Service

Workshop Manual
OCTAVIA II 2004 ➤
1,2/77 kW TSI engine
Engine ID
CBZ
B
Edition 12.09

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

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankgear
15 - Cylinder Head, Valve Gear
17 - Lubrication
19 - Cooling system
20 - Fuel Supply
21 - Turbocharging
24 - Fuel Formation, Injection
26 - Exhaust System
28 - Ignition system

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

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 ŠKODA AUTO a. s. D3E8027F572

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Unit mounting - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Checking and adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 V-ribbed belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3 Removing and installing bracket for top auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Removing and installing bracket for bottom auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Camshaft drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2 Removing and installing the top timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Removing and installing the bottom timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 Sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Removing and installing crankshaft belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.5 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Crankshaft . . . . . . . . . . . . . .Protected
. . . . . by
. .copyright.
. . . . . Copying
. . . . .for. private
. . . . or. commercial
. . . . . . .purposes,
. . . . . in. part
. . .or.in. whole,
. . . .is. not
. .permitted
50
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
4.1 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� . . . . 50
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2 Inspect piston, piston rings and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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

1 Cylinder head - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Contents i
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.2 Test timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.3 Setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.4 Removing and installing timing chain and drive chain for oil pump . . . . . . . . . . . . . . . . . . 66
2 Cylinder head - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Removing and installing cylinder head cover and camshaft . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.4 Check combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.1 Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.2 inspect camshaft, axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.3 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4 Replacing valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.4 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.5 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

19 - Cooling system
Protected. by
. copyright.
. . . . .Copying
. . . for
. .private
. . .or.commercial
. . . . . purposes,
. . . . in. part
. . or. in. whole,
. . . is. not
. .permitted
. . . . . . . . . . . . . . 98
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
1 Cooling system
with respect .to. the
. .correctness
. . . . . . of. information
. . . . . . in
. .this
. .document.
. . . . . Copyright
. . . . . .by. ŠKODA
. . . . .AUTO
. . . A.. .S.�. . . . . . . . . . . . . . . 98
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.2 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.1 Coolant regulator - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.2 Removing and installing belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.4 Removing and installing coolant recirculation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Parts of cooling system on the side next to the body - Summary of components . . . . . . . . 106
3.2 Removing and installing fan shroud for radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.4 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1 Fuel tank and fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Fuel tank - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.2 Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.3 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.4 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.5 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.6 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 119
1.7 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2 Electronic Engine Power Control (Electronic throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3 Activated charcoal container system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.1 Activated charcoal container system - Summary of components . . . . . . . . . . . . . . . . . . . . 139
3.2 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

21 - Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

ii Contents
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.1 Charge air system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

24 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

1 Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2 Intake manifold and fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.2 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 157
2.3 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.4 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.1 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.2 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.1 High pressure pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.1 Removing and installing injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.2 Replace Teflon gasket ring and supporting washer at injection valve . . . . . . . . . . . . . . . . 169
6 Testing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.1 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Catalytic converter and component parts - Summary of components . . . . . . . . . . . . . . . . 178
1.2 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.3 Replacing middle or rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.5 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1 Ignition system . . . . . . . . . .Protected
. . . . . by. .copyright.
. . . . .Copying
. . . . for
. .private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. in. .whole,
. . . is. not
. . permitted
. 183
1.1 Ignition system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liability
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any 183
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Contents iii
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

iv Contents
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

00 – Technical data
1 Technical data

1.1 Engine number

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

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

number” are indicated on the vehicle data sticker -arrow- which is
located on the air guide pipe.
♦ As of letter “C”, four-digit engine identification characters are
used.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched together with the serial number
on the cylinder block.
♦ The fourth digit indicates the output and the torque of the en‐
gine and depends upon the engine control unit.

1.2 Engine characteristics

Engine identification characters CBZB
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in part or
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Displacement cm 3 1197
Power output kW at rpm 77/5000
Torque Nm at rpm 175/1550-4100
Bore ∅ mm 71,0
Stroke mm 75,6
Compression 10:1
Cylinder / valves per cylinder 4/2
RON unleaded 95 1)
Ignition system, fuel injection Simos 10
Type of fuel preparation Direct injection homogeneous
Knock control 1 sensor

1. Technical data 1
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Engine identification characters CBZB

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

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

2 Rep. Gr.00 - Technical data

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

1.2 Safety precautions when working on the

fuel supply system

WARNING

♦ The safety measures for the pressure reduction in the high

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

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

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

and the door contact switch of the driver door. Before opening
the fuel system and for reasons of safety, if the battery is not
disconnected, the plug -3- must be disconnected from the fuel
pump control unit -1-.

Caution

When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel!
♦ Wear fuel-resistant gloves!

1.3 Release pressure in the high pressure

area of the fuel system

WARNING

♦ The injection system consists of a high pressure part

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

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

tem VAS 5051 and carry out the targeted function “remove
high fuel pressure”.
– Switch off ignition.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4 Rep. Gr.01 - Self-diagnosis

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– For safety reasons before opening the fuel system disconnect

the plug from the fuel pump control unit -3-.

WARNING

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

– Now lay a clean cleaning cloth around the connection point

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

Note

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

1.4 Rules of cleanliness to observe when

working on the fuel supply system
Carefully observe the following 5 rules for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
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♦ Carefully cover or close
unless opened
authorised bycomponents
ŠKODA AUTO A.ifS.the repair
ŠKODA AUTOisA.not
S. does not guarantee or accept any liability
completed immediately. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.

1.5 Safety measures to apply when working

on the fuel injection and ignition system

WARNING

♦ The safety measures for the pressure reduction in the high

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

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

damage to the injection and preheating system:

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

 OCTAVIA II 2004 ➤
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♦ Do not touch or remove ignition leads and ignition coils with

power output stages with the engine running or at start speed.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure,
open lid of fuse carrier in the engine compartment and unplug
fuse for Motronic current supply relay -J271- ⇒ Current flow
diagrams and Fitting locations.
♦ The fuel delivery unit is activated by switching on the ignition
and the door contact switch of the driver door. Before opening
the fuel system and for reasons of safety, if the battery is not
disconnected, the plug -3- must be disconnected from the fuel
pump control unit.

Caution

When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger can be injured by the release of
the passenger airbag in the event of an accident.

1.6 General notes on the injection system

Repairing ignition ⇒ page 183 .
♦ The engine control unit is equipped with a self-diagnosis sys‐
tem. Before repairs as well as trouble shooting first interrogate
the fault memory. Also check the vacuum hoses and connec‐
tions (unmetered air).
♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ byelectronic
Protected catalogue
copyright. Copying for privateof original purposes,
or commercial parts . in part or in whole, is not permitted
The use of clamp-type or screw-type clips is not allowed.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ A minimum voltage of 11.5 V is required for perfect functioning

of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
♦ When opening the driver door the fuel pump is activated for 2
seconds in order to build up the pressure in the fuel system.

6 Rep. Gr.01 - Self-diagnosis

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

♦ Certain inspections may cause the control unit to detect and

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

1.7 General notes on the ignition system

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

1.8 General instructions for charge air sys‐

tem

WARNING

When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such
Protected a way
by copyright. thatforthe
Copying original
private line purposes,
or commercial guide is re-estab‐
in part or in whole, is not permitted
lished.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Ensure that there is adequate free access to all moving or
hot components.

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Caution

In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change the engine oil and replace the oil filter
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
charge-air routing must be cleaned and the charge air cooler
must be replaced.

♦ The charge-air system must be tight.

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

1.9 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system

WARNING

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

tem.

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

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

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

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

engine without opening the refrigerant circuit:
– Unscrew the holding clamp(s) on the refrigerent lines
– Remove AC compressor from the bracket ⇒ page 23 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

8 Rep. Gr.01 - Self-diagnosis

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

10 – Removing and installing engine

1 Removing and installing engine

1.1 Removing engine

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

Note

♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be fitted again in the same location
when the engine is installed again.
♦ Leave the ignition key in the ignition lock so that the steering
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
lock does not click tointo
with respect place. of information in this document. Copyright by ŠKODA AUTO A. S.�
the correctness

♦ Collect drained coolant in a clean container for reuse or proper

disposal.

Caution

When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

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

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Remove air filter ⇒ page 161 .

– Before disconnecting the battery, if necessary remove the
adapter for the anti-theft wheel bolts from the luggage com‐
partment.

1. Removing and installing engine 9

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.

Gr. 27 .
– Remove the right and left wheelhouse liner ⇒ Body Work ⇒
Rep. Gr. 66 .
– Remove bottom noise insulation ⇒ Body Work ⇒ Rep. Gr.
50 .
– Drain the coolant from the cooling system ⇒ page 99 .
– Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box.
– Unscrew the nut of the left coupling rod -2- and press the cou‐
pling rod off the anti-roll bar.
– Unscrew the nuts from the left steering joint -3- and press the
steering joint out of the suspension arm.

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

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

– Pull off top coolant hose -2- and bottom coolant hose from
expansion reservoir.
– Disconnect the feed line -3- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.
– Detach the connecting hose -4- to the activated charcoal filter
system.

10 Rep. Gr.10 - Removing and installing engine

 OCTAVIA II 2004 ➤
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– Remove the hose -1- from the activated charcoal filter and
from the activated charcoal filter solenoid valve 1 -N80- .
– Remove activated charcoal filter -2-.
– Slacken the clamp -4- and detach the coolant hose -3- from
the engine.

– Release the coolant hoses at the heat exchanger -arrows- and

pull them off.

– Detach vacuum hose -1- from intake manifold.

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

WARNING

After removing the slave cylinder or after separating the hy‐

draulic line, do not depress the clutch pedal.

– Remove/unclamp all electrical lines from the gearbox, gener‐

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

– Disconnect the vacuum and bleeder hoses from the engine.

– Disconnect the plug from the thermal switch and the radiator
fan.
– Disconnect the plug of the engine wiring harness from the en‐
gine control unit (front plug) ⇒ page 176 .

1. Removing and installing engine 11

 OCTAVIA II 2004 ➤
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– Release guide for engine wiring harness and pull out upwards
-arrow-.

– Open all fuses for the engine wiring harness at frame side rail
-arrows-.
– Open other attachments of the engine wiring harness, remove
engine wiring harness and attach to engine.
– Attach the cables with a cable strap at the engine.

– Disconnect plugs -1 and 2-.

– Remove pre-exhaust pipe Pos. 9 ⇒ page 178 .
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Unscrew the screw -2- and remove the bottom coolant pipe
-1-.
Vehicles with auxiliary heating.
– Slacken clamps -3- and pull off the coolant hoses -4 and 5-.

12 Rep. Gr.10 - Removing and installing engine

 OCTAVIA II 2004 ➤
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– Unscrew the screws -1 and 2- of the brackets for the coolant

pipes for the auxiliary heating -3-.
Continued for all vehicles

– Disconnect plug -2- from oil level and oil temperature sender
-G266- .
– Remove the hold-down device for the cable guide of the oil
level and oil temperature sender -G266- from the assembly
carrier at the front and place down on the assembly carrier.

– Unbolt the pendulum support -arrows-.

For vehicles with air conditioning
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– Remove V-ribbed belt ⇒ page 26 .
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Removing and installing engine 13

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

pressor.

WARNING

Risk of injury through refrigerant.

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

Caution

Risk of damaging refrigerant lines and hoses.

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

– Release screws -arrows- for AC compressor.

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

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

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

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

14 Rep. Gr.10 - Removing and installing engine

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

Note

♦ Check whether all hose and line connections between engine,

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

– Release the screws -2- of the assembly bracket at the engine.

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– Release the screws -2- of the assembly bracketby at
unless authorised the AUTO
ŠKODA gear‐ A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
box. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

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

of a second mechanic.
♦ When lowering carefully guide the engine/gearbox assembly,
in order to avoid damage.

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

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

1.2 Securing the engine to the assembly

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

1. Removing and installing engine 15

 OCTAVIA II 2004 ➤
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Work procedure
• Separate engine from gearbox.
– Attach lifting device -MP9-201 (2024 A)- at workshop crane
(e.g. -VAS 6100- ) and at engine as shown. (The figure shows
the 1.4 ltr./90 kW TSI Engine; the engine mounting is identi‐
cal).

WARNING

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

– Lift off engine with installed engine mount -T10416- with work‐
shop crane (e.g. -VAS 6100- ) from engine/gearbox jack -
V.A.G 1383 A- .
– Remove engine mount -T10416- .

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

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

1.3 Installing the engine

Special tools and workshop equipment required
♦ Double ladder , e. g. -VAS 5085 -
♦ Catch pan for workshop crane , e.g. -VAS 6208 -
♦ Pliers for spring strap clamps
♦ Grease -G 000 100-
♦ Cable strap
Condition
• Engine and gearbox with mounted engine mount -T10416- to
engine and gearbox jack -V.A.G 1383 A- .
Work procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Installation is carried out in the reverse order. Pay
with respect attention
to the correctnessto
of the
information in this document. Copyright by ŠKODA AUTO A. S.�
following:

16 Rep. Gr.10 - Removing and installing engine

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Caution

When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

Note

♦ All cable straps should be fitted on again in the same place

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

Observe all safety measures and notes for assembly work on the
fuel, injection and ignition system and the charge air system as
well as rules for cleanliness ⇒ page 3 .
– Check whether the dowel sleeves for centering the engine/
gearbox are present in the cylinder block; insert if necessary.
– Ensure that the intermediate plate has been inserted on the
sealing flange and is pushed onto the dowel sleeves
-arrows-.
For vehicles with manual gearbox
– Clean the serration on the drive shaft and if the clutch disc has
been used clean the hub serration, remove corrosion and only
apply a very thin layer of grease -G 000 100- to the serration
on the drive shaft. Subsequently move the clutch disc up and
down on the drive shaft until the hub fits smoothly on the shaft.
Always remove excess grease.
– After installing the coupling, check the centering of the clutch
disc ⇒ gearbox ⇒ Rep. Gr. 30 .
– Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ gearbox ⇒ Rep. Gr. 30 .
For models with automatic gearbox

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

1. Removing and installing engine 17

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Replace the needle bearing -arrow- in the crankshaft

⇒ page 50 .
– Attach the selector lever control cable at the gearbox ⇒ Gear‐
box ⇒ Rep. Gr. 34 .
Continued for all vehicles
– Screw on gearbox to engine ⇒ gearbox ⇒ Rep. Gr. 34 .
– When installing the engine/gearbox assembly, ensure clear‐
ance to the assembly carrier, AC compressor as well as to the
radiator fans.
– Tighten the new screws by hand for attaching the engine/
gearbox assembly at the engine and gearbox mounts.
– Adjust assembly bracket ⇒ page 20 and tighten screws
⇒ page 19 .
– Install pendulum support ⇒ page 19 .
– Install drive shafts ⇒ Chassis ⇒ Rep. Gr. 40 .
For vehicles with air conditioning
– Install AC compressor ⇒ page 23 .
– Install the V-ribbed belt ⇒ page 26 .
Continued for all vehicles
– Install slave cylinder ⇒ Gearbox ⇒ Rep. Gr. 30 .
– Attach shift mechanism and adjust if necessary ⇒ Gearbox ⇒
Rep. Gr. 34 .
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Install the engine wiring
with respect to theharness and
correctness of connect
information in this to the engine
document. Copyright by ŠKODA AUTO A. S.�
control unit ⇒ page 176 .
– Install exhaust system ⇒ page 178 .
– Install the battery and pay attention to the necessary work after
re-connecting the battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Checking the oil level ⇒ Maintenance ; Octavia II .
– Top up and bleed cooling system ⇒ page 99 .
– Interrogate all fault memories and delete all fault entries, which
are caused by removing and installing the engine ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
After deleting the fault memory of the engine control unit the
readiness code must be re-generated.
– Perform a test drive.
– Then perform a vehicle system test and if necessary eliminate
the resulting faults.
Tightening torques
Component Nm
Screws/nuts M6 10
M7 13
M8 20
M10 45
M12 60
deviations:
Engine/gearbox connecting screws ⇒ gearbox ⇒ Rep. Gr. 34
Screws for assembly bracket ⇒ page 19

18 Rep. Gr.10 - Removing and installing engine

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2 Assembly bracket

2.1 Unit mounting - summary of components

1 - Gearbox support bracket

2 - Screw
❑ Tightening torque ⇒
gearbox ⇒ Rep. Gr. 34
3 - Unit mounting for engine
4 - 40 Nm + torque a further 90°
(1/4 turn)
❑ replace
5 - Bracket for activated char‐
coal filter
6 - 9 Nm
7 - 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
8 - 20 Nm + torque a further 90°
(1/4 turn)
❑ replace
9 - 20 Nm + torque a further 90°
(1/4 turn)
❑ replace
10 - Connecting part
11 - 40 Nm + torque a further
90° (1/4 turn)
❑ replace
12 - 60 Nm + torque a further
90° (1/4 turn)
❑ replace
13 - Pendulum support
❑ removing: first unscrew
screw -14-, then screws
-15-
❑ installing: first tighten screws -15-, then screw -14-
14 - 100 Nm + torque a further 90° (1/4 turn)
❑ replace
15 - Screws
❑ replace
❑ Strength category 8.8: 40 Nm + torque a further 90° (1/4 turn).
❑ Strength category 10.9: 50 Nm + torque a further 90° (1/4 turn).

16 - 60 Nm + torque a further 90° (1/4 turn)

❑ replace
17 - 40 Nm + torque a further 90° (1/4 turn)
❑ replace

2. Assembly bracket 19
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

18 - Unit mounting for gearbox

2.2 Checking and adjusting the assembly

bracket

2.2.1 Checking the assembly bracket

– Check dimensions on the right hanger for engine/gearbox unit:
• Between engine bracket and engine support there must be a
distance -a- = 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- can also be checked e.g. with suitable round
bars.

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

on the frame side byrail
Protected whenCopying
copyright. cornering)
for privateand the dimension
or commercial -a-orisin whole, is not permitted
purposes, in part
not 10 mm:unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Adjust the assembly bracket ⇒ page 20 .

2.2.2 Adjusting the unit mounting

Special tools and workshop equipment required
♦ Supporting device -T30099-
♦ Shim -T30099/1-
♦ Adapter -MP9-200/3 (10-222A/3)-
♦ Lifting eye -10-222A/12-
♦ Snap hook
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
Gr. 66 .

20 Rep. Gr.10 - Removing and installing engine

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Install supporting device -T30099- and support engine in fitting

position. (The figure shows the version with the 1.4 ltr./90 kW
TSI Engine; the engine mounting is identical).
– Uniformly pre-tension the engine/gearbox assembly at both
spindles, but do not raise.

