Service

Workshop Manual
SUPERB 2002 ➤
Inspection and Maintenance
Edition 10.01

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
02 - Inspection and Maintenance
 SUPERB 2002 ➤
Inspection and Maintenance - Edition 10.01

Contents

02 - Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Storage of ŠKODA new vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Vehicle handover from stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Additional customer information regarding inspection and maintenance . . . . . . . . . . . . . . 3
2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Pre-Delivery Inspection -PDI- (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Pre-sales Inspection - (the Czech Republic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Delivery Inspection (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Engine fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Visual inspection of engine for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Replace engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Replacing the timing belt or also the tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Inspecting timing belt for camshaft drive for wear and running (petrol engine) . . . . . . . . . . 16
3.7 Inspecting engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.9 Inspecting antifreeze protection, replenishing coolant additive if necessary . . . . . . . . . . . . 18
3.10 Inspecting coolant level (volume) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.11 Ribbed V-belt: Inspect condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.12 Routing of V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.13 Replace spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.14 Replace air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.15 Replacing the fuel filter (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.16 Draining the fuel filter (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Gearbox/Final drive: Check the oil level and top it if necessary . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Inspecting ATF level, if necessary topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 Inspecting thickness of front and rear brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Inspecting brake system for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3 Changing brake fluid (every 2 years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4 Inspecting the brake fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5 Track rod ends: Inspect play, correct attachment and joint boots . . . . . . . . . . . . . . . . . . . . 37
5.6 Inspecting tyres (including spare wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.7 Inspecting the tyre tread depth (including spare wheel) and entering . . . . . . . . . . . . . . . . 38
5.8 Tightening wheel bolts to specific torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.9 Inspecting the tyre inflation pressure (including spare wheel) and correcting the tyre inflation
pressure if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.10 Power-assisted steering: Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1 Power windows: Inspect positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.2 Electrical components: Check for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Battery: Testing no-load voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 Battery: Inspecting electrolyte level, topping up with distilled water if necessary . . . . . . . . 41
6.5 Radio: Check for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.6 Setting clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.7 Connect diagnostic unit and interrogate fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents i
 SUPERB 2002 ➤
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6.8 Resetting service interval display (SID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.9 Select the language in the dash panel insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.10 Changing the code of the service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.11 Inspecting headlight beam setting and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . 42
6.12 Setting the main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.13 Replacing the own power supply for the alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.14 Climatronic: Adjust the temperature to 22 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.15 Check proper operation of key switch for front passenger airbag deactivation . . . . . . . . . . 44
7 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Airbag units: Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Check underbody protection and body paintwork for damage . . . . . . . . . . . . . . . . . . . . . . 45
7.3 Inspecting plenum chamber and water drain openings for dirt, cleaning if necessary . . . . 46
7.4 Windscreen wiper/washer system: Check for proper operation . . . . . . . . . . . . . . . . . . . . . . 46
7.5 Sun roof: Cleaning and greasing runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.6 Door locks, locking buttons, child safety locks: Check for proper operation . . . . . . . . . . . . 47
7.7 Replace the dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.8 Sticking the vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8 Exhaust-emission Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Exhaust-Emission Analysis on Models with Fuel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 Test Values for Exhaust-Emission Analysis on Petrol Engines . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Exhaust-Emission Analysis on Models with Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 51
8.4 Test Values for Exhaust-Emission Analysis on Diesel Engines . . . . . . . . . . . . . . . . . . . . . . 52
9 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.1 Tow starting/Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.2 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.3 Raising the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ii Contents
 SUPERB 2002 ➤
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02 – Inspection and Maintenance

1 General points

1.1 Vehicle identification data

The vehicle identification number (chassis number) is type-
punched into the bulkhead on the engine compartment side of the
plenum chamber.

The vehicle identification number (chassis number) can also be

found at the bottom left of the front window corner.

1.1.1 Vehicle identification number

1 - Manufacturer's world code
2 - Model and version:
B - SUPERB Elegance
C - SUPERB Comfort
D - SUPERB Classic
3 - Engine type:
E - 2.0/85 kW/Fuel engine
L - 1.8 / 110 kW / petrol engine
T - 2.8 / 140 kW / petrol engine and 2.8 / 142 kW / petrol engine
S - 1.9 TDI / 74 kW / Diesel engine
U - 1.9 TDI / 96 kW / diesel engine
V - 2.5 TDI / 114 kW / diesel engine
G - 2.5 TDI / 120 kW / diesel engine
4 - Airbag System:
2 - 2 Front + 2 side airbags
6 - 2 front + 2 side airbags + 2 head airbags

1. General points 1
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5 - Model:
3U - SUPERB
6 - Internal code
7 - Model year:
2 - 2002
3 - 2003
4 - 2004
8 - Manufacturing plant:
9 - Kvasiny
N - Kvasiny
9 - Vehicle body number

1.1.2 Type plate

The type plate is attached to the left wheel house at the front.

1.1.3 Vehicle data sticker

The vehicle data sticker is located at the rear left on the floor of
the boot.

1.2 Storage of ŠKODA new vehicles

Notes on storage of new vehicles ⇒ Technical Service Hand‐
book .

1.3 Vehicle handover from stock

– Before starting a stock vehicle, carry out a Pre-sales Inspec‐
tion.
– If the vehicle has been in stock for more than 6 months, replace
the brake fluid.
– Inspect the electrolyte level of the battery and top up, if nec‐
essary.
– Before the vehicle is sold, the recharging table must be re‐
moved from the battery.
– If the battery is more than 52 weeks old or has been recharged
more than twice, it must be replaced with a new battery.

2 Rep. Gr.02 - Inspection and Maintenance

 SUPERB 2002 ➤
Inspection and Maintenance - Edition 10.01

1.4 Additional customer information regard‐

ing inspection and maintenance

1.4.1 Information regarding the use of vehi‐

cles under “severe conditions”:
– The service advisor should always point out to the customer
that the inspection intervals are based on normal operating
conditions.
– Under “severe conditions” the inspection intervals must be
shortened.
“Severe conditions” exist, for instance, if the vehicle is operated
continuously in one or several of the conditions stated below:
♦ Towing a trailer or when fitted with a roof rack.
♦ Operated on dusty, poor, muddy roads or roads treated with
road salt.
♦ Driven for short distances and at ambient temperatures below
freezing point.
– If one or several of these “severe conditions” exists, please
advise your customer whether it is necessary to have work
carried out between the normal service intervals, such as:
♦ Changing the engine oil before the normal specified interval.
♦ Cleaning or replacing the air filter element in the air filter hous‐
ing.

1.4.2 General information:

– Inform your customer about this so that he has each inspection
carried out at the right time and none are forgetten.
– Draw the attention of your customer to the sticker affixed to
the side of the dash panel (driver's side) indicating when the
next service event is due.
– In addition, enter in the boxes provided in the pages of the
Service Schedule when the next service or other additional
operations should be carried out.
– An oil change service should be undertaken at the prescribed
interval ⇒ Chapter 02-2 .
– Advise your customer that to maintain the vehicle in a safe and
roadworthy condition and also to ensure that the warranty
terms are complied with, it is essential to have the additional
following operations carried out in addition to the annual in‐
spections:
♦ Every 2 years change the brake fluid (have this done if possi‐
ble during an inspection service).

1.4.3 Extended service intervals

Service interval extension has been introduced for all SUPERB
vehicles.
Vehicles with extended service intervals are identified by the ab‐
breviation WIV (which stands for Extended service interval).

1. General points 3
 SUPERB 2002 ➤
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The service interval type is set at the factory and is visible on the
sticker in the luggage compartment. The set service interval is
stated by the PR outfitting number on the vehicle data carrier
-arrow-.
QG1 - vehicles with variable service intervals - an inspection
service1) according to the indicator
QG2 - vehicles with a fixed oil change limit - an inspection service
1)
every 15 000 km or once a year2)
1) An inspection service can include the inspection “Oil change service” or “In‐
spection service” ⇒ Chapter 02-2 .
2) The 7500 km interval applies for diesel operation with high sulphur content -
this does not apply for the Czech Republic ⇒ Chapter 02-2 .

The period between inspection services (vehicles QG1) is de‐

pendent on the loading on the engine when the vehicle is oper‐
ating. The period will also be calculated after which the inspection
service on the vehicle should be undertaken.

Enter the next service date on the “Next Service” sticker and affix
sticker to the side of the dash panel (on the driver's side).
Service interval display

4 Rep. Gr.02 - Inspection and Maintenance

 SUPERB 2002 ➤
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If the point in time when a service is due is reached then the let‐
tering SERVICE will appear in the daily driven kilometres field
below the speedometer after switching on the ignition -2-; this in‐
dicator also blinks after starting up the engine for a further 20
seconds or so and there may also appear the lettering SERVICE
NOW -1- in the language which has been set.
A service event due is already displayed 1500 km prior to the
event.
Certain data values are evaluated for vehicles with petrol engines
in order to calculate the service intervals including: Distance driv‐
en, petrol consumption and oil temperature. This allows determi‐
nation of the degree of wear or the thermal loading on the engine
oil. This data is used to aid determination of the service interval.
Certain data values are evaluated for vehicles with diesel engines
in order to calculate the service intervals including: Engine speed,
thermal loading on the engine oil and distance driven. This data
is used to aid determination of the service interval.

Note

In case of use of oil which does not conform to the VW standard

503 00 (in case of petrol engines), the VW standard 506 00 or the
VW standard 506 01 (in case of diesel engines) (for diesel en‐
gines TDI PD with unit injector and for V6 TDI only engine oil VW
506 01), then the dash panel insert for Service intervals must be
coded with a fixed limit for the oil change ⇒ Chap. 02-6 .

Engine oil level sensor

The sensor records the engine oil temperature and engine oil lev‐
el. Topping up with engine oil is recognised by the warning lamp
on the dash panel insert.
The brake lining wear indicator
Brake lining wear is recognised by the warning lamp on the dash
panel insert. This warning lamp flashes when the brake linings
need replacing. The condition of the brake linings is measured at
the brake valves of the front axle.
Engine oils with a high operating life
Oils for petrol engines have the VW standard 503 00.
Oils for diesel engines have the VW standard 506 00 or VW 506
01 (for diesel engines TDI PD with unit injector and for V6 TDI
only engine oil VW 506 01).

