page 103
2 - Cylinder head/cylinder
block
ant ⇒ page 97
3 - Radiator for exhaust gas re‐
circulation
ant ⇒ page 97
⇒ page 164
4 - Heat exchanger for heating
ant ⇒ page 97
ant ⇒ page 97
⇒ page 87
6 - Radiator
⇒ page 100
ant ⇒ page 97
8 - Coolant pump
For vehicles with auxiliary heating

OCTAVIA II 2004 ➤

voir
❑ with cap
❑ Testing the pressure re‐
lief valve in the cap
⇒ page 103
2 - Cylinder head/cylinder
block
ant ⇒ page 97
circulation
ant ⇒ page 97
⇒ page 164
4 - Heat exchanger for heating
ant ⇒ page 97
ant ⇒ page 97
⇒ page 87
6 - Radiator
⇒ page 100
ant ⇒ page 97
8 - Coolant pump
9 - Auxiliary heating
1.4 Draining and filling up coolant

♦ Refractomer -T10007-
Draining
Note
Collect drained coolant in a clean container for proper disposal or

reuse.

OCTAVIA II 2004 ➤
WARNING

is opened.
– Open the cap of the coolant expansion reservoir.

– Place a catch pan under the engine.
– Remove right charge air hose, to do so slightly pull out the
retaining clips -arrows-.
WARNING
Shut off the opening of the charge air cooler, e.g. with a clean
foam piece, so that no coolant can penetrate.
– Remove the right coolant hose from the radiator; to do so pull

the retaining clip -arrow-.
⇒ page 148 .
– Remove the rear coolant hose on the engine oil cooler

-arrow- and drain residual coolant.
Filling up

OCTAVIA II 2004 ➤
– Connect coolant hose on the right of radiator -arrow-.
– Connect the rear coolant hose on the engine oil cooler

-arrow-.
Select the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts or from the list of allowed coolant ad‐
ditives ⇒ Maintenance ; Octavia II .
– In a clean reservoir mix water and coolant additive in the cor‐
rect mixing ratio ⇒ Maintenance ; Octavia II .
– Top up coolant through the connection of the coolant expan‐

sion reservoir, until the MAX. marking of the coolant level is
reached.
– Switch off the heating and air-conditioning system.
– Start engine and run for maximum 2 minutes at approx. 1500
rpm. While doing so, fill with coolant up to the MAX. marking
in the coolant expansion reservoir.
– Tighten cap at coolant expansion reservoir.
– Tighten cap at coolant expansion reservoir.
– Run engine until fan starts.
– Check coolant level when the coolant expansion reservoir is

closed.
• When engine is at operating temperature the coolant level
must be at the MAX. marking, when engine is cold between
the MIN. and MAX. markings.
WARNING

is opened.
– If necessary, top up with coolant.

Further assembly is carried out in the reverse order.

OCTAVIA II 2004 ➤
1.5 Removing and installing fan shroud for

radiator fan -V7- and right radiator fan -
V35-
Removing
⇒ page 148 .
– Disconnect plug connection -1-.
– Screw out screws -arrows- and remove fan shroud with radi‐
ator fans upwards.
Install
the following:
♦ Tightening torques: ⇒ page 93
1.6 Removing and installing radiator

Removing
Note
Collect drained coolant in a clean container for proper disposal or

reuse.

– Pull off coolant hose at top of radiator -arrow-.
– Remove fan shroud with radiator fans ⇒ page 100 .
– Unplug connector from high pressure sender -G65- .

OCTAVIA II 2004 ➤
– Screw out screws -arrows- and remove the radiator upwards.

Install
the following:
♦ Tightening torques: ⇒ page 93
– If a new radiator is installed, the old (drained) coolant must not
be reused.
1.7 Removing and installing coolant pump

Removing
– Unscrew fixing bolts -1- of the coolant pump and remove the
coolant pump -2-.
– Remove O-ring -3-.
Install
the following:
Note
Replace O-ring.
– Clean sealing surface for O-ring, if necessary smoothen.
– Moisten new O-ring -3- with coolant.

– Attach the coolant pump -2-.
• Fitting position: Plug in housing points down.
– Tighten screws -1- of coolant pump to 15 Nm.
1.8 Removing and installing coolant regula‐

tor
Removing
– Disconnect battery ⇒ Electrical System ⇒ Rep. Gr. 27 .

OCTAVIA II 2004 ➤

– Place fuel filter with connected hoses to the side.
– Unscrew AC generator ⇒ Electrical System ⇒ Rep. Gr. 27
and lay to the right upwards. The hoses remain connected.
– Remove coolant hose -2- from connection fittings.

– Disconnect plug -1- at the coolant temperature sender at ra‐
diator outlet -G83- .
– Unscrew screws -arrows- and remove connection fittings.
– Turn coolant thermostat -1- approx. 90° (1/4 turn) anti-clock‐

wise -arrow- and remove from connection fitting.
– Remove O-ring -2-.
Install
the following:
Note
Replace O-ring.
– Clean sealing surface for O-ring, if necessary smoothen.

– Insert the coolant regulator with the new O-ring.
• Fitting position: the coolant regulator clamp must stand hori‐
zonally.
– Moisten O-ring with coolant.
– Fit connection fitting onto cylinder block, tighten screws to 15
Nm and connect hose of radiator.
– Install alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Carry out work after reconnecting the battery ⇒ Electrical
System ⇒ Rep. Gr. 27 .
1.9 Checking the coolant system for leak‐

tightness
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter , e.g. -V.A.G 1274/8-

OCTAVIA II 2004 ➤
♦ Adapter , e.g. -V.A.G 1274/9-

Test condition
• Engine must be warm.
Test sequence
WARNING

is opened.
– Open the cap of the coolant expansion reservoir.

– Position the cooling system testing device -V.A.G 1274- with
adapter -V.A.G 1274/8- on the coolant expansion reservoir.
– Generate an overpressure of approx. 0.1 MPar (1.0 bar) for
testing the cooling system.
If the pressure drops:
– Search position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Position the cooling system testing device -V.A.G 1274- with
adapter -V.A.G 1274/9- on the coolant expansion reservoir.
– Generate an overpressure for testing the pressure relief valve.
• The pressure relief valve should open at a pressure of
0.14 … 0.16 MPa (1.4 … 1.6 bar).
If the pressure relief valve does not open:
– Replace cap.

OCTAVIA II 2004 ➤
20 – Fuel Supply
fuel supply system
Note
♦ Fuel lines are secured with quick-release couplings.

♦ Fuel hoses must be secured only with spring strap clips. The
use of clamp-type or screw-type clips is not allowed.
♦ Use pliers for spring strap clips to fit the spring strap clips.
Observe safety measures ⇒ page 3 .

Observe rules for cleanliness ⇒ page 4 .
1.1 Fuel tank with attached parts
1 - Mounting part
2 - Screw cap
❑ replace the O-ring if it is
damaged
3 - Earth connection
4 - 11 Nm
5 - Support
6 - 25 Nm
❑ replace
7 - Fuel tank
❑ when removing, support
using the engine and
gearbox jack , e.g. -
V.A.G 1383 A-
⇒ page 109
8 - Circlip
9 - Bracket for the exhaust sys‐
tem
10 - Tensioning strap
11 - Heat shield
12 - Fuel cooler
⇒ page 109
13 - to fuel filter
14 - 20 Nm
15 - Gasket ring
❑ replace
❑ to be inserted dry into the opening of the fuel tank
❑ must be moistened on the inside with fuel before assembly of the fuel delivery unit
104 Rep. Gr.20 - Fuel Supply

OCTAVIA II 2004 ➤
16 - Fuel delivery unit

❑ with sender for fuel gauge display
❑ note the installed position of the fuel tank ⇒ page 105
❑ Check fuel delivery unit ⇒ page 119
❑ Clean strainer if dirty
❑ removing and installing the sender for fuel gauge display ⇒ page 113
17 - Lock ring - 110 Nm
❑ use wrench -T30101 (3087)- for removing and installing
18 - Fuel return-flow line
❑ from fuel cooler
❑ clipped in place on fuel tank
❑ blue
19 - Fuel feed line
❑ to fuel filter
❑ clipped in place on fuel tank
❑ black
20 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work ⇒ Rep. Gr. 55
Fitting location of the fuel delivery unit

Marking -3- on the flange of the fuel delivery unit points against
the direction of travel.
Note
The fuel delivery unit can only be installed in this position.
Blue fuel return-flow line -1-.