– Release the screws -2- of the assembly bracket at the engine.

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

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

2. Assembly bracket 21
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Move the engine/gearbox assembly with an assembly lever

between the supporting arm of the engine mount -1- and the
engine support -2- 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 of the engine mount -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 for the engine side assembly bracket

⇒ page 19 .

– Make sure that on the gearbox side the edges of the support‐
ing arm of the gearbox mount -2- and the gearbox support
-1- are parallel.
• The dimension -x- must be the same on both mount sides.
– Tighten the screws for the gearbox side assembly bracket
⇒ page 19 .
Further installation occurs in reverse order.

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

22 Rep. Gr.10 - Removing and installing engine

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

13 – Crankgear
1 V-ribbed belt drive

1.1 V-ribbed belt - Summary of components

1.1.1 Summary of components - Vehicles without air conditioning

1 - V-ribbed belt
❑ Routing of the ribbed V-
belt ⇒ page 24
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ removing and installing
⇒ page 26
2 - Fixing screw
❑ for crankshaft belt pulley
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
❑ tighten ⇒ page 41
3 - Belt pulley for crankshaft
❑ Clamping surfaces must
be free of oil and grease.
4 - Diamond coated washer
❑ replace
5 - 20 Nm
❑ When loosening and Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
tightening, counterhold unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with the wrench for the with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
water pump and power-
assisted steering -MP
1-308 (V.A.G 1590)- to
this end rework wrench
for the water pump and
power-assisted steering
- MP 1-308 (V.A.G 1590)- ⇒ page 103
6 - Belt pulley - coolant pump
❑ removing and installing ⇒ page 41
7 - 9 Nm
8 - Vacuum hose
❑ to solenoid valve for coolant circuit -N492- at intake manifold
9 - Coolant pump
❑ removing and installing ⇒ page 104

1. V-ribbed belt drive 23

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

10 - 25 Nm
11 - AC generator
❑ removing and installing ⇒ Electrical System ⇒ Rep. Gr. 27
❑ to facilitate positioning, drive the threaded bushings for the screws at the generator slightly backwards
12 - Bracket for auxiliary units
❑ for tensioning device and AC compressor
❑ removing and installing ⇒ page 29
13 - 40 Nm + torque a further 90° (1/4 turn)
❑ replace
14 - 25 Nm
15 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with wrench to slacken the V-ribbed belt
❑ Secure tensioning device with a 4 mm hexagon wrench or locating pin -T10060 A- .
❑ to remove, release screw -Pos. 12-

Routing of the V-ribbed belt

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

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

24 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.1.2 Summary of components - Vehicles with air conditioning

1 - V-ribbed belt
❑ Routing of the ribbed V-
belt ⇒ page 26
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ removing and installing
⇒ page 26
2 - Fixing screw
❑ for crankshaft belt pulley
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ tighten ⇒ page 41 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
3 - Belt pulley for crankshaft
❑ Clamping surfaces must
be free of oil and grease.
4 - Diamond coated washer
❑ replace
5 - 20 Nm
❑ When loosening and
tightening, counterhold
with the wrench for the
water pump and power-
assisted steering -MP
1-308 (V.A.G 1590)- to
this end rework wrench
for the water pump and
power-assisted steering
- MP 1-308 (V.A.G 1590)- ⇒ page 103
6 - Belt pulley - coolant pump
❑ removing and installing ⇒ page 41
7 - 9 Nm
8 - Vacuum hose
❑ to solenoid valve for coolant circuit -N492- at intake manifold
9 - Coolant pump
❑ removing and installing ⇒ page 104
10 - 25 Nm
11 - Guide pulley, 40 Nm
12 - AC generator
❑ removing and installing ⇒ Electrical System ⇒ Rep. Gr. 27
❑ to facilitate positioning, drive the threaded bushings for the screws at the generator slightly backwards
13 - 40 Nm + torque a further 90° (1/4 turn)
❑ replace

1. V-ribbed belt drive 25

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

14 - 25 Nm
15 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning ⇒ Rep. Gr. 87
16 - 25 Nm
17 - Fitting sleeve
18 - Bracket for auxiliary units
❑ for tensioning device and AC compressor
❑ removing and installing ⇒ page 29
19 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with wrench to slacken the V-ribbed belt
❑ Secure tensioning device with a 4 mm hexagon wrench or locating pin -T10060 A- .
❑ to remove, release screw -Pos. 12-

Routing of the V-ribbed belt

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

1.2 Removing and installing V-ribbed belt

Special tools and workshop equipment required
♦ Locking pin -T10060 A-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Removing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove bottom noise insulation ⇒ Body Work ⇒ Rep. Gr.
50 .

Caution

Risk of damage through reversing the rotation direction of an

already used V-ribbed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the V-ribbed belt.

26 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

For vehicles with air conditioning

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

Note

♦ Before fitting the V-ribbed belt make sure that all assemblies
(AC generator, AC compressor, coolant pump) are securely
mounted.
♦ Pay attention to the correct position and rotation direction of
the V-ribbed belt in the belt pulley when installing it.

– First of all place the ribbed V-belt onto the crankshaft - belt
pulley. Then shift the belt onto the tensioning roller.
Further installation occurs in reverse order to removal.
– Start engine and check ribbed V-belt run.

1.3 Removing and installing bracket for top

auxiliary units
Removing
Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Hose binding claw
Removing
– Remove V-ribbed belt ⇒ page 26 .
– Remove alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Drain the coolant from
Protected the cooling
by copyright. Copyingsystem ⇒commercial
for private or page 99purposes,
. in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove lambdawithprobe
respect -G39- -1-. of information in this document. Copyright by ŠKODA AUTO A. S.�
to the correctness

1. V-ribbed belt drive 27

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

Note

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

– Unscrew hollow screw -2- and fixing screw -3- and remove the
oil feed line.

– Unscrew fixing screws -1- and remove bracket.

Install

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

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

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

28 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Connect the coolant hose -1- and attach it to the engine oil
cooler and remove the hose clamp -MP7-602 (3094)- .
– Top up and bleed cooling system ⇒ page 99 .
– Inspect coolant level in the expansion reservoir, top up with
coolant if necessary.
– Install alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install the V-ribbed belt ⇒ page 26 .
The further assembly is carried out in reverse order to disassem‐
bly.

1.4 Removing and installing bracket for bot‐

tom auxiliary units
Removing
– Remove V-ribbed belt ⇒ page 26 .
– Remove alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .

WARNING

Risk of injury through refrigerant.

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

Caution

Risk of damaging refrigerant lines and hoses.

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

– Remove AC compressor from the bracket ⇒ page 23 .

– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
– Unscrew fixing screws -1- and remove holder with tensioning
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element. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Install
– Fit the bracket for auxiliary units to the cylinder block.

1. V-ribbed belt drive 29

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Tighten fixing screws -1- to 25 Nm.

Tightening torque of tensioning device: ⇒ page 23
The further assembly is carried out in reverse order to disassem‐
bly.

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

30 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2 Camshaft drive

2.1 Camshaft drive - Summary of compo‐

nents

Note

♦ Before assembly oil all bearing and contact surfaces.

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

– Carefully clean the oil galleries.

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

1 - Cylinder head with cylinder

head cover
❑ Removing and installing
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
cylinder head
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ page 80
❑ Removing and installing
cylinder head cover
⇒ page 73
❑ Do not rework the seal‐
ing surface
2 - Cylinder block
❑ Disassembling and as‐
sembling pistons and
conrods ⇒ page 52
3 - Bracket for bottom auxiliary
units
❑ for tensioning device
and AC compressor
❑ removing and installing
⇒ page 29
4 - 25 Nm
5 - Oil pan
❑ removing and installing
⇒ page 93
❑ fit with silicone sealant D
176 600 A1
6 - 13 Nm
7 - 150 Nm + torque a further
180° (1/2 turn)
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.

2. Camshaft drive 31
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09
❑ insert oiled (thread)
❑ Secure belt pulley with counterholder -3415- to prevent it from turning
8 - Belt pulley
❑ Pay attention to tightening process ⇒ page 41
❑ Clamping surfaces must be free of oil and grease.
❑ Secure belt pulley with counterholder -T30004 (3415)- with bolts -T30004/2 (3415/2)- to prevent it from
turning
9 - Diamond coated washer
❑ replace
10 - Sealing ring
❑ replace
❑ removing and installing ⇒ page 40
11 - 50 Nm
12 - Engine support bracket
13 - 20 Nm + torque a further 90° (1/4 turn)
❑ replace
14 - Sprocket
❑ for oil pump drive
❑ Clamping surfaces must be free of oil and grease.
❑ Lock chain sprocket with counterholder -T10172-
15 - Drive chain for oil pump
❑ mark running direction (installed position) before removing
16 - Bottom cover
17 - 5 Nm + torque a further 30°
❑ Screw: M6x40
18 - 5 Nm + torque a further 30°
❑ Screw: M6x20
19 - Bottom timing case
❑ removing and installing ⇒ page 35
20 - Bearing bolt - 18 Nm
21 - Guide rail
❑ for timing chain
22 - Bearing bolt - 18 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
23 - 50 Nm + torque a further 90° (1/by4 ŠKODA
unless authorised turn) AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ replace
24 - Tensioning rail
❑ for timing chain
25 - 8 Nm
26 - Top timing case
❑ removing and installing ⇒ page 33

Caution
Pay attention to tighten‐
ing process!

32 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

27 - Timing chain
❑ removing and installing ⇒ page 66
28 - Sprocket
❑ Lock chain sprocket with counterholder -T10172-
29 - Chain tensioner - 60 Nm
❑ for timing chain
30 - Sealing ring
❑ replace

2.2 Removing and installing the top timing

case
Special tools and workshop equipment required
♦ Hose binding claw
♦ Sealant -D 176 501 A1-
♦ Screw M6x70 (2x): screws with sawn off head
♦ Sealant remover gasket stripper (bearing code GST, part
number R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing
– Drain coolant ⇒ page 99 .
– Slacken clamps -1- and -2- and detach coolant hoses.
– Unlatch the clamp -3- and pull it towards the top with the cool‐
ant hoses.
– Place the coolant hoses to the rear.

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

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

2. Camshaft drive 33
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– To better guide the timing case cover, screw two pin screws
M6x70 -1- into the cylinder head cover.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove residual sealant from the sealing surfaces on the top

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

Note

♦ The installation procedure must not last longer than 6 minutes

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

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

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

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

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

34 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

-E-.
Stage ll of the tightening process.

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

-G-.

– Push the clamp -3- from above fully into the bracket.
– Fit on the coolant hoses and attach the spring strap clamps
-1- and -2-.
– Top up coolant ⇒ page 99 .

2.3 Removing and installing the bottom tim‐

ing case
Special tools and workshop equipment required
♦ Assembly device -T10417/1-
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ Sealant remover gasket stripper (bearing code GST, part
number R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Sealant - D 176unless
600 A1- by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
authorised
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Removing
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Remove the front right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .

2. Camshaft drive 35
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Remove V-ribbed belt ⇒ page 26 .

– If present, remove dust cap -1-.
– Remove guide pulley -2-.
– Remove belt pulley for coolant pump, to do so counterhold the
belt pulley with the water pump wrench -V.A.G 1590- .
– Remove belt pulley for crankshaft ⇒ page 41 .
– Removing the oil pan ⇒ page 93 .

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

WARNING

Wear protective gloves when working with sealant and grease

remover!

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

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

Note

♦ The installation procedure must not last longer than 6 minutes

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

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

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
The sealant bead must be 2…3 mmwith thick and
respect must
to the run past
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
the area of the bolt holes all around the holes.

36 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

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

Caution

Pay attention to the tightening torque of the fixing screws!

When installing, use new screws.

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

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

Tightening torque: 5 Nm + torque a further 30°
Install the crankshaft belt pulley ⇒ page 41 .
Tightening torques
Belt pulley for coolant pump: 20 Nm
Guide pulley: 40 Nm.

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

2. Camshaft drive 37
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

3 Sealing flanges and flywheel

3.1 Summary of components

1 - 150 Nm + torque a further

180° (1/2 turn)
❑ replace
❑ The clamping surface of
the fixing screw must be
free of grease and oil.
❑ insert oiled (thread)
❑ Secure belt pulley with
counterholder -T30004
(3415)- with bolts -
T30004/2 (3415/2)- to
prevent it from turning
2 - Belt pulley
❑ removing and installing
⇒ page 41
❑ Clamping surfaces must
be free of oil and grease.
3 - Diamond coated washer
❑ replace
4 - Sealing ring
❑ replace
5 - Engine
6 - 60 Nm + torque a further 90°
(1/4 turn)
❑ replace
7 - Flywheel
❑ on vehicles with auto‐
matic gearbox DSG -
two-mass flywheel ver‐
sion
❑ removing and installing
⇒ page 39
8 - Intermediate plate
❑ must be positioned on dowel sleeves
❑ do not damage/bend during assembly work
9 - 10 Nm
❑ replace
10 - Sealing flange on the gearbox side
❑ Only replace sealing flange complete with gasket ring and rotor
❑ replace ⇒ page 44
11 - Engine speed sender -G28- , 5 Nm
❑ with captive screw
❑ removing and installing ⇒ page 184
12 - 5 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

38 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

3.2 Removing and installing flywheel

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

♦ Engine mount -MP 1-202 (VW 540)-

♦ Bushing -T30010 (VW 540/1B)-
♦ Flywheel lock -MP 1-504-
Removing
• Gearbox is removed.
– Remove clutch on vehicles with manual gearbox ⇒ Gearbox;
Rep. Gr. 30 .
Engine installed
– Insert the counterholder -MP1-223 (3067)- into the bore hole
on the cylinder block.
• Fitting position of the counterholder:
A - for tightening Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
B - for slackening

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

3. Sealing flanges and flywheel 39

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Vehicles with two-mass flywheel

– Rotate the secondary side -A- of the two-mass flywheel in such
a way that the screws -B- are positioned in the middle of the
holes -arrows-.

Caution

When unscrewing the screws -B-, ensure that the screw head
does not jam on the secondary side -A- of the two-mass fly‐
wheel, otherwise the flywheel will be damaged.

Continued for all

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

Note

Use new screws for attaching.

Vehicles with two-mass flywheel

– Rotate the secondary side -A- of the two-mass flywheel in such

a way that the screws -B- are positioned in the middle of the
holes -arrows-. unless
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Continued for all
1. Screw in all the screws by hand.
2. Tighten all the screws crosswise to 60 Nm.
3. Torque all the screws crosswise a further 90° (1/4 turn).

3.3 Replacing crankshaft seal on belt pulley

side
Special tools and workshop equipment required
♦ Gasket ring extractor -T30003 (3240)-
♦ Assembly device -T10417-
♦ Thrust piece -T30015 (3161)-
Removing
– Remove V-ribbed belt ⇒ page 26 .
– Rotate the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 58 .
– Remove belt pulley for crankshaft ⇒ page 41 .

40 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

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

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

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

striking uniformly up to the stop in the timing case.
Install the crankshaft belt pulley ⇒ page 41 .
Further installation occurs in reverse order to removal.

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

3.4 Removing and installing crankshaft belt

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

3. Sealing flanges and flywheel 41

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Note

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

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

Caution

Risk of engine damage!

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

Removing
– Remove V-ribbed belt ⇒ page 26 .
– Rotate the crankshaft in direction of rotation of engine on TDC
for cylinder 1 ⇒ page 58 .
– Counterhold belt pulley with counterholder -T30004 (3415)-
with bolt -T30004/2 (3415/2)- and release fixing screw for belt
pulley.
Install
Vehicles with auxiliary
Protectedheating.
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Unscrew the screws -1 and 2- of the brackets for the coolant

pipes for the auxiliary heating -3-.
Continued for all vehicles

42 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

Note

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

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

– Release screw plug -arrow- at cylinder block.

Note

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

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

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

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

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

– Unscrew the fixing screw.

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

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

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

Caution

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

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

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

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

3. Sealing flanges and flywheel 43

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

– Install bracket for coolant pipe -2- and tighten screws -1-.
Tightening torque
Screw M6 = 10 Nm
Screw M8 = 20 Nm
– Install the V-ribbed belt ⇒ page 26 .
Further installation occurs in reverse order to removal.

3.5 Replace sealing flange on the gearbox

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

3.5.1 Removing
• Gearbox is removed.
– Remove the flywheel.
– Remove intermediate plate.
– Position engine on TDC of cylinder 1 ⇒ page 58 (do not re‐
move the caps for the camshafts).
– Removing the oil pan ⇒ page unless
93 . authorised
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

44 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Remove engine speed sender -G28- -arrow-.

– Unscrew the fixing screws of the sealing flange.

Note

Sealing flange and rotor are pressed together with 3 M6x35 mm

screws from the crankshaft.

– Screw three screws M6x35 into the threaded bores of the

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

3.5.2 Install

Note

♦ The sealing flange

Protected withCopying
by copyright. PTFEforgasket ring is provided
private or commercial purposes, in with
part or in whole, is not permitted
sealingunless
lip supporting ring. AUTO
authorised by ŠKODA ThisA.supporting
S. ŠKODA AUTO ring isdoes
A. S. intended as or accept any liability
not guarantee
an assembly sleeve
with respect to theand mustofnot
correctness be removed
information before
in this document. instal‐
Copyright by ŠKODA AUTO A. S.�

ling.
♦ Do not separate or turn the sealing flange and rotor after re‐
moving them from the spare part package.
♦ The rotor is given its fitting location by fixing the assembly de‐
vice -T10134 - to the positioning pin.
♦ The sealing flange and gasket ring form one unit and must be
replaced together with the rotor.
♦ The assembly device -T10134- is given its fitting location to
the crankshaft by means of a guide bolt, which is guided into
a hole of the crankshaft.

Assembly device -T10134-

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

3. Sealing flanges and flywheel 45

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

– Remove the securing clip -arrow- from the new sealing flange.

Note

Do not remove or turn the rotor from the sealing flange.

– Lay the front side of the sealing flange on a clean and level
surface.
– Press down sealing lips supporting ring -A- in
-direction of the arrow-, until it rests on the level surface.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

The top side of the rotor and the front side of the sealing flange
must be flush.

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

46 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Lay the sealing flange with the front side on the assembly de‐
vice -T10134- in such a way that the positioning pin -A- en‐
gages into the hole -B- of the rotor.

Note

Make sure the sealing flange lies flat on the assembly device.

– When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly device in
such a way that the positioning pin cannot slide out of the rotor
hole.
B - Mount the assembly device -T10134- on the crankshaft flange
• The crankshaft flange must be free of grease and oil
• Crankshaft is at TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.