Note

Vehicles are already filled at the factory with oils which conform
to the VW 503 00 (petrol engines), VW 506 00 or VW 506 01
(diesel engines) (for diesel engines TDI PD with unit injector and
for V6 TDI only engine oil VW 506 01). The dash panel insert
should be coded with a fixed oil change service interval ⇒ Chapter
02-6 if the vehicle is filled with an oil which does not conform with
the above-mentioned VW standards.

1. General points 5
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2 Inspection

2.1 Pre-Delivery Inspection -PDI- (Export)

The operations marked with * apply to all countries; other opera‐
tions are applicable to certain countries only!
Compare as-delivered condition of vehicle with order form Chapter
♦ Engine fitted

♦ Type plate in engine compartment

♦ Vehicle data sticker (compare with stamped identification number)

♦ Colour of paintwork, badges, inscriptions

♦ Seats (cover, colour) interior trim (colour)

♦ Radio, speakers, aerial

♦ Central locking system, anti-theft alarm system

♦ Wheels, tyres

♦ Sun roof

♦ Check the vehicle log book for completion: Owner's manual and Service Schedule
(correct language and date of issue), short instructions, technical data, breakdown
assistance, other instructions (Radio, ...) - everything in a leather bag.

♦ Other equipment (all equipment fitted in proper condition)

Inspections and operations to be completed

* Inspect for transport damage (bodywork, paintwork, upholstery, interior trim, carpeting, 02-5, 02-7
footmats, coverings, wheels and tyres)
Vehicle (exterior)
– Check that all car keys and key number fobs have been provided; check that the
sticker with the key numbers and code number for the electronic immobiliser is com‐
plete and legible
– Check proper operation of all locks (side doors, door handles, release, child safety 02-7
locks, safety lock, engine hood, protective gloves, luggage compartment lid, fuel tank
cap) and keys (including spare keys).
– Check operation of the anti-theft alarm system
Engine compartment (from above)
– Check battery no-load voltage and recharge if necessary 02-6
– Check tight connection of electric cables and plug connections (in particular battery
cables)
– Inspect engine, gearbox, cooling system, brake system and fuel system for leaks 02-3
– Check the engine oil level (to be in-between the markings on the dipstick) 02-3
– Check the oil level in the power-assisted steering system 02-5
– Check the brake fluid level (at MAX marking) 02-5
– Check the coolant level (in-between marking), for special equipment antifreeze down 02-3
to -35 °C
– Check the fluid level in the windshield washer reservoir (about 0.5 litre), with antifreeze
protection
Vehicle interior
– Check proper operation of seat belts, seat belt height adjuster, power windows and 02-6
sun roof

6 Rep. Gr.02 - Inspection and Maintenance

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– Check the car tool kit, spare wheel and accessories, that they have all been supplied
and are properly secured
Underside of vehicle (on lift platform)
– Inspect underbody/underbody protection for damage 02-7
– Check engine, gearbox, final drive, joint boots and brake system for leaks and dam‐ 02-3, 02-5
age.

– Check for proper routing of the brake hoses and brake lines and fuel lines, including
ventilation lines of the fuel system.

2.2 Pre-sales Inspection - (the Czech Republic)

Compare as-delivered condition of vehicle with order form Chapter
♦ Engine fitted

♦ Type plate in engine compartment

♦ Vehicle data sticker (compare with stamped identification number)

♦ Colour of paintwork, badges, inscriptions

♦ Seats (cover, colour) interior trim (colour)

♦ Radio, speakers, aerial

♦ Central locking system, anti-theft alarm system

♦ Wheels, tyres

♦ Sun roof

♦ Check the vehicle log book for completion: Owner's manual and Service Schedule
(correct language and date of issue), short instructions, technical data, breakdown
assistance, list of Dealers, other instructions (Radio, ... ) - everything in a leather bag.

♦ Other equipment (all equipment fitted in proper condition)

♦ Vehicles in stock for more than 6 months: Change brake fluid 02-5

Inspections and operations to be completed

Vehicle (exterior)
– Check plastic and rubber parts for cleanliness and damage
– Inspect bodywork and paintwork for damage 02-7
– Check that all car keys and key number fobs have been provided; check that the
sticker with the key numbers and code number for the electronic immobiliser is com‐
plete and legible
– Inspect proper operation of door handles, door locks, child safety locks, door contact 02-7
switches and all locks and keys (including spare keys), doors, luggage compartment
lid, fuel filler cap, bonnet lock
– Check operation of the anti-theft alarm system
– Check the wheel bolts for the specified torque (steel and light alloy wheels 120 Nm), 02-5
fit wheel caps
– Check the tyre inflation pressure (including spare wheel), if necessary correct the tyre 02-5
inflation pressure, fit valve caps
– Fit roof aerial
– Mount the damping base under the vehicle identification plate
Engine compartment (from above)
– Check battery no-load voltage; recharge if necessary 02-6

2. Inspection 7
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– Check tight connection of electric cables and plug connections (in particular battery
cables)
– Inspect engine, gearbox, cooling system, brake system and fuel system for leaks 02-3, 02-5
– Check the engine oil level (to be in-between the markings on the dipstick) 02-3
– Check the oil level in the power-assisted steering system 02-5
– Check the brake fluid level (at “MAX” marking) 02-5
– Check the coolant level (in-between markings) 02-3
– Fill up liquid in washer reservoir and ensure that there is antifreeze protection if there
is any risk of frost
– Check the function of all washer nozzles (windscreen, headlights) and adjust if nec‐ 02-7
essary
Vehicle interior
– Inspect all switches, all electrical components, all gauges/indicators and controls 02-6
– Inspect upholstery, interior trim, carpeting and footmats for cleanliness and damage
– Check proper operation of key switch for front passenger airbag “ON/OFF” and posi‐ 02-6
tion to “ON”
– Set the temperature to 22 °C (Climatronic) 02-6
– Inspect proper operation of radio, set clock 02-6
– Reset service interval display 02-6
– Adjust the power window lifter 02-6
– Fit net in luggage compartment (if available)
– Inspect proper operation of seat belts and seat belt height adjustment, power windows
and sun roof
– Check the car tool kit, spare wheel and accessories, that they have all been supplied
and are properly secured
– Fit enclosed carpets in the vehicle
Underside of vehicle (on lift platform)
– Inspect underbody (underbody protection for damage) 02-7
– Inspect for leaks and damage: Engine, gearbox, final drive, steering, brake system, 02-3, 02-5
axles, joint boots. Check proper routing of the brake hoses and brake lines, fuel lines
including ventilation of the fuel system
– Inspect tyres and wheels for damage 02-5
– Perform a test drive 02-9
Concluding operations
– Interrogate fault memory of all systems, if necessary erase 02-6
– Remove protective covering
– Remove recharging table (if affixed)
– Complete the service schedule, affix the vehicle data sticker in the Service Schedule 02-7
to the floor of the luggage compartment next to the spare wheel, complete the “Next
Service Date” sticker and affix to the side of the dash panel on the driver's side, hand
the card “Škoda Assistance” to the customer
– Final inspection to ensure proper condition for handover to the customer

2.3 Delivery Inspection (Export)

Inspections and operations to be completed Chapter
Vehicle (exterior)
– Check plastic and rubber parts for cleanliness and damage
– Inspect bodywork and paintwork for damage 02-7

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– Check the function of all locks (side doors, door grip, unlocking, child safety locks, 02-7
bonnet lock, glove compartment, luggage compartment lid, fuel tank lid) and all other
keys (including the spare key).
– Check operation of the anti-theft alarm system
– Tighten the wheel bolts to the specified torque, attach the wheel caps 02-5
– Check the tyre inflation pressure (including spare wheel), if necessary correct the tyre 02-5
inflation pressure, fit valve caps
– Vehicles in stock for more than 6 months: Change brake fluid 02-5
– Fit roof aerial
– Mount the damping base under the vehicle identification plate
Engine compartment (from above)
– Check battery no-load voltage and recharge if necessary 02-6
– Check tight connection of electric cables and plug connections (in particular battery
cables)
– Check the oil level in the power-assisted steering system 02-5
– Check the engine oil level (to be in-between the markings on the dipstick) 02-3
– Check the brake fluid level (at “MAX” marking) 02-5
– Check the coolant level (in-between marking), for special equipment antifreeze down 02-3
to -35 °C
– Fill up liquid in washer reservoir and ensure that there is antifreeze protection if there
is any risk of frost
– Check windscreen wiper and washer system, the washer nozzle adjustment and the 02-7
resting position of the windscreen wipers
Vehicle interior
– Inspect upholstery, upholstery, carpeting, footmats and coverings for cleanliness and
damage
– Inspect all switches, all electrical components, all gauges/indicators and controls 02-6
– Set the temperature to 22 °C (Climatronic) 02-6
– Check proper operation of key switch for front passenger airbag “ON/OFF” and posi‐ 02-6
tion to “ON”
– Radio: Inspect for proper operation, store stations, set clock. 02-6
– Fit net in luggage compartment (if available)
– Reset service interval display 02-6
– Select a language (on vehicles with an information in display) - LHD vehicles 02-6
– Adjust the power window lifter 02-6
– Check the vehicle log book for completion: Owner's manual and Service Schedule
(correct language and date of issue), short instructions, technical data, breakdown
assistance, other instructions (Radio, ...) - everything in a leather bag.
Underside of vehicle (on lift platform)
– Inspect underbody (underbody protection for damage) 02-7
– Inspect for leaks and damage: Engine, gearbox, final drive, steering, brake system, 02-3, 02-5
axles, joint boots. Check proper routing of the brake hoses and brake lines, fuel lines
including ventilation of the fuel system
– Inspect tyres and wheels for damage 02-5
– Perform a test drive 02-9
– Interrogate fault memory of all systems, if necessary erase 02-6
Concluding operations
– Complete the service schedule, affix the vehicle data sticker in the Service Schedule 02-7
to the floor of the luggage compartment next to the spare wheel, complete the “Next
Service” sticker and affix to the side of the dash panel on the driver's side
– Remove recharging table (if affixed)
– Fit enclosed carpets in the vehicle

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– Remove protective covering

– Final inspection to ensure proper condition for handover to customer

2.4 Oil change

After about 15.000 km3) or 1 year: Vehicles with variable service
intervals and extreme operating conditions
Every 15.000 km3) or 1 year: Vehicles with fixed service intervals
for changing the oil
Work involved Chapter
– Change engine oil 02-3

– Replace engine oil filter

– Disc brake pads: Inspect thickness 02-5
– Reset service interval display 02-6
– Drain away water from the fuel filter (diesel engine with biodiesel operation)
After each oil change
– Complete “Next Service” sticker (max. 1 year or 15 000 km) and affix sticker to the
side of the dash panel (on the driver's side)
– Complete and attach service mirror tag to the interior rear-view mirror
– Hand customer the completed and signed form

