Service

Workshop Manual
Octavia II 2004 ➤
Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation)
Engine ID
CLC CLC CFH CFH
A B C F
Edition 01.2011

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

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system

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

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

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 ŠKODA AUTO a. s. D3E802A90C1

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Contents

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

01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Regulations concerning safety precautions when working on the fuel system . . . . . . . . . . 3
1.4 Regulations concerning cleanliness when working on the fuel supply/fuel injection system
........................................................................ 4
1.5 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 5
1.6 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Removing and installing a V-ribbed belt and a toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
1.2 Removing and
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authorised byV-ribbed
ŠKODA AUTO belt
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ŠKODA AUTO A.without
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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1.3 Removing and installing V-ribbed belt for vehicles with air conditioning system . . . . . . . . 27
1.4 Removing and installing crankshaft-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5 Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Timing belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.7 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 Removing and installing sealing flange and two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 47
2.3 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3 Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.4 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.5 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

1 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.1 Cylinder head cover - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.3 Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Contents i
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.6 Removing and installing the vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.7 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.2 Replacing camshaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.4 Measuring the axial play of the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.5 Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.6 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.7 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.8 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Removing and installing parts of the lubrication system - Summary of components . . . . . . 96
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 97
1.3 Oil filter with engine oil cooler - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.4 Removing and installing the oil filter holder with the engine oil cooler . . . . . . . . . . . . . . . . 99
1.5 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.6 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.7 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.9 Testing oil pressure switch F1 and oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.1 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.2 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.3 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.4 Remove and install coolant recirculation pump 2 V178 . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.5 Replace coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.6 Replace coolant temperature sender at radiator outlet G83 . . . . . . . . . . . . . . . . . . . . . . . . 119
2 Coolant pump and 4/2 way valve with coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.1 Coolant pump and 4/2 way valve with coolant regulator - Summary of components . . . . . . 121
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.3 Removing and installing 4/2 way valve with coolant regulator . . . . . . . . . . . . . . . . . . . . . . 122
2.4 Testing coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3 Radiator and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.1 Radiator with a radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.2 Radiator with two radiator fans - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 127
3.3 Removing and installing fan shroud and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.5 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Behaviour in case of misfuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Summary of components of fuel tank with attached parts - Vehicles with front-wheel drive
........................................................................ 135
1.3 Summary of components of fuel tank with attached parts - Vehicles with four-wheel drive
........................................................................ 138
1.4 Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.5 Protected
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1.7 Removing and installing the fuel delivery unit on vehicles with four-wheel drive . . . . . . . . 145
1.8 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 148

ii Contents
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.9 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1.10 Removing and installing suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.11 Remove and install the fuel tank for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . 151
1.12 Removing and installing fuel tank for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . 153
1.13 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.14 Removing and installing additional fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.3 Disconnect connector for accelerator pedal module and fit on . . . . . . . . . . . . . . . . . . . . . . 164

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1 Charge-air system - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.1 Exhaust gas turbocharger with component parts - Summary of components . . . . . . . . . . 165
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.3 Removing and installing exhaust gas temperature sender 1 G235 ( temperature sender
upstream turbocharger G507 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.4 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.5 Inspect the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2 Charge-air system - radiator, leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.1 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.2 Hose connections with screw clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.4 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

1 Diesel direct injection system - fitting locations, system overview . . . . . . . . . . . . . . . . . . . . 181
1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.2 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2 Fuel system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.1 High pressure pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.3 Filling and bleeding the high pressure pump/fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.4 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.5 Injection units (solenoid injectors) - Summary of components . . . . . . . . . . . . . . . . . . . . . . 191
2.6 Adaptation for injector quantity adjustment (IQA code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.7 Always search for injection units in open state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.8 Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.9 Installing the high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.10 Removing and installing fuel high pressure reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.11 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.12 Check the low pressure fuel system . . .A.. S.. .ŠKODA
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. . . A.
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. .guarantee
. . . . . or
. .accept
. . . any
. . .liability
........ 203
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO
2.13 Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
205
2.14 Replace fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3 Intake manifold, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.1 Intake manifold with component parts - Summary of components . . . . . . . . . . . . . . . . . . . . 208
3.2 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 209
3.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.4 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.5 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Contents iii
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