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

the stop onto the crankshaft flange.

– Screw in two M6x35 mm screws -A- by about 3 turns for seal‐

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

3. Sealing flanges and flywheel 47

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Move the assembly cup -C- by hand in the

-direction of the arrow- until the rotor -B- rests on the crank‐
shaft flange -A-. Subsequently insert the guide bolt with red
ball -F- fully into the threaded bore of the crankshaft. If the
guide bolt is correctly pushed in, then the handle has a dis‐
tance of approx. 10 mm from the assembly cup -C-. This gives
the rotor its final fitting location.
C - Pressing the rotor onto the crankshaft flange
– Screw in hexagon nut by hand onto the threaded spindle until
it rests against the assembly cup.

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

wrench with adapter.
Tightening torque: 35 Nm.

Note

After tightening the hexagon nut to 35 mm there must still be a

narrow air gap between the cylinder block and the sealing flange.

D - Inspecting the fitting position of the rotor on the crankshaft

– Unscrew hexagon nut -E- up to the end of the threaded spin‐

dle.
– Unscrew two M6x35 mm screws -A- from the cylinder block.
– Release three knurled screws -B- from the sealing flange.
– Unscrew two Allan screws and remove assembly device -
T10134- .
– Remove sealing lips supporting ring. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- = 0.5 mm between the crankshaft flange
-A- and the rotor -B-.

48 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– 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 49 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing alternately cross‐
wise.
Tightening torque: 10 Nm.

– Install engine speed sender -arrow-.

Tightening torque: 5 Nm.
– Installing the oil pan ⇒ page 93 .
– Installing intermediate plate.
– Install flywheel with new screws.
E - Pressing down the rotor

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Screw assembly device -T10134- with Allan screws up to the
stop onto the crankshaft flange.
– Screw in three knurled screws -A- into the flange.
– Subsequently insert the guide bolt with red ball -E- fully into
the threaded bore of the crankshaft. If the guide bolt is correctly
slipped on, then the handle has a distance of approx. 10 mm
from the assembly cup -B-.

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

wrench with adapter.
Tightening torque: 40 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 48 .
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 48 .

3. Sealing flanges and flywheel 49

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

4 Crankshaft

Caution

The crankshaft must not be removed. Merely releasing the

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

4.1 Replace needle bearing for crankshaft

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

Note

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

its installed condition.

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

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

50 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Depth of installation of the needle bearing:

• Dimension -a- = 1.5 up to 2 mm

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

4. Crankshaft 51
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

5 Pistons and conrods

5.1 Summary of components

Note

Before assembly oil all bearing and contact surfaces.

1 - Circlip
2 - Piston pin
❑ if stiff, heat piston to 60°
C
❑ use drift -T10046- for re‐
moving and installing
3 - Piston
❑ check ⇒ page 54
❑ mark installation posi‐
tion and matching cylin‐
der
❑ arrow on piston crown
faces towards the belt
pulley side
❑ use piston ring tension‐
ing strap for installing
❑ Piston ∅: 70,95 mm
(nominal dimension)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Cylinder ∅: 71,00 mm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
(nominal dimension) with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4 - Gasket rings
❑ Offset joint 120°
❑ use piston ring pliers for
removing and installing
compression rings
❑ Marking “TOP” faces
piston crown
❑ Inspect gap clearance
⇒ page 53
❑ Inspect end clearance
⇒ page 53
5 - Oil scraper rings
❑ carefully remove and in‐
stall 3-part oil scraper rings by hand
❑ Inspect gap clearance ⇒ page 53
❑ End clearance cannot be measured
6 - 30 Nm + torque a further 90° (1/4 turn)
❑ replace
❑ Oil thread and contact surface
7 - Conrod bearing cap
❑ as a result of the conrods separated in the cracking process, the cover fits only in one position and only
to the relevant conrod
❑ Mark the assignment of the cylinder before removal -A-

52 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09
❑ Fitting position: Marking -B- points to the belt pulley side (mark before removing if marking is missing)
8 - Bearing shell
❑ do not mix up used bearing shells
❑ insert bearing shells in the centre
9 - Pressure relief valve, 27 Nm
❑ Opening pressure: 0,2 MPa (2,0 bar)
10 - Oil injection nozzle
❑ for cooling pistons
❑ Align the guide edge of the oil injection nozzle -arrow- to the area of the cylinder block being worked on.
11 - Conrod
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Marking -B- points to the belt pulley side (mark before removing if marking is missing)
❑ located axially by pistons
❑ separate new conrod ⇒ page 55

5.2 Inspect piston, piston rings and cylinder

bore
Inspecting piston ring gap clearance

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

Special tools and workshop equipment required

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

Special tools and workshop equipment required

5. Pistons and conrods 53

 OCTAVIA II 2004 ➤
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♦ Feeler gauge
– Clean ring groove before inspecting.
Piston ring New Wear limit
dimensions in mm
1. Compression ring 0,03…0,09 0,15
2. Compression ring 0,02…0,06 0,15
Oil scraper ring cannot be measured
Inspecting pistons

Special tools and workshop equipment required

♦ External micrometer 75...100 mm
– Measure about 7 mm from the lower edge and offset 90° to
piston pin axis.
• Deviations from specified dimension: max. 0.04 mm
Inspecting cylinder bore

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

Special tools and workshop equipment required

♦ Internal precision measuring instrument 50...100 mm
– Measure at 3 points crosswise in a transverse direction -A- and
lengthwise -B-.
• Deviations from specified dimension: max. 0.08 mm

54 Rep. Gr.13 - Crankgear

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Note

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

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

5.3 Separating new conrod

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

Note

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

♦ The conrod is clamped below the broken line.

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

– Carefully knock against the conrod bearing cap with a rubber

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

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

5. Pistons and conrods 55

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

15 – Cylinder Head, Valve Gear

1 Cylinder head - part 1

1.1 Summary of components

Testing compression pressure ⇒ page 83 .

Note

♦ When installing a replacement cylinder head, all the contact

surfaces between the hydraulic tappets, the cam followers and
the cam tracks must be oiled before installing the cylinder head
cover.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ If the cylinder head is replaced, also the entire coolant must
be replaced.
♦ Before assembly moisten all bearing and contact surfaces with
oil.
♦ Removing and installing intake manifold ⇒ page 159 .

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

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

 OCTAVIA II 2004 ➤
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1 - 8 Nm
2 - High pressure pump
❑ for fuel supply
❑ with fuel pressure regu‐
lating valve -N276-
❑ removing and installing
⇒ page 163
3 - 10 Nm
4 - Hall sender -G40-
❑ with O-ring
❑ replace the O-ring if it is
damaged
5 - 20 Nm
6 - Lifting eye
7 - 8 Nm + torque a further 90°
(1/4 turn)
❑ replace
❑ order of tightening
⇒ page 73
8 - Cylinder head cover
❑ removing and installing
⇒ page 73
9 - 10 Nm
10 - Coolant temperature
sender -G62-
❑ before removing, re‐
duce pressure in cooling
system
11 - O-ring
❑ replace
12 - Cylinder head gasket
❑ replace
❑ metal gasket
❑ after replacing fill entire system with fresh coolant
13 - Cylinder head
❑ removing and installing ⇒ page 80
❑ check for distortion ⇒ page 58
❑ Sealing surfaces must be free of oil and grease
❑ after replacing fill entire system with fresh coolant
14 - Supporting element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ oil contact surfaces
15 - Oil pressure switch -F1- , 20 Nm
❑ check ⇒ page 96
❑ Cut open gasket ring if leaking and replace
16 - Roller rocker arm
❑ inspect roller bearings for smooth operation
❑ oil contact surfaces
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cylinder head - part 1 57

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09
❑ to install clip onto the supporting element with the locking clips
17 - Cylinder head bolt
❑ replace
❑ observe the mounting instructions and sequence for loosening and tightening ⇒ page 80
18 - Roller tappet
❑ Lightly moisten the contact surface with engine oil
19 - O-ring
❑ replace
❑ moisten with oil before inserting

Inspecting the cylinder head for distortion

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

1.2 Test timing

Special tools and workshop equipment required
♦ Locking bolt -T10414-
♦ Locating screw -T10340-
Test sequence
Vehicles with auxiliary heating.
– Unscrew the screws -1 and 2- of the brackets for the coolant
pipes for the auxiliary heating -3-.
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Continued for all vehicles unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 OCTAVIA II 2004 ➤
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– Release fixing screws -1- and remove bracket for coolant pipe
-2-.

– Release screw plug -arrow- at cylinder block.

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

block.

Caution

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

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

– Unscrew the fixing screw.

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

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

block.
– Tighten fixing screw -T10340- to 30 Nm.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– unless
Turnauthorised
crankshaft upAUTO
by ŠKODA to the stop
A. S. in direction
ŠKODA of rotation
AUTO A. S. does of orengine.
not guarantee accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .

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

1. Cylinder head - part 1 59

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

shown.

– Insert the locking bolt -T10414- up to the stop into the cylinder
head cover.
If the locking bolt -T10414- cannot be inserted up to the stop into
the camshaft opening, the timing is not correct and must be set
⇒ page 60 .
The timing is O.K., if the locking bolt -T10414- can be pushed up
to the stop into the cylinder head cover.
– Remove locking bolt -T10414- and fixing screw -T10340- .
Further installation occurs in reverse order to removal.

1.3 Setting the timing

Special tools and workshop equipment required
♦ Locking bolt -T10414-
♦ Locating screw -T10340-
♦ Counterholder -T10172 -
Work procedure
– Drain coolant ⇒ page 99 .
– Remove top timing
Protected case
by copyright. ⇒ page
Copying 33or. commercial purposes, in part or in whole, is not permitted
for private
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Pull off both coolant
with respect to the hoses -1-of information
correctness from thein non-return valve.by ŠKODA AUTO A. S.�
this document. Copyright

– Release the fixing screw -2- and pull the non-return valve out
of the cylinder head cover.
Vehicles with auxiliary heating.

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Unscrew the screws -1 and 2- of the brackets for the coolant

pipes for the auxiliary heating -3-.
Continued for all vehicles

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

– Release screw plug -arrow- at cylinder block.

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

1. Cylinder head - part 1 61

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

block.

Caution

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

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

– Unscrew the fixing screw.

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

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

block.
– Tighten fixing screw -T10340- to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
The crankshaft is locked in direction of rotation of engine with the
fixing screw -T10340- .
– Removing the oil pan ⇒ page 93 .

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

– Release chain tensioner -arrow- for timing chain.

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

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Hold the camshaft sprocket with the counterholder -T10172-

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

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

-arrow- in the timing case.

Note

The integrated peg on the inner side of the timing case prevents
the chain sprocket from falling down.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

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

Note

When subsequently adjusting the camshaft, damage to the valves

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

– Turn the camshaft until the grooves -arrows- are in the position
shown.

1. Cylinder head - part 1 63

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

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

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

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

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Hold the camshaft sprocket with the counterholder -T10172-

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

Note

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

– Install chain tensioner and tighten to 60 Nm.

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

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Remove locking bolt -T10414- and fixing screw -T10340- .
– Install top timing case ⇒ page 33 .

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

-2-: 8 Nm.
– Fit on hoses -1-.
– Install oil pan ⇒ page 93 .
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Cylinder head - part 1 65

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Install screw plug. Tightening torque: 30 Nm

– Top up coolant ⇒ page 99 .
Further installation occurs in reverse order to removal.

1.4 Removing and installing timing chain

and drive chain for oil pump

Note

First of all, the timing chain mustProtected

be removed
by copyright.inCopying
orderfortoprivate
remove
or commercial purposes, in part or in whole, is not permitted
the drive chain for oil pump. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Remove timing chain ⇒ page 66

Remove and install the drive chain for oil pump ⇒ page 70
Install timing chain ⇒ page 71
Special tools and workshop equipment required
♦ Locking bolt -T10414-
♦ Locating screw -T10340-
♦ Counterholder -T10172 -
♦ Counterholder -T30004 (3415)-
♦ Bolt -T30004/2 (3415/2)-
♦ Assembly device -T10417/1-

1.4.1 Remove timing chain

– Remove bottom noise insulation ⇒ Body Work ⇒ Rep. Gr.
50 .
– Drain coolant ⇒ page 99 .
– Remove the front right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Remove V-ribbed belt ⇒ page 26 .
– Remove top timing case ⇒ page 33 .

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Vehicles with auxiliary heating.

– Unscrew the screws -1 and 2- of the brackets for the coolant
pipes for the auxiliary heating -3-.
Continued for all vehicles

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

– Release screw plug -arrow- at cylinder block.

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

1. Cylinder head - part 1 67

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

block.

Caution

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

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

– Unscrew the fixing screw.

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

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

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

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

– Insert the locking bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.
– Removing the oil pan ⇒ page 93 .

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

– If present, remove dust cap -1-.

– Remove guide pulley -2-.
– Remove belt pulley for coolant pump, to do so counterhold the
belt pulley with the water pump wrench -V.A.G 1590- .
– Remove belt pulley for crankshaft ⇒ page 41 .

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

– Release chain tensioner -arrow- for timing chain.

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

– Hold the camshaft sprocket with the counterholder -T10172-

and slacken the fixing screw -1- of the camshaft sprocket.
– Remove the camshaft sprocket together with the fixing screw.
– Remove timing chain downwards.
Install timing chain ⇒ page 71

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

1. Cylinder head - part 1 69

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.4.2 Removing and installing the drive chain

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

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

– Remove the complete oil pump from the drive chain.

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

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

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

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

1.4.3 Installing timing chain

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

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

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

– Hold the camshaft sprocket with the counterholder -T10172-

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

Note

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

1. Cylinder head - part 1 71

 OCTAVIA II 2004 ➤
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– Tighten chain tensioner -arrow- to 60 Nm.

– Remove the locking bolt -T10414 - from the camshaft.
– Unscrew the fixing screw -T10340- from the cylinder block.
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Test timing ⇒ page 58 .
If timing is o.k.:

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Install bottom timing case ⇒ page 35 .

– Fit the cover -1- on the oil pump.

– Install oil pan ⇒ page 93 .
– Install the crankshaft belt pulley ⇒ page 41 .
– Install the V-ribbed belt ⇒ page 26 .
– Install top timing case ⇒ page 33 .
– Top up coolant ⇒ page 99 .
Further installation occurs in reverse order to removal.

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

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2 Cylinder head - part 2

2.1 Removing and installing cylinder head

cover and camshaft

Note

The camshaft is located in the cylinder head cover.

Special tools and workshop equipment required

♦ Locking bolt -T10414-
♦ Locating screw -T10340-
♦ Counterholder -T10172 -
♦ Sealant - D 154 103 A1- (cylinder head cover/cylinder head)
♦ Sealant - D 189 500 A1- (cylinder head cover/cylinder head)
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
♦ Screw M6x70 (2x) : adapt the screws by sawing off the heads

2.1.1 Remove cylinder head cover

– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐
trical System ⇒ Rep. Gr. 27 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Drain coolant ⇒ page 99 .
– Remove top timing case ⇒ page 33 .
Vehicles with auxiliary heating.
– Unscrew the screws -1 and 2- of the brackets for the coolant
pipes for the auxiliary heating -3-.
Continued for all vehicles

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

2. Cylinder head - part 2 73

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

– Release screw plug -arrow- at cylinder block.

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

block.

Caution

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

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

– Unscrew the fixing screw.

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

– Turn the fixing screw -T10340- upProtected

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

– Tighten fixing screw -T10340- to 30 Nm.

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

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

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

 OCTAVIA II 2004 ➤
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– Insert the locking bolt -T10414- up to the stop into the cylinder
head cover.
– Tighten fixing screw -1- by hand.
– Removing the oil pan ⇒ page 93 .

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

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Release chain tensioner -arrow- for timing chain.

– Hold the camshaft sprocket with the counterholder -T10172-

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

2. Cylinder head - part 2 75

 OCTAVIA II 2004 ➤
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– Place the chain sprocket -1- down on the integrated peg

-arrow- in the timing case.

Note

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

– Detach hose to air filter from cylinder head cover.

– Release screws -1- and remove retaining clip.

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

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

spark plugs using the extractor -T10112 A- and lay the ignition
cables to the rear.
– Remove the high pressure pump ⇒ page 164 .
– Unplug connectors from the fuel injection valves.

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

tor from the injection valves.
– Remove exhaust turbocharger ⇒ page 144 .
– Disconnect the plug from the Hall sender -G40- .
– Pull out oil dipstick.
– Slacken the fixing screws of the cylinder head cover crosswise
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
from outside to inside and unscrew. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Carefully remove the cylinder head cover.

Note

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

Remove and install camshaft ⇒ page 77 .

Install cylinder head cover ⇒ page 78 .

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2.1.2 Removing and installing camshaft

Removing
– Remove locking bolt -T10414- .
– Place the cylinder head cover on the work bench as shown.
– Release the fixing screws for the bearing frame in the specified
order -A- to -J-.
– Remove bearing frame.

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

Note

Before fitting, moisten the camshaft and the camshaft bearings

lightly with engine oil.

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

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

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

-J-.
Install cylinder head cover ⇒ page 78 .

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

2. Cylinder head - part 2 77

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2.1.3 Install cylinder head cover

Caution

Before installing the cylinder head cover, screw in the pin

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

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

WARNING

Wear protective gloves when working with sealant and grease

remover!

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

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

Caution

The cylinder head cover is sealed with 2 different sealants!

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

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

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

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

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

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

 OCTAVIA II 2004 ➤
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– Tighten the new fixing screws of the cylinder head cover in the
specified order -A- to -J-.
Tightening torque: 8 Nm + torque a further 90° (1/4 turn).

Caution

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

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

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

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

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

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

2. Cylinder head - part 2 79

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

– Hold the camshaft sprocket with the counterholder -T10172-

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

Note

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

– Tighten chain tensioner to 60 Nm.

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

– Hold the camshaft sprocket with the counterholder -T10172-

and torque the fixing screw -1- a further 90° (1/4 turn).
– Remove locking bolt -T10414- and fixing screw -T10340- .
– Install top timing case ⇒ page 33 .
– Install exhaust turbocharger ⇒ page 144 .
– Installing the oil pan ⇒ page 93 .
– Install the crankshaft belt pulley ⇒ page 41 .
– Install high pressure pump ⇒ page 164 .
– Install fuel lines ⇒ page 163 .
Further installation occurs in reverse order to removal.

2.2 Removing and installing cylinder head

Special tools and workshop equipment required

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

♦ Supporting device -T30099-

♦ Shim -T30099/1-
♦ Support -T10358-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing
Requirements
• The engine temperature should not exceed 35°C, because the
cylinder head could be twisted when slackening the screws.
• The pistons must not be in TDC.
Observe safety measures ⇒ page 3 .
Observe rules for cleanliness ⇒ page 5 .