3) The 7500 km interval applies for diesel operation with high sulphur content - it
does not apply for the Czech Republic (for further information refer to Technical
Service Handbook)

2.5 Inspection Service

Chapter
Every 2 years 02-5
– Change brake fluid
Every 90 000 km 02-3
– Replace the toothed belt and the tensioning pulley (PD Diesel engine up to 07.
2003)
Every 120 000 km 02-3
– Replace the timing belt and tensioning pulley (6-cylinder petrol engine)

– Replace timing belt for camshaft drive and timing belt for injection pump drive,
and tensioning pulley 059 109 243 L (6-cylinder diesel engine)

– Replace the toothed belt and the tensioning pulley for the camshaft drive (PD
Diesel engine as of 08. 2003)
Every 180.000 km 02-3
– Replace timing belt (1.8 ltr. petrol engines)
Exhaust-emission analysis (EEA): Expiry date - see EEA tag on the vehicle identifi‐
cation plate (only valid for some countries)
At each inspection - check the 'use by date' of the first aid kit
Recommendation: Replace windscreen wiper blades every 12 months

Work involved Chapter

– Interrogate fault memory of all systems, if necessary erase 02-6
– Visual inspection of engine and parts in the engine compartment for leaks and 02-3
damage

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Work involved Chapter

– Change the engine oil, replace the oil filter 02-3
– Conduct a visual inspection of the airbag units for external damage 02-7
– Reset service interval display 02-6
– Inspecting brake system for leaks and damage 02-5
– Check the brake lining thickness 02-5
– Check gearbox, final drive and joint boots for leaks and damage 02-5
– Inspect the axle joints and joint boots for leaks and damage 02-5
– Inspect play, correct attachment and seals on the track rod ends 02-5
– Check the tyre inflation pressure (including spare wheel), correct if necessary 02-5
– Inspect the tyre wear pattern (including spare wheel) 02-5
– Inspect tyre tread depth (including spare wheel) and record (FL..., FR..., RR..., 02-5
RL..., SP...)
– Inspect exhaust system for leaks, damage and attachment
– Inspect brake fluid level and top up if necessary 02-5
– Check the battery 02-6
– Check the anti-freeze in the cooling system and record ...... °C, check for leaks, 02-3
top up coolant if necessary
– Lubricate the door arrester and hinged lock for the engine compartment hood
– Inspect operation of all switches, all electrical components, controls and gauges/ 02-6
indicators for proper operation
– Check the windscreen wiper system and the condition of the wiper blades 02-7
– Check and set the windscreen wiper system, top up with fluid if necessary 02-7
– Inspect plenum chamber for dirt, clean if necessary 02-7
– Check the timing belt for the camshaft on a 4-cylinder petrol engine at 90.000 km. 02-3
and then every 30.000 km after that
– Inspect operation of tilting roof and grease the runners 02-7
– Inspect the headlights and adjust if necessary 02-6
– Inspect the gearbox oil level and top up with oil if necessary (manual gearbox/ 02-4
final drive)
– Remove water from the fuel filter on a 4-cylinder diesel engine or replace for 02-3
biodiesel operation
– Replace the fuel filter (6-cylinder diesel engine) 02-3
– Check the underbody protection and body paintwork 02-7
– Replace the dust filter 02-7
– Check the timing belt for camshaft drive and injection pump drive (6 cylinder diesel
engine)
– Check the V-ribbed belt - every 60.000 km. 02-3
– Replace the fuel filter for a diesel engine - every 60.000 km. 02-3
– Replace the air filter insert and clean the housing - every 2 years or 60.000 km 02-3
– Check the ATF level, and top up if necessary, every 60.000 km 02-4
– In case of automatic gearbox check the oil in the final drive mechanism, if nec‐ 02-4
essary top it up - every 60 000 km
– Replace spark plugs - every 60.000 km 02-3
– Check the oil level in the power-assisted steering system - every 60.000 km 02-5
– Replace the timing belt for the camshaft drive ⇒ page 10 02-3
– Replace the own power supply of the alarm system - every 5 years
After each inspection service

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Work involved Chapter

– Enter the next service date on the “Next Service” sticker and affix sticker to the
side of the dash panel (on the driver's side), that is according to the indicator or
the time and kilometer schedule (also the date for changing the brake fluid)
– Perform a test drive 02-9
– Complete and attach service mirror tag to the interior rear-view mirror
– Hand customer the completed and signed form

4) PD Diesel engine (diesel engine)

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3 Engines

3.1 Engine overview

Engine identification AWT AVB5) AWX5) AVF5) AZM
characters
Emission standard EU-4 EU-3 EU-3 EU-3 EU-4
(EU-2)
Manufacturing 10.01 06.02 12.01 01.04 12.01
(from...through)
Displacement in li‐ 1,8 1,9 1,9 1,9 2,0
tres
Output (kW at rpm) 110 / 5700 74 / 4000 96 / 4000 96 / 4000 85 / 5400
Max. torque (Nm at 210 / 1750 250 / 1900 285 / 1750 310/1900 172 / 3500
rpm)
Bore (∅ mm) 81 79,5 79,5 79,5 82,5
Stroke (mm) 86,4 95,5 95,5 95,5 92,8
Compression 9,3 19 19 19,0 10,3
Hydraulic valve X X X X X
clearance compen‐
sation
Mixture formation Motronic Bosch PDE - in‐ Bosch PDE - Bosch PDE - Simos 3.2
ME7.5 jectors injectors injectors
Fuel RON (mini‐ unleaded 956) - - - unleaded 956)
mum)
Fuel CN (minimum) - 49 49 49 -
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Exhaust gas recircu‐ - X X X -
lation
Ignition system/fuel Motronic Bosch PDE - in‐ Bosch PDE - Bosch PDE - Simos 3.2
injection ME7.5 jectors injectors injectors
Self-diagnosis X X X X X
Catalytic converter X X X X X
Turbocharging X X X X -
Charge air cooler X X X X -
Lambda probe X - - - X
Camshaft adjust‐ X - - - -
ment
5) PD diesel engine (TDI diesel engine with unit injector).
6) Regular grade petrol (min. 91 ROZ) can be used although engine power output is slightly reduced.

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Engine identification AYM BBG AMX BDG

characters
Emission standard EU-3 EU-2 EU-4 EU-4
Manufacturing 01.02...08.03 06.02 11.01 08.03
(from...through)
Displacement in litres 2,5 2,8 2,8 2,5
Output (kW at rpm) 114 / 4000 140 / 6000 142 / 6000 120/4000
Max. torque (Nm at rpm) 310 / 1400 260 / 3000 280 / 3200 350 / 1250
Bore (∅ mm) 78,3 82,5 82,5 78,3
Stroke (mm) 86,4 86,4 86,4 86,4
Compression 18,5 10,1 10,6 18,5
Hydraulic valve clear‐ X X X X
ance compensation
Mixture formation Bosch Motronic ME7.1 Motronic ME7.1 Bosch
Fuel RON (minimum) - unleaded 957) unleaded 988) -
Fuel CN (minimum) 49 - - 49
Firing order 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5
Exhaust gas recirculation X - - X
Ignition system/fuel injec‐ Bosch Motronic ME7.1 Motronic ME7.1 Bosch
tion
Self-diagnosis X X X X
Catalytic converter X X X X
Turbocharging X - - X
Charge air cooler X - - X
Lambda probe - X X -
Camshaft adjustment - X X -
7) Regular grade petrol (min. 91 ROZ) can be used although engine power output is slightly reduced.
8) Regular grade petrol (min. 95 ROZ) can be used although engine power output is slightly reduced.

3.2 Engine fitted

Engine with identification characters AWT, AZM and AVF. The
engine identification characters and serial number are located at
the engine/gearbox joint.
In addition, a sticker with the engine identification characters and
serial number is affixed to the timing belt guard.

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Engine with identification characters AWX and AVB. The engine

identification characters and serial number are located at the en‐
gine/gearbox joint.
In addition, a sticker with the engine identification characters and
serial number is affixed to the timing belt guard.

Engine with identification characters AYM and BDG. The engine

identification characters and serial number are located at the end
face of the cylinder block, in front of the row of cylinders on the
right.
In addition, a sticker with the engine identification characters and
serial number is affixed to the timing belt guard.

Engine with identification characters BBG and AMX. The engine

identification characters and serial number are located at the end
face of the cylinder block, in front of the row of cylinders on the
right.
A sticker with the engine identification characters and serial num‐
ber is also affixed to the intake manifold.

3.3 Visual inspection of engine for leaks and

damage
– Inspect engine for leaks and damage.
– Inspect all lines, hoses and connections of the fuel system and
of the cooling and heating system for leaks, chafing points,
porous and brittle joints.
– Inspect gearbox or final drive for leaks (e.g. drain plug, drive
shafts, shift linkage etc.).
– Inspect steering, sealing boots of track rod ends as well as
steering boots for damage and correct installation.
– Inspect boots of steering joints for damage, leaks and correct
installation.

3.4 Replace engine oil filter

3.4.1 Vehicles with petrol engine

Special tools and workshop equipment required

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♦ Oil filter wrench

– Loosen oil filter and remove.
– Clean sealing surface at engine.
– Oil rubber seal slightly.
– Screw in new filter and tighten by hand.
– After filling with oil, run engine until it is at operating tempera‐
ture and inspect for leaks.

3.4.2 Vehicles with diesel engine

Special tools and workshop equipment required
♦ Oil filter wrench -3417- or wrench 36
– Release cap -1-.
– Replace O-rings -2- as well as the oil filter element -3-.
– Tighten cap -1-.
Tightening torque of the cap: 25 Nm

3.5 Replacing the timing belt or also the ten‐

sioning roller
– Removing and installing the timing belt and also the tensioning
roller as required ⇒ Rep. Gr. 13 ; Engine ...

3.6 Inspecting timing belt for camshaft drive

for wear and running (petrol engine)
Check timing belt for:
♦ Tears or splits -A-, cross-sectional fractures
♦ Lateral catches -B-
♦ Fraying or chunking -C-
♦ Crack in the base tooth -D-
♦ Separation of layers (timing belt housing, cords)
♦ Traces of oil and grease

Note

The timing belt must most definitely be replaced if any shortcom‐

ings are found. This will help prevent any failures or operational
problems. Replacing the timing belt is a repair measure.