Black fuel feed line -2-.
Note
After installing the fuel delivery unit, check whether the fuel feed
line and the fuel return-flow line are still clipped in place on the
fuel tank.
1. Removing and installing parts of the fuel supply system 105

OCTAVIA II 2004 ➤
1.2 Removing and installing fuel filter

Fuel filter type one
Note
Before disconnecting the fuel hoses, mark assignment to the pipe supports.
1 - Fuel intake hose

❑ from fuel tank
❑ white marking
2 - 8 Nm
3 - Fuel return-flow hose
❑ to fuel cooler
❑ blue marking
4 - Drain plug
❑ release and drain
(catch) approx. 0.1 litre
fluid using the diesel ex‐
tractor , e.g. -VAS 5226-
or using the hand vac‐
uum pump , e.g. -VAS
6213- , and ventilation
reservoir , e.g. -V.A.G
1390/1-
5 - Gasket ring
❑ replace
❑ to the tandem pump
❑ white marking
7 - Fuel filter - top part
8 - Retaining clip
9 - Fuel temperature sender -
G81-
❑ from the tandem pump
❑ blue marking
❑ with connection fitting for fuel temperature sender -G81-
11 - Fuel filter element
❑ pay attention to change intervals ⇒ Maintenance ; Octavia ll.
12 - Fuel filter with integrated bracket
13 - 8 Nm
❑ to remove fuel filter only slacken screw

OCTAVIA II 2004 ➤
Fuel filter type two and three
Note
Before disconnecting the fuel hoses, mark assignment to the pipe supports.

❑ from fuel tank
❑ white marking
❑ to fuel cooler
❑ blue marking
3 - Intake hose
❑ to the tandem pump
❑ white marking
4 - Screw
❑ for type 2 (left illustra‐
tion): 9 Nm
❑ for type 3 (right illustra‐
tion): 5 Nm
5 - Retaining clip
6 - Fuel temperature sender -
G81-
7 - Gasket ring
❑ replace
❑ from the tandem pump
❑ blue marking
❑ with connection fitting
for fuel temperature
sender -G81-
9 - Fuel filter - top part
❑ with integrated preheat‐
ing valve
10 - Filter insert
❑ pay attention to change intervals ⇒ Maintenance ; Octavia ll.
❑ Pay attention to the part number
11 - Fuel filter with integrated bracket - bottom part.
1.3 Drain the fuel tank

♦ Hose adapter , e.g. -V.A.G 1318-16-
♦ Adapter , e.g. -V.A.G 1318-17-
♦ Battery
♦ Fuel tank

OCTAVIA II 2004 ➤
Note
If there are functional problems of the fuel delivery unit suction off
fuel with fuel extraction device, e.g. -VAS 5190- .
Procedure
Note
♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .
– Unclip retaining catches -arrows- of cover for the fuel delivery
unit and remove cover.
Note
For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must be disconnected additionally.
– Unplug the 5-pin connector -1- and the black fuel feed line
-2-.
Note
Press in securing ring in order to unlock the line.

OCTAVIA II 2004 ➤
– Connect the adapter -V.A.G 1318-16- and the adapter -V.A.G

1318/17- and fit the “drain pipe” onto the feed support of the
fuel delivery unit.
– Hold the “drain pipe” in a suitable fuel tank.
– Connect the battery and the contacts of the fuel pump with
adapter cables -A- from the adapter cable set as follows:
Battery positive (+) to contact -1- of the fuel pump
Battery minus (-) to contact -5- of the fuel pump
The fuel pump runs and delivers fuel.
WARNING
In order to prevent an overflow of fuel in case of a too small

fuel tank, the fuel pump must not run unattended.
1.4 Removing and installing fuel cooler

Removing
Note
♦ The fuel cooler is located at the fuel return-flow line to the fuel
tank. It is attached to the underfloor of the vehicle body.
⇒ page 3 .
– Removing the right underfloor trim panel.
– Separate fuel lines at fuel cooler.
– Unscrew fixing nuts for fuel cooler -arrows- and remove fuel
cooler.
Install
the following:
– Tighten fixing nuts for the fuel cooler to 15 Nm.
1.5 Removing and installing the fuel tank

♦ Engine and gearbox jack , e.g. -V.A.G 1383 A-

OCTAVIA II 2004 ➤
Removing
Note

⇒ page 3 .
Note
dosing pump -V54- must also be disconnected.
– Unplug connector -arrow-.

– Remove right rear wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew fuel filler cap from fuel filler neck.
– Seal the filler neck with a clean foam piece in order to avoid
any foreign bodies from entering.
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .

OCTAVIA II 2004 ➤
– Unscrew screws -1- for filler neck on the body.

– Unclip the wiring loom from the holder -2- at the top and bottom
of the filler neck.
– Remove rear tunnel bridge ⇒ page 154 .
– Slacken front double clamp at exhaust pipe and push to the
rear.
– Push out all suspensions of the middle and rear part of the
exhaust system from the retaining straps.
– Slightly lower the middle and rear part of the exhaust system
and tie with wire to the body.
– Disconnect the fuel feed line and the fuel return-flow line on
the front right of the fuel tank.
Note
♦ For vehicles with auxiliary heating, the fuel line for the dosing
pump -V54- must also be disconnected.
♦ Press down the securing rings in order to unlock the connec‐
tions of the fuel lines.
– Unscrew tensioning strap.

– Support fuel tank using the engine and gearbox jack -V.A.G
1383 A- .
– Unscrew securing bolts.
– Lower fuel tank and swivel out.
Install
the following:
♦ Lay the fuel lines avoiding any kinks.
♦ Do not mix-up the fuel feed line (black) and the fuel return-flow
line (blue).
♦ Make sure the fuel line connections fit tightly.
♦ Check fuel feed line and the fuel return-flow line at fuel tank
for firm seating.
♦ Check earth connection of fuel tank/body at filler neck.
1.6 Removing and installing fuel delivery

unit
♦ Wrench for the lock ring -T30101 (3087)-
Condition
• The fuel tank must not be more than 3/4 full.

OCTAVIA II 2004 ➤
Removing
Note
♦ If necessary, drain the fuel tank ⇒ page 107 .

⇒ page 3 .
Note
– Disconnect the plug as well as the black fuel feed line -2- and
the blue fuel return-flow line -1- from the flange.
Note
♦ Press in securing ring in order to unlock the lines.

♦ For vehicles with auxiliary heating the suction hose for the
dosing pump -V54- must be pulled out additionally (open lower
clamp).
– Open lock ring with the wrench -T30101- .
Note
When removing the fuel delivery unit, ensure that the float arm of
the sender for fuel gauge display -G- is not bent.
– Pull the fuel delivery unit and the gasket ring out of the opening
of the fuel tank.
Note
You must empty the old fuel delivery unit before disposing of it if
you wish to replace it.
Install
the following:

OCTAVIA II 2004 ➤
Note
♦ Insert new dry gasket ring into the opening of the fuel tank.
♦ The gasket must only be moistened from inside with fuel be‐
fore assembly of the fuel delivery unit.
♦ Do not bend the sender for fuel gauge display when installing
it.
♦ Observe the fitting location of the fuel delivery unit. Marking
-3- on the flange must point against the direction of travel. The
fuel delivery unit can only be installed in this position.
♦ Do not mix-up the fuel feed line and the fuel return-flow line.
♦ Tighten the lock ring to 110 Nm.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the fuel
feed line and the fuel return-flow line are clipped in place on
the fuel tank.
1.7 Removing and installing the sender for

fuel gauge display -G-
Note
In the vehicles there are 2 types of senders for fuel gauge display
-G- installed.
Sender for fuel gauge display -G- type 1

Removing
– Remove fuel delivery unit ⇒ page 111 .
– Unlatch and disconnect the plug connection of the lines -1-
(brown), -2- (blue) and -3- (black).
– Raise catches -4- and -5- with a screwdriver and remove the
sender for fuel gauge display -G- from the bottom -arrow-.
Install
– Insert the sender for the fuel gauge display -G- in the guides
at the fuel delivery unit and press upwards until it latches into
position.
– Connect the lines and check the connector for secure catch.
– Install fuel delivery unit ⇒ page 111 .
Sender for fuel gauge display -G- type 2
Removing
– Remove fuel delivery unit ⇒ page 111 .

OCTAVIA II 2004 ➤
– Unlock the catches -arrows- using a screwdriver and pull out

the sender for fuel gauge display -G- towards the top.
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the lines and check the connector for secure catch.
– Insert the sender for fuel gauge display -G- in the guides at the
fuel delivery unit and press downwards until it latches into po‐
sition.
– Install fuel delivery unit ⇒ page 111 .
1.8 Removing and installing the tandem

pump
♦ Diesel extractor , e.g. -VAS 5226-
WARNING
Under no circumstances must the tandem pump be disassem‐

bled, otherwise it can lead to malfunction of the vacuum part.
This will result in a failure of the brake booster.
Caution
Observe instructions for installing again a used tandem pump

⇒ page 117 .

OCTAVIA II 2004 ➤
Removing
Note

⇒ page 3 .