1.1 Pre-exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.2 Middle or rear part of the exhaust system - Summary of components . . . . . . . . . . . . . . . . 222
1.3 Replacing differential pressure sender G505 (for engine with engine identification characters
CFHC, CFHF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.4 Removing and installing pre-exhaust pipe with diesel particle filter (for engine with
identification characters CFHC, CFHF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.5 Removing and installing pre-exhaust pipe (for engines with engine identification characters
CLCA, CLCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.6 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.7 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.8 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.1 Exhaust gas recirculation with radiator - Summary of components . . . . . . . . . . . . . . . . . . 233
2.2 Removing and installing radiator for exhaust gas recirculation with exhaust gas recirculation
valve N18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.3 Checking change-over flap for radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . 236

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.1 Removing and installing glow plugs
Protected . . . Copying
by copyright. . . . . .for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . .in. part
. . or
. .in.whole,
. . . .is .not. .permitted
. . . 238
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

iv Contents
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

00 – Technical data
1 Technical data

1.1 Engine number

The engine number („engine identification characters“ and „serial
number“) is located in the front at the engine/gearbox joint
-arrow-.
In addition, a sticker with the „engine identification characters“
and „serial number“ is affixed to the timing belt guard.
The engine identification characters are also indicated on the ve‐
hicle data sticker.
♦ The engine identification characters have 4 digits starting with
the letter „C“.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched in the cylinder block including the
serial number.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine control unit.

1.2 Engine characteristics

Engine identification CLCA CLCB CFHC CFHF
characters
Manu‐ 03.2010 ► 03.2010 ► 05.2010 ► 01.2011►
factured
Exhaust limit values con‐ EU-4 / BS-4 EU-4 / BS-4 EU5 EU5
forming to
Dis‐ l 1,968 1,968 1,968 1,968
place‐
ment
Power kW at rpm 81/4200 103/4200 103/4200 81/4200
output
Torque Nm at rpm 250/1500...2500 320/1750...2500 320/1750 … 2500 280/1750 … 2750
Bore ∅ mm 81 81 81 81
Stroke mm 95,5 95,5 95,5 95,5
Cylinder / valves per cyl‐ 4/4 4/4 4/4 4/4
inder
Compression ratio 16,5 16,5 16,0 16,0
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Catalytic yes yes yes yes
convert‐
er
Exhaust gas recirculation yes yes yes yes
with radiator
Turbo‐ yes yes Copying for private or commercial
Protected by copyright. yes purposes, in part or in whole,
yes is not permitted
charging unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Charge air cooler yes yes yes yes
Diesel particle filter no yes yes yes

1. Technical data 1
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations and direc‐
tions

1.1 Self-diagnosis
This Rep.-Gr. is deleted.
For this use the „Vehicle self-diagnosis“, „Measuring method“ and
„Fault finding“ ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.

1.2 Supplementary instructions and assem‐

bly work on vehicles with an air condi‐
tioning system

WARNING

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

tem.

Note

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

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

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

engine without opening the refrigerant circuit:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Unscrew the holding clamp(s) on the refrigerent lines
– Remove V-ribbed belt ⇒ page 27 .
– Remove AC compressor from the bracket for auxiliary units
⇒ page 24 .
– Mount the air conditioning compressor and the condenser in
such a way that the refrigerent lines/hoses are not under ten‐
sion.

2 Rep. gr.01 - Self-diagnosis

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.3 Regulations concerning safety precau‐

tions when working on the fuel system

WARNING

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds in such a way that the original line
guide is re-established.
♦ Ensure that there is adequate free access to all moving or
hot components.
♦ The fuel or the fuel lines in the fuel system can become
very hot (risk of burning)!
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
For reasons of safety the current supply to the fuel pump must
be interrupted before opening the fuel system. Otherwise the
fuel pump is activated when opening the driver's door. One of
the following options must be used to interrupt the current sup‐
ply:
♦ Disconnect battery
or
♦ Take out fuse for fuel pump relay -J17-
or
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Disconnect the plug onauthorised
unless the flange of the
by ŠKODA fuel
AUTO A. S.delivery unit
ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Caution

In order to avoid the high pressure pump to run dry and to ach‐
ieve a quick engine start after parts are replaced, the following
points must be observed:
♦ If the fuel system was opened, starting with the fuel tank
through to the high pressure pump, the ventilation of the
fuel system must be carried out before starting the engine.
For this purpose, switch on the ignition and only switch it
off once the fuel pump has come to a standstill. Repeat
this procedure at least »5 times«.
♦ If the high pressure pump is removed or replaced, the in‐
itial fuel filling of the high pressure pump must be carried
out before the first engine start ⇒ page 189 .
♦ If the high pressure system was opened, it must be
checked for tightness ⇒ page 190 .