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3.7 Inspecting engine oil level

Note

♦ The oil level must not, under any circumstances, be above the
area -a- - danger of damage to the catalytic converter.
♦ The vehicle must be standing on level ground when measuring
the oil level. Wait a few minutes after switching off the engine
to allow the oil to flow back into the oil pan.

– Withdraw dipstick, wipe off with a clean cloth and re-insert

dipstick fully.
– Withdraw dipstick once again and read off oil level.
The oil level in area -a-
– The oil must not be topped up.
The oil level in area -b-
– The oil can be topped up. It is possible that the oil level will rise
to the area -a-.
The oil level in area -c-
– The oil must be topped up. It is sufficient when the oil level
rises to the area -b-.

3.8 Change engine oil

Note

♦ The engine oil should always be changed, if possible, when

the engine is at normal operating temperature.
♦ If the engine oil is drained, replace the seal of the oil drain plug.
♦ It is absolutely necessary to observe the oil disposal instruc‐
tions!
♦ It is not permitted to clean and re-use the oil filter!

– Remove oil filler cap.

– Remove the noise insulation.
– Screw out the oil drain plug and collect the flowing out oil in a
suitable vessel.
– Clean oil drain plug, screw in with a new seal and tighten to
the specified tightening torque:
Engine-oil pan: 30 Nm
– Pour in oil as stated in the specifications.

3.8.1 Engine oil capacities:

♦ with oil filter change approx.:
3.5 litre (1.8 litre/110 kW, 2.0 litre/85 kW - engine)
3.6 litre (1.9 litre/74 kW, 1.9 litre/96 kW - engine)
5.4 litre (2.5 litre/114 kW, 2.5 litre/120 kW - engine)

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5.7 litre (2.8 litre/140 kW, 2.8 litre/142 kW - engine)

The engine is factory-filled with quality multigrade oil, which can
also be used as an all-season oil, except in extremely cold climatic
zones.
Vehicles with fixed service intervals (QG2)
Denomination Oil specification for Oil specification for
petrol engines diesel engines
Multigrade high-lu‐ VW 500 00 VW 505 01
bricity oils:
VW 502 00 VW 505 009)
Multigrade oils VW 501 01 ACEA B310), or B4
10)
ACEA A210), or A3
10)

9) Not valid for a PD engine.

10) Such oils must only be used once for topping up if no approved engine oil is
available.

Vehicles with variable service intervals (QG1)

Oil specification
Fuel engines VW 503 00
Diesel engines VW 506 01
VW 506 0011)
11) Not valid for PD and V6 TDI engine.

– Close the oil filler opening again.

– Start engine and check for leaks.
– Check the engine oil level again and top up with oil if neces‐
sary.
– Wait at least 3 minutes after topping up the oil again before
inspecting the oil level again.
– Install the noise insulation.

Note

The oil level must not be above the -max- marking to avoid dam‐
age to the catalytic converter. See Inspecting engine oil level
⇒ page 17 .

3.9 Inspecting antifreeze protection, replen‐

ishing coolant additive if necessary

WARNING

♦ Coolant additives are toxic!

♦ Do not inhale coolant vapours, do not swallow coolant,
avoid contact with skin and eyes; hazardous if consumed!

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Note

♦ Collect drained coolant for proper disposal.

♦ Observe the disposal instructions for the drained coolant.

Special tools and workshop equipment required

♦ Refractometer, e.g. -T10007-

3.9.1 Inspecting antifreeze protection of the

coolant
– Extract a small quantity of coolant with the pipette and place
on the measuring glass. Hold unit against a light source and
read off the temperature down to which antifreeze protection
exists on the scale for ethylene glycol.

Note

♦ Antifreeze protection must be ensured down to about -25°C.

♦ Down to about -35 °C in countries with an arctic climate.
♦ If a greater antifreeze concentration is required for climatic
reasons, the concentration may be increased up to 60 % (i.e.
antifreeze protection down to approx -40 °C). Any further in‐
crease in concentration increase would reduce the cooling and
corrosion protection of the coolant.

3.9.2 Replenishing coolant additive

Note

♦ Coolant additive G12 - red in colour, complying with standard

TL VW 774 D, must not be mixed with other coolant additives
which comply with standard TL VW 774 C(B)
-bluish-green in colour-. If these two coolants are mixed the
coolant will turn brown. Brown coolant must be drained imme‐
diately, the cooling system flushed out with drinking water and
filled with fresh coolant. If this is not done the engine and cool‐
ing system may suffer damage.
♦ Vehicles produced as of MJ 03 are filled with coolant additive
G12 PLUS which has a lilac colour and conforms with the
standard TL VW 774 F.
♦ Coolant additive G12 PLUS must only be mixed with coolant
additives G12 and G11.
♦ Coolant additive G12 PLUS is recommended for use on all
vehicles when changing the coolant.

If the vehicle is filled with the recommended coolant and the an‐
tifreeze protection is not adequate, drain part of the coolant from
the cooling system.
– After this, fill the cooling system with concentrated coolant ad‐
ditive.
Quantities of coolant in the cooling system:
Engine Amount (I)
1.8 ltr./110 kW 6,5

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Engine Amount (I)

1.9 ltr./74 kW and 1.9 ltr./96 6,5
kW
2.0 ltr./85 kW 6,5
2.5 ltr./114 kW and 2.5 ltr./ 8,6
120 kW
2.9 ltr./140 kW and 2.8 ltr./ 10,5
142 kW
– Perform a test drive and again check the coolant antifreeze
protection.

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3.10 Inspecting coolant level (volume)

– The coolant expansion reservoir is located on the right of the
engine compartment.
– Inspect coolant level only when the engine is not running.
Specified coolant level for the Inspection Service:
• Engine cold: between“MAX” and “MIN” marking.
• Engine warm: slightly above the “MAX” marking.

WARNING

♦ Coolant additives are toxic!

♦ Do not inhale coolant vapours, do not swallow coolant,
avoid contact with skin and eyes; hazardous if consumed!

Note

♦ The cooling system is filled all year round with a mixture of

water and antifreeze/anti-corrosion agent. Coolant additives
prevent damage from frost and corrosion and the accumula‐
tion of lime scale while also raising the boiling point of the
coolant. For these reasons the cooling system must always be
filled all year round with radiator antifreeze and anti-corrosion
agent offering these properties.
♦ Coolant additive G12 - red in colour, complying with standard
TL VW 774 D, must not be mixed with other coolant additives
which comply with standard TL VW 774 C(B)
-bluish-green in colour-. If these two coolants are mixed the
coolant will turn brown. Brown coolant must be drained imme‐
diately, the cooling system flushed out with drinking water and
filled with fresh coolant. If this is not done the engine and cool‐
ing system may suffer damage.
♦ Vehicles produced as of MJ 03 are filled with coolant additive
G12 PLUS which has a lilac colour and conforms with the
standard TL VW 774 F.
♦ Coolant additive G12 PLUS must only be mixed with coolant
additives G12 and G11.
♦ Coolant additive G12 PLUS is recommended for use on all
vehicles when changing the coolant.

Do not use coolant additives that have not been recommended

by ŠKODA AUTO a.s.
Other coolant additives may specifically impair the provided cor‐
rosion protection.
The resulting corrosion damage may lead to a loss of coolant and
subsequently cause major engine damage.
Coolant additives conforming to the standard TL VW 774 D (G12)
or TL VW 774 F (G12 PLUS) prevent frost and corrosion damage,
as well as the formation of scale, and also increase the boiling
point of the coolant.
For these reasons you must use coolant additives 12 months a
year.

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The higher boiling temperature of the coolant contributes to the

engine's reliability when the engine is stressed, especially in
countries with a tropical climate.

3.10.1 Coolant additives G12 - an overview

Coolant additives from the ŠKODA Genuine Parts List which
comply with Standard TL VW 774 D:
Coolant additive Manufacturer
Glysantin G 30-72 BASF AG
XT 4030 ELF OIL AG
Coolant ETX 6280 TEXACO
FROSTOX SF-D 12 HENKEL HÄRTOL GmbH

Note

The indicated G12 coolant additives may be intermixed.

3.10.2 Coolant additives G12 PLUS - an over‐

view
Coolant additives from the ŠKODA Genuine Parts List which
comply with the standard TL VW 774 F:
Coolant additive Manufacturer
Havoline XLC+B (VL 02) ARTECO
Glysantin G 30-81 BASF AG
Frostox SF D12 PLUS HENKEL HÄRTOL GmbH

Note

The listed G12 PLUS coolant additives may be intermixed.

3.11 Ribbed V-belt: Inspect condition

Special tools and workshop equipment required
♦ Wrench socket

3.11.1 Perform the following procedure:

– Raise vehicle.
– Remove right noise insulation.
– Use a socket wrench to crank the engine at vibration damper/
belt pulley -2-.
– Inspect V-ribbed belt from below for:

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♦ Splits in the carcass (initial splits, splits in core, splits across

carcass).
♦ Separation of layers (top layer, cords).
♦ Sections of carcass broken out.
♦ Fraying of cords.
♦ Wear to sides (abrasion of material, frayed sides, hardening
of sides, glazed and hardened surfaces).
♦ Traces of oil and grease.
♦ Correct tension.

Note

It is essential to replace the V-ribbed belt if defects are found. This

will help avoid any failures or operational problems. Replacing the
ribbed V-belt is a repair measure.

3.12 Routing of V-ribbed belt

1.8 litre/110 kW, engine identification characters AWT
2.0 litre/85 kW, engine identification characters AZM

1.9 litre/74 kW, engine identification characters AVB

1.9 litre/96 kW, engine identification characters AWX
1 - AC compressor
2 - Tensioning pulley
3 - Fan
4 - AC generator
5 - V-ribbed belt
6 - Hydraulic pump for power-assisted steering
7 - Belt pulley with vibration damper
8 - Tensioning pulley
9 - V-ribbed belt

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2.5 litre/114 kW, engine identification characters AYM

2.5 litre/120 kW, engine identification characters BDG
1 - AC generator
2 - V-ribbed belt
3 - Tensioning pulley
4 - Fan
5 - Hydraulic pump for power-assisted steering
6 - AC compressor
7 - Crankshaft

2.8 litre/140 kW, engine identification characters BBG

2.8 litre/142 kW, engine identification characters AMX
1 - AC generator
2 - V-ribbed belt
3 - Hydraulic pump for power-assisted steering
4 - Fan
5 - AC compressor
6 - Vibration damper
7 - Tensioning pulley

3.13 Replace spark plugs

Note

♦ To replace the spark plugs use the special spark plug wrench.
♦ Observe the disposal instructions for the spark plugs.
♦ Change interval: every 60 000 km.
♦ Tightening torque: 30 Nm.
♦ Use assembly tool -T10029- for unplugging the spark plug
connector (not applicable to cable with fixture).