– Disconnect the fuel intake hose -1- (marked in white) and the
fuel return-flow hose -2- (marked in blue) from the fuel filter.
– Connect diesel extractor -VAS 5226- at fuel return-flow hose
-2-.
– Apply compressed air to diesel extractor -VAS 5226- .
– Operate diesel extractor -VAS 5226- until no more fuel comes
out of the fuel return-flow hose.
– Remove air filter with air mass meter -G70- ⇒ page 148 .
– Separate vacuum line -1- for brake servo unit from tandem
pump -4-.
– Disconnect the fuel intake hose -2- (marked in white) and the
fuel return-flow hose -3- (marked in blue) from the tandem
pump -4-.
– Release fixing screws -arrows- and remove tandem pump
-4- from cylinder head.
Install
the following:
Caution
Observe instructions for installing again a used tandem pump

⇒ page 117 .
Note
♦ Ensure that the tandem pump coupling is correctly seated in

the camshaft.
♦ Always replace the gasket of the tandem pump.

OCTAVIA II 2004 ➤
– Install tandem pump and tighten the fixing screws -arrows- to

20 Nm.
– Connect fuel intake hose -1- (marked in white) to fuel filter.

– Connect diesel extractor -VAS 5226- to return-flow hose -2-.
– Operate diesel extractor -VAS 5226- until fuel flows out of the
fuel return-flow hose.
– Connect fuel return-flow hose -2- (marked in blue) to fuel filter.
1.9 Inspecting a tandem pump
1.9.1 Checking feed pressure of tandem

pump
♦ Tandem pump testing device , e.g. -VAS 5187- with hollow
screw -VAS 5187/1A-
♦ Hose clamps -MP 7-602 (3094)-
Test conditions
• Coolant temperature must be at least 85°C.
• Unit injectors O.K.
• The fuel filter and fuel lines must not be blocked.
Procedure
Note

⇒ page 3 .

– Remove air filter with air mass meter -G70- ⇒ page 148 .

OCTAVIA II 2004 ➤
– Release screw plug -arrow-.
– Connect tandem pump testing device -VAS 5187- with hollow

screw -VAS 5187/1A- , as shown.
– Install air filter.
– Start engine and engine speed must increase to 4000 rpm.
– Observe the pressure displayed on the tandem pump testing
device .
• Specified value: at least 1.05 MPa (10.5 bar)
If the specified value is not reached:
– Press together fuel return-flow line between tandem pump and
fuel filter with hose clamp -MP 7-602 - .
– Start engine and engine speed must increase to 4000 rpm.
– Observe the pressure displayed on the tandem pump testing
device .
• Specified value: at least 1.05 MPa (10.5 bar)
If the specified value is now reached:
♦ Pressure loss at the unit injectors.
– Replace O-rings for unit injectors ⇒ page 146 .
If the specified value is not reached:
– Replace tandem pump ⇒ page 114 .
Note
After removing the testing device tighten the plug to 25 Nm. Al‐
ways replace the gasket ring.
1.9.2 Checking the tandem pump for tight‐

ness (internal)
Caution
♦ After re-installing an already used tandem pump e.g. after

changing or repairing the cylinder head and/or after
changing an engine without component parts, the tandem
pump must be absolutely checked for internal tightness
between fuel and oil part.
♦ In case of leakage fuel and oil can be mixed, which can
cause an engine damage.

OCTAVIA II 2004 ➤

♦ Tester , e. g. -V.A.G 1687-
Procedure
Note

⇒ page 3 .

– Disconnect the fuel intake hose (white marking) -2- and the
fuel return-flow hose (blue marking) -1- from the tandem
pump.
– Close fuel return-flow connection at tandem pump with a plug.
Secure plugs with spring strap clips.
Prepare tester -V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
– Connect test connection -5- with a commercially available
connection for compressed air und a piece of fuel hose to the
connection of the fuel feed line for the tandem pump. Secure
connection with spring strap clips.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect the pneumatic hose -1- (pneumatic support) at tester.
Note
If there is water in the transparent water drain reservoir, drain

water via the drain plug -6-.
– Open valve -3-.

– Set the pressure to 0.1 MPa (1.0 bar) with the pressure control
valve -2-.
WARNING
The maximum test pressure is 0.13 MPa (1.3 bar) and it must
not be exceeded.

OCTAVIA II 2004 ➤
– Open valve -4- and wait until the test circuit is filled up. If nec‐
essary readjust pressure to 0.1 MPa (1.0 bar).
– Close the valve -3- to maintain the pressure and observe the
drop in pressure for 1 minute.
If the pressure does not drop, the tandem pump can still be used.
In case of drop in pressure the tandem pump must be re‐
placed.
1.10 Checking fuel delivery unit

♦ Remote control , e.g. -V.A.G 1348/3A-
♦ Adapter , e.g. -V.A.G 1318/16-
♦ Adapter , e.g. -V.A.G 1318/17-
♦ Measuring glass
Checking the function and supply voltage
Test conditions
• Battery voltage at least 11.5 V.
• Fuses o.k. (No. 27)
• All electrical components such as lights and rear window heat‐
er must be switched off.
Test sequence

OCTAVIA II 2004 ➤

– Switch on ignition.
• The fuel pump must be heard to start running.
– Switch off ignition.
If the fuel pump does not run:
– Continuing searching for faults using a multimeter ⇒ Current
flow diagrams and Fitting locations.
Check fuel flow rate
Test conditions
• Battery voltage at least 11.5 volts
• Fuel temperature 15 … 30°C
• Fuel tank at least 1/4 full.
Test sequence
Note

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

Note
– Unplug connector -arrow-.

OCTAVIA II 2004 ➤
– Connect remote control -V.A.G 1348/3A- with connection lines

from measuring tool set to contact -1- of the fuel pump and to
battery positive terminal.
– Use connection lines from the measuring tool set to connect
the contacts -5- to the plug and to the fuel pump.
– Pull off the fuel feed line from the flange of the fuel delivery
unit.
– Connect adapter -V.A.G 1318/17- and adapter -
V.A.G 1318/16- , fit onto the feed support and hold in a
measuring glass.
– Activate the remote control -V.A.G 1348/3A- for 30 seconds.
– Measure the battery voltage.
– Compare the fuel rate with the specified value.
Note
♦ The amount of the fuel pumped is dependent on the voltage.

♦ The diagram refers to the voltage which exists at the fuel
pump.
♦ The voltage at the fuel pump is about 2 volts less than the
battery voltage.
If the minimum flow rate is not reached:

– Remove the fuel delivery unit and check whether the pump
strainer is not clogged up.
If no fault was detected until now:
– Replace fuel delivery unit.

OCTAVIA II 2004 ➤
2 Accelerator control
2.1 Accelerator pedal module - Summary of components
1 - Connector
❑ black
❑ 6-pin
2 - Accelerator pedal module
❑ with accelerator pedal
position sender -G79-
and accelerator pedal
position sender 2 -
G185-
❑ -A- openings for release
tool -T10238- or -
T10240-
❑ not adjustable
⇒ page 122
❑ adapt this for a replace‐
ment engine control unit
⇒ Vehicle diagnosis,
testing and information
system VAS 5051
3 - 10 Nm
4 - Cap
2.2 Removing and installing accelerator

pedal module
♦ Release tool -T10238- (for left-hand drive vehicle)
♦ Release tool -T10240- (for right-hand drive vehicle)

OCTAVIA II 2004 ➤
Removing
– Remove cover for the steering column -arrows-.
– Lever out the cap ( ⇒ page 122 , position 4) with a screwdriver.
– Unscrew the fixing screw ( ⇒ page 122 , position 3).
– Push the release tool -T10238- (on right-hand drive vehicles

release tool -T10240- ), as shown up to the stop into the pro‐
vided openings and remove the accelerator pedal module.
– Unplug connector from accelerator pedal module. To do so
press down securing element from connector.
Install
– Fit connector -2- onto the accelerator pedal module -5-.

The locking of the connector must be audible.
– Push accelerator pedal module onto the fixing bolts -6-.
– Insert centering pin -7- in the hole on the vehicle floor.
– Fasten accelerator pedal module with screw -3- (10 Nm) and
fit on cap -4-.
– Re-install cover for steering column.
– If the accelerator pedal module was replaced, the engine con‐
trol unit has to be adapted ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
2. Accelerator control 123

OCTAVIA II 2004 ➤
21 – Turbocharging
1 Charge air system with exhaust gas
turbocharger
Note

♦ The charge-air system must be tight.
♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
1.1 Connection diagram for vacuum hoses
1 - Air filter housing

❑ with connection for ven‐
tilation line for charge
pressure control sole‐
noid valve -N75-
2 - Solenoid valve for charge
pressure control -N75-
❑ with vacuum reservoir
4 - Non-return valve
5 - Vacuum line to brake boos‐
ter
6 - Changeover valve for radi‐
ator of exhaust gas recircula‐
tion -N345-
7 - Intake manifold flap valve -
N316-
8 - Vacuum setting element
❑ for changeover of radia‐
tor for exhaust gas recir‐
culation
❑ for air flow control
❑ at exhaust gas turbo‐
charger
❑ with position sender for
charge pressure regula‐
tor -G581-
124 Rep. Gr.21 - Turbocharging