WARNING

Release pressure in the high pressure area of the fuel system

⇒ page 4 .

– Drain the coolant from the cooling system ⇒ page 99 .

– Remove coolant regulator housing from cylinder head.
– Remove top timing case ⇒ page 33 .
– Remove bottom timing case ⇒ page 35 .
– Remove exhaust turbocharger ⇒ page 144 .
– Removing the intake manifold ⇒ page 159 .
– Fit supporting device -T30099- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
–unless
Unscrew
authorisedthe fixingAUTO
by ŠKODA screw
A. S. for
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respect to asofshown.
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in this document. Copyrightthe version
by ŠKODA AUTO A. S.�

with the 1.4 ltr./90 kW TSI Engine; the engine mounting is

identical).
– Support the engine via the spindle in its installed position and
slightly pre-tension.

2. Cylinder head - part 2 81

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Disconnect the fuel feed line -1- and the cable to the activated
charcoal filter -2-. To do so press the release buttons.

WARNING

The fuel feed line is pressurized! Wear safety goggles and

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

– Release the fixing screws -2- and pull the activated charcoal
filter upwards.

– Unscrew screws -arrows- and remove engine mounting.

– Remove cylinder head cover ⇒ page 73 .
– Remove the tensioning rail and the sliding rail of the timing
chain.
– Remove the roller rocker arm together with the supporting el‐
ements and lay aside on a clean surface.
– Ensure that the roller rocker arms and the supporting elements
are not mixed up.

– Release the cylinder head bolts in the specified sequence and

remove.
– Carefully remove the cylinder head.
Install

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

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

Condition
• The pistons must not be in TDC.

Note

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

– Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
– Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.
– Position piston of cylinder 1 to top dead centre and slightly turn
the crankshaft anticlockwise again.
– Position the new cylinder heads. The legend (part number)
must be legible.
– Insert the cylinder head. Pay attention to the centering pins in
the cylinder block.
– Insert new cylinder head bolts and tighten by hand.
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unless–authorised
Tighten cylinder
by ŠKODA AUTOhead boltsAUTO
A. S. ŠKODA in the
A. S.tightening order
does not guarantee shown
or accept as
any liability
follows:
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Tighten all screws to 40 Nm.

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

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

tion the relevant roller rocker arm on the valve stem ends or
supporting elements.
– Install cylinder head cover ⇒ page 73 .
– Setting the timing ⇒ page 60 .
Further installation occurs in reverse order to removal.
– Top up and bleed cooling system ⇒ page 99 .

2.3 Testing the compression

Special tools and workshop equipment required

2. Cylinder head - part 2 83

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

♦ Spark plug wrench -3122 B-

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

Note

Use of tester ⇒ Operating Instructions .

– Operate starter until the tester no longer indicates a pressure

rise.
Compression readings
New engine Wear limit Difference between
cylinders
1...1.5 MPa 0.7 MPa 0.3 MPa
(10...15 bar) (7 bar) (3 bar)
If the specified values are not reached, test the combustion cham‐
ber for tightness ⇒ page 84 .
Further installation occurs in reverse order to removal. Pay at‐
tention to the following:
– Delete the contents of the fault memory for the engine control
unit at the end of the work as error messages were stored due
to disconnecting the plugs ⇒ Vehicle diagnosis, testing and
information system VAS 5051.

2.4 Check combustion chamber for tight‐

ness unless
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authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Special tools and workshop equipment required
♦ Pressure hose -MP1-210 (VW 653/3)- (replace gasket ring
with a spark plug gasket ring)
♦ Extractor -T10112 A-
♦ Spark plug wrench -3122 B-
Test sequence
– Unscrew the spark plugs with the spark plug wrench -3122 B- .
– Position piston of the relevant cylinder to dead centre.
– Screw the pressure hose MP 1-210 into the spark plug thread.
– Connect pressure hose to compressed air.

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

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

2. Cylinder head - part 2 85

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

3 Valve gear

3.1 Valve gear - Summary of components

1 - 50 Nm + torque a further 90°

(1/4 turn)
❑ replace
2 - Camshaft sprocket
❑ take note of the position
when installing the tim‐
ing chain
3 - 10 Nm
4 - Hall sender -G40-
❑ with O-ring
❑ replace the O-ring if it is
damaged
5 - Cylinder head cover
❑ removing and installing
⇒ page 73
6 - Non-return valve
7 - 10 Nm
8 - O-ring
❑ replace if damaged
❑ before fitting moisten
lightly with engine oil
9 - Camshaft
❑ removing and installing
⇒ page 73
❑ Inspecting axial play
⇒ page 87
❑ moisten with oil before
installing (also axial
bearing collar)
10 - Valve collet
11 - Valve spring retainer
12 - Valve stem seal
❑ replace
13 - Valve spring
❑ with the cylinder head removed, remove and install with blank holder -3362-
❑ (with cylinder head installed) ⇒ page 88
14 - Valve guide
❑ check ⇒ page 87
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15 - Cylinder head unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ removing and installing ⇒ page 80
16 - Valves
❑ do not rework, only grinding in is permissible
❑ Valve dimensions ⇒ page 87

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

17 - 15 Nm
18 - Gasket
❑ replace
19 - Dowel pins
20 - 8 Nm
❑ observe the order of tightening up
❑ removing and installing ⇒ page 73
21 - Bearing frame
❑ for camshaft
❑ removing and installing ⇒ page 73

3.2 inspect camshaft, axial play

Special tools and workshop equipment required
♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge
Perform measurement with the cylinder head cover installed.
Checking the axial play of the camshaft
• Wear limit: 0,4 mm
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Valve dimensions

Note

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

Dimension Inlet valve Exhaust valve

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

3.3 Inspect valve guides

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

3. Valve gear 87
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Work procedure

Note

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

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

Note

If the wear limit is exceeded, repeat measurement with new

valves.

If the valve rock is exceeded:

– Replace the cylinder head.

3.4 Replacing valve stem seal

Special tools and workshop equipment required
♦ Spark plug wrench -3122 B-
♦ Valve lever -MP 1-211 (VW 541/1A/5) -
♦ Pressure hose -MP 1-210 (VW 653/3)-
♦ Assembly device -MP 1-213 (2036)-
♦ Valve supporting plate -MP 1-218-
♦ Insertion tool - MP 1-233 (3365)-
♦ Valve stem seal extractor -MP 1-230 (3364)-
Removing

Note

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

With cylinder head installed:

– Remove cylinder head cover ⇒ page 73 .
– Remove roller rocker arm and place on a clean surface. Make
sure the roller rocker arms are not interchanged.
– Unscrew the spark plugs with the spark plug wrench -3122 B- .
– Put the piston of the relevant cylinder at “bottom dead centre”.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

– Insert the new valve stem seal -1- into the insertion tool for
valve stem seal -MP 1-233 (3365)- .
– Oil the sealing lip of the valve stem seal and carefully slide
over the valve -2- onto the valve guide.
– Installing camshaft housing ⇒ page 73 .
The further assembly is carried out in reverse order to disassem‐
bly.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Valve gear 89
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

17 – Lubrication
1 Lubrication system

Note

♦ The oil level must not be above the max. marking - risk of
damage to catalytic converter!
♦ If considerable quantities of metal swarf or abrasion is found
when carrying out engine repairs, this can be subject to dam‐
age to the crankshaft and conrod bearings. In order to avoid
consequential damage, after the repair perform the following
tasks:

– Carefully clean the oil galleries.

– Replace oil spray jets.
– Replace engine oil cooler.
– Replace oil filter.
Inspecting oil pressure ⇒ page 96 .
Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Octavia II .

1.1 Summary of components

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

90 Rep. Gr.17 - Lubrication

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1 - Screw cap
❑ replace damaged gas‐
ket
2 - Oil feed line
❑ to exhaust gas turbo‐
charger
3 - Dipstick
❑ oil level must not exceed
max. marking!
4 - Bracket for top auxiliary
units
❑ removing and installing
⇒ page 27
5 - Gasket
❑ replace if damaged
6 - Guide bushing
7 - Oil filter, 20 Nm

Note

When removing, make sure that the

oil does not penetrateProtected
into the gen‐
erator! Therefore, cover
unlessthe gener‐
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authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ator with a clean cloth! with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ with gasket rings
❑ with non-return valve
❑ slacken and tighten with
oil filter wrench -3417-
❑ Keep to change inter‐
vals ⇒ Maintenance ;
Octavia II
8 - 25 Nm
9 - Gasket
❑ replace if damaged
10 - 8 Nm + torque a further 90° (1/4 turn)
❑ replace
11 - Engine oil cooler
❑ removing and installing ⇒ page 95
12 - 8 Nm
13 - Top timing case
❑ removing and installing ⇒ page 33

Caution
Pay attention to tighten‐
ing process!

14 - 25 Nm
15 - Bottom timing case
❑ removing and installing ⇒ page 35

1. Lubrication system 91
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

16 - 5 Nm + torque a further 30°

❑ Screw: M6x20
17 - 5 Nm + torque a further 30°
❑ Screw: M6x40
18 - Drive chain
❑ removing and installing ⇒ page 66
❑ for oil pump
❑ mark running direction (installed position) before removing
19 - 150 Nm + torque a further 180° (1/2 turn)
❑ replace
❑ The clamping surface of the fixing screw must be free of grease and oil.
❑ insert oiled (thread)
❑ Secure belt pulley with counterholder -3415- to prevent it from turning
20 - Belt pulley
❑ Pay attention to tightening process ⇒ page 41
❑ Clamping surfaces must be free of oil and grease.
❑ Secure belt pulley with counterholder -T30004 (3415)- with bolts -T30004/2 (3415/2)- to prevent it from
turning
21 - Diamond coated washer
❑ replace
22 - Sealing ring
❑ replace
❑ removing and installing ⇒ page 40
23 - Bottom cover
24 - 20 Nm + torque a further 90° (1/4 turn)
25 - Sprocket
❑ for oil pump drive
❑ Clamping surfaces must be free of oil and grease.
❑ Lock chain sprocket with counterholder -T10172-
26 - Oil pump
❑ removing and installing ⇒ page 95
❑ must be replaced completely
27 - 13 Nm
❑ replace
❑ slacken and tighten only the bolts at the gearbox side with socket insert -T10058-
28 - 10 Nm
29 - Oil level and oil temperature sender -G266 -
❑ replace if damaged
❑ check ⇒ Current flow diagrams andAUTO
Fitting locations
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
30 - Sealing ring
❑ replace if damaged
31 - Drain plug, 30 Nm
❑ with captive seal
❑ replace
32 - Oil pan
❑ removing and installing ⇒ page 93

92 Rep. Gr.17 - Lubrication

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

1.2 Removing and installing oil pan

Special tools and workshop equipment required
♦ Socket insert -T10058-
♦ Sealant remover gasket stripper (bearing code GST, part
number R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
♦ Silicone sealant -D 176 600 A1-
♦ Catch pan , e.g. -VAS 6208-
Removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Remove bottom noise insulation ⇒ Body
unless authorised Work
by ŠKODA ⇒ A.
AUTO Rep. Gr. AUTO A. S. does not guarantee or accept any liability
S. ŠKODA
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
50 .
– Drain engine oil ⇒ Maintenance ; Octavia II .
– Remove exhaust pipe Pos. 9 ⇒ page 178 .
– Disconnect plug at oil level and oil temperature sender -
G266- .

1. Lubrication system 93
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove the remaining sealant on the cylinder block and on

the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
Install

Note

♦ Replace M6 oil pan bolts.

♦ Pay attention to the use by date on sealant.
♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant.

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

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

Note

The sealant bead must notA.be thicker otherwise excess

guaranteesealant
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO S. ŠKODA AUTO A. S. does not or accept any liability
maywith
getrespect
into tothe oil pan and
the correctness block inthe
of information this strainer in the by
document. Copyright oilŠKODA
suctionAUTO A. S.�
pipe.

– Fit oil pan immediately and lightly tighten all oil pan screws.
– Tighten the screws of the oil pan to 13 Nm.
– Tighten the fixing screws of the cover plate at the gearbox to
40 Nm.
The further assembly is carried out in reverse order to disassem‐
bly.

Note

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

– Topping up with engine oil ⇒ Maintenance ; Octavia II .

94 Rep. Gr.17 - Lubrication

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.3 Removing and installing oil pump

Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
– Removing the oil pan ⇒ page 93 .
– Pull off the cover -1- from the oil pump.

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

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

– Hook the oil pump with the chain sprocket into the drive chain
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
and tighten the new screwswith-arrows- tocorrectness
respect to the 14 Nm + torque ain fur‐
of information this document. Copyright by ŠKODA AUTO A. S.�
ther 90° (1/4 turn.).
Tightening torque of the suction line: 8 Nm
– Install oil pan ⇒ page 93 .

1.4 Removing and installing engine oil cool‐

er
Special tools and workshop equipment required
♦ Catch pan , e.g. -VAS 6208-
♦ Hose binding claw
Removing
– Drain the coolant from the cooling system ⇒ page 99 .

1. Lubrication system 95
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Open the spring strap clamp with the hose binding claw and
detach the coolant hose -1-.
– Release the four fixing screws from the engine oil cooler and
remove the engine oil cooler.
Install

Note

Replace gasket if damaged.

– Position the engine oil cooler -2- at the bracket and tighten the
fixing screws crosswise to 8 Nm + torque a further 90° (1/4
turn).
– Place the coolant hose -1- onto the oil cooler fitting and attach
it with the spring strap clip.
– Top up and bleed cooling system ⇒ page 99 .
– Inspect coolant level in the expansion reservoir, top up with
coolant if necessary.

Note

If the engine oil cooler was replaced, the coolant must be

changed.

1.5 Testing oil pressure and oil pressure

switch
Special tools and workshop equipment required
♦ Oil pressure tester , e.g. -V.A.G 1342 -
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Vehicle diagnosis, measurement and information system -
VAS 5051-
Conditions
• Engine oil level o.k., test ⇒ Maintenance ; Octavia II .
• Coolant temperature at least 80°C (radiator fan must have run
at least once).

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Functional test and repair of the visual and acoustic oiltopressure
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
display ⇒ Current flow diagrams and Fitting locations, ⇒ Vehicle
diagnosis, testing and information system VAS 5051.

96 Rep. Gr.17 - Lubrication

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

– Screw oil pressure switch into the test equipment.

– Screw tester in the cylinder head instead of the oil pressure
switch.
– Connect brown cable of tester to earth (-).
– Connect voltage tester to battery positive and to oil pressure
switch.
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch -F1- .
If the LED does not light up:
– Start engine and slowly increase engine speed.
• The LED must light up at an oil overpressure of 0.03…0.07
MPa (0.3...0.7 bar), if not replace oil pressure switch.
– Increase engine speed further.
• At 2000 rpm and an oil temperature of 80°C the oil overpres‐
sure should be at least 0.2 MPa (2.0 bar).
At a higher engine speed the oil overpressure must not be greater
than 0.7 MPa (7 bar).
Tightening torque of the oil pressure switch: 20 Nm

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

1. Lubrication system 97
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

19 – Cooling system
1 Cooling system

WARNING

Hot steam may escape when the coolant expansion reservoir

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

Note

♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ The hose connections are secured with spring-type clips. In
case of repair only assign the spring strap clamps via the ⇒
Electronic catalogue of original parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection and hose).
♦ The arrows which are on the coolant pipes and the coolant
hose ends must stand opposite to each other.

1.1 Connection diagram for coolant hoses

Note

♦ This engine is fitted with a radiator combination of engine and

low temperature radiators for charge air system.
♦ Engine and low temperature radiators are arranged as one
component part.

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

98 Rep. Gr.19 - Cooling system

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1 - Expansion reservoir
2 - Coolant recirculation pump
-V50-
❑ removing and installing
⇒ page 105
3 - Coolant pump
❑ removing and installing
⇒ page 104
4 - Charge air cooler
❑ in the intake manifold
⇒ page 149
5 - Heat exchanger for heating
6 - Coolant regulator housing
7 - Non-return valve
❑ in the coolant hose, not
visible from the outside
8 - Throttle valve
❑ in the coolant hose, not
visible from the outside
9 - Radiator
❑ removing and installing
⇒ page 108
10 - Exhaust gas turbocharger
❑ removing and installing
⇒ page 144
11 - Low temperature radiator
for charge air system
❑ Engine and low temper‐
ature radiators are ar‐
ranged as one compo‐
nent part
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
12 unless
- Cylinder head/cylinder block
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ fill with fresh coolant after replacing
13 - Engine oil cooler
14 - Non-return valve
❑ in the coolant hose, not visible from the outside
15 - Auxiliary heating
❑ only for vehicles fitted with optional equipment:

1.2 Draining and filling up coolant

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

1. Cooling system 99
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Draining

Note

♦ Collect drained coolant in a clean container for reuse or proper

disposal.
♦ Observe the disposal instructions.

WARNING

Hot steam may escape when the coolant expansion reservoir

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

– Open compensation bottle.

– Remove bottom noise insulation ⇒ Body Work ⇒ Rep. Gr.
50 .
– Place a catch pan - VAS 6208- under the radiator.

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Depending on the components which must be removed
⇒ page 98 , the coolant from the cooling system, from the
charge air cooling system or from both cooling systems must
be drained.
♦ If the coolant must be replaced, it should be drained from both
cooling systems.

Drain the coolant from the cooling system

– Disconnect plug -1- from coolant temperature sender at radi‐
ator outlet -G83- .
– Open spring strap clamp -arrow- and pull off the coolant hose
from the bottom radiator connection.

Note

Observe all the disposal instructions!

Drain the coolant from the charge air cooling system

100 Rep. Gr.19 - Cooling system

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Separate the coolant hose (quick coupling) -arrow- on the bot‐

tom connection fitting of the additional radiator for coolant of
charge air system.

Note

Observe all the disposal instructions!

Top up and bleed cooling system.

Select the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts or from the list of allowed coolant ad‐
ditives ⇒ Maintenance ; Octavia II .
– In a clean reservoir mix water with coolant in the correct ratio
⇒ Maintenance ; Octavia II .
– Reposition the removed coolant hose onto the relevant sup‐
port and connect the coolant temperature sender at radiator
outlet -G83 - .
– Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Switch off the air-conditioning system and the heating.