Engine fitted Spark plug man‐ Parts No. Electrode spacing

ufacturer's desig‐
nation
1.8 litre/110 kW, engine identifica‐ NGK PFR6Q 101 000 063AA 0.7+0.1 mm12)
tion characters AWT
2.0 litre/85 kW, engine identifica‐ NGK BKUR 101 000 033AA 1,0±0.1 mm12)
tion characters AZM 6ET-10
2.8 litre/140 kW, engine identifica‐ NGK BKR 101 000 035HJ 0,5±0.1 mm12)
tion characters BBG 6EKUB
2.8 litre/142 kW, engine identifica‐ NGK BKR 101 000 035HJ 0,5±0.1 mm12)
tion characters AMX 6EKUB

12) Distance between earth electrode and spark plug insulator.

3.14 Replace air filter element

– Remove the filter housing cover.

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– Release the air guide hose.

– Open the filter housing.
– Replace the filter element and clean the filter housing.
– Close filter housing and check correct fitting.

3.15 Replacing the fuel filter (diesel engine)

Note

♦ Make sure no diesel fuel comes into contact with the coolant
hoses. If necessary clean the hoses immediately!
♦ It is absolutely necessary to observe the oil disposal instruc‐
tions!
♦ Observe the disposal instructions!

3.15.1 Removing
For 2.5 litre engine
– Remove retaining clips -3-.
– Remove regulating valve -4- with the connected fuel hoses.
– Remove fuel hoses -1- and -2- on the filter.
– Loosen the fuel filter and remove.
For 1.9 litre engine
– Pull off the fuel hose.
– Loosen the fuel filter and remove.

3.15.2 Installing
For 2.5 litre engine
– Insert a new fuel filter filled with fuel
– Fit the new O-ring for the regulating valve.
– Install regulating valve -4- with the connected fuel hoses.
– Attach retaining clips -3-.
– Install the fuel hoses -1- and -2- and secure with hose clamps.

Note

The direction of flow is indicated with arrows (do not switch con‐
nections).

– Inspect the fuel system for tightness (visual inspection).

For 1.9 litre engine
– Fill the new fuel filter with fuel.
– Insert the fuel filter in the holder and fix it in place.
– Fit the fuel hoses and secure with hose clamps.
– Inspect the fuel system for tightness (visual inspection).

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3.16 Draining the fuel filter (diesel engine)

Note

♦ Make sure no diesel fuel comes into contact with the coolant
hoses. If necessary clean the hoses immediately!
♦ Collect fuel in a suitable vessel!
♦ It is absolutely necessary to observe the oil disposal instruc‐
tions!

For 2.5 litre engine

– Remove retaining clip -3- and remove regulating valve -4- with
the connected fuel hoses.
– Release the fuel hose and pull it off.
– Loosen the fuel filter and remove.

– Loosen the drain plug -arrow- and drain off approximately 0.1
litres of fluid.
– Tighten the drain plug.
– Inspect the fuel system for tightness (visual inspection).
For 1.9 litre engine

– Remove Allan screw (8 Nm).

– Remove the upper part with the connected hoses and lay it to
one side.

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– Release screw -1- and remove fuel filter.

– Loosen the drain plug and drain off approximately 0.1 litres of
fluid.
– Tighten the drain plug.
– Inspect the fuel system for tightness (visual inspection).

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4 Gearbox

4.1 Gearbox/Final drive: Check the oil level

and top it if necessary

4.1.1 5 or 6 speed manual gearbox 01E

Gearbox oil specification: G 052 911 A SAE 75W 90 (synthetic
oil)
– Unscrew the the gearbox oil filler threaded plug -B-.
The oil level is correct if the gearbox is filled up to the lower edge
of the oil filler hole.
– Tighten the gearbox oil filler threaded plug, 40 Nm.
When topping up, pay attention to the following points:
– Unscrew the the gearbox oil filler threaded plug -B-.
– Pour in gearbox oil up to lower edge of filler hole.
– Tighten the gearbox oil filler threaded plug, 40 Nm.

4.1.2 5 speed manual gearbox 01W and 5

speed manual gearbox 012
Special tools and workshop equipment required
♦ Socket wrench -T30023-
Gearbox oil specification: G 052 911 A1 SAE 75W 90 (synthetic
oil)

Note

Depending on different version, either a wrench socket -T30023-

or a hexagonal headed wrench 17 mm, can be used to release
the gearbox oil filler threaded plug.

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– Unscrew the gearbox oil filler threaded plug.

The oil level is correct if the gearbox is filled up to the lower edge
of the oil filler hole.
– Tighten the gearbox oil filler threaded plug, 25 Nm.
When topping up, pay attention to the following points:
– Unscrew the gearbox oil filler threaded plug.
– Pour in gearbox oil up to lower edge of filler hole.
– Tighten the gearbox oil filler threaded plug, 25 Nm.

Note

♦ The surface of the plug is reworked and hence it must be de‐

termined whether the gearbox is made out of aluminium or
magnesium ⇒ Prevodovka 01w/012; Rep. Gr. 00-1 .
♦ Determine the category of the most suitable threaded plug in
accordance with the spare parts catalogue.

4.2 Inspecting ATF level, if necessary top‐

ping up

Note

Wear safety goggles during work.

Special tools and workshop equipment required

♦ Catch pan, e.g. -V.A.G 1306-
♦ Refilling reservoir -V.A.G 1924-
♦ Devices for diagnosis, measurement and information -VAS
5051-
♦ Diagnostic cable -VAS 5051/3-
• All electrical components and air conditioning systems must
be switched off.
• Gearbox not in emergency running mode, ATF temperature
not above 30° C.
• Vehicle on level ground.
• With selector lever in “P” position, let the engine idle.
The ATF level varies depending upon the ATF temperature.
ATF level check at lower ATF temperatures, leads to overfilling.
ATF level check at higher ATF temperatures, leads to inadequate
filling.
Overfilling or inadequate filling impairs the proper working of the
gearbox.

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Overview
1 - Oil drain plug with seal (must always be replaced)
2 - ATF level check screw
3 - ATF level (varies depending on the ATF temperature)
4 - Drilled cap for refilling reservoir -V.A.G 1924-
šipka - O-Ring (must always be replaced)

Note

When inserting the container in the drilled cap -4-, the cap must
not be allowed to drain into the oil tank.

– Fix the refilling reservoir firmly to the vehicle.

– Removing the noise insulation ⇒ Body Work; Rep. Gr. 50 .

– Switch ignition off to connect the diagnostic, measuring and

information devices -VAS 5051- to the diagnostic plug socket
of the vehicle.
– Select the vehicle self diagnosis and the address word 0 2
“Automatic gearbox”
– Select function 0 8 “Read measured value block” and display
group 0 4 .

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Position 1 on the display shows the ATF temperature.

The ATF temperature must not exceed 30° C at the start of the
test.
– Start engine.
– Place the catch pan beneath e.g. -V.A.G 1306- .
– Bring ATF to test temperature.
Test temperature: 35 °C to 45°C

– Remow the ATF level check screw -arrow- of the oil pan

If the ATF drips from the hole, then the level of ATF -arrow- is
correct.
On starting the engine, only a small quantity of ATF should drip
out of the inspection hole.

– Tighten the ATF level check screw -arrow- with a new seal, 80
Nm. This completes the ATF inspection.
– Vehicle diagnosis is completed.
– Switch off the engine.
– Switch ignition off to disconnect the diagnostic, measuring and
information devices -VAS 5051- from the diagnostic plug sock‐
et of the vehicle.
– Installing the noise insulation ⇒ Body Work; Rep. Gr. 50 .
If no ATF drips out of the hole, top up ATF.

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– e.g. -V.A.G 1924- fit the drilled cap -arrow- without pressing
the cap down.

– Top up ATF with the ATF refilling reservoir -V.A.G 1924- until
ATF flows out of the inspection hole -arrow-.

– Tighten the ATF level check screw -arrow- with a new seal, 80
Nm.
– Vehicle diagnosis is completed.
– Switch off the engine.
– Switch ignition off to disconnect the diagnostic, measuring and
information devices -VAS 5051- from the diagnostic plug sock‐
et of the vehicle.
– Installing the noise insulation ⇒ Body Work; Rep. Gr. 50 .

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5 Chassis

5.1 Inspecting thickness of front and rear

brake pads/linings

5.1.1 Front disc brake pads:

Note

For a better assessment of the residual pad thickness remove

wheels.

– Mark the position of the wheel.

– Release the wheel bolts and remove wheel.
-a- - the wear limit is reached at a pad thickness of 7.5 mm, in‐
cluding the backing plate.
If a wear case exists, thickness of pad less than 7.5 mm (including
backing plate), always replace the brake pads on both sides (re‐
pair measure)
– Fit on wheels in the marked position and tighten the wheel
bolts to 120 Nm.

Note

After replacing the brake pads, depress brake pedal firmly several
times when the vehicle is stationary to ensure the brake pads are
properly seated in their normal operating position.

5.1.2 Rear disc brake pads

Note

For a better assessment of the residual pad thickness remove

wheels.

– Mark the position of the wheel.

– Release the wheel bolts and remove wheel.

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-a- - the wear limit is reached at a pad thickness of 7.5 mm, in‐
cluding the backing plate.
If a wear case exists, thickness of pad less than 7.5 mm (including
backing plate), always replace the brake pads on both sides (re‐
pair measure)
– Fit on wheels in the marked position and tighten the wheel
bolts to 120 Nm.

Note

After replacing the brake pads, depress brake pedal firmly several
times when the vehicle is stationary to ensure the brake pads are
properly seated in their normal operating position.

5.2 Inspecting brake system for leaks and

damage
– Inspect master brake cylinder, brake servo unit (for ABS: hy‐
draulic unit), brake pressure regulator, brake calipers for leaks
and damage.
– Inspect brake hoses for twisting.
– Ensure that the brake hoses do not touch any parts of the ve‐
hicle when the steering is turned to full left or full right lock.
– Inspect the brake hoses for porous and brittle points. Inspect
the brake hoses and brake lines for chafing points.
– Inspect the brake connections and attachments to ensure they
are correctly fitted, free of leaks and corrosion.

WARNING

Any defects found must be rectified (repair measure).