OCTAVIA II 2004 ➤
1.2 Removing and installing turbocharger
1 - 10 Nm
2 - Support
3 - Heat shield
4 - Oil feed hose
❑ to connection fitting of
oil feed line at exhaust
gas turbocharger
5 - Exhaust gas turbocharger
tor -G581-
❑ to be replaced together
with the exhaust mani‐
fold
6 - Vacuum hose
❑ from charge pressure
control solenoid valve -
N75-
7 - Gasket
❑ replace
8 - for diesel particle filter
9 - Clamp - 7 Nm
❑ replace
❑ for exhaust gas turbo‐
charger/diesel particle
filter
10 - Exhaust manifold
❑ only to be replaced to‐
gether with the exhaust gas turbocharger
11 - 25 Nm
❑ replace
12 - Connecting tube
❑ to radiator for exhaust gas recirculation
13 - Gasket
❑ replace
14 - 25 Nm
❑ replace
15 - 25 Nm
16 - 15 Nm
17 - O-ring
❑ replace
18 - Hollow screw - 60 Nm
19 - Support
❑ for exhaust gas turbocharger
1. Charge air system with exhaust gas turbocharger 125

OCTAVIA II 2004 ➤
❑ for oil return-flow line
20 - Exhaust gas temperature sender 1 -G235- ( Temperature sender upstream turbocharger -G507- )
❑ 45 Nm
❑ the thread of new temperature senders must be coated with assembly paste
❑ grease only the thread with hot bolt paste -G 052 112 A3- for re-used temperature sender.
21 - Heat shield
22 - 25 Nm
❑ replace
❑ for suction hose of air filter
24 - 9 Nm

Caution
In case of mechanical damage to the exhaust gas turbocharg‐

er, e.g. damage of the compressor wheel, it is not sufficient to
only replace the exhaust gas turbocharger. In order to prevent
consequential damage to the engine, perform the following
tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter housing, air filter element and charge air
pipes as well as charge air hoses for soiling.
♦ Check all air guides and charge air cooler for foreign bod‐
ies.
If foreign bodies are detected in the charge air system, the
charge-air routing must be cleaned and the charge air cooler
must be replaced.
Removing
Note
Observe regulations concerning cleanliness when working on the

exhaust gas turbocharger ⇒ page 4 .

⇒ page 148 .
– Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Remove diesel particle filter ⇒ page 155 .

OCTAVIA II 2004 ➤

– Release plug -1- and -3- and expose electrical cables.
– Detach vacuum line -4-.
– Remove oil intake hose -3- from exhaust gas turbocharger.

– Pull out retaining clips -Pfeile- slightly and remove charge air
hose.
– Expose electrical cable to exhaust gas temperature sender 1

-G235- ( temperature sender upstream turbocharger -G507- )
-1-.
– Release screws -arrows- and remove heat shield.
– Release plug -1- from oil level and oil temperature sender -
G266- and remove bracket -2- from assembly carrier.

OCTAVIA II 2004 ➤
– Release nuts -1- and remove left heat shield from exhaust
manifold.
– Disconnect plug connection for exhaust gas temperature

sender 1 -G235- ( temperature sender upstream turbocharger
-G507- ) and unscrew exhaust gas temperature sender 1 -
G235- ( temperature sender upstream turbocharger -G507- )
-1- from the exhaust manifold.


OCTAVIA II 2004 ➤

– Remove exhaust turbocharger with exhaust manifold down‐
wards. To do so slightly press the engine/gearbox assembly
forwards.
Install
the following:
Note

nuts.
♦ Fill exhaust turbocharger with engine oil through the connec‐
tion fitting of the oil feed line.
♦ Remove oil and grease from the charge air pipes and hoses
and from their connections before installing.
– Install exhaust system and align free of stress ⇒ page 159 .

– Observe the assembly instruction for hose connections with
Note
after installing the exhaust turbocharger run the engine approx. 1

minute in idle and do not increase speed immediately in order to
ensure the supply of oil to the turbocharger.

OCTAVIA II 2004 ➤
1.3 Charge air cooling - Summary of components
Note
Observe general instructions for charge air system ⇒ page 5 .
1 - 5 Nm
2 - Support
3 - Charge air cooler
⇒ page 130
4 - top seal
❑ placed onto charge air
cooler
5 - To intake manifold
6 - Charge air hose
7 - Spring strap clamp
8 - Charge air pipe
9 - 3 Nm
10 - Charge pressure sender -
G31- / Intake air temperature
sender -G42-
11 - 8 Nm
12 - Right charge air hose
13 - from exhaust turbocharger
14 - Charge air hose
16 - Left charge air hose
17 - 15 Nm
18 - bottom seal
❑ placed onto charge air
cooler
1.4 Removing and installing charge air cool‐

er
Removing
– Removing coolant cooler ⇒ page 100 .
– Remove front bumper ⇒ Body Work ⇒ Rep. Gr. 63 .
– Remove the charge air hose on the left from the charge air
cooler.
– Release the screws of the brackets for charge air cooler
( ⇒ page 130 , position 1).

OCTAVIA II 2004 ➤
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Caution
To avoid causing damage to the condenser and to the refrig‐

erant lines and hoses make sure the lines and hoses are not
over-extended, kinked or bent.
Note
For the following work, a second mechanic is required to hold the

charge-air cooler.
– Swivel the charge air cooler towards the rear, remove the lat‐
eral brackets for charge air cooler and unhook out of the lower
bearings.
– Release the securing bolts -arrows- of the condenser.
– Remove charge air cooler downwards.
Install
the following:
♦ Observe the assembly instruction for hose connections with
1.5 Hose connections with push-fit cou‐

plings
Caution
The gasket ring for the push-fit coupling can be damaged, if

the locking clip is in the lock position during the assembly. This
could result in a leakage. Observe the assembly instruction.

OCTAVIA II 2004 ➤
Removing
– Release push-fit coupling by pulling the locking clip -arrow-.
Disconnect hose/pipe without auxiliary tool.
Install
– When replacing the gasket ring, place the gasket ring in the
groove of the charge air hose. Make sure that the gasket ring
is fully seated all round in the groove and not twisted.
– Oil the sealing surface and the gasket ring.
– Put the locking clip into the release position -1-.

– Push the charge air hose up to the stop into the coupling.
– Put the locking clip into the lock position -2- and then press
down once again the charge air hose.
– Check for correct seating and the correct locking in place of
the push-fit coupling by pulling on the hose.
1.6 Checking the charge-air system for

leaktightness
♦ Charge-air system testing device , e. g. -V.A.G 1687-
♦ Adapter , e.g. -V.A.G 1687/10-

OCTAVIA II 2004 ➤
Test sequence
– Remove the suction hose -1- from the air filter.
– Fit adapter -1687/10- into the suction hose -1- and secure with
a clamp.
Prepare tester for charge air system -V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect the tester for charge air system -V.A.G 1687- , as

shown, at the adapter -1687/10- .

OCTAVIA II 2004 ➤
– Connect the pneumatic hose -1- (pneumatic support) at tester.
Note
If there is water in the transparent water drain reservoir, drain

water via the drain plug -6-.
– Open valve -3-.

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

charger, because the suction hose is not designed for over‐
pressure.
♦ A small amount of air escapes via the valves into the engine.
For this reason no pressure test is possible.
♦ Use of ultrasonic measuring device -V.A.G 1842- ⇒ operating
instructions .
♦ In case of a leak point, observe the instructions for charge air
system ⇒ page 5 during the installation.
♦ Before removing the adapter, depressurize the test circuit by
detaching the coupling from the adapter -1687/10- .

OCTAVIA II 2004 ➤
23 – Fuel Formation, Injection

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

adjustment work is being undertaken and then saved. It is
therefore absolutely necessary to delete the fault memory af‐
ter completing all checking and adjustment work ⇒ Vehicle
diagnosis, testing and information system VAS 5051
♦ Observe the safety precautions when working on the diesel
direct injection system ⇒ page 3 .
1.1 Overview of fitting locations
1 - Pressure sensor 1 for ex‐

haust gas -G450-
2 - lambda probe -G39- with
heating for lambda probe -Z19-
3 - Diesel direct injection sys‐
tem control unit -J248-
❑ with altitude sender -
F96-
⇒ page 152
4 - Exhaust gas temperature
sender 3 -G495- ( Tempera‐
ture sender downstream parti‐
cle filter -G527- )
tion -N345-
ture sender upstream particle
filter -G506- )
7 - Unit injectors and ceramic
pencil type glow plugs
❑ Unit injector valve of cyl‐
inder 1 -N240-
inder 2 -N241-
inder 3 -N242-
inder 4 -N243-
❑ Removing and installing
unit injectors
1. Repairing the diesel direct injection system control unit 135