Caution

In order to secure the refrigerating capacity of the charge air

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

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

1. Cooling system 101

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Fill up the coolant slowly up to the top marking of the criss-

crossed field (max.) on the expansion reservoir.
– Seal expansion reservoir.
Vehicles without auxiliary heating.
– Start the engine and maintain the engine speed for about 3
minutes at approx. 2000 r.p.m.
– Run engine until radiator fan -V7- starts.
Vehicles with auxiliary heating.

Caution

The auxiliary heating must only be switched on, if the refriger‐

ant circuit is filled up - as described below.

– Connect diagnostic unit -VAS 5051- .

– Start the engine and maintain the engine revolutions for about
3 minutes at about 2000 r.p.m.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”, “18 - Auxiliary heating system” and “03 - Ac‐
tuator diagnosis”.
– Press the right arrow on the display so often until the coolant
shut-off valve of heating system - N279- is shown.
– Perform self-diagnosis of the coolant shut-off valve of heating
system -N279- and maintain the engine speed at approx. 2000
rpm for about 1 minute.
For all vehicles

WARNING

Hot steam may escape when the compensation bottle is

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

– Check the level of coolant when the expansion reservoir is

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

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

102 Rep. Gr.19 - Cooling system

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2 Parts of cooling system engine side

2.1 Coolant regulator - Summary of components

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

2.2 Removing and installing belt pulley for

coolant pump
Special tools and workshop equipment required
♦ Water pump wrench -MP 1-308 (V.A.G 1590) -

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

2. Parts of cooling system engine side 103

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Modify water pump wrench -MP 1-308-

– Because of modified fixing screws for the belt pulley of the
coolant pump, these 3 curvatures must be filed open.
-a- at least 1 mm
Removing
– Remove V-ribbed belt ⇒ page 26 .

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

Note

The bracket at the timing case only serves as transport security

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

– Release the screws for the belt pulley for coolant pump, to do
so counterhold with water pump wrench -V.A.G 1590- .
Install
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Installation is performed in the reverse order, pay attention
unless authorised by ŠKODAto theA. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
AUTO
following points: with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Tightening torque: 20 Nm

2.3 Removing and installing coolant pump

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

Note

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

rated from the coolant pump.
♦ If damage and leak present, replace coolant pump with gasket
completely.

– Drain the coolant from the cooling system ⇒ page 99 .

– Remove belt pulley for control pump ⇒ page 103 .

104 Rep. Gr.19 - Cooling system

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Disconnect the vacuum line -1- of the solenoid valve for cool‐
ant circuit -N492- from the coolant pump.
– Release screws -arrows- and remove coolant pump.
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ Tightening torque: 9 Nm
– Install belt pulley for coolant pump ⇒ page 103 .
– Top up and bleed cooling system ⇒ page 99 .

2.4 Removing and installing coolant recircu‐

lation pump -V50-
Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094) -
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-
Removing
– Remove bottom noise insulation ⇒ Body Work ⇒ Rep. Gr.
50 .
– Unplug connector -1-.
– Release screw -3- and remove coolant recirculation pump -
V50- from bracket.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Place a catch pan -with
VAS 6208-
respect under the
to the correctness engine.in this document. Copyright by ŠKODA AUTO A. S.�
of information

– Disconnect coolant hoses -2- with hose clamps -MP7-601-

and detach from the pump -V50- .

Install
♦ Tightening torque: 8 Nm.
Installation is performed in the reverse order, pay attention to the
following points:
– Inspect coolant level, if necessary top up cooling system and
bleed ⇒ page 99 .

2. Parts of cooling system engine side 105

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

3 Radiator and radiator fan

3.1 Parts of cooling system on the side next

to the body - Summary of components

Note

♦ This engine is fitted with a radiator combination of engine and

low temperature radiators for charge air system.
♦ Engine and low temperature radiators are arranged as one
component part.

1 - Radiator with low tempera‐

ture radiator for charge air sys‐
tem
❑ removing and installing
⇒ page 108
❑ after replacing fill entire
system with fresh cool‐
ant
2 - Coolant hose
❑ to exhaust gas turbo‐
charger
3 - Coolant hose
❑ to low temperature radi‐
ator for charge air sys‐
tem
4 - Coolant hose
❑ to exhaust gas turbo‐
charger
5 - Coolant hose
❑ to charge-air cooler in
the intake manifold
6 - Radiator fan -V7-
❑ with radiator fan control
unit -J293-
❑ removing and installing
⇒ page 107
7 - Coolant hose
❑ to coolant pipe below
the intake manifold
8 - Coolant hose
❑ to engine oil cooler
9 - Expansion reservoir
❑ with coolant shortage warning light sender -G32-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ authorised
unless Check by the cooling
ŠKODA AUTO system
A. S. ŠKODA forAUTO
tightness
A. S. does ⇒
notpage
guarantee109
or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
10 - Connector
11 - Screw cap
❑ Testing the pressure relief valve in the cap ⇒ page 109

106 Rep. Gr.19 - Cooling system

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

12 - 5 Nm
13 - Plastic inserts
❑ for fixing screws
14 - Support
15 - Coolant hose
❑ at coolant recirculation pump -V50-
16 - Fan shroud
❑ removing and installing ⇒ page 107
17 - 5 Nm
18 - 5 Nm
19 - Coolant hose
❑ at coolant regulator housing
20 - Coolant hose
❑ to heat exchanger for heating
21 - Connection fittings
❑ for top coolant hose
22 - Connection fittings
❑ for bottom coolant hose
23 - Retaining clip
❑ check tightness
24 - Coolant temperature sender at radiator outlet -G83-
25 - O-ring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ replace if damaged
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

26 - Bottom radiator bearing

27 - Top radiator bearing
28 - 5 Nm

3.2 Removing and installing fan shroud for

radiator fan -V7-
Removing
– Remove air filter ⇒ page 161 .
– Unscrew the top fixing screws of the fan shroud -arrows-.
– Remove bottom noise insulation ⇒ Body Work ⇒ Rep. Gr.
50 .
– Disconnect the plug connection -1- and unscrew the bottom
fixing screws of the fan shroud -arrows-.
– Take out fan shroud downwards.

3. Radiator and radiator fan 107

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Release screws -arrows- and remove radiator fan -V7 - .

Install
Installation is performed in the reverse order, pay attention to the
following points:
Tightening torques:
Component Nm
Radiator fan at fan shroud 5
Fan shroud at radiator 5

3.3 Removing and installing radiator

Special tools and workshop equipment required
♦ Catch pan , e.g. - VAS 6208-
♦ Pliers for spring strap clamps
Removing
– Drain coolant ⇒ page 99 .
– Removing fan shroud ⇒ page 107 .
– Remove top left coolant fitting fom radiator, to do so raise the
retaining clip -arrow-.
– Detach theProtected
connection fitting
by copyright. offorthe
Copying toporright
private coolant
commercial hose
purposes, for
in part or in whole, is not permitted
the low temperature
unless authorisedradiator.
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove front bumper ⇒ Body Work ⇒ Rep. Gr. 63 .
– Remove headlights ⇒ Electrical System ⇒ Rep. Gr. 94 .
Vehicles with air conditioning

WARNING

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

tem.
In order to avoid damage to the condenser as well as to the
refrigerant lines and hoses, ensure that the lines and hoses are
not over-tensioned, kinked or bent.

– Screw out the fixing screws -2- of the condenser.

108 Rep. Gr.19 - Cooling system

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Release the securing bolts -arrows- of the condenser.

Continued for all vehicles

– Release screws -1- at radiator.
– Swivel the radiator slightly backwards.
– Unhook radiator upwards and remove downwards.
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Top up and bleed cooling system ⇒ page 99 .
Tightening torques: ⇒ page 106

3.4 Checking the coolant system for leak‐

tightness
Special tools and workshop equipment required
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter for cooling system testingunless
device
Protected by, copyright.
e.g. -V.A.GCopying1274/8-
for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/9-
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Test condition
• Engine must be warm.
Test sequence

WARNING

Hot steam may escape when the coolant expansion reservoir

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

– Open compensation bottle.

3. Radiator and radiator fan 109

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Position the cooling system testing device -V.A.G 1274- with

adapter -V.A.G 1274/8 - on the coolant expansion reservoir.
– Using the hand pump of the testing device generate an over‐
pressure of approx. 0.1 MPa (1.0 bar).
If the pressure drops:
– Determine position of the leak and repair fault.
Testing the pressure relief valve in the cap

– Position the cooling system testing device -V.A.G 1274- with

adapter -V.A.G 1274/9 - on the cap.
– Operate the handpump.
• The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).
If the pressure relief valve does not open:
– Replace cap.

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

110 Rep. Gr.19 - Cooling system

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

20 – Fuel Supply
1 Fuel tank and fuel delivery unit

Note

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

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

1.1 Fuel tank - Summary of components

1 - Mounting part
2 - Screw cap
❑ replace if damaged
3 - Earth connection
❑ check for firm seating
4 - 11 Nm
5 - Wiring
6 - 25 Nm
❑ replace
7 - Fuel tank
❑ removing and installing
⇒ page 115
8 - Circlip
9 - Bracket for the exhaust sys‐
tem
10 - Support strap
❑ Check fitting position
11 - Cover plate
12 - Feed line
❑ to fuel rail
❑ check for firm seating
13 - Fuel filter
❑ removing and installing
⇒ page 113
14 - Vent line
❑ clipped in place on the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
side of the fuel tank unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ check for firm seating
15 - Sealing ring
❑ replace
❑ to be inserted dry into the opening of the fuel tank
❑ only moisten the inner seal of the flange with fuel for fitting purposes
16 - Fuel delivery unit
❑ removing and installing ⇒ page 117

1. Fuel tank and fuel delivery unit 111

 OCTAVIA II 2004 ➤
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❑ inspecting fuel pump ⇒ page 120
❑ note the installed position of the fuel tank ⇒ page 112
❑ with sender for fuel gauge display -G -
❑ Removing and installing the sender for fuel gauge display -G- ⇒ page 119
❑ Clean strainer if dirty
17 - Lock ring, 110 Nm
❑ check for firm seating
❑ use wrench -T30101 (3087)- for removing and installing
18 - Feed line
❑ black
❑ clipped in place on the side of the fuel tank
❑ check for firm seating
19 - Return-flow line
❑ blue
❑ clipped in place on the side of the fuel tank
❑ check for firm seating
20 - Fuel pump control unit -J538 -
❑ after replacing, adapt the engine control unit -J623 - to the fuel pump control unit -J538- ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051.
❑ check ⇒ Vehicle diagnosis, testing and information system VAS 5051
21 - Fuel tankbylid unitAUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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unless authorised ŠKODA
❑ with rubber bowl
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ removing and installing ⇒ Body Work ⇒ Rep. Gr. 55

Fitting location of the fuel delivery unit

The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-.

Note

♦ -Arrow- points in direction of travel.

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

112 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
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1.2 Fuel filter - Summary of components

1 - Fuel filter
❑ with installed pressure
limiting valve for fuel re‐
turn-flow line
Opening pressure:
0.60…0.68 MPa (6.0…
6.8 bar)
❑ do not interchange con‐
nections
❑ Fitting position
⇒ page 113
2 - Fuel feed line
❑ black
❑ from fuel tank
❑ press in securing ring in
order to unlock
3 - Fuel return-flow line
❑ blue
❑ to fuel tank
❑ press in securing ring in
order to unlock
4 - Fuel feed line
❑ black
❑ to the engine
❑ press in securing ring in
order to unlock
5 - 3 Nm
6 - Support
❑ for fuel filter
❑ attached to the fuel tank

Fitting position of the fuel filter

The pin -2- at the filter housing must engage in the recess -1- of
the bracket.
The direction of flow is marked by arrows.

1.3 Extract fuel from the fuel tank

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

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

♦ Adapter , e.g. -V.A.G 1318 -17-
♦ Measuring tool set , e.g. -V.A.G 1594 C-

1. Fuel tank and fuel delivery unit 113

 OCTAVIA II 2004 ➤
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♦ Battery
♦ Catch pan for fuel

Note

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

Work procedure

Note

♦ Safety precautions when working on the fuel supply system

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

– Switch off the ignition and all electrical components and take
out the ignition key.
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .
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– Unclip the cover -4- with the fuel unless
pump control unit -J538-
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
-1-.
Vehicles with auxiliary heating.
– Unplug the 2-pin plug of the dosing pump -V54- .
Continued for all vehicles

– Unplug the 5-pin plug -1- from the black feed line -2-.

Note

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

114 Rep. Gr.20 - Fuel Supply

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

1318/17- and fit this “drain pipe” thus prepared 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 -V.A.G 1594/C-
as follows:
Battery positive (+) to contact -1- of the fuel pump
Battery minus (-) to contact -5- of the fuel pump
The fuel pump runs and suctions off fuel.

WARNING

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

fuel tank, the fuel pump must not run unattended.

1.4 Removing and installing the fuel tank

Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. - V.A.G 1383 A-
Removing
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 113 .

Note

♦ Safety precautions when working on the fuel supply system

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

– Switch off the ignition and all electrical components and take
out the ignition key.
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .
– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.

Note

For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must also be disconnected.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Fuel tank and fuel delivery unit 115

 OCTAVIA II 2004 ➤
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– Unplug the 5-pin plug -1- from the fuel pump.

– Clean around the fuel filler neck.
– Unscrew right rear wheel.
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .

– Unscrew screws -1- for filler neck on the body.

– Unclip the electrical cable from the bracket -2- at the top and
bottom of the filler neck.

– Disconnect vent line -1- (white) and fuel feed line -2- (black)
at the connection point.

Note

♦ For vehicles with auxiliary heating, the fuel line of the dosing
pump -V54- must also be disconnected.
♦ Press in the securing ring in order to unlock the line.

– Remove middle silencer ⇒ page 180 .

– Release fixing screws -2- and -4- and remove the tensioning
strap.
– Support fuel tank using the engine/gearbox jack -V.A.G 1383
A- .
– Release fixing screws -1- and -3-.
– Slightly lower the fuel tank.

Note

The filler neck must be “extracted” between structure and rear

axle Lift down the fuel tank with a 2nd mechanic from engine/
gearbox jack -V.A.G 1383 A- .

Install
– Check if the earth lead shows traces of oxidation on both con‐
nections, remove if necessary.

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

116 Rep. Gr.20 - Fuel Supply

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Check fitting position of the earth lead -1-.

• The plug -1- on the metal plate ring -2- must be placed on
firmly.
• The contact tab -4- must be hung in the fuel tank -3- and se‐
cured with the spacer bush -5-.
– Guide the filler neck between rear axle and structure with the
assistance of a 2nd mechanic. Then position the fuel tank onto
the engine/gearbox jack -V.A.G 1383 A- .
Further installation occurs in reverse order. Pay attention to the
following:
♦ Lay the vent and fuel lines without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ Check earth connection of fuel tank/body at filler neck.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.

– Clip on cover -4- with fuel pump control unit -J538- -1-.
The arrow -2- on the cover points in direction of travel.

1.5 Removing and installing fuel delivery

unit
Special tools and workshop equipment required
♦ Key -T30101 (3087)-
Removing
• The fuel tank must not be more than 3/4 full.

Note

♦ If necessary, extract fuel from the fuel tank ⇒ page 113 .

♦ Observe the safety instructions before starting fitting work
⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 5 .

– Switch off the ignition and all electrical components and take
out the ignition key.
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Fuel tank and fuel delivery unit 117

 OCTAVIA II 2004 ➤
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– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.

Note

For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must be disconnected additionally.

– Unplug the 5-pin plug, the black feed line -1- and the blue re‐
turn-flow line -2-.

Note

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

♦ On vehicles with auxiliary heating the suction line for the dos‐
ing pump -V54- must be pulled out additionally (open lower
clamp).

– Open lock ring with the wrench -T30101 - .

Note

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

– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
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Installation occurs in reverse order. Pay attention tounless
the following:
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Insert the new dry gasket ring of the flange into the opening of
the fuel tank and only moisten the inside with fuel.
– Insert the fuel delivery unit into the fuel tank in such a way that
the float arm of the sender for the fuel gauge display -G- is not
bent.
– Press the closing flange downwards, install the lock ring and
connect the fuel lines.

118 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
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Note

♦ Pay attention to installed position of flange of fuel delivery unit:

The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-. -Arrow- points in direction of travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange the black feed line with the blue return-flow
line (arrows on the flange of the fuel delivery unit).
♦ Make sure the line connections and the 5-pin plug fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
and return-flow lines are also clipped on the fuel tank.

– Clip on cover -4- with fuel pump control unit -J538- -1-.
The arrow -2- on the cover points in direction of travel.

1.6 Removing and installing the sender for

fuel gauge display -G-
Removing
– Remove fuel delivery unit ⇒ page 117 .
– Unlock the catches -arrows- using a screwdriver and pull out
the sender for fuel gauge display - G- towards the top.

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

1. Fuel tank and fuel delivery unit 119

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– 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 117 .

1.7 Testing fuel pump

Special tools and workshop equipment required
♦ Key -T30101 (3087)-
♦ Pressure gauge , e.g. -V.A.G 1318- or pressure gauge , e.g. -
VAS 6550-
♦ Adapter , e.g. -V.A.G 1318/11-
♦ Hose adapter , e.g. -V.A.G 1318/16 -
♦ Adapter set , e.g. - V.A.G 1318/17A -
♦ Double connection piece , e.g. - V.A.G 1318/23 -
♦ Remote control , e.g. -V.A.G 1348/3A - with adapter cable ,
e.g. -V.A.G 1348/3-3 -
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Multimeter , e.g. -V.A.G 1715 -
♦ Adapter for measuring method/DSO (5-pin) , e.g. -VAS 5565-
♦ Vehicle diagnosis, measurement and information system -
VAS 505X-
♦ Measuring vessel

Note

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

V.A.G 1318/17- .
♦ The figures shown in the descriptions were not changed for
this reason. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

120 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Inspect proper operation and power supply ⇒ page 121

Check fuel pressure with pressure gauge -V.A.G 1318-
⇒ page 122
Check fuel pressure with pressure gauge -VAS 6550-
⇒ page 123
Check holding pressure with pressure gauge - V.A.G 1318 -
⇒ page 125
Check holding pressure with pressure gauge - VAS 6550-
⇒ page 127
Check fuel flow rate with pressure gauge -V.A.G 1318 -
⇒ page 128
Check fuel flow rate with pressure gauge -VAS 6550-
⇒ page 131
Check power consumption ⇒ page 134

1.7.1 Inspecting proper operation and power

supply
Test conditions
• Battery voltage at least 11.5 V.
• Fuel pump fuse O.K. ⇒ Current flow diagrams and Fitting lo‐
cations.
• Fuel pump control unit -J538- O.K.
Test sequence

Note

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

– Connect vehicle diagnosis, measurement and information

system -VAS 5051- .
– Switch on ignition.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”,“01 - Engine electronics” and “03 - Actuator di‐
agnosis”.
– On the display press the right arrow button up to the actuator
diagnosis of the fuel pump electronics.
• The fuel pump must now run slowly to the maximum speed.