When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐

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

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
If the test and measuring devices are operated from the passen‐
ger seat, the passenger can be injured by the release of the
passenger airbag in the event of an accident.

WARNING

Secure the diagnostic device to the rear seat and operate from
that position.

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

damage to the injection and preheating system:
♦ People, who have a heart pacemaker implant, should not bend
over the engine compartment when the engine is running, as
the injection units (solenoid valve injectors) generate an output
high voltage pulse.
♦ No fuel lines must be opened when the engine is running.
♦ Disconnect and connect wires of the preheating and injection
system as well as measuring device wires when the ignition is
switched off.
♦ Do not carry out engine wash unless the ignition is switched
off.
♦ If the engine must be operated, without it starting, unplug the
connector -arrow- at the fuel pressure regulating valve -
N276- .
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the 4AV control unit.
♦ After connecting the battery, carry out certain additional oper‐
ations ⇒ Electrical System ⇒ Rep. gr. 27 .

1.4 Regulations concerning cleanliness

when working on the fuel supply/fuel in‐
jection system
Carefully observe the following „6 rules“ for cleanliness when
working on the fuel supply/injection system: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Thoroughly clean the connection points and their
withsurroundings
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box
etc...).

4 Rep. gr.01 - Self-diagnosis

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

♦ When the system is opened: Avoid using compressed air.

Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately. Replace imme‐
diately any hoses which have suffered damage.

1.5 Regulations concerning cleanliness

when working on the exhaust gas turbo‐
charger
Carefully observe the following „5 rules“ for cleanliness when
working on the exhaust gas turbocharger:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box
etc...).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.

1.6unless General
Protected by copyright. Copying instructions
for private or commercialfor charge
purposes, in part or air sys‐
in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect tem
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

WARNING

When undertaking all installation work, particularly in the en‐

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

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

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Caution

In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter, air filter insert and charge air hoses as well
as charge air pipes for soiling.
♦ Check all the air guides and the charge air cooler for for‐
eign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.

♦ The charge-air system must be tight, check ⇒ page 178 .

♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.
♦ Observe markings on the hoses and components.
♦ All hose connections of the charging system are secured with
screw clamps.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ Electronic Catalogue of Original Parts .
♦ Observe the instructions for installing the charge air hoses and
tightening torques of the screw clamps ⇒ page 177 .
♦ Before screwing down the oil feed line, fill the exhaust turbo‐
charger via the connection fitting with engine oil.
♦ After installing the exhaust turbocharger, run engine at idling
speed for about 1 minute to ensure that oil is supplied to the
turbocharger bearing.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

6 Rep. gr.01 - Self-diagnosis

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

10 – Removing and installing engine

1 Removing and installing engine

1.1 Removing and installing engine trim

panel
Removing

Caution

The brackets of the engine cover on the cylinder head cover

can break off when they are incorrectly removed.
♦ It is therefore necessary to remove the engine cover ac‐
cording to the following instruction.

– Successively slacken the engine cover in the marked se‐

quence -1 ... 4- from the fixing points. To do so, grip the engine
cover from underneath as far as possible in the area of the
-arrows- and pull it upwards out of the attachment.
Install

Caution

Before installing the engine cover, check the correct fitting po‐
sition of the 4 fixing elements (ball sockets), if necessary move
them into the correct position. Otherwise this can lead to dam‐
age to the engine cover.

– If necessary, adjust the ball sockets of the engine cover to the

correct position.
– Position the engine cover onto the fixing points and press it in
at the corners until it clicks into place.

1.2 Removing engine

Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel -MP8-602/1-
♦ Engine mount
Protected by -T10012-
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Removing and installing engine 7

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

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

♦ Catch pan , e.g. -VAS 6208-
♦ Double ladder , e. g. -VAS 5085-
♦ Pliers for spring strap clamps

Note

♦ The engine is removed downwards together with the gearbox.