OCTAVIA II 2004 ➤
⇒ page 142
❑ Glow plug 1 -Q10-
❑ Removing the ceramic pencil type glow plugs ⇒ page 167
8 - Position sender for charge pressure regulator -G581-
9 - Exhaust gas temperature sender 1 -G235- ( Temperature sender upstream turbocharger -G507- )
10 - Solenoid valve for charge pressure control -N75-
11 - Electrical plug connections
❑ left at the bulkhead plenum chamber
❑ Summary of components ⇒ page 137
12 - Air mass meter -G70-
13 - Coolant temperature sender -G62-
14 - Tandem pump
15 - Multipin plug connection
❑ Central plug connection for unit injectors and for ceramic pencil type glow plugs
16 - Engine speed sender -G28-
17 - Fuel temperature sender -G81-
18 - Intake manifold flap motor -V157-
19 - 3-pin plug connection
❑ for hall sender -G40-
20 - Exhaust gas return valve -N18-
❑ consists of:
♦ mechanical valve (electrically operated)
♦ EGR control motor -V338-
♦ EGR potentiometer -G212-
21 - Coolant temperature sender at radiator outlet -G83-
22 - Charge pressure sender -G31- with intake air temperature sender -G42-
23 - Intake manifold flap valve -N316-
24 - Hall sender -G40-
❑ for camshaft position
136 Rep. Gr.23 - Fuel Formation, Injection

OCTAVIA II 2004 ➤
Plug connections at the bulkhead plenum chamber - Summary of

components
1 - Plug (black) for charge pressure control solenoid valve -N75-
3 - Plug connection (black) for exhaust gas temperature sender
1 -G235- ( temperature sender upstream turbocharger -G507- )
1.2 Intake manifold with component parts - Summary of components
1 - 10 Nm
2 - Support
3 - 22 Nm
4 - Gasket
❑ replace
5 - Intake manifold
❑ with air flow control
6 - Support
❑ for wiring loom
7 - 22 Nm
8 - 10 Nm
9 - Connecting tube
gas recirculation
10 - 22 Nm
11 - Gasket
❑ replace
12 - 10 Nm
13 - Intake manifold flap motor
-V157-
❑ The intake manifold flap
is closed for about 3
seconds after switching
off the engine and then
opens again. This re‐
duces the switch-off im‐
pact.
14 - O-ring
❑ replace

OCTAVIA II 2004 ➤
15 - Exhaust gas return valve -N18-

❑ consists of:
1.3 Pre-wiring for unit injectors and for ceramic pencil type glow plugs - Sum‐
mary of components
1 - Plug for ceramic pencil type

glow plug
2 - Stainless steel clamps
❑ do not bend up
3 - Fixing screw
❑ tighten to 10 Nm
4 - Adapter ring
❑ when assembling pay
attention to correct posi‐
tion ⇒ page 138
5 - Central plug
❑ when assembling pay
attention to correct posi‐
tion ⇒ page 138
6 - Connector
❑ 2-pin
❑ for pump-nozzle unit
7 - Cable guide
❑ only remove and install
together with stainless
steel clamps (Pos. 2)
1.4 Removing and installing pre-wiring for

unit injectors and ceramic pencil type
glow plugs

OCTAVIA II 2004 ➤
♦ Key -T10310-
Removing
Caution
The disassembly/assembly of the pre-wiring must only be per‐

formed by unscrewing/screwing the clamps. Slackening the
cable guide from the clamps causes them to bend up and it can
lead to cable fracture due to high play. This applies also when
changing the unit injectors as well as all work which does not
require the complete removal of the pre-wiring.
Note
For Piezo unit injectors the disassembly of the plug must only be
performed with the special tool extractor -T10312- .
– Disconnect central plug conection at cylinder head. To do so,
pull release pin in -direction of arrow 1- and open the knurled
– Position wrench -T10310- at adapter ring and slacken by a 90°

turn (1/4 turn) in -direction of arrow-.
– Pull the locking clip -1- slightly upwards using a screwdriver

and press through central plug -2- to the inside.

OCTAVIA II 2004 ➤
– Push extractor -T10312- from the side onto the plugs of the
unit injectors
and pull them off in -direction of arrow-.
– Disconnect plug from the ceramic pencil type glow plugs -1-.
Unscrew fixing screws -2- of stainless steel clamps and re‐
move complete pre-wiring.
Install
the following:
– Position pre-wiring and tighten fixing screws to 10 Nm.
– Guide the central plug through the opening in the bearing

frame. To do so pay attention to the correct seating of the
locking clip -arrows-.
– Position adapter ring (colour marked “long” leg -arrow- points

to 12 o'clock).

OCTAVIA II 2004 ➤
– Position wrench -T10310- at adapter ring and interlock by a

90° turn (1/4 turn) opposite the -direction of arrow-.
Note
After correct assembly of the adapter ring the colour marked

“short” leg points to 12 o'clock.
– Position central plug connection at cylinder head and lock.

1.5 Unit injectors - Summary of components
Note
Observe rules for cleanliness ⇒ page 4 .

(3/4 turn)
❑ replace
Note
⇒ page 142
(1/4 turn)
❑ replace
4 - Adjusting screw
❑ replace
❑ Grease the contact sur‐
face of the unit injector
to the ball pin using
grease -G 000 100-
5 - Counternut - 30 Nm
6 - The unit injector
⇒ page 142
❑ Release plug with ex‐
tractor -T10312-
❑ When installing, oil the
O-rings and the lines in
the cylinder head
7 - O-ring
8 - O-ring
9 - Cylinder head

OCTAVIA II 2004 ➤
1.6 Removing and installing unit injectors

♦ Valve lever -MP1-211 (VW 541/1A)-
♦ Assembly device for valves -MP1-213 (2036)-
♦ Retaining plates -MP1-213/1 (2036/1)-
♦ Striking hammer -T10133/3-
♦ Socket insert -T10054- (XZN 6, total length at least 75 mm)
♦ Dial gauge
♦ Counterholder -T10172 - or -MP 1-216-
1.6.1 Removing
– Release the counternuts -2- of the adjusting screws -1- on all
unit injectors and unscrew the adjusting screws until the rele‐
vant valve lever rests against the spring cap of the unit injector.
Note
Do not pull out screws of valve-lever shaft, so that the individual

parts on the valve-lever shaft remain attached. If necessary mark
assignment of the valve lever.

– Loosen screws -2- and -4-, release alternatively in several
stages and remove valve-lever shaft.

OCTAVIA II 2004 ➤
– Disconnect plug -A- from the ceramic pencil type glow plugs.
– Disconnect plug -B- from the unit injectors using the extractor
-T10312- ⇒ page 140 .
Caution
To remove and install the unit injectors, the screws for the re‐
taining clips must be loosened or tightened. If the electrical
wiring loom is loosened from the retaining clips, they can be
bent and it can lead to cable fracture due to high play.
– Release screws -arrows- at the retaining clips and lay the

complete electrical wiring loom to the side.
– Screw out screws -arrows- with socket insert -T10054- and

pull out of holes.
– Always pull the ball pin -1- out of the relevant unit injector.
– Insert extractor -T10163- into the holes for the screws on the
unit injector.
– Tighten spindle -A- moderately against the unit injector. Tight‐
en counternut -B- by hand.
– With careful knocks on the striking hammer -T10133/3- pull
the unit injector out of the cylinder head seat upwards.
Note
Do not interchange the unit injectors, if necessary mark the as‐

signment to each cylinder.

OCTAVIA II 2004 ➤
1.6.2 Install
Caution
• For any work procedure involving an adjustment of the unit

injector via the adjusting screw, it is necessary to replace
the adjusting screw in the valve lever and the ball pin of
the unit injector, otherwise this can lead to considerable
wear of these components.
• The fixing screws of the unit injectors must definitely be
replaced as well.
Note
♦ When installing, oil the O-rings and the lines in the cylinder
head.
♦ New unit injectors are supplied with new O-rings.
♦ If the old unit injectors are installed again, all O-rings must be
replaced ⇒ page 146 .
♦ Grease the contact surfaces of the ball pin and the adjusting
screw using Grease - G 000 100- .
– Before installing the unit injector check the correct position of

both O-rings.
• The O-rings must not be twisted.
• The white marked O-ring is located in the bottom groove of the
unit injector.
– Oil O-rings and shank of the unit injector.
– Check seat of unit injector in cylinder head for any dirt or for‐
eign bodies (swarfs/carbon deposits etc..) and if necessary
clean with compressed air.
– Insert the unit injector with the greatest of care into the cylinder
head seat.
– Fit assembly device for valves -2036- with the retaining plates
-2036/1- , as shown, onto the bearing frame of the cylinder
head.
Note
If the fixing plates -2036/1- cannot be fitted due to the exhaust

gas recirculation radiator, place large body washers underneath.
Caution
If the unit injector is pulled down by the fixing screws, there is

the risk that the unit injector is pulled skewed into its seat. This
can result in poor vehicle handling and starting problems. For
this reason the unit injector must be pressed into its seat and
must only then be screwed on.