5.3 Changing brake fluid (every 2 years)

Special tools and workshop equipment required
♦ Extraction device
♦ Brake pedal support, e.g. - V.A.G 1869/2-
Use only fresh genuine brake fluid FMVSS 571.116 DOT 4 .

WARNING

♦ Brake fluid must never come into contact with fluids con‐
taining mineral oils (oil, petrol, cleaning agent). Mineral
oils damage the gaskets and boots of the brake system.
♦ Brake fluid is toxic. Because of its caustic effect brake fluid
must not come into contact with paint.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air . Therefore it should always be stored in
airtight containers.
♦ Wash any parts stained with brake fluid with large volumes
of water.
♦ Observe the disposal instructions!

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– Unscrew cap -1- from the brake fluid reservoir

– Remove strainer and clean.

– Use an extraction device -1- to extract as much brake fluid as

possible from the brake fluid reservoir.

WARNING

Drained (used) brake fluid must never be used again.

– Insert strainer and fill expansion reservoir with new brake fluid.
Vehicles fitted with a manual gearbox

– Fit hose of extraction device -Arrow- onto the bleeder screw

of the clutch slave cylinder -1-.
– Open the bleeder screw and by depressing the clutch pedal
allow approx. 0.1 litre of brake fluid to flow out.
– Secure the clutch with the brake pedal depressor, e.g. -V.A.G
1869/2- in bottom position.
– Tightne bleeder screw and remove the hose.
– Put the clutch pedal in home position.
All vehicles
Sequence: Wheel brake cylin‐ Quantity of brake fluid that
der, brale caliper, clutch slave must flow out of the wheel
cylinder brake cylinders or brake cali‐
pers and clutch slave cylinder:
Rear right 0.2 ltr
Rear left 0.2 ltr
Front right 0.2 ltr
Front left 0.2 ltr

Note

While changing the brake fluid it is necessary to replenish the

expansion bottle with brake fluid.

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– Fit hose of extraction device -1- onto the bleeder screw of the
rear right wheel. 13)
13) On vehicles with right-hand steering: fit hose of extraction device onto the
bleeder screw of the rear left wheel

– Open the bleeder screw and by depressing the brake pedal

allow approx. 0.2 litres of brake fluid to flow out.
– Secure the clutch with the brake pedal depressor, e.g. -V.A.G
1869/2- in bottom position.
– Tighten bleeder screw and remove the hose.
– Put the brake pedal in home position.
– Repeat the procedure for all wheels in the following sequence:
rear left, front right and front left. 14)
14) For right-hand drive vehicles the following sequence applies: rear right, front
left and front right.

– In the expansion reservoir fill with brake fluid up to the speci‐

fied level.
– Inspect pedal position and idle travel at brake pedal. Idle trav‐
el: max. 1/3 of pedal travel.
Vehicles with ABS or ABS/EDL:
A road test on such models must be carried out after bleeding the
brake system. While doing so perform at least one ABS adjust‐
ment!

5.4 Inspecting the brake fluid level

Use only fresh genuine brake fluid FMVSS 571.116 DOT 4 .

WARNING

♦ Brake fluid is toxic. Because of its caustic effect brake fluid

must not come into contact with paint.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air . Therefore it should always be stored in
airtight containers.

Note

The brake fluid must not be above the “MAX” marking to prevent
fluid flowing out of the reservoir.

5.4.1 Delivery Inspection

The brake fluid level during the delivery inspection should be at
the “MAX” marking.

5.4.2 Inspection Service:

– The brake fluid level (volume) must always be assessed on
the basis of the brake pad wear. When driving a slight drop in
the brake fluid level in the expansion reservoir occurs as a
result of wear-and-tear and the automatic slack adjustment of
the brake pads.
– If the fluid brake level is on the “MIN” marking or slightly above,
it is not necessary to top up the brake fluid if the brake pads
have practically reached their wear limit.

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– If the brake pads are new or far off the brake wear limit, the
brake fluid level must be between the “MIN” and “MAX” mark‐
ings.
– If the brake fluid level has dropped below the “MIN” marking,
it is necessary to inspect the brake system before topping up
the brake fluid ⇒ page 34 ; carry out repair measures if nec‐
essary.

5.5 Track rod ends: Inspect play, correct at‐

tachment and joint boots
– Raise vehicle (wheel clear of the ground) and inspect play by
moving the track rods and wheels. Clearance: There must not
be any play present.
– Inspect attachment.
– Inspect seals for damage and correct installation.

5.6 Inspecting tyres (including spare wheel)

Note

Only tyres of the same type may be fitted to the vehicle. Tyres of
the same brand and tread pattern must always be fitted to wheels
on the same axle!

WARNING

Tyres that are more than 6 years old must only be used in case
of emergency and while driving very carefully.

5.6.1 Delivery Inspection:

– Inspect the tyre tread and side wall for damage, if necessary
remove any foreign bodies from the tyres, such as nails or
glass splinters.

5.6.2 Inspection Service:

– Inspect the tyre tread and side wall for damage, if necessary
remove any foreign bodies from the tyres, such as nails or
glass splinters.
– Inspect tyres for scrubbing, tread worn down on one side, po‐
rous side walls, cuts and punctures. Any defects found must
be advised to the customer and the customer's attention must
be drawn to any necessary repair measures!

5.6.3 Inspecting tyre wear

– The wear pattern on the front tyres makes it possible to assess
whether it is necessary to inspect the wheel toe and camber:
♦ The formation of ridges on the tyre tread is an indication of
wheel toe errors.
♦ Tread worn on one side is usually attributable to camber er‐
rors.

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– If such signs of wear are found, determine the cause by check‐

ing the chassis alignment (repair measure).

5.7 Inspecting the tyre tread depth (includ‐

ing spare wheel) and entering
This value may differ in individual countries as a result of differing
statutory requirements.
If the tyre tread depth is close to the legal minimum, in other words
if no further tread exists at the points around the circumference
of the tyre at which the 1.6 mm high wear indicators are posi‐
tioned, the customer should be informed of the necessary repair
measures .

5.8 Tightening wheel bolts to specific torque

Special tools and workshop equipment required
♦ Torque wrench
Tightening torque for steel and light alloy wheels 120 Nm.

5.9 Inspecting the tyre inflation pressure (in‐

cluding spare wheel) and correcting the
tyre inflation pressure if necessary
Special tools and workshop equipment required
♦ Tyre inflation pressure tester

Note

♦ The tyre inflation pressures are indicated on a sticker,which is

affixed to the inside of the fuel filler flap.
♦ The tyre inflation pressures indicated on the sticker apply only
to the tyres when cold. Do not reduce the higher inflation pres‐
sure of warm tyres.
♦ If winter tyres are fitted, the relevant tyre inflation pressure
should be increased by 0.2 bar/20 kPa.

5.9.1 Tyre inflation pressure table

Superb ▸ 05.02
Engine Tyres Tyre inflation pressure (kPa/bar)
Partial load Full load
Front axle Rear axle Front axle Rear axle
1.8 l/110 kW 205/55 R16 240/2.4 220/2.2 260/2.6 320/3.2
1.9 l/96 kW 225/45 R17
2.0 ltr/85 kW 210/2.1 200/2,0 230/2.3 280/2.8
2.8 l/140 kW 260/2.6 240/2.4 290/2.9 340/3.4
2.8 l/142 kW
2.5 l/114 kW
1.9 ltr./74kW 220/2.2 200/2.0 240/2.4 290/2.9

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Superb 06.02 ▸
Engine Tyres Tyre inflation pressure (kPa/bar)
Partial load Full load
Front axle Rear axle Front axle Rear axle
1.8 l/110 kW 205/55 R16 240/2.4 220/2.2 260/2.6 320/3.2
1.9 l/96 kW 225/45 R17
2.0 ltr/85 kW 210/2.1 200/2.0 250/2.5 300/3.0
2.8 l/140 kW 260/2.6 240/2.4 290/2.9 340/3.4
2.8 l/142 kW
2.5 l/114 kW
2.5 l/120 kW
1.9 ltr./74kW 210/2.1 200/2.0 250/2.5 300/3.0

5.10 Power-assisted steering: Checking the

oil level
Check the oil level with the front wheels pointing straight ahead.
Oil cold with the engine switched off
– The oil level must be in the area of the “MIN” marking (that up
to 2 mm above or below this marking).
Oil in a warm condition (above approx. 50 °C), engine idling
– The oil level must be between the “MIN” and “MAX” markings.

Note

Only the oil level for a previously fully screwed in lid applies.

– Top up the oil as required: -TL 52 146- , -N 052 146 00- , e.g.
Pentosin -CHF 11S- ( -G 002 000- ).

Note

♦ If the oil level is below the given range the power-assisted

steering system must be checked (repair work). It is not
enough to simply top up the oil.
♦ If the oil level is above the upper marking suck some of the oil
out.

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6 Electrical System

6.1 Power windows: Inspect positioning

If the battery is diconnected the power windows forget their cur‐
rent position.
Test conditions:
• All car doors closed
The inspection procedure is carried out from the outside
Close window with the car key using the convenience closing
system.
– Turn car key into close position and hold until all the windows
are closed.
– After closing the windows hold the key in the close position for
approximately another 3 seconds.

6.2 Electrical components: Check for proper

operation
– Inspect lighting, headlights, headlight beam control, fog lights,
turn signal lights, hazard warning light system, tail lights, rear
fog lights, reversing lights, brake lights, parking light control for
brightness and proper operation.
– Inspect interior lights, illuminated storage compartment, illu‐
minated ashtray for proper operation.
– Airbag warning lamps: Check operation ⇒ Chapter 02-7 .
– Inspect warning buzzer, onboard computer, all switches in the
centre console as well as in the dash panel insert and horn for
proper operation.
– Inspect power windows, exterior mirrors (heated and electri‐
cally adjustable), central locking system and convenience
closing system for proper operation
– Inspect heating of front seats for proper operation.
– Inspect radio for proper reception and absence of interference,
also inspect speakers ⇒ page 41 .

6.3 Battery: Testing no-load voltage

Special tools and workshop equipment required
♦ Multimeter e.g. -V.A.G 1526 A-
Prior to the measurement the vehicle must have been in the no-
load state for at least two hours (no engine starts, no charging or
discharging of battery).
The following procedure applies to measuring the battery voltage
in the no-load state (after at least two hours):
– With the battery installed measure the voltage between the
terminals (ignition switched off).
If the tester indicates a voltage of 12.5 Volts or more, the battery
is O.K.
If the voltage is less than 12.5 Volts determine the cause (repair
measure).