Note

The fuel pump runs very quietly.

– Switch off ignition.

The fuel pump does not run:
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .

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121
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1. Fuel tank and fuel delivery unit
 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Disconnect plug -3- from fuel pump control unit -J538- .

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

1527B- between contact -1- and -6-.
• The LED must light up.
The LED does not light up:
– Determine and remove open circuit in the wiring according to
the current flow diagram ⇒ Current flow diagrams and Fitting
locations.
The LED lights up (power supply O.K.):
– Remove fuel delivery unit ⇒ page 117 .
– Check whether the electric wiring between the flange and fuel
pump is connected.
If there is no open circuit in the wiring:
– Fuel pump defective, replace the fuel delivery unit
⇒ page 117 .
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1.7.2 Check fuel pressure with pressure

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

gauge -V.A.G 1318 -

• The function of the fuel pump was checked ⇒ page 121 .

Note

♦ Safety precautions when working on the fuel supply system

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

– Remove the fuel feed line -2- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.

122 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Install the pressure gauge -V.A.G 1318 - with the adapter set
-V.A.G 1318/17A- instead of the fuel feed line.
– Open shut-off cock of the pressure gauge. The lever then
points in position -A-.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.4…0.7 MPa (4…7.0 bar)
If fuel line is o.k.:
– Test holding pressure ⇒ page 125 .
If the specified pressure is exceeded:
– Check the return line between the fuel filter and fuel pump for
kinks and blockages.
If no fault is found:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.
If the specified value is not reached:

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

Caution

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

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

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

vice. The pressure must rise to at least 0.6 MPa (6.0 bar). If
the 0.6 MPa (6.0 bar) is reached,
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or commercial purposes, in part or in whole, is not permitted
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If the pressure has risen:
– Fuel pump O.K., pressure limiting valve in the fuel filter defec‐
tive, replace the fuel filter.
If the pressure does not rise:
– Fuel pump defective, replace the fuel delivery unit
⇒ page 117 .

1.7.3 Check fuel pressure with pressure

gauge -VAS 6550 -
• The function of the fuel pump was checked ⇒ page 121 .

1. Fuel tank and fuel delivery unit 123

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Note

♦ Safety precautions when working on the fuel supply system

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

– Remove the fuel feed line -2- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.

– Connect the pressure gauge -VAS 6550- with adapter -VAS

6550/1- and -VAS 6550/2- to the fuel feed line.
– Make sure that the discharge cock is closed and the shut-off
cocks are opened.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.4…0.7 MPa (4…7.0 bar)
If fuel line is o.k.:
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– Test holding pressure ⇒ page
unless authorised 125 . AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
by ŠKODA
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
If the specified pressure is exceeded:
– Check the fuel return-flow line between the fuel filter and fuel
pump for kinks and blockages.
If no fault is found:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.
If the specified value is not reached:
– Check the fuel pressure before the fuel filter; to do so proceed
as follows:

– Disconnect fuel feed line -arrow- at fuel filter.

124 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Connect the pressure gauge -VAS 6550- with adapter -VAS

6550/1- and -VAS 6550/2- between the fuel filter and the fuel
feed line.
– Make sure that the discharge cock is closed and the shut-off
cocks are opened.
– Start engine and run in idle.

– Slowly close the shutoff cock -A-.

• The pressure must rise to at least 0.7 MPa (7.0 bar).
– If the 0.7 MPa (7.0 bar) is reached, immediately open the shut-
off cock again!
If the pressure has risen:
– Fuel pump O.K., pressure limiting valve in the fuel filter defec‐
tive, replace the fuel filter.
If the pressure does not rise:
– Fuel pump defective, replace fuel delivery unit ⇒ page 117 .

1.7.4 Checking holding pressure with pres‐

sure gauge -V.A.G 1318-
• Fuel pressure O.K. and pressure gauge - V.A.G 1318- con‐
nected in the engine compartment ⇒ page 122 .
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

♦ Safety precautions when working on the fuel supply system

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

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

1. Fuel tank and fuel delivery unit 125

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Immediately close the shutoff cock of the pressure measuring

device. The lever then points in the position -B-.
If the pressure again drops:
– Check the low pressure pipe to the high pressure pump for
tightness.
If no fault is found:
– Replace high pressure pump ⇒ page 164 .
Now the pressure does no longer drop:
– Check the fuel line to the fuel filter for tightness.
If the fuel line is not found to be faulty:

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

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

device after the pressure has built up.
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure drops:
– Non-return valve in the fuel pump faulty, replace fuel delivery
unit ⇒ page 117 .
If the pressure does not drop:by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Pressure limiting valve in the fuel filter defective, replace the
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fuel filter.

126 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.7.5 Checking holding pressure with pres‐

sure gauge -VAS 6550-
• Fuel pressure O.K. and pressure gauge - VAS 6550- connec‐
ted in the engine compartment ⇒ page 123 .

Note

♦ Safety precautions when working on the fuel supply system

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

– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.4…0.7 MPa (4…7.0 bar)
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
If the pressure still drops:
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.

– Immediately close the shut-off cock -B- of the pressure gauge

after the pressure has built up. The lever points at right angles
in the direction of flow of the fuel arrow.
Now the pressure does no longer drop:

Note

Search for leakage on the engine side. Repeat the holding pres‐
sure test. This time, however, the shut-off cock -A- is closed in
order to determine if in fact there is a leakage on the engine side.

– Check the low-pressure line to the high pressure pump for

tightness.
If no fault is found:
– Replace high pressure pump ⇒ page 164 .
If the pressure again drops:
Search for leakage on the fuel tank side, to do so proceed in the
following manner:
– Check the fuel line to the fuel filter for tightness.
If the fuel line is not found to be faulty:
– Check the pressure holding valve in the fuel delivery unit. To
do so proceed in the following manner:

1. Fuel tank and fuel delivery unit 127

 OCTAVIA II 2004 ➤
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– Disconnect fuel feed line -arrow- at fuel filter.

– Connect the pressure gauge -VAS 6550- with adapter -VAS

6550/1- and -VAS 6550/2- between the fuel filter and the fuel
feed line.
– Make sure that the discharge cock is closed and the shut-off
cocks are opened.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
• Specified value: 0.4…0.7 MPa (4…7.0 bar)

– After the pressure has built up, close the shut-off cock -A-.
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure drops:
– Non-return valve in the fuel pump faulty, replace fuel delivery
unit ⇒ page 117 .
If the pressure does not drop:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.

1.7.6 Checking fuel flow rate with pressure

gauge -V.A.G 1318 -

Note

♦ Safety precautions when working on the fuel supply system

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

– Switch off the ignition and all electrical components and take
out the ignition key.

128 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
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– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .

– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.
Vehicles with auxiliary heating.
– Unplug the 2-pin plug of the dosing pump -V54- .
Continued for all vehicles

– First of all check the plug -1- for correct fit. To do so, pull on
the plug without pressing the catch. If the plug connection was
not correctly positioned, this could cause a fault.
– Now unplug the plug -1-.
– Check the contacts at the plug and at the fuel delivery unit for
damage.

– Connect the adapter for measuring method/DSO (5-pin) -VAS

5565- to the plug connection and to the fuel delivery unit.
– Connect remote control -V.A.G 1348/3A- to adapter -VAS
5565- and to battery positive (+).

Note

This step is only intended to ensure that the fuel delivery unit runs
when the engine is switched off.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Remove the fuel feed line -2- (press in the securing ring to the
top) and catch the fuel which flows out with a cleaning cloth.

1. Fuel tank and fuel delivery unit 129

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

WARNING

Danger of liquid spraying out when opening the shut-off valve.

Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact. Hold the container in front of the free
connection to the pressure gauge.

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

points in the direction of flow -A-.
– Activate remote control -V.A.G 1348/3A - . While doing so,
slowly close the shut-off cock until the pressure gauge dis‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
plays 0.4 MPa (4 bar) overpressure. Now do
with respect to the correctness not make
of information any
in this document. Copyright by ŠKODA AUTO A. S.�
further changes to the position of the shut-off cock.
– Empty measuring glass.

– The fuel flow rate of the fuel delivery unit is dependent on the
battery voltage. For this reason, additionally connect the mul‐
timeter - V.A.G 1715- to the outgoing circuits -1 and 5- of the
adapter for measuring method/DSO (5-pin) -VAS 5565- .
– Activate remote control for 30 seconds while measuring the
battery voltage.

– Compare the fuel rate with the specified value.

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

130 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Disconnect the feed hose -1- from the fuel filter inlet.
– Connect pressure gauge -V.A.G 1318- with the adapter set -
V.A.G 1318/17A- to the hose.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
– Replace fuel filter.
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and inspect the filter strainer for
soiling.
If you have still not found any fault up to this stage:
– Replacing fuel delivery unit ⇒ page 117 .
If the required fuel delivery volume has been achieved, but a fault
is still suspected in the fuel supply system (e.g. intermittent break‐
down of the fuel supply):
– Check power consumption of the fuel delivery unit
⇒ page 134 .

1.7.7 Checking fuel flow rate with pressure

gauge -VAS 6550 -
– Switch off the ignition and all electrical components and take
out the ignition key.
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .
– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.

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

– First of all check the plug -1- for correct fit. To do so, pull on
the plug without pressing the catch. If the plug connection was
not correctly positioned, this could cause a fault.
– Now unplug the plug -1-.
– Check the contacts at the plug and at the fuel delivery unit for
damage.

1. Fuel tank and fuel delivery unit 131

 OCTAVIA II 2004 ➤
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– Connect the adapter for measuring method/DSO (5-pin) -VAS

5565- to the plug connection and to the fuel delivery unit.
– Connect remote control -V.A.G 1348/3A- to adapter -VAS
5565- and to battery positive (+).

Note

This step is only intended to ensure that the fuel delivery unit runs
when the engine is switched off.

– Disconnect the fuel feed line -2- (press in the securing ring to
the top) and catch the fuel which flows out with a cleaning
cloth.

– Connect the pressure gauge -VAS 6550- with the adapter -

VAS 6550/2- to the fuel feed line. Hold the adapter -VAS
6550/1- in a measuring vessel.
– Make sure that the discharge cock is closed and the shut-off
cocks are opened.

WARNING

Danger of liquid spraying out when opening the shut-off valve.

Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact with fuel. Hold the container in front of
the free connection to the pressure gauge.

– Activate remote control -V.A.G 1348/3A - . While

Protected by copyright. doing
Copying this,or commercial purposes, in part or in whole, is not permitted
for private
slowly close the shut-off cock -arrow- until the
unless authorised pressure
by ŠKODA AUTO gauge
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
displays 0.4 MPa (4 bar) overpressure. Now do not make any
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

further changes to the position of the shut-off cock.

– Empty measuring glass.

132 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– The fuel flow rate of the fuel pump is dependent on the battery
voltage. For this reason, additionally connect the multimeter -
V.A.G 1715- to the outgoing circuits -1 and 5- of the adapter
for measuring method/DSO (5-pin) -VAS 5565- .
– Activate remote control for 30 seconds while measuring the
battery voltage.

– Compare the fuel rate with the specified value.

*) minimum flow rate 1 cm3/30 s
**) Voltage at fuel delivery unit when engine not running and de‐
livery unit operating.
Read out examples:
During the test a voltage of 10.5 V was measured. Thus a mini‐
mum flow rate of 580 cm3/30 s is obtained.
If the minimum delivery volume is not reached:
– Check the fuel lines for possible restrictions (kinks) or block‐
ing.
If no fault is found:
– Take cap off fuel filler neck and repeat the test.
If the fuel flow rate is now reached:
– Check the ventilation of the fuel tank.
If the minimum flow rate is again not reached:
– Check the fuel filter, to do so proceed as follows:

– Disconnect fuel feed line -arrow- at fuel filter.

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

1. Fuel tank and fuel delivery unit 133

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Connect the pressure gauge -VAS 6550- with the adapter -

VAS 6550/1- to the fuel feed line. Hold the adapter -VAS
6550/2- in a measuring vessel.
– Make sure that the discharge cock is closed and the shut-off
cocks are opened.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
– Replace fuel filter.
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and inspect filter strainer for soiling.
If you have still not found any fault up to this stage:
– Replacing fuel delivery unit ⇒ page 117 .
If the required fuel flow rate has been achieved, but a fault is still
suspected in the fuel supply system (e.g. intermittent breakdown
of the fuel supply):
– Check power consumption of the fuel pump ⇒ page 134 .

1.7.8 Check power consumption

– Fold up rear seat.
– Unclip the cover -4- with the fuel pump control unit -J538-
-1-.

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

urement and information system - VAS 5051- on the line -B-
to contact 1 of the 5-pin plug.
If the current probe cannot be connected on the line -B- to contact
1 of the 5-pin plug because of the length of the insulation:

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

134 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Connect the adapter for measuring method/DSO (5-pin) -VAS

5565- to the plug connection and to the fuel delivery unit.
– Connect the current probe -A- to the red cable - with the let‐
tering “current probe” - of the adapter for measuring method/
DSO (5-pin) -VAS 5565- .
Continued for all
– Start engine and run in idle.
– Measure voltage consumption of the fuel pump.
Specified value: max. 9 A

Note

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

If the specfied current uptake is exceeded:

– Fuel pump defective, replace the fuel delivery unit
⇒ page 117 .

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

1. Fuel tank and fuel delivery unit 135

 OCTAVIA II 2004 ➤
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2 Electronic Engine Power Control

(Electronic throttle)

2.1 Accelerator pedal module - Summary of components

1 - Connector
❑ black, 6 pin
2 - Accelerator pedal position
sender -G79- with accelerator
pedal position sender 2 -G185-
❑ not adjustable
❑ the accelerator pedal
sender transmits the
driver's instructions to
the engine control unit
❑ -A- openings for release
tool
❑ removing and installing
⇒ page 136
❑ when replacing, the en‐
gine control unit must be
adapted ⇒ Vehicle diag‐
nosis, testing and infor‐
mation system VAS
5051 on vehicles with
automatic gearbox
3 - 10 Nm
4 - Cap

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

2.2 Removing and installing accelerator

pedal module
Special tools and workshop equipment required
♦ Release tool -T10238- (for left-hand drive vehicle)
♦ Release tool -T10240- (for right-hand drive vehicle)

136 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
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Removing
– Remove cover for the steering column -arrows-.
– Lever out the cap with a screwdriver ( ⇒ page 136 , Pos. 4).
– Unscrew fixing screw ( ⇒ page 136 , Pos. 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.
– Disconnect connector at accelerator pedal module
⇒ page 138 .
Install

– Mount plug -2- at accelerator pedal module -5- ⇒ page 138 .

The connector must lock audibly.
– Push accelerator pedal module onto the retaining bolts -6-.
– Insert the centering pin -7- into the hole on the underbody.
– Fasten accelerator pedal module with screw -3- (10 Nm) and
fit on cap -4-.
– Re-install the cover for the steering column.
– If the accelerator pedal module was replaced, an adaptation
of the engine control unit has to be performed on vehicles with
automatic gearbox ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051.

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

2. Electronic Engine Power Control (Electronic throttle) 137

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2.2.1 Disconnect connector for accelerator

pedal module and fit on

Note

The plugs for the accelerator pedal module which are inserted,
must be disconnected and fit on in a different manner.

Disconnect connector 1K0 973 706

– Slightly press the piston slide valve -A- (grey) in
-direction of arrow 1- and push it up to the stop in
-direction of arrow 2-.
– Hold the piston slide valve in this position and disconnect the
socket housing -B- upwards in -direction of arrow 3-.
The piston slide valve -A- remains in the bottom position.

Fit on connector 1K0 973 706

– Push the socket housing -B- down in -direction of arrow- until
the housing can be heard to lock in place.
The piston slide valve -A- moves automatically upwards.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.

Disconnect connector 8K0 973 706

– Pull piston slide valve -A- (red) upwards in
-direction of arrow 1- up to the stop.
– Press the piston slide valve in -direction of arrow 2- and dis‐
connect the socket housing -B- upwards in
-direction of arrow 3-.
The piston slide valve -A- remains in the top position.

Fit on connector 8K0 973 706

– Push the socket housing -B- down in -direction of arrow 1- up
to the stop.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Slightly press the piston slide valve in -direction of arrow 2-
and push it down in -direction of arrow 3-.
The piston slide valve -A- can only be pushed down if the
socket housing was pushed “up to the stop”.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.

138 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
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3 Activated charcoal container system

3.1 Activated charcoal container system - Summary of components

Note

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

1 - Activated charcoal filter

❑ Fitting position: in right
of engine compartment
❑ if the catch peg is un‐
locked, the activated
charcoal filter can be re‐
moved from the holder
❑ Checking the fuel tank
venting ⇒ page 139
2 - Pressure holding valve with
connection hose
3 - 8 Nm
4 - Vent line
❑ unless
check for firm seating
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ from fuel tank
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5 - 8 Nm
6 - Support
❑ for activated charcoal fil‐
ter
7 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
❑ Valve closed when igni‐
tion is switched off
❑ valve is actuated
(pulsed) by engine con‐
trol unit when engine is
warm
8 - Connecting hose
❑ To intake manifold
❑ check for firm seating
9 - Air admission fitting

3.2 Checking the fuel tank venting

Special tools and workshop equipment required
♦ Hand vacuum pump , e.g. -VAS 6213-

3. Activated charcoal container system 139

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

♦ Adapter set , e.g. - V.A.G 1318/17A-

♦ Adapter , e.g. -V.A.G 1318/20-1-

Note

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

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

Test condition
• The ignition must be switched off.
Test sequence
– Detach vent line -1-. To do so press in the securing ring.

– Slide the control ring -1- on the hand vacuum pump -VAS
6213- in -the direction of arrow B- up to the stop.
– Operate the hand vacuum pump -VAS 6213 - several times.

– Then connect the hand vacuum pump - VAS 6213- -1- on the
vent line -2- as shown in the figure.
– Operate the hand vacuum pump -VAS 6213- several times.
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• No vacuum should build up. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
If a vacuum builds up.
– Check the air admission fitting on the activated charcoal filter
for dirt and clean as required.
If no vacuum builds up:

140 Rep. Gr.20 - Fuel Supply

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Shut off air admission fitting -arrow- and once again operate
the vacuum pump several times.
• A vacuum should build up.
If no vacuum builds up:
– Replace activated charcoal filter.