OCTAVIA II 2004 ➤
– Position new fixing screws using socket insert -T10054- and

carefully screw in without using force up to the stop -arrow-.
– Position valve lever -VW 541/1 A- with pressure plate -VW

541/5- .
– Carefully press the unit injector into its seat with the valve lever
and hold with a force.
– Screw in fixing screws of the unit injector carefully and without
using force up to the stop.
– Tighten screws of unit injector -arrows- alternatively as follows

with a socket insert -T10054- :
Stage Tighten
I – Tighten with the torque wrench to 3 Nm.
II – Using a rigid wrench torque a further 270° (3/4
turn).
Note
The torquing angle of 270° must absolutely be carried out in one

working step!
– Before inserting the valve-lever shaft, check whether all the

ball pins -1- and O-rings -2- are inserted in the unit injectors.

OCTAVIA II 2004 ➤
– Screw on valve-lever shaft with new screws as follows:

Se‐ Tighten
quence
I – Tighten screws -2- and -4- alternatively in several
stages, until the valve-lever shaft rests on the
bearing frame.
II – Tighten screws -1-, -3- and -5- to 20 Nm and tor‐
que a further 90° (1/4 turn).
III – Tighten screws -2- and -4- to 20 Nm and torque
a further 90° (1/4 turn).
– Replace adjusting screws and ball pin of the unit injector (ex‐
cept for new unit injectors).
– Place a dial gauge, as shown, onto the adjusting screw of the

unit injector.
Caution

– Turn the crankshaft in the running direction of the engine until

the roller of the roller rocker arm is on the drive cam tip.
• Roller side of roller rocker arm -arrow A- is on the highest point.
• Dial gauge -arrow B- is on the lowest point.
– Remove the dial gauge.
– Turn the adjusting screw in the roller rocker arm until one feels
a significant resistance (the unit injector is against the stop).
– Turn the adjusting screw in the opposite direction from the stop
by about 180°.
– Hold the adjusting screw in this position and tighten up the lock
nut using a torque of 30 Nm
Further installation occurs in reverse order to removal. Pay at‐
tention to the following:
– Mount plug for unit injectors and for ceramic pencil type glow
plugs.
– Fasten retaining clips.
1.7 Replacing O-rings of the unit injector

♦ Assembly sleeve -T10308/1-
♦ Assembly sleeve -T10308/2-
Removing
– Remove unit injector ⇒ page 142 .
– Lever off the old O-rings from the unit injector with extreme
care.
Make sure that no burr arises at the base of the O-rings.

OCTAVIA II 2004 ➤
Install
Note
♦ Always use the assembly sleeves to install the O-rings. If they

are not used, the O-rings can be damaged.
♦ Observe the correct allocation of the O-rings to the channels.
♦ When installing, slide on the O-rings, do not roll. They must
not be turned inwards on the seat of the unit injector.
– Clean the contact surfaces for the O-rings at the unit injector
with great care.
– Insert the assembly sleeve -T10308/1- on the unit injector up
to the stop.
– Carefully slide the top, thicker O-ring onto the assembly sleeve
and insert it in the groove of the unit injector.
– Remove assembly sleeve.
– Insert the assembly sleeve -T10308/2- on the unit injector up

to the stop.
– Carefully slide the lower, white marked O-ring onto the as‐
sembly sleeve and insert it in the groove of the unit injector.
– Remove assembly sleeve.
– Install unit injector ⇒ page 142 .

OCTAVIA II 2004 ➤
1.8 Air filter - Summary of components

Removing and installing air filter ⇒ page 148 .
1 - Inlet hose
❑ to exhaust gas turbo‐
charger
2 - Air mass meter -G70- -G70-
3 - O-ring
4 - Vacuum hose
❑ To the solenoid valve for
charge pressure limita‐
tion -N75-
5 - 2 Nm
6 - Air filter top part
❑ if during repairs the air
filter housing is opened
(except for air filter ele‐
ment change), it should
be entered in the Serv‐
ice Schedule (change
interval for air filter ele‐
ment is shortened)
7 - Air intake connection
❑ screwed onto lock carri‐
er
8 - 2 Nm
9 - Air intake hose
10 - Drain pipe
11 - Air filter bottom part
❑ with supports for drain
pipe
12 - 8 Nm
13 - Air filter element
14 - 2 Nm
15 - Connecting tube
❑ from cylinder head cover
❑ for crankcase ventilation
1.9 Removing and installing air filter


OCTAVIA II 2004 ➤
Removing
– Remove cover for air intake connection, to do so release lat‐
eral retaining clasps -arrows-.
– Release screws -arrows- for the air intake connection -1- and
take air intake hose -2- out of the guide.
– Press in catches -1- and -3- and pull off air intake hose -4- from
air filter -2-.
– Unplug connector -1- from air mass meter -G70- .

– Detach vacuum hose -3- and suction hose -2-.
– Slacken screw -4- and remove air filter housing.
Remove suction hose
Note
Due to the poor access of the pliers for spring strap clips to the
bottom intake manifold it is preferable to remove the connection
fitting from the exhaust turbocharger.

OCTAVIA II 2004 ➤
– Unclip hoses -2- and -3- from suction hose.

– Remove the connection pipe -1-.

– Swivel connection fitting -3- in the -direction of the arrow A-
and remove with the suction hose -1-.
Install
the following:
– When attaching the connection fitting -3- at the exhaust gas
turbocharger make sure that the connection fitting is correctly
seated on the bolt of the exhaust gas turbocharger -arrow B-.
1.10 Removing and installing engine speed

sender -G28-
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-
♦ Assembly tool -T10118-
Removing
– Press together the coolant hoses at the engine oil cooler with
one hose clamp each and remove the coolant hoses.
– Remove the oil filter holder ⇒ page 87 .
– Remove the plug -arrow- on the engine speed sender -G28-
with the assembly tool -T10118- and expose the electrical line.
Note
To unlock the plug without using the assembly tool -T10118- , the
unlock button must be pressed at the plug using the screwdriver
and at the same time raise the unlock button with a thin wire hook.

OCTAVIA II 2004 ➤
– Unscrew the fixing screw -2- of the engine speed sender -G28-
-1-.
Install
the following:
– Install the oil filter holder ⇒ page 87 .
Tightening torque
Component Nm
Engine speed sender -G28- on the flange 5

OCTAVIA II 2004 ➤
2 Engine control unit
2.1 Removing and installing engine control

unit
Note
If the engine control unit should be replaced, connect vehicle di‐

agnosis, measurement and information system -VAS 5051- and
in the guided fault detection system carry out “replace engine
control unit”.

♦ Body saw e.g. -V.A.G 1523 A-
Removing
– Switch off ignition.
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Remove bulkhead plenum chamber -arrows-.
– Remove windscreen wiper and washer system ⇒ Electrical
System ⇒ Rep. Gr. 92 .
For vehicles with protective cover
– Cut with body saw -1- a slot for the cross-head screwdriver in
the heads of the pull-off screws -2-.
Note
♦ It must be sawed twice with the body saw, so that the slot is
wide enough, in order to be able to unscrew the screws with
a suitable screwdriver.
♦ The pull-off screws until are inserted with locking agent.
– Unscrew bolts -2-.

OCTAVIA II 2004 ➤
– Lift locking tab of protective cover with cross-head screwdriv‐

er.
– Push the protective cover in the -direction of the arrow- out of
the bracket for engine control unit.
– Disconnect front plug -1- and remove from engine control unit.
– Lever off retaining bracket -2- slightly.

– Push engine control unit out of the bracket -arrow-.
– Disconnect rear plug and remove from engine control unit.
Install
Note
For vehicles with protective cover, the metal swarfs must be suc‐
tioned out of the plenum chamber before installing the engine
control unit.
– Connect rear plug to engine control unit and lock.
– Push engine control unit into the bracket and lock the retaining
bracket -2-.
– Connect front plug to engine control unit and lock.
For vehicles with protective cover
– Fasten protective cover with new pull-off screws (before tight‐
ening align the protective cover in such a way that it does not
come into contact with the surrounding components)
– Install windscreen wiper and washer system ⇒ Electrical Sys‐
tem ⇒ Rep. Gr. 92 .
– Install bulkhead plenum chamber and plenum chamber cover
⇒ Body Work ⇒ Rep. Gr. 66 .
2. Engine control unit 153

OCTAVIA II 2004 ➤
26 – Exhaust System
exhaust system
Note
♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - danger of damaging it.
♦ Replace the gaskets and the self-locking nuts.
♦ When performing installation work on the exhaust system,
make sure the exhaust system is not mounted under tension
and has adequate clearance from the vehicle body. If neces‐
sary slacken the double clamp and align the exhaust system
so as to create adequate clearance between these compo‐
nents and the vehicle body, and that the weight of the exhaust
system is evenly distributed over the hangers.
1 - Pressure sensor 1 for ex‐

haust gas -G450-
2 - Support
❑ for pressure lines
3 - Pressure line - 45 Nm
4 - 10 Nm
5 - Lambda probe -G39- , 50
Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3- ;
the hot bolt paste -G 052
112 A3- must not get in‐
to the slot of the probe
body
ture sender upstream particle
filter -G506- )
❑ 45 Nm
❑ the thread of new tem‐
perature senders must
be coated with assem‐
bly paste
❑ grease only the thread
with hot bolt paste -G
052 112 A3- for re-used
temperature sender.
7 - Pre-exhaust pipe with die‐
154 Rep. Gr.26 - Exhaust System