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6.4 Battery: Inspecting electrolyte level, top‐

ping up with distilled water if necessary
– Inspect electrolyte level:

WARNING

When working on the battery wear proper protection and ob‐

serve safety precautions.

– The electrolyte level must be between the “MIN” and “MAX”

markings.

Note

There are no “MIN”- and “MAX” markings available on the Battery

⇒ Electrical system; Rep. Gr. 27 .

6.5 Radio: Check for proper operation

Precise information on how to operate the radio should be ob‐
tained from the operating instructions before inspecting proper
operation of the radio set.
– Switch radio set on and off.
– Operate the volume control.
– Carry out station programming 15)
.
– Inspect station search 15)
.
– Inspect cassette player (insert cassette and play) 15)
.
– Activate anti-theft code of radio 15)
.
15) These functions are model specific and are not present on all types of radio
sets. For operation refer to Radio Operating Instructions.

6.6 Setting clock

A rotary knob is provided next to the rev counter for setting the
time. The hours (h) are set by turning the knob -2- to the left, and
the minutes (min) are set by turning the knob to the right:
– By briefly turning the knob the time is advanced by one hour
or one minute. It is possible to move the hours or minutes back
or forward continuously by holding the knob in the left or right
position respectively.

6.7 Connect diagnostic unit and interrogate

fault memory
These tasks are carried out using the diagnostic, measuring and
information system -VAS 5051- together with the diagnostic cable
-VAS 5051/3- .

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6.8 Resetting service interval display (SID)

These tasks are carried out using the diagnostic, measuring and
information system -VAS 5051- together with the diagnostic cable
-VAS 5051/3- .

6.9 Select the language in the dash panel

insert.
These tasks are carried out using the diagnostic, measuring and
information system -VAS 5051- together with the diagnostic cable
-VAS 5051/3- .

6.10 Changing the code of the service inter‐

vals
These tasks are carried out using the diagnostic, measuring and
information system -VAS 5051- together with the diagnostic cable
-VAS 5051/3- .

6.11 Inspecting headlight beam setting and

adjusting if necessary
Special tools and workshop equipment required
♦ Headlight beam setting device
In principle the following inspection and setting description ap‐
plies for all countries. However, comply with national guidelines
and legislation of the relevant country. ⇒ Operating instructions
for the headlight beam setting device
Test and setting conditions
• Tyre inflation pressure o.k.
• Lenses must neither be damaged nor soiled.
• Reflectors and bulbs o.k.
• Vehicle load must be achieved.
Load: With an individual or 75 kg on the driver's seat in an other‐
wise unladen vehicle (dead weight).
The unladen weight is the weight of the vehicle with full fuel tank
(at least 90 %) including the weight of all the operational equip‐
ment elements (e.g. spare wheel, tool kit, jack etc.).
The vehicle must have rolled a few metres or have been de‐
pressed a few times at the front and rear to allow the springs to
settle.
• Both the vehicel and headlight beam setting device must be
on a level flat surface.
• Align the vehicle and headlight beam setting device in accord‐
ance with the device manufaturer's indications.
• Check the control system of vehicles equipped with headlight
beam control by repeatedly turning the thumbwheel in the
dash panel. Then turn the thumbwheel to basic position.
• Set the inclination value.
Inclination value:
The inclination value is marked in “%” at the top of the headlight
housing. The main headlights must be set to this value. The per‐
centage value on the sticker applies up to 10 metres projection
distance. This will be 12 cm for an inclination value of e.g. 1.2 %.

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6.11.1 Inspecting headlight beam setting and

adjusting if necessary
Main headlights:
– Check whether the horizontal light/dark limit touches the sep‐
aration mark -1- on the test surface when the low beam light
is on .
– Check whether the kink -2- between the left horizontal part and
the ascending right part of the light/dark limit intersects with
the central mark -3- on the vertical line. The light core of the
light beam must be located to the right of the vertical line.

Note

♦ To easily determine the kink -2- alternately cover and uncover

the left half of the headlight (in the driving direction) a few
times. After this, check the low beam once again.
♦ Once the low beam light has been correctly set the centre of
the light beam of the main beam must be positioned on the
central mark -3-.
♦ The adjustment foreseen for the new control screen also ap‐
plies for the previous one, which has a 15° adjusting line. To
avoid incorrect settings disregard the 15° adjusting line.

Other additional headlights:

Additionally fitted headlights must be inspected or set in compli‐
ance with the relevant applicable directives.

6.12 Setting the main beam

Note

The headlight adjusting device is used to set up the headlight.

The specified values ⇒ page 42 .

Left headlight (right headlight in mirror image)

1 - Adjust the low beam (adjustment for height)
2 - Adjust the low beam (adjustment from side to side)
3 - Adjust the fog light beam
– Adjust with relevant thumbwheel.

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6.13 Replacing the own power supply for the

alarm system
– Replacing the alarm of the alarm system ⇒ Electrical System;
Rep. Gr. 94.

6.14 Climatronic: Adjust the temperature to

22 °C

Note

♦ The fastest way to obtain a comfortable climate (temperature)

in the vehicle, is by adjusting the temperature to 22 °C.
♦ Hence if personal health conditions demand, only a regulation
in the adjustment is necessary.

– Switch on ignition.
– Check if the display -3- indicates 22 °C.
If adjustment of temperature is necessary, proceed as follows:
– Press key -1- for automatic operation. “AUTO” appears on the
display -2-.
– By pressing the keys -4- (cooler) -5- (warmer), adjust the tem‐
perature to 22 °C.
– Switch off ignition.

6.15 Check proper operation of key switch for

front passenger airbag deactivation
– Switch off ignition.
– Turn the key switch for the front passenger airbag with the
ignition key into the position “OFF”.
When the ignition is switched on, the warning lamp in the centre
console must light up.
– Switch off ignition.
– Turn the key switch for the front passenger airbag with the
ignition key into the position “ON”.
When the ignition is switched on, the warning lamp in the centre
console must go out after a few seconds.

WARNING

The key switch for the front passenger airbag must only be
operated when the ignition is switched off. Non compliance
may result in a fault at the airbag system (risk from the following
airbag deployment).

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7 Body

7.1 Airbag units: Visual inspection

7.1.1 Inspecting operation of airbag unit

When the ignition is switched on the airbag warning lamp K75
lights up for approximately 4 seconds. If subsequently the warning
lamp flashes for a further 12 seconds, this indicates that the front
passenger airbag unit is blocked.
♦ If the warning lamp K75 does not go out after 4 seconds, there
is a fault.
♦ If the warning lamp goes out and then lights up again the con‐
trol unit is not coded, the wrong control unit has been fitted or
there is a fault.
♦ If the airbag warning light K75 flashes constantly, it is then
necessary to replace the airbag control unit J234.
If the warning light indicates a fault, the fault must be rectified
(repair measure) ⇒ Body Work; Rep. Gr. 01 .

7.1.2 Inspecting airbag for external damage

7.1.3 Driver and front passenger airbag units
The logo “AIRBAG” on the padded boss of the steering wheel
(driver's side) and on the right side of the dash panel (passenger
side) indicates that an airbag is fitted.
– Carry out a visual inspection of the padded boss of the steering
wheel -1- and surface of the dash panel -2- on the front pas‐
senger side for external damage.

Note

Do not affix any stickers or cover over the padded boss of the
steering wheel -1- and the foam-lined surface of the airbag unit
on the front passenger side -2- or do not carry out any modifica‐
tions to these parts. These parts must only be cleaned with a dry
and slightly moistened cloth.

7.2 Check underbody protection and body

paintwork for damage
The inspection of the underbody sealant and paintwork should
cover the following points:
1) undamaged layer of PVC Plastisol
– Vehicle floor
– Wings and wheel housings
– Sills
2) undamaged paintwork
– all body joints
– surround of windscreen
– surround of rear window

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– flange of inner surface of engine hood

– horizontal and vertical painted surfaces
– Connection of the roof in the region of the tailgate
It is essential to rectify any defects found!
The materials and the corresponding work instructions are listed
in the ⇒ Technical Service Handbook, Part 6 - Technology of
paint repairs, chemical materials .

7.3 Inspecting plenum chamber and water

drain openings for dirt, cleaning if nec‐
essary
Carry out a visual inspection for soiling through the cover of the
plenum chamber -arrows-. Remove the cover if it is necessary to
clean the plenum chamber (repair measure).

Note

The water drain openings must not be blocked with wax or un‐
derbody sealant.

7.4 Windscreen wiper/washer system:

Check for proper operation

7.4.1 Inspecting setting of nozzles of wind‐

screen washer system, adjusting noz‐
zles if necessary:
7.4.2 Fluid in windscreen washer fluid reser‐
voir
The fluid reservoir for the windscreen washer system must be
filled up to the brim.

Note

♦ If it is necessary to add fluid, always mix windscreen cleaner

to the water (in summer) or antifreeze agent (in the winter).
♦ If the vehicle is fitted with a headlight washing system and the
headlights have plastic - (polycarbonate) - lenses, one must
only use fluids which do not damage the polycarbonate.

7.4.3 Nozzles for windscreen washer system

The windscreen washer system is set by the manufacturer and
cannot be subsequently altered -arrow-.

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– The water spray should strike the windscreen in a cone-sha‐

ped pattern.

Note

If the spray flows out unevenly, adjust the spray nozzle.

7.4.4 Windscreen wiper arms: Inspecting park

position, adjusting if necessary
– Adjust the wiper arms as shown in the figure.
– Observe the dimension -a- (25 mm)
Tightening torque for the windscreen wiper arms is 20 Nm.

7.5 Sun roof: Cleaning and greasing run‐

ners
– Carry out a visual inspection of the sun roof for leaks and cor‐
rosion damage
– Clean the runners -1- and grease with lubricant -G 052 778- .
– Inspect proper operation of the sun roof, pay attention to pos‐
sible abrasive residue.

7.6 Door locks, locking buttons, child safety

locks: Check for proper operation

7.6.1 Door locks and locking buttons:

– Unlock and lock the driver and front passenger doors. Check
whether the locking buttons move up and down when this is
done.
– Press down the locking button on the front passenger door and
on the rear doors and close the doors. The doors must be
locked.

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The safety knob on the driver's door must not be pressed in as

long as the door is open.

7.6.2 Child safety locks (rear doors):

The rear doors are additionally equipped with a child safety lock.
– Insert car key in the lock.
– The child safety lock is activated when the key is turned to the
left in -the direction of the arrow-. The inner door opening lever
is blocked. The door can only be opened from the outside.