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

3. Activated charcoal container system 141

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

21 – Turbocharging
1 Exhaust gas turbocharger

Note

Observe the general notes for assembly work on the charge air
system ⇒ page 7 .

1.1 Exhaust turbocharger - Summary of

components
Part I. ⇒ page 143
Part II. ⇒ page 144

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

142 Rep. Gr.21 - Turbocharging

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.1.1 Part I.

1 - Activated charcoal filter sol‐

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

Note

The exhaust turbocharger can only

be replaced complete with exhaust
manifold and charge pressure reg‐
ulator -V465- .
❑ removing and installing
⇒ page 144
7 - O-ring
❑ replace
8 - Connector

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

1. Exhaust gas turbocharger 143

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.1.2 Part Il.

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

Note

The exhaust turbocharger can only

be replaced complete with exhaust
manifold and charge pressure reg‐
ulator -V465- .
❑ removing and installing
⇒ page 144
5 - O-ring
❑ replace
6 - Oil return pipe
7 - 8 Nm
8 - 10 Nm
9 - Heat shield
10 - 8 Nm
11 - Coolant pipes
12 - 8 Nm
13 - 18 Nm
❑ observe the order of
tightening up
⇒ page 144
❑ Tightening torque of pin screw in cylinder head: 18 Nm (insert oiled)
14 - Sealing ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ replace with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

15 - Hollow screw
❑ Tightening torque: 20 Nm
16 - Oil feed pipe
17 - O-ring
❑ replace
18 - 8 Nm

1.2 Removing and installing exhaust gas

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

144 Rep. Gr.21 - Turbocharging

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

♦ Hot screw paste -G 052 112 A3-

Caution

In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change the engine oil and replace the oil filter
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
charge-air routing must be cleaned and the charge air cooler
must be replaced.

Note

♦ Observe the rules for cleanliness ⇒ page 3 .

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

Removing
– Disconnect battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Remove V-ribbed belt ⇒ page 26 .
– Drain coolant ⇒ page 99 .
– Detach hoses -1- and plugs -2- from exhaust gas turbocharg‐
er.
– Release screws -1- and remove retaining clip.

– Disconnect plug -2- at charge pressure sender -G31- with in‐

take air temperature sender 2 -G299 - .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338- and then from the exhaust gas turbocharger.
– byFold
Protected open
copyright. theforcover
Copying -4-
private or and release
commercial purposes,the fixing
in part screw.
or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Exhaust gas turbocharger 145

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

Note

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

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

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

– Remove holder -1-.

– Unscrew fixing nuts -arrows- at exhaust gas turbocharger.
– Remove bottom noise insulation ⇒ Body Work ⇒ Rep. Gr.
50 .
– Separate plug connections -1-.

– Unscrew fixing nuts -2-.

– Release the fixing screws of the bracket -3- and remove the
catalytic converter downwards.

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

146 Rep. Gr.21 - Turbocharging

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

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

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

1. Exhaust gas turbocharger 147

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

Note

♦ After installing the turbocharger, run engine at idling speed for

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

Tightening torques:
Exhaust gas turbocharger - Summary of components part I.
⇒ page 143
Exhaust gas turbocharger - Summary of components part lI.
⇒ pageProtected
144 by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Catalyticwith
converter
respect to theand component
correctness parts
of information in this-document.
Summary of compo‐
Copyright by ŠKODA AUTO A. S.�
nents ⇒ page 178
– Attach AC generator ⇒ Electrical System; Rep. Gr. 27 ; re‐
moving and installing AC generator .
– Install the V-ribbed belt ⇒ page 26 .
– Top up coolant ⇒ page 99 .
– Connect battery ⇒ Electrical System ⇒ Rep. Gr. 27 .

148 Rep. Gr.21 - Turbocharging

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2 Charge air system with exhaust gas

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

2.1 Charge air system - Summary of com‐

ponents

Note

♦ This engine is fitted with a radiator combination of engine and

low temperature radiators for charge air system.
♦ Engine and low temperature radiators are arranged as one
component part.

1 - Radiator with low tempera‐

ture radiator for charge air sys‐
tem
❑ removing and installing
⇒ page 108
2 - Intake manifold
❑ removing and installing
⇒ page 159
3 - Seal
❑ pay attention to correct
seating when installing
the charge air cooler
4 - Gasket
❑ replace if damaged
5 - Charge air cooler
❑ removing and installing
⇒ page 150
6 - Coolant hose
❑ to exhaust gas turbo‐
charger
7 - 7 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ when installing
with respect tofirst
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
tighten evenly by hand,
then tighten crosswise
from the inside to the
outside to the recom‐
mended tightening tor‐
que
8 - Coolant hose
❑ to the expansion reser‐
voir
9 - Hose clamp
❑ attached to the timing case
10 - Coolant hose
❑ to exhaust gas turbocharger

2. Charge air system with exhaust gas turbocharger 149

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

11 - Coolant recirculation pump -V50-

❑ removing and installing ⇒ page 105
12 - 8 Nm
13 - Support
14 - Connector
15 - 10 Nm
16 - Coolant hose
❑ to engine oil cooler
17 - Coolant pipe
❑ attached to the oil pan
18 - 8 Nm
19 - Bottom coolant hose
20 - Connection fittings
21 - O-ring
❑ replace if damaged

2.2 Removing and installing charge air cool‐

er
Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094) -
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Observe the general notes for assembly work on the charge air
system ⇒ page 7 .

150 Rep. Gr.21 - Turbocharging

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

Note

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

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

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

Note

Do not tilt the charge-air cooler when installing.

– First tighten the fixing screws uniformly crosswise until the

screw head is positioned.
– Tighten the fixing screws crosswise to 7 Nm.

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

2. Charge air system with exhaust gas turbocharger 151

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

24 – Fuel Formation, Injection

1 Fitting location of the injection system

1 - Oil pressure switch -F1-

❑ in the left cylinder head
❑ check ⇒ page 96
2 - Solenoid valve for coolant
circuit -N492-
3 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
4 - Intake manifold pressure
sender -G71- and intake air
temperature sender -G42-
5 - Engine control unit -J623-
❑ removing and installing
⇒ page 176
6 - Control valve for fuel pres‐
sure -N276-
7 - Knock sensor 1 -G61-
❑ at rear cylinder block
❑ 20 Nm
8 - Hall sender -G40-
9 - Ignition transformer -N152-
♦ D ignition transformer = ig‐
nition cable cyl. 1
♦ B ignition transformer = ig‐
nition cable cyl. 2
♦ C ignition transformer = ig‐
nition cable cyl. 3
♦ A ignition transformer = ig‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
nition cable cyl. 4 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

10 - Injection valves
❑ Injection valve for cylin‐
der 1 -N30-
❑ Injection valve for cylinder 2 -N31-
❑ Injection valve for cylinder 3 -N32-
❑ Injection valve for cylinder 4 -N33-
❑ with Teflon gasket ring and supporting washer
❑ after removing the injection valve, the Teflon gasket ring and the supporting washer must be replaced
⇒ page 169
❑ Removing and installing the injection valves ⇒ page 167
11 - Charge pressure sender -G31- with intake air temperature sender 2 -G299-
12 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 157
❑ clean ⇒ page 159
❑ in case of replacement, erase initialisation values and adapt the engine control unit -J623- ⇒ Vehicle
diagnosis, testing and information system VAS 5051.

152 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

13 - Fuel pressure sender -G247-

❑ check ⇒ page 173
14 - Engine speed sender -G28-
❑ removing and installing ⇒ page 184
15 - Coolant temperature sender -G62-
16 - Coolant temperature sender at radiator outlet -G83-
17 - Charge pressure regulator -V465 -

Note

The charge pressure regulator -

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

18 - Lambda probe downstream of catalytic converter -G130- and heater of lambda probe 1 downstream of
catalytic converter -Z29-
19 - Spark plugs, 25 Nm
20 - lambda probe -G39- and heating for lambda probe -Z19-
21 - High pressure pump with fuel pressure regulating valve -N276-
❑ removing and installing ⇒ page 164

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

1. Fitting location of the injection system 153

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2 Intake manifold and fuel distributor

2.1 Intake manifold - Summary of compo‐

nents
Part I. ⇒ page 155
Part II. ⇒ page 156

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

154 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2.1.1 Part I.

1 - Connecting hose
❑ at camshaft housing
2 - Connector
❑ for intake manifold pres‐
sure sender -G71-
3 - Connector
❑ for solenoid valve for
coolant pump control
4 - 10 Nm
5 - Non-return valve
❑ for crankcase ventila‐
tion
6 - Connecting hose
❑ to exhaust gas turbo‐
charger
7 - O-ring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ replace unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
8 - Intake manifold
❑ removing and installing
⇒ page 159
❑ with intake manifold
pressure sender -G71-
♦ The intake manifold pres‐
sure sender -G71- is at‐
tached to the intake mani‐
fold only using a plastic clip.
♦ If the plastic clip is dam‐
aged, attach the sender to
the intake manifold with
screws ⇒ Electronic Cata‐
logue of Original Parts .
Tightening torque: 3 Nm.
9 - Connecting hose
❑ to the coolant pump
10 - Solenoid valve for coolant circuit -N492-
11 - Connection fittings
12 - Clamp
13 - Fuel hose
❑ to high pressure pump
14 - Solenoid valve 1 for activated charcoal filter -N80-
15 - Connecting hose
❑ to the activated charcoal filter system
16 - Connecting hose
17 - Connector
❑ for throttle valve control unit -J338-

2. Intake manifold and fuel distributor 155

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

2.1.2 Part II.

1 - Pressure pipe
2 - 7 Nm
3 - Retaining clip
4 - Fuel pressure sender -
G247- , 22 Nm
❑ Check fuel pressure
sender -G247 -
⇒ page 173
5 - Fuel distributor
6 - 20 Nm
7 - 30 Nm
8 - 25 Nm
9 - 25 Nm
10 - O-ring
❑ replace
11 - Spring element
❑ replace each time the
bottom part of the intake
manifold is removed
❑ check for correct seat‐
ing on injector
12 - Injection valve for cylinder
1 -N30-
❑ Injection valve for cylin‐
der 2 -N31-
❑ Injection valve for cylin‐
der 3 -N32-
❑ Injection valve for cylin‐
der 4 -N33-
❑ with Teflon gasket ring
and supporting washer
❑ after removing the injection valve, the Teflon gasket ring and the supporting washer must be replaced
⇒ page 169
❑ Removing and installing the injection valves ⇒ page 167
13 - Cylinder head
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ removing and installing ⇒ page 80
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

14 - 20 Nm
15 - Intake manifold
❑ removing and installing ⇒ page 159
❑ with intake manifold pressure sender -G71-
♦ The intake manifold pressure sender -G71- is attached to the intake manifold only using a plastic clip.
♦ If the plastic clip is damaged, attach the sender to the intake manifold with screws ⇒ Electronic Catalogue
of Original Parts . Tightening torque: 3 Nm.

156 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

16 - Gasket
❑ replace
17 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 157
❑ clean ⇒ page 159
❑ in case of replacement, erase initialisation values and adapt the engine control unit -J623- ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
18 - Adapter
19 - O-ring
❑ replace
20 - 7 Nm
21 - O-ring
❑ replace
22 - Charge pressure sender -G31- with intake air temperature sender 2 -G299-
23 - 5 Nm

2.2 Removing and installing the throttle

valve control unit -J338 -

Note

♦ Safety precautions when working on the fuel supply system

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

Removing
– Release screws -1- and remove retaining clip.
– Disconnect plug -2- at charge pressure sender -G31- with in‐
take air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.

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

2. Intake manifold and fuel distributor 157

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

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

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

– Tighten fixing screws -2- to 7 Nm.

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

Note

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

pressure pipe moisten slightly with engine oil.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Fit the pressure pipe -3- at the unless
turbocharger.
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Press the pressure pipe -3- onto the throttle valve control unit.
• During this procedure the retaining clips must click audibly into
place.
– Tighten screws -1- of retaining clip to 7 Nm.
– Connect plug -2- at charge pressure sender -G31- with intake
air temperature sender 2 -G299 - .
If a new throttle valve control unit was installed:
– Erase initialisation values and adapt the engine control unit -
J623- to the throttle valve control unit ⇒ Vehicle diagnosis,
testing and information system VAS 5051.

158 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

2.3 Clean throttle valve control unit -J338-

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .
♦ If a new engine control unit -J623- is fitted, the throttle valve
control unit must be adapted. The adaptation must only be
carried out with a new or cleaned throttle valve control unit,
because dirt/carbon deposits in the end stop of the throttle
valve can lead to incorrect adaptation values.
♦ The throttle valve support must not be scratched when clean‐
ing.

– Remove the throttle valve control unit ⇒ page 157 .

– Open the throttle valve manually and block the throttle valve
in the opened position with a suitable object (e.g. plastic or
wooden wedge)-arrow-.

WARNING

Acetone is easily inflammable. Observe the accident preven‐

tion regulations and the safety instructions when handling
easily inflammable fluids. Do not use compressed air when
cleaning the throttle valve. Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Thoroughly
unless authorised clean
by ŠKODA AUTO the
A. S. throttle
ŠKODA AUTO valve support,
A. S. does in orparticular
not guarantee the
accept any liability
area
with respect to theof the closed
correctness throttle
of information valve
in this -arrows-,
document. Copyright with commercially
by ŠKODA AUTO A. S.�

available acetone and a paint brush.

– Wipe the throttle valve support with a fluffy cloth.
– Let the acetone dry off completely and re-install the cleaned
throttle valve control unit.

2.4 Removing and installing intake manifold

Special tools and workshop equipment required
♦ Pliers for spring strap clamps
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-

2. Intake manifold and fuel distributor 159

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Removing

Note

♦ Safety precautions when working on the fuel supply system

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

– Switch off the ignition and all electrical components and take
out the ignition key.
– Remove the throttle valve control unit ⇒ page 157 .
– Disconnect the fuel intake hose -9- and the plug from the ac‐
tivated charcoal filter system solenoid valve 1 -N80- and re‐
move the valve from the intake manifold.
– Disconnect plugs -1- and -4-.
– Release the fixing screws -7- and carefully place the ignition
transformer -N152- -6- onto the cylinder head cover.
– Detach connecting hose -5- from intake manifold.
– Disconnect the vacuum line of the solenoid valve for coolant
circuit -N492- -2- from the coolant pump.
– Pinch off coolant hoses for charge-air cooler with hose clamps
-MP7-601- .
– Slacken the clamps -3- and detach the coolant hoses from the
charge-air cooler.

– Slacken the fixing screws -arrows- crosswise and carefully re‐

move the intake manifold upwards.

Note

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

Install
Installation is carried out in the reverse order.
♦ Tightening torque of fixing screws for intake manifold: 20 Nm
♦ Tightening torque and tightening sequence for charge-air cool‐
er: ⇒ page 149
– Check, top up and bleed cooling system ⇒ page 99 .

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

160 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

3 Air filter

3.1 Air filter - Summary of components

Removing and installing air filter ⇒ page 161 .

1 - Air filter top part

2 - 2 Nm
3 - 2 Nm
4 - Support
5 - Filter element
6 - Rubber-metal bearing, 8
Nm
❑ with captive screw
7 - Seals
❑ replace if damaged
8 - Air filter bottom part
❑ removing and installing
⇒ page 161
9 - Rubber bearing
10 - Inlet connection
❑ with cover
11 - 2 Nm
12 - Intake air duct
13 - 2 Nm
14 - Spring strap clamp
❑ use spring strap clips ,
e.g. -VAS 6340- for re‐
moving and installing -
VAS 6340-
15 - Suction hose
16 - Vacuum hose
❑ replace if damaged
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ to cylinder head cover unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3.2 Removing and installing air filter

Special tools and workshop equipment required
♦ Pliers for spring strap clamps

3. Air filter 161

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

Removing
– Press the catches -arrows- and take the cover -1- from the inlet
connection.
– Pull the inlet connection out of the intake air duct.
– Remove the spring strap clamp -2- with the intake hose from
the exhaust gas turbocharger.

– Detach vacuum hose -1- from air filter housing.

– Unscrew the fixing screw -2- and pull the air filter housing to‐
wards the top from the bearing bolts -3-.
Install
Installation is carried out in the reverse order. Pay attention to the
following:

– Press the air filter housing from the top onto the bearing bolts
-3-.
– Tighten fixing screw -2- to 8 Nm.
– Fit the vacuum hose -1- at the connection fitting of the air filter
housing.

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

162 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

4 High pressure pump

4.1 High pressure pump - Summary of com‐

ponents

WARNING

The injection system consists of a high pressure part (maxi‐

mum 12 MPa/120 bar) and a low pressure part (approx. 0.6
MPa/6 bar).
Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

1 - 15 Nm
2 - Fuel hose
❑ Low pressure
❑ with spring strap clamp
3 - Spring strap clamp
4 - Union nut, 25 Nm
❑ hold the connection fit‐
ting on the high pres‐
sure pump for loosening
5 - Union nut, 25 Nm
❑ hold the connection fit‐
ting on the high pres‐
sure pump for loosening
6 - High pressure pump with
fuel pressure regulating valve -
N276-
❑ removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ page 164 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

7 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
8 - Roller tappet
❑ before fitting moisten
lightly with clean engine
oil
9 - Connector

4. High pressure pump 163

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

4.2 Removing and installing the high pres‐

sure pump
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
Condition
• The engine must be cold.
Removing

Note

♦ Safety precautions when working on the fuel supply system

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

– Switch off the ignition and all electrical components and take
out the ignition key.

WARNING

The injection system consists of a high pressure part (maxi‐

mum 12 MPa/120 bar) and a low pressure part (approx. 0.6
MPa/6 bar).
Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

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

164 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Disconnect the plug -1- and the fuel feed line -2- from the high
pressure pump.

Note

Collect the fuel which flows out with a cleaning cloth.

– Slacken the union nuts -3- at the high pressure line.

Note

Hold the screwed connections at the high pressure pump and at

the fuel distributor when slackening the union nuts with a wrench.

– Uniformly release the fixing screws -4- and remove the high
pressure pump with roller tappet from the cylinder head cover.
Install

Note

♦ Moisten the roller tappet of the high pressure pump with clean
engine oil.
♦ Always replace the O-ring of the high pressure pump.

– Slide the roller tappet -1- into the camshaft housing.

– Insert a new, oiled O-ring -2- into the slot of the high pressure
pump -3-.
– Position the high pressure pump -3- on the cylinder head cov‐
er.

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

4. High pressure pump 165

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– First of all screw in the fixing screws -4- sufficiently until the
bolt heads are positioned on the flange.
– Then tighten the fixing screws -4- evenly.
Tightening torque: 20 Nm
– Screw on the union nuts of the high pressure line -3- by hand.