OCTAVIA II 2004 ➤
sel particle filter

8 - Identification
❑ for front double clamp
9 - to middle part of exhaust system
10 - 23 Nm
11 - Retaining strap
❑ Pay attention to the part number
12 - Double clamp
❑ align exhaust system free of stress before tightening ⇒ page 159
❑ Tighten bolted connections evenly
13 - Front tunnel bridge
14 - Rear part of exhaust system
❑ for first equipment building unit with middle part of exhaust gas system, replace individually when carrying
out repairs
❑ Align exhaust system free of stress ⇒ page 159
15 - Rear tunnel bridge
16 - Hanger
17 - Middle part of exhaust system
❑ for first equipment building unit with rear part of exhaust gas system, replace individually when carrying
out repairs
❑ Align exhaust system free of stress ⇒ page 159
18 - Exhaust gas temperature sender 3 -G495- ( Temperature sender downstream particle filter -G527- )
❑ 45 Nm
❑ the thread of new temperature senders must be coated with assembly paste
❑ grease only the thread with hot bolt paste -G 052 112 A3- for re-used temperature sender.
19 - from exhaust turbocharger
20 - Clamp - 7 Nm
❑ replace
21 - Gasket
❑ replace
22 - 23 Nm
23 - Support
❑ screwed onto the cylinder block
24 - 8 Nm
1.2 Removing and installing pre-exhaust

pipe with diesel particle filter
♦ Supporting device for engine -MP3-470 (3300 A)-
♦ Ring spanner set for lambda probe
1. Removing and installing parts of the exhaust system 155

OCTAVIA II 2004 ➤

♦ Hot screw paste -G 052 112 A3-
Removing
– Release plug -1- and expose the electrical cables.
– Unplug the following plug connections at the bulkhead plenum

chamber and expose lines:
– Unscrew lambda probe -G39- -3- and exhaust gas tempera‐

ture sender 2 -G448- ( temperature sender upstream particle
filter -G506- ) -5-.
– Unbolt bracket -2- for pressure lines and pressure line -4-.
– Slacken clamp -1- for diesel particle filter and remove it.
– Remove exhaust pipe of auxiliary heating ⇒ Heating, Air Con‐
ditioning ⇒ Rep. Gr. 82 .

OCTAVIA II 2004 ➤
– Unbolt exhaust gas temperature sender 3 -G495- ( tempera‐

ture sender downstream particle filter -G527- ) -1- and pres‐
sure pipe -2-.
– Remove exhaust gas pressure sensor 1 -G450- and pressure
lines.
– Unscrew the right drive shaft from the gearbox flange and lay
towards the front.
– Screw out screws -2- and -3- for pendulum support.
– Release screws -arrows- at holder for diesel particle filter.
– Press forward the engine/gearbox assembly with the support‐

ing device for engine -3300 A- to the dimension -a-.
• Dimension -a-: 25 mm
Caution
The charge air pipe must not touch the radiator fan.

OCTAVIA II 2004 ➤
– Remove front tunnel bridge -arrows-.

– Release double clamp -1-.
Note
The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - danger of damaging it.
– Unbolt bracket for exhaust system -arrows-.

– Turn diesel particle filter 180° clockwise and swivel out.
Install
the following:
♦ Replace gasket and clamp for diesel particle filter.
♦ Tightening torques ⇒ page 154 .
– First fasten the diesel particle filter loosely to the exhaust gas
turbocharger and then fasten to the bottom bracket.
– Align exhaust system free of stress ⇒ page 159 .
After replacing the diesel particle filter, an adaption must be per‐
formed in the function “Targeted functions” ⇒ Vehicle diagnosis,
testing and information system VAS 5051.
1.3 Replacing middle or rear part of the ex‐

haust system
♦ Body saw , e.g. -V.A.G 1523 A- or chain pipe cutter , e.g. -VAS
6254-
Procedure
Note
♦ For individually replacing the middle or rear part of the exhaust

system, a separation point is provided in the connecting pipe.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.
WARNING
In order to avoid injuries because of metal swarfs, wear safety

goggles and safety clothing.

OCTAVIA II 2004 ➤
– Separate exhaust pipe at right angles at the separation point

-arrow 2- with a body saw .
– When installing, position rear double clamp -4- at the side
markings -arrow 1- and -arrow 3-.
– Rotate the rear double clamp -4- in such a way that the ends
of the screws are as far upwards as possible.
– Align rear part of exhaust system horizontally and tighten rear
double clamp to 23 Nm.
– Align exhaust system free of stress ⇒ page 159 .
1.4 Aligning exhaust system free of stress

• The exhaust gas system must be cold for aligning.
– Slacken front double clamp -1- and align to pre-exhaust pipe
-2- (-arrow- points in direction of travel).
-a- = 5 mm
The fixing screws must be on the right. They must not protrude
beyond the bottom edge of the double clamp.
– Tighten the front nut by hand.
– Push the exhaust system so far forward until the initial load on
the retaining strap at the middle part of the exhaust system
-a- is 9 … 11 mm.
– Tighten the nuts of the front double clamp evenly to 23 Nm.
Align exhaust tailpipes
– Align rear part of exhaust system:

• an equal distance between bumper opening and tailpipe -a-.
• The distance -b- from the bumper opening to the tailpipes is
parallel.
For aligning, loosen the hangers of the exhaust gas system.
1.5 Inspecting the exhaust system for leak‐

tightness
– Start engine and run in idle.

OCTAVIA II 2004 ➤
– Seal off exhaust tailpipes for the duration of the leak check
(e.g. with cloth or plug).
– Inspect connection points of cylinder head/exhaust manifold,
exhaust gas turbocharger/pre-exhaust pipe etc. for leaktight‐
ness by listening and visual inspection.
– Eliminate any leak found.

OCTAVIA II 2004 ➤
2 Exhaust gas recirculation system
Note
♦ The actuation of the exhaust gas recirculation system is per‐

formed by the diesel direct injection system control unit -J248-
for the EGR valve -N18- .
♦ The EGR valve -N18- consists of the mechanical valve, the
EGR control motor -V338- and the EGR potentiometer -
G212- .
♦ The electrically operated valve with cone-shaped valve plung‐
er makes it possible to achieve different opening cross-sec‐
tions at different valve strokes.
♦ Always replace self-locking nuts.
2.1 Exhaust gas recirculation system - Summary of components
1 - 10 Nm
2 - Support
3 - 22 Nm
4 - Gasket
❑ replace
5 - Intake manifold
❑ with air flow control
6 - Cable strap
7 - 22 Nm
8 - 10 Nm
9 - Connecting tube
gas recirculation
10 - 22 Nm
11 - Gasket
❑ replace
12 - 10 Nm
13 - Intake manifold flap motor
-V157-
❑ The intake manifold flap
is closed for about 3
seconds after switching
off the engine and then
opens again. This re‐
duces the switch-off im‐
pact.
14 - O-ring
❑ replace
15 - Exhaust gas return valve -
N18-
❑ consists of:
2. Exhaust gas recirculation system 161

OCTAVIA II 2004 ➤

2.2 Radiator for exhaust gas recirculation - Summary of components
1 - 22 Nm
2 - Connection pipe for exhaust
gas recirculation
❑ to exhaust gas recircu‐
lation valve -N18-
3 - Gasket
❑ replace
4 - 10 Nm
5 - from exhaust manifold
6 - 25 Nm
❑ replace
7 - Connecting tube
circulation
❑ with change-over flap
❑ Check change-over for
radiator for exhaust gas
recirculation
⇒ page 163
⇒ page 164
9 - Vacuum hose
❑ Connection diagram for
vacuum hoses
⇒ page 163
❑ for change-over flap
❑ always replace together
with radiator for exhaust
gas recirculation

OCTAVIA II 2004 ➤
2.3 Connection diagram for vacuum hoses
1 - Air filter housing

❑ with connection for ven‐
tilation line for charge
pressure control sole‐
noid valve -N75-
2 - Solenoid valve for charge
pressure control -N75-
❑ with vacuum reservoir
4 - Non-return valve
5 - Vacuum line to brake boos‐
ter
tion -N345-
7 - Intake manifold flap valve -
N316-
❑ for changeover of radia‐
tor for exhaust gas recir‐
culation
❑ at exhaust gas turbo‐
charger
tor -G581-
2.4 Check change-over for radiator for ex‐

haust gas recirculation
♦ Hand vacuum pump , e.g. -VAS 6213-
Procedure
Note
The vacuum setting element for change-over flap is accessible

from below.


OCTAVIA II 2004 ➤
– Put sliding ring -1- of hand vacuum pump -VAS 6213- in po‐
sition -A- for “vacuum”.
– Detach vacuum hose from vacuum setting element.