7.7 Replace the dust filter

7.7.1 Removing:
– Remove the cooling water tank cover ⇒ Body work; Rep. Gr.
66 .
– Push back the catch for the air filter -1-.
– Remove air filter unit -2-.

7.7.2 Installing:
Installation is carried out in the reverse order.

7.8 Sticking the vehicle data sticker

– Stick the vehicle data sticker to the floor of the luggage com‐
partment inside the vehicle next to the spare wheel -arrow-.

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8 Exhaust-emission Analysis

Note

The exhaust-emission analysis must be carried out according to

the relevant national legislation of the particular country.

8.1 Exhaust-Emission Analysis on Models

with Fuel Engines

Note

Perform the following visual inspections as well as comply with

the setting conditions below before performing the exhaust-emis‐
sion analysis:

Visual inspection
♦ Lambda probes are connected
♦ All vacuum hoses are connected
♦ All wires of the activated charcoal filter system are connected
♦ All the electrical wires of the ignition and injection system are
connected
♦ Hose for crankcase ventilation is connected
♦ The exhaust system must be undamaged and tight
♦ Catalyst must be undamaged
Test and setting conditions
• Perfect operation of the engine
• Perfect operation of the ignition system
• Intake system tight
• All electrical components are switched off (radiator fan must
not run during the test)

Note

♦ If any shortcomings are noticed they must be repaired.

♦ The idling speed, ignition point and CO content are only meas‐
ured as they cannot be adjusted.
♦ The CO content is set to nominal value by the lambda control.
Faults in the lambda control are detected by the self-diagnosis
and stored in the fault memory.
♦ When interrogating the fault memory (engine electronics) all
detected faults must be repaired and the fault memory must
be erased.
♦ To prevent injury to persons and/or damage to the ignition and
injection system make sure the ignition is switched off when
disconnecting and connecting the wires of the ignition system.

Connect the test equipment to the vehicle

To prevent industrial accidents or avoid causing damage to the
ignition system, pay attention to the following:

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♦ Disconnect and connect wires of the ignition system (including

high-voltage wires) when the ignition is switched off.
– Connect the tester in compliance with the operating instruc‐
tions.
Connect the diagnostic unit -1- to the diagnostic connector
-arrow-.

Note

The exhaust gas probe must be fully inserted into the exhaust
tailpipe (do not insert into the suction tube)!

– Start engine and run in idle.

– Measure idle speed and CO content.

8.2 Test Values for Exhaust-Emission Analysis on Petrol Engines

Engine identifica‐ Engine identifica‐ Engine identifica‐ Engine identifica‐
tion characters tion characters tion characters tion characters
AWT AZM AMX BBG
Oil temperature min. 80 °C min. 80 °C min. 80 °C min. 80 °C
Catalyst warming-up time 2 min at 3000 rpm 2 min at 3000 rpm 2 min at 3000 rpm 2 min at 2500 rpm
Idling speed (1/min) 760 - 960 680 - 880 620 - 820 620 - 820
CO content at idle speed 0 … 0,5 % 0 … 0,5 % 0 … 0,5 % 0 … 0,5 %
(measured after catalyst)
Increased idling speed (rpm) 2400 - 2600 2400 - 2600 2400 - 2600 2400 - 2600
Lambda value at 2850 - 2900 0,97 - 1,03 0,97 - 1,03 0,97 - 1,03 0,97 - 1,03
rpm
CO content at 2850 - 2900 0,3 % 0,3 % 0,3 % 0,3 %
rpm
Speed for control loop test 660 - 1060 580 - 980 520 - 920 520 - 920
(rpm)
Lambda probe version Wide band probe Jump probe Jump probe -
(lambda)
Voltage jump (V) - 0,3 0,3 -
DELTA-lambda 0,03 0,03 0,03 0,03
Test speed Idling speed Idling speed Idling speed -

Note

All tubes and plug connections, which had been removed or dis‐
connected for the test and adjustment, must be correctly re-
inserted or connected.

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Technical data of the spark plugs ⇒ Chapter 02-3 .

8.3 Exhaust-Emission Analysis on Models

with Diesel Engines

Note

♦ When possible the test should be carried out immediately after

the road test and also outdoors. If specific reasons prevent this
(weather conditions, excessive noise in residential areas) the
test may also be performed in the workshop.
♦ Secure the engine bonnet in the first stop while measuring to
reduce the noise.

Visual inspection
♦ Hose for crankcase ventilation is connected
♦ Fuel system and injection pump must be tight
♦ The exhaust system must be undamaged and tight
♦ All vacuum hoses are connected
Test and setting conditions
• Engine oil temperature at least 80 °C
• All electrical components disconnected
• No fault stored in the fault memory ⇒ Chapter 02-6, connect
diagnostic unit and interrogate fault memory

Note

Correct detected faults before measuring (repair measure).

Connect the test equipment

– Connect the tester in compliance with the operating instruc‐
tions.
– Start engine, warm up to normal temperature and run in idle.
– Perform the exhaust-emission analysis.

Note

♦ Activate and inspect auxiliary equipment such as e.g. power

steering, automatic gearbox or air conditioning system. Check
whether the engine continues to run perfectly under this load.
♦ All tubes and plug connections, which had been removed or
disconnected for the test and adjustment, must be correctly
re-inserted or connected.

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8.4 Test Values for Exhaust-Emission Analysis on Diesel Engines

Engine identifi‐ Engine identifi‐ Engine identi‐ Engine identi‐ Engine identi‐
cation charac‐ cation charac‐ fication char‐ fication char‐ fication char‐
ters AWX ters AYM acters AVB acters BDG acters AVF
Oil temperature 16) min. 80 °C min. 80 °C min. 80 °C min. 80 °C min. 80 °C
Idling speed (1/min) 800 - 950 650 - 850 800 - 950 660 - 860 800 - 950
Cutoff speed (1/min) 4900 - 5300 4650 - 4950 4600 - 5000 4650 - 4950 4900 - 5300
Soot emission max. 0,6 1,2 0,8 1,3 0,6
opacity value17) (1/m)
Probe no. 1 1 1 1 1
Measurement mode B B B B B
Measurement time 0.5 s 0.5 s 0.5 s 0.5 s 0.5 s
slice
16) From an engine oil temperature of min. 60°C warm up the engine to min. 80°C with 10 free accelerations up to cutoff speed. heat up
to 80 °C.
17) After the process - free acceleration.

If the actual values differ from the nominal values: Repair and
again perform an exhaust-emission analysis.

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9 Miscellaneous

9.1 Tow starting/Towing

Note

♦ A towing rope or towing bar must only be fitted to the appro‐

priate towing lugs.
♦ The towing rope must be elastic to protect the vehicle. There‐
fore only use synthetic ropes or ropes manufactured in an
equally elastic material. However, it is safer to use a towing
bar!
♦ Make sure no unauthorised traction forces or no jolting loads
are exerted. During towing manoeuvres away from hardened
road surfaces there is a risk of overloading and damaging of
the fastening parts.
♦ Before starting the engine by towing, first use the battery of
another vehicle as a start aid.

Front: The towing lug -1- is located in the front right-hand part of
the bumper behind the plastic cover grill.
Rear: The towing lug is located below the rear right part of the
bumper.

Note

♦ Comply with the legal regulations on towing.

♦ Both drivers must be familiar with the specificities of the towing
process.
♦ When using a towing rope the driver of the towing vehicle must
press the clutch very smoothly when driving off and changing
gear.
♦ The driver of the towed vehicle must make sure that the rope
is kept taut.
♦ The ignition must be switched on to ensure the steering wheel
does not lock and that the turn signals, horn, windscreen wip‐
ers and windscreen washer system can be activated.
♦ As the brake servo unit only operates with the engine running,
the brake pedal must be pressed much harder when the en‐
gine is switched off.
♦ On vehicles with power steering the steering is much harder
when the engine is switched off.
♦ If there is no lubricant in the gearbox or automatic gearbox the
vehicle must only be towed with the drive wheels raised.

9.1.1 When towing vehicles with a manual

gearbox pay attention to the following:
– Before towing engage 2nd or 3rd gear.
– Switch on ignition.
– As soon as the engine starts, press clutch and remove gear to
avoid driving into the towing vehicle.

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Note

Do not start the engine of vehicles fitted with an exhaust catalyst

by towing over a long distance as unburnt fuel may get into the
catalyst and burn there. This may result in overheating and hence
in the destruction of the catalyst.

9.2 Road test

The following must be assessed within the scope of a test drive
according to the vehicle equipment and the available possibilities
(city/country, weather)
– Inspect engine for performance, misfiring, idling behaviour,
acceleration and starting behaviour.
– Foot and handbrake: Functional test (jerking, squeaking, pull‐
ing to one side) ABS operation. Brake pedal-idle travel: max.
1/ of the idle travel.
3
– Inspect the lever position and smooth operation of the gear‐
shifts.
– Inspect the driving behaviour of the clutch as well as the pedal
force and smell.
– Inspect automatic gearbox: Selector lever position, selector
lever lock, shifting behaviour, display indication in dash panel
insert.
– Inspect steering clearance of the vehicle standing on its
wheels, with engine running by turning the steering wheel one
way and then the other (wheels straight ahead). There must
be no play on the steering.
– Inspecting the sun roof operation.
– Pay attention to pulling and to the straigt ahead position of the
steering wheel during driving.
– Inspect the imbalance of the wheels, drive shafts and prop‐
shafts.
– Inspecting functions: Heating, air conditioning, ventilation, in‐
struments and warning lights, mirror adjustment.
– Inspect engine, gearbox, axles, steering, brakes, clutch, body‐
work for abnormal noises

9.3 Raising the vehicle

9.3.1 Using a lift platform and a workshop jack

The vehicle must only be raised with a workshop jack at the indi‐
cated jacking points arrows.

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Jacking point at the front -arrow-

Jacking point at the rear -arrow 1-

It is absolutely vital to use a suitable rubber or wooden intermedi‐
ate layer in order to avoid any damage to the contact surfaces
-arrow 1- on the vehicle stay -3-.
The rear support points are located in the make axle embossed
in the sill -arrow 2-.

WARNING

♦ Under no circumstances may the arms of the lift platform

or jack be positioned under the engine, the gearbox, the
front or rear axles.
♦ Never start the engine or engage a gear when the vehicle
is raised, while even one driving wheel is still in contact
with the ground.
♦ Secure the vehicle on the lift platform before its centre of
gravity shifts considerably because of successive disas‐
sembly operations.
♦ The vehicle must not be supported at the front under the
sill.

9. Miscellaneous 55