Note

Hold the screwed connections at the high pressure pump and at

the bottom part of intake manifold/fuel distributor when tightening
the union nuts with a wrench.

– Tighten the union nuts -3- at the high pressure line to 25 Nm.
– Attach the fuel feed line -2- and the plug -1- on the high pres‐
sure pump.
The further assembly is carried out in reverse order to disassem‐
bly.

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

166 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

5 Injection valves

5.1 Removing and installing injection valves

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 5 .
♦ Observe the safety instructions before starting fitting work
⇒ page 5 .

Note

The Teflon gasket ring on the injection valve must be replaced

each time after removing the injection valve ⇒ page 169 .

Special tools and workshop equipment required

♦ Set of tools -T10133-
Removing
– Release screws -1- and remove retaining clip.
– Disconnect plug -2- at charge pressure sender -G31- with in‐
take air temperature sender 2 -G299- .
– Release the catches in -direction of arrow- and detach the
pressure pipe -3- first of all from the throttle valve control unit
-J338 - and then from the exhaust gas turbocharger.
– Remove the high pressure pump ⇒ page 164 .

– Release the fixing screws -arrows- and carefully remove the

fuel distributor from the injection valves.

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

5. Injection valves 167

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Press the O-ring upwards by hand as shown and remove it

from the injection valve.
– Screw the striking hammer -T10133/3- with the extractor -
T10133/15- .

– Then insert the extractor -T10133/15- into the groove -arrow-

on the injection valve.

– Pull out the injection valve withbycareful

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

– Thoroughly clean the holes of the injection valves in the cyl‐

inder head with the nylon brush -T10133/4- .
– Check the supporting washer made of plastic for damage, re‐
place if necessary ⇒ page 169 .

168 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Replace the spring element -arrow- as well as the Teflon gas‐

ket ring each time after removing the injection valves
⇒ page 169 .
– Replace O-rings between injection valve and bottom part of
the intake manifold/fuel distributor and moisten lightly with
clean engine oil.

Note

♦ The Teflon gasket ring of the injection valve must neither be

oiled nor greased.
♦ The injection valve must insert easily, if necessary wait until
the gasket ring has been drawn together sufficiently.

– Press the injection valve -1- by hand up to the stop into the
hole of the cylinder head. The injection valve should be press‐
ed evenly into the countersink -2- on the cylinder head.

Note

♦ The injection valve must never rest against the countersink

edge on the cylinder head -arrow A-, but it must always be
pressed evenly into the countersink -2- on the cylinder head.
♦ After installing, carry out a visual inspection of the fitting loca‐
tion of the injection valve.

Further installation occurs in a similar way in reverse order to re‐

moval.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
5.2 Replace Teflon gasket ring and support‐
ing washer at injection valve

Note

♦ Safety precautions when working on the fuel supply system

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

Special tools and workshop equipment required

♦ Set of tools -T10133-
Work procedure
Replace Teflon gasket ring
– Remove injection valves ⇒ page 167 .
– Carefully clean the injection valve.

5. Injection valves 169

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Carefully cut open the gasket ring with a knife as shown

-arrow-. Absolutely try to avoid the contact of the knife blade
with the valve body.
– Remove the old gasket ring and clean the gasket ring nut in
the area of the gasket ring -arrow-. Remove the existing de‐
posits (carbon deposits) with a wire brush.

– Fit a new gasket ring -1- onto the assembly cone -T10133/5- .
Slightly push the gasket ring with the assembly sleeve -
T10133/6- (knurling points to the gasket ring -1-) as far as
possible onto the assembly cone -T10133/5 - .

– Turn the assembly sleeve -T10133/6 - around (now the knurl‐

ing points away from the gasket ring), and push the gasket ring
-1- up to the end onto the assembly cone -T10133/5 - .
– Now position the assembly cone -T10133/5- with the gasket
ring from the front onto the injection valve. Push the gasket
ring with the assembly sleeve -T10133/6- further onto the in‐
jection valve.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

The gasket ring is not yet seated in its groove.

– Remove the assembly sleeve -T10133/6 - and the assembly
cone -T10133/5- .
– Push the gasket ring by hand into the annular groove.
– Fit the spacer sleeve -T10133/11 - onto the valve body.

170 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Now press the calibration sleeve - T10133/7- via the gasket

ring up to the stop at the spacer sleeve -T10133/11- .
– Pull off again the calibration sleeve -T10133/7- .

– Now press the calibration sleeve - T10133/8- via the gasket

ring up to the stop at the spacer sleeve -T10133/11- .
– Pull off again the calibration sleeve -T10133/8- .
Now the Teflon gasket ring has its correct fitting dimension.
Replace supporting washer

– Remove O-ring -3-.

– Cut open the supporting washer -2- with a small side cutter
and take it off.
– Pull off the spring element at the injection valve -1- and instead
push on the lock washer -T10133/12 - .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Mount a new supporting washer -1- on the assembly cone -
T10133/13- and fit it onto the injection valve as shown.
– Push the supporting washer -1- with the calibration sleeve -
T10133/17- (knurled side points to the injection valve) up to
the first nut -arrow- onto the injection valve.

5. Injection valves 171

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Now turn the calibration sleeve -T10133/17 - around (knurled

side points away from the injection valve). Push the calibration
sleeve via the supporting washer -1- in -direction of arrow- up
to the stop on the lock washer -T10133/12- .
– Pull off again the calibration sleeve -T10133/17- .
Now the supporting washer has its correct fitting dimension.

– Now fit a new spring element -1- for the lock washer -
T10133/12 - and push a new O-ring -3- in front of the support‐
ing washer -2-.

Note

The Teflon gasket ring -arrow- must not be oiled when installing
the injection valve.

– Install injection valves ⇒ page 167 .

Further installation occurs in reverse order to removal.

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

172 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

6 Testing components

6.1 Check fuel pressure sender -G247-

Special tools and workshop equipment required
♦ Assembly tool -T10118-
♦ Open ring spanner with 3/8" drive, wrench size 27 mm
♦ Pressure sensor tester , e.g. -VAS 6394- (includes digital
manometer -VAS 6394/1- )
♦ Adapter , e.g. -VAS 6394/3-
♦ Test adapter , e.g. -VAS 5570-
♦ Vehicle diagnosis, measurement and information system -
VAS 5051-

WARNING

The injection system consists

Protected of a Copying
by copyright. high pressure part (maxi‐
for private or commercial purposes, in part or in whole, is not permitted
mum 12 MPa/120 bar)unless and a low
authorised pressure
by ŠKODA AUTO A.part (approx.
S. ŠKODA AUTO A.0.6
S. does not guarantee or accept any liability
MPa/6 bar). with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Before opening the high pressure area, e.g. removing the high
pressure pump, the fuel distributor, the injection valves, the fuel
pipes or the fuel pressure sender -G247- , the fuel pressure in
the high pressure area with a remaining pressure of approx.
0.6 MPa (6 bar) must be reduced. The procedure for this is
described in the chapter “release pressure in the high pressure
area of the fuel system” ⇒ page 4 .

Work procedure
– Disconnect the plug -1- and remove the fuel pressure sender
-G247- -1- with the wrench.

– Moisten the sealing cone of the adapter -VAS 6294/3- with

clean engine oil and screw it into the fuel distributor.
Tightening torque: 22 Nm

6. Testing components 173

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Unscrew the screw plug -2- and screw the fuel pressure send‐
er -G247- into the tester -VAS 6394/1- .
Tightening torque: 22 Nm
– Screw the pressure line -1- of the digital manometer -VAS
6394/1- by hand onto the adapter -VAS 6394/3- .

– Connect the test adapter -VAS 5570- to the fuel pressure

sender -G247- -1- and to the plug.

– Switch on the tester -VAS 6394/1 - , for this step, briefly press
the button -A- once.

Note

♦ If the button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If the tester -VAS 6394/1- does not indicate 0 MPa (0 bar),
carry out a zero point of the balance by means of the ⇒ op‐
erating instructions .

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

174 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Connect the vehicle diagnosis, measurement and information

system -VAS 5051- -1- to the diagnostic connection.
– Switch on ignition.
– On the display press consecutively the following buttons:
Vehicle self-diagnosis

Self-diagnosis ?

01 - Engine Electronics ?

011 - Measured values ?

– Select measured value block 1 4 0 and confirm with the key

Q.

The actual value which is transmitted to the vehicle by the fuel

pressure sender -G247- is shown in the display field 3.
– Start engine.
– Compare the displayed pressure on the digital manometer -
VAS 6394/1- with the actual value on the vehicle diagnosis,
measurement and information system -VAS 5051- .
• The pressures may deviate maximum 0.5 MPa (5 bar) from
one another.
If the deviation is greater than 0.5 MPa (5 bar):
– Perform a vehicle diagnosis, measurement and information
system -VAS 5051- of the guided function “remove high fuel
pressure”.
– Replace fuel pressure sender -G247- .
– Repeat the test with the new fuel pressure sender -G247- and
compare both measured values.
If the measured values do not correspond again:
– Perform a cable testing ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.

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

6. Testing components 175

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

7 Engine control unit

7.1 Removing and installing engine control

unit
Special tools and workshop equipment required
♦ Body saw, e.g. -V.A.G 1523 A-

Note

♦ In order to be able to unplug the plugs from the control unit,

the control unit must always be removed.
♦ If the engine control unit is replaced, connect the vehicle di‐
agnosis, measurement and information system - VAS 5051-
and carry out the function “replace engine control unit”.

Removing
– Switch off ignition.
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Open retaining clip -arrow- and remove the engine control unit
-J623 - .
Vehicles with protective cover

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

176 Rep. Gr.24 - Fuel Formation, Injection

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

– Cut with body saw a slot for the cross-head screwdriver in the
heads of the pull-off screws -3 and 4-.

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 the screws and remove the protective cover for plug
connections -2 and 5-.
Continued for all vehicles
– Disconnect both plugs at engine control unit and unplug.
Install
– Connect both plugs and lock.
Vehicles with protective cover
– Fasten protective cover with new pull-off screws.
– Tighten pull-off screws evenly until the screw heads are pulled
off.
Continued for all vehicles

– Push engine control unit into the bracket and lock with retain‐
ingProtected
clip -arrow-.
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Install
withwater
respect tobox cover ⇒of information
the correctness Body Work in this ⇒ Rep.Copyright
document. Gr. 66 by .ŠKODA AUTO A. S.�

7. Engine control unit 177

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

26 – Exhaust System
1 Removing and installing parts of the
exhaust system

1.1 Catalytic converter and component parts - Summary of components

1 - Lambda probe -G39- , 50

Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3- ;
the paste must not get
into the slots of the
probe body
2 - 23 Nm
❑ replace
❑ Coat pin screws of ex‐
haust manifold with ex‐
haust gas turbocharger
using hot bolt paste -G
052 112 A3-
❑ pay attention to mount‐
ing instructions and or‐
der for tightening
⇒ page 179
3 - Catalytic converter with ex‐
haust pipe
❑ pay attention to mount‐
ing instructions and or‐
der for tightening
⇒ page 179
4 - Gasket
❑ replace
5 - Gasket
❑ replace
6 - Intermediate pipe
7 - Double clamp, 23 Nm
❑ Tighten bolted connections evenly
8 - 25 Nm
❑ replace
9 - Exhaust pipe
❑ with decoupling element
❑ do not twist decoupling element more than 10° - risk of damage
❑ secure the decoupling element with the transport device -T10403- against overtensioning and flexion
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

178 Rep. Gr.26 - Exhaust System

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

10 - Hanger
11 - 25 Nm
12 - 25 Nm
❑ replace
13 - Gasket
❑ replace
14 - 25 Nm
❑ replace
❑ Coat pin screws of exhaust pipe with hot bolt paste -G 052 112 A3-
15 - 20 Nm
16 - Support
17 - Exhaust gas turbocharger
❑ removing and installing ⇒ page 144
❑ The exhaust gas turbocharger with charge pressure regulator -V465- and exhaust manifold can only be
replaced together
18 - Heat shield
19 - 10 Nm
❑ first of all screw in all fixing screws by hand when installing
20 - Heat shield
21 - 10 Nm
22 - 10 Nm
23 - Lambda probe downstream of catalytic converter -G130- , 50 Nm
❑ the thread of new lambda probes must be coated with assembly paste
❑ for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3- ; the paste must not
get into the slots of the probe body
24 - 10 Nm
25 - 25 Nm

Catalytic converter with exhaust pipe - mounting instructions and

sequence for tightening
Tighten nuts and screws in 4 stages:
Stage Screws/nuts Tightening torque
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
1. -Arrows-
unless authorised by ŠKODA AUTO Tighten nuts
A. S. ŠKODA AUTObyA. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
hand up to contact
surface.
2. -1- 25 Nm
3. -2- 25 Nm
4. -Arrows- 23 Nm

1. Removing and installing parts of the exhaust system 179

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

1.2 Middle and rear silencer - Summary of components

1 - From pre-exhaust pipe with

catalytic converter
2 - Hanger
❑ replace if damaged
3 - Retaining strap
❑ replace if damaged
4 - 23 Nm
5 - Double clamp
❑ Tighten bolted connec‐
tions evenly
❑ Fitting position
⇒ page 180
6 - 23 Nm
7 - Rear silencer
❑ for first equipment build‐
ing unit with middle si‐
lencer; replace individu‐
ally when carrying out
repairs
❑ Align exhaust system
free of stress
⇒ page 181
❑ Separate the exhaust
system ⇒ page 180
8 - Hanger
❑ replace if damaged
9 - Tunnel bridge
10 - The middle silencer
❑ for first equipment build‐
ing unit with rear silenc‐
er; replace individually
when carrying out repairs
❑ Align exhaust system free of stress ⇒ page 181
❑ Separate the exhaust system ⇒ page 180

1.3 Replacing middle or rear silencer

Special tools and workshop equipment required
♦ Body saw e.g. -V.A.G 1523 A -
♦ Protective goggles

Note

♦ For individually replacing the front or rear silencer, a separa‐

tion point isProtected
provided in theCopying
by copyright. connecting
for privatepipe.
or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ The separation
withpoint
respect is marked
to the byofindentations
correctness information in this on the circum‐
document. Copyright by ŠKODA AUTO A. S.�
ference of the exhaust pipe.

180 Rep. Gr.26 - Exhaust System

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

WARNING

In order to avoid injuries because of metal swarfs, wear safety

goggles and safety clothing.

– Separate exhaust pipe at right angles at the separation point

-arrow 2- with body saw.
– When installing, position double clamp -4- at the side markings
-arrow 1- and -arrow 3-.

– Turn the double clamp in such a way that the ends of the
screws -arrow- do not protrude beyond the bottom edge of the
double clamp.
– Align the rear silencer horizontally and tighten the double
clamp to 23 Nm.
– Align exhaust system in cold condition free of stress
⇒ page 181 .

1.4 Aligning exhaust system free of stress

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
• Theunless
exhaust system is aligned when cold.
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Slacken the nuts at the double clamp -1- and align the inter‐
mediate pipe -2- (-arrow- points in direction of travel).
-a- = 5 mm

1. Removing and installing parts of the exhaust system 181

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

The fixing screws must be located on the right. The screws must
not protrude beyond the bottom edge of the double clamp
-arrow-.
– Tighten the front nut by hand.

– Push the exhaust system so far forward until the dimension

-a- of 7...9 mm is achieved between hanger/body and hanger/
middle silencer.
– Tighten bolted connections of the double clamp evenly to 23
Nm.

Align exhaust tailpipes

– Align rear silencer in such a way that there is an equal distance
-a- right and left between bumper opening and exhaust tail‐
pipe.
– For centering the exhaust tailpipe, if necessary loosen the
suspension of the rear silencer.

1.5 Inspecting the exhaust system for leak‐

tightness
– Start engine and run in idle.
– Seal off exhaust tailpipes for the duration of the leak check
(e.g. with cloth or plug).
– Inspect connection points of cylinder head/exhaust manifold,
exhaust gas turbocharger/exhaust pipe etc. for tightness by
listening and visual inspection.
– Eliminate any leak found.

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

182 Rep. Gr.26 - Exhaust System

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

28 – Ignition system
1 Ignition system

1.1 Ignition system - Summary of components

1 - Cable guide
2 - 8 Nm
3 - Cover
4 - Connector
5 - Hall sender -G40-
6 - 10 Nm
7 - Ignition cable with spark
plug connector
❑ Remove the spark plug
connector from the
spark plugs using the
extractor -T10112 A- .
♦ D ignition transformer = ig‐
nition cable cyl. 1
♦ B ignition transformer = ig‐
nition cable cyl. 2
♦ C ignition transformer = ig‐
nition cable cyl. 3
♦ A ignition transformer = ig‐
nition cable cyl. 4
8 - Spark plug, 25 Nm

Note

♦ When installing new spark plugs,

the spark plug connectors must
be regreased with lubricating
paste -G 052 141 A2- . In doing
so, the sealing hose of the spark
plug connector does not stick to
the spark plug. The lubricating
paste must spread over the
spark plug when fitting on the
spark plug connector
⇒ page 184 .
♦ The new spark plug cables are
supplied greased.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
9 - Knock sensor 1 -G61-
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ at rear cylinder block
❑ 20 Nm
10 - Connector
11 - 20 Nm
❑ The tightening torque influences the knock sensor function

1. Ignition system 183

 OCTAVIA II 2004 ➤
1,2/77 kW TSI engine - Edition 12.09

12 - Ignition transformer -N152-

♦ D ignition transformer = ignition cable cyl. 1
♦ B ignition transformer = ignition cable cyl. 2
♦ C ignition transformer = ignition cable cyl. 3
♦ A ignition transformer = ignition cable cyl. 4
13 - Engine speed sender -G28-
❑ removing and installing ⇒ page 184
14 - 5 Nm
15 - 7 Nm

Grease spark plug connector

Note

The new spark plug cables are supplied greased.

– Apply a thin bead of lubricating paste G 052 141 A2 all around

the sealing hose of the spark plug connector -arrow-. The bead
must be 1...2 mm thick.

1.2 Removing and installing engine speed

sender -G28-
Special tools and workshop equipment required
♦ Socket insert -T10370-
Removing
– Disconnect plug -arrow- from engine speed sender -G28- .
– Unscrew fixing screw for engine speed sender -G28- with
socket insert -T10370 - .
– Remove engine speed sender -G28- from cylinder block.
Install
– Install engine speed sender -G28- and tighten the fixing screw
to 5 Nm.
The further assembly is carried out in reverse order to disassem‐
bly.

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184
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Rep. Gr.28 - Ignition system