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

Caution

When undertaking all installation work, particularly in the en‐

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

Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .
– If present, take the adapter for the anti-theft wheel bolts out of
the luggage compartment.
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐
trical System ⇒ Rep. gr. 27 .
– Remove engine cover ⇒ page 7 .
– Remove air filter, air mass meter -G70- and suction hose
⇒ page 214 .
– Remove battery with battery tray ⇒ Electrical System ⇒ Rep.
gr. 27 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

8 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Engine with identification characters CFHC, CFHF

– Unplug the following plug connections at the bulkhead:
2 - Exhaust gas temperature sender 4 -G648- (orange)
3 - Exhaust gas temperature sender 1 -G235- ( Temperature
sender upstream turbocharger -G507 - ) (black)
4 - Lambda probe -G39- (black)
6 - Exhaust gas temperature sender 3 -G495- (braun)
Continued for all engines
– Pull off the vacuum hose -5- from the charge pressure control
solenoid valve -N75 - .
– Drain coolant ⇒ page 115 .

– Disconnect plug -1- from oil level and oil temperature sender
-G266- .
– Remove bracket -2- for the wiring harness of the oil level and
oil temperature sender -G266- from the assembly carrier.
Vehicles with front-wheel-drive

– If present, unscrew heat shield for right drive shaft -arrows-.

Continued for all vehicles
– Unscrew left front wheel.
– Remove the right and left wheelhouse liner ⇒ Body Work ⇒
Rep. gr. 66 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box.
– Remove pre-exhaust pipe:
♦ Engine identification characters CFHC, CFHF ⇒ page 225
♦ Engine identification characters CLCA, CLCB ⇒ page 228
Vehicles with four-wheel drive
– Unscrew propshaft from angle gearbox ⇒ Gearbox ⇒ Rep.
gr. 39 .
Continued for all vehicles

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

1. Removing and installing engine 9

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Swivel the steering joint outwards and secure the drive shaft
-1- with a band -A- in the wheelhouse. The assembly carrier
is already removed.

– Release screws -arrows-.

– Expose coolant hose -1-.
– Loosen hose clamp -3-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Disconnect plug -2- at the charge pressure sender -G31- and
remove the right charge air pipe.

– Unscrew screw -arrow- and push the coolant recirculation

pump 2 -V178- to the side.

10 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Remove vacuum hose -2- from vacuum setting element of ex‐

haust turbocharger.
– Disconnect vacuum hose -3-.

– Remove the vacuum hose -arrow- from the brake servo unit.

– Separate fuel feed line -2- and fuel return-flow line -1-, to do
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
so press in securing rings. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Disconnect plug -4- at fuel temperature sender -G81- .

– Remove fuel feed line as well as fuel return-flow line, to do so
loosen hose clamps -2 and 3-.

1. Removing and installing engine 11

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Unscrew bolt -1-.

– Push the filler tube with the filler neck -2- for the washer-fluid
reservoir to the side.

Note

For reasons of clarity the fuel filter is not shown.

– Unhook the fuel hose -2- from the bracket.

– Remove the bracket for the fuel lines upwards in
-direction of arrow- and place it to the side.
– Disconnect plug -1- from the additional fuel pump -V393- .
– Unscrew bolts -3-.

– Loosen screw -1- by 2 turns.

– Release screw -2- and nut -3-.
– Unclip bracket for coolant line at fuel filter.
– Remove the fuel filter with the hoses connected and the brack‐
et together with the additional fuel pump -V393- .
Vehicles with air conditioning
– Remove V-ribbed belt ⇒ page 27 .

WARNING

Risk of injury through refrigerant.

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

Note

In order to avoid damage to the AC compressor as well as to the

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

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

12 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Remove the AC compressor from the bracket for auxiliary

units, to protect the charge air cooler place cardboard -A- on
it and secure the AC compressor with connected refrigerant
hoses to the lock carrier.
Continued for all vehicles
– Unlatch the fuse and disconnect the front plug from the engine
control unit ⇒ page 216 .

– Release duct for engine wiring harness -arrow- and pull out
upwards.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Open the cable guides -arrows-, remove the engine wiring

harness and place down to the side.

1. Removing and installing engine 13

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Expose the plug connection -1- and disconnect it.

– Open the bracket -2- lying below the cable guide.
– Remove the wiring loom to the engine control unit from the
cable guide using the removal tool -MP8-602/1- and lay it on
the engine.

– Disconnect plug connection -arrow- at the bottom left frame

side rail.

Note

For purposes of presentation, the fitting position is shown from

below.

– Remove the cable strap of the -arrow- protective cover, if

present.
– Unbolt earth strap -1-.
– Unplug connector -2-.
– Pull back the protective cover and unscrew the cable from the
solenoid switch of the starter.
– Disconnect further necessary plug connections at the engine
and gearbox or line connections to engine and gearbox.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

14 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

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

– Pull off coolant hose from the top and bottom of the coolant
expansion reservoir.