– Connect hand vacuum pump to the vacuum setting element.
– Operate hand vacuum pump.
• The vacuum setting element must open the change-over flap
up to the stop at maximum 0.08 MPa (0.8 bar) negative pres‐
sure and in case of ventilation close it up to the stop
-arrows-.
Note
♦ For this test the opening of the change-over flap can be per‐
formed in jolts. In driving mode the change-over flap opens
suddenly due to the large negative pressure volume.
♦ The closing of the change-over flap must be carried out sud‐
denly when ventilating (e.g. put sliding ring -1- of hand vacuum
pump -VAS 6213- in position -B- or detach vacuum hose).
If the vacuum setting element does not open or close the change-
over flap up to the stop:
– Replace radiator for exhaust gas recirculation with vacuum
setting element ⇒ page 164 .
2.5 Removing and installing radiator for ex‐

haust gas recirculation
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-
Removing
– Remove diesel particle filter ⇒ page 155 .

OCTAVIA II 2004 ➤
– Place a catch pan under the engine.
– Press together coolant hoses with hose clamps up to ∅ 25 mm

-3094- and remove from radiator for exhaust gas recirculation.
– Remove heat shield collar from vacuum setting element.


OCTAVIA II 2004 ➤
– Release screws -1- for connection pipe for exhaust gas recir‐
culation.
– Remove vacuum hose -2- from vacuum setting element and
expose.
– Release screws -arrows- and remove radiator for exhaust gas
recirculation.
Install
the following:
nuts.
♦ Tightening torques ⇒ page 162 and ⇒ page 125 .
– Inspect coolant level and top up if necessary ⇒ page 97 .

OCTAVIA II 2004 ➤
28 – Glow Plug System

1 Glow Plug System
1.1 Removing and installing ceramic pencil

type glow plugs
♦ Hand multimeter , e.g. -V.A.G 1526 B-
♦ Socket insert 8 mm
♦ Hose -N 020 150 5- ⇒ Electronic Catalogue of Original Parts ,
approximately 250 mm long
♦ Means for loosening the screwed connections
For ceramic pencil type glow plugs the following points must be
observed:
Note
♦ The ceramic pencil type glow plugs are very sensitive due to
special material properties and require the utmost care when
removing and installing.
♦ They must only be transported and stored in original transport
packaging or wrapped individually in air cushion foil.
♦ Remove ceramic pencil type glow plugs from their wrapping
immediately before fitting.
♦ The ceramic pencil type glow plugs are very sensitive to im‐
pacts and flexion. If they have fallen from a low height i.e. 2
cm, they must no longer be used. Although no exterior damage
is visible, hairline cracks can nevertheless be present.
♦ Always replace the ceramic pencil type glow plugs in case of
doubt regarding the proper state.
♦ If the pin of the ceramic pencil type glow plug is damaged or
fractured this results in an engine damage.
♦ In case of fracture of the ceramic pencil type glow plug pin, all
broken pieces must be removed from the cylinder before start‐
ing the engine, otherwise this could result in engine damage
due to seizures.
♦ The ceramic pencil type glow plugs must not be removed from
the engine for testing the compression pressure.
♦ Always perform the compression pressure test on installed
ceramic pencil type glow plugs in the function “Targeted fault
finding” ⇒ Vehicle diagnosis, testing and information system
VAS 5051.
♦ The software of the engine control unit is matched to a specific
type of pencil type glow plugs (ceramic or metal). Therefore
only the relevant pencil type glow plugs must be installed.
♦ A mixed fitting of ceramic and metal pencil type glow plugs is
not permissible.
1.1.1 Removing
– Before removal, the ceramic pencil type glow plugs must be
unplugged ⇒ Vehicle diagnosis, testing and information sys‐
1. Glow Plug System 167

OCTAVIA II 2004 ➤
tem VAS 5051 Self-diagnosis; Actuator diagnosis of the auto‐

matic glow period control unit -J179- .
– Release the plug of the ceramic pencil type glow plug.
Caution
♦ When slackening the ceramic pencil type glow plug the

maximum permissible torque of 20 Nm must not be ex‐
ceeded.
♦ Slacken the ceramic pencil type glow plug with the rec‐
ommended socket insert and with a torque wrench.
– Carefully slacken the ceramic pencil type glow plug in compli‐

ance with the maximum permissible torque of 20 Nm with the
socket insert -arrow-.
If the ceramic pencil type glow plug cannot be slackened with a
maximum torque of 20 Nm:
– Use commercially available tool to slacken the screwed con‐
nections and repeat the slackening procedure.
Note
♦ If the ceramic pencil type glow plug cannot be slackened with

a maximum torque of 20 Nm using the tool for slackening, re‐
move the cylinder head and then unscrew the pencil type glow
plug.
♦ The removed ceramic pencil type glow plug must on no ac‐
count be re-installed.
– Put a hose -N 020 150 5- of approx. 250 mm onto the loosened

ceramic pencil type glow plug and carefully unscrew the glow
plug. It must not tilt.
– Pull up the unscrewed ceramic pencil type glow plug with
hose. It must on no account touch somewhere.
1.1.2 Install
Note
The threads in the cylinder head and of the ceramic pencil type
glow plugs must be clean and dry, free from oil and lubricant.
– Eliminate fixed combustion residues in the holes for the ce‐

ramic pencil type glow plugs in the cylinder head.
– Screw ceramic pencil type glow plugs into the holes and tight‐
en by hand.
168 Rep. Gr.28 - Glow Plug System

OCTAVIA II 2004 ➤
Caution
♦ The maximum permissible tightening torque for ceramic

pencil type glow plugs is 12 Nm and must not be exceeded
(thread clean and dry, free of oil and lubricant).
♦ If this is not observed there is a risk of fracture of the pin,
which can always lead to severe engine damage.
– Tighten the ceramic pencil type glow plugs with the recom‐
mended socket insert and with a torque wrench of 12 Nm.
Check the state of the installed ceramic pencil type glow plugs as
follows:
– Connect handheld multimeter for resistance measurement be‐
tween contact and ceramic pencil type glow plug housing.
• Specified value: less than 1 Ω
If the specified value is exceeded (greater than 1 Ω):
– Remove ceramic pencil type glow plug and check for fracture
of the pin.
Caution
If the faulty ceramic pencil type glow plug is broken, all broken
pieces must be removed from the cylinder before starting the
engine, otherwise this could result in a major engine damage.
If required, the cylinder head must be removed.
– Fit the connector onto the ceramic pencil type glow plugs.
– Check the installed ceramic pencil type glow plugs via the self-
diagnosis ⇒ Vehicle diagnosis, testing and information system
VAS 5051.
Caution
The engine must not be started as long as a fault concerning

the ceramic pencil type glow plugs is stored in the fault mem‐
ory!
– Check electrical wiring and plug connections for ceramic pen‐

cil type glow plugs.
If there is no fault:
1. Glow Plug System 169

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.6 Check hydraulic supporting elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.5 Unit injectors - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

1.1 Engine number

1.2 Engine characteristics

1.2 Supplementary instructions and assem‐

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

To avoid causing damage to the condenser and to the refrigerant

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

2 Rep. Gr.01 - Self-diagnosis

1.3 Safety precautions when working on the

♦ On vehicles with pump injector engine, the temperature of

♦ The fuel pump is activated when the ignition is switched on

Please observe the following when undertaking all assembly

Pay attention to the following points when removing and installing

1.4 Safety precautions when working on the

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

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

1.5 Regulations concerning cleanliness

1.6 Regulations concerning cleanliness

4 Rep. Gr.01 - Self-diagnosis

1.7 General instructions for charge air sys‐

Please observe the following when undertaking all assembly

In case a mechanical damage to the exhaust gas turbocharger

♦ The charge-air system must be tight, check ⇒ page 132 .

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

♦ after installing the exhaust gas turbocharger run the engine

6 Rep. Gr.01 - Self-diagnosis

10 – Removing and installing engine

1.1 Removing engine

♦ The engine is removed downwards together with the gearbox.

Please observe the following when undertaking all assembly

1. Removing and installing engine 7

8 Rep. Gr.10 - Removing and installing engine

– Disconnect plug -2- from charge pressure sender -G31- / in‐

– Remove radiator ⇒ page 100 .

1. Removing and installing engine 9

– Release screw -1- by one turn.

Mark the direction of rotation with chalk or a felt-tip pen before

– Remove V-ribbed belt ⇒ page 22 .

Refrigerant circuit of the air conditioning system must not be

To avoid causing damage to the AC compressor as well as to the

– Remove AC compressor from the bracket for auxiliary units

10 Rep. Gr.10 - Removing and installing engine

– Separate the quick couplings -arrows- at the heat exchanger.

After separating the hydraulic line, do not operate the clutch

1. Removing and installing engine 11

– Screw engine mount -T10012- to the cylinder block with nut

– Successively release screws for engine mounting -arrows-.

– Successively release screws for gearbox mounting -arrows-.

♦ Check whether all hose and line connections between engine,

– Carefully lower engine with gearbox.

12 Rep. Gr.10 - Removing and installing engine

1.1.1 Removing and installing engine trim

Before installing the engine cover, check the correct position

– If necessary, press the ball sockets of the engine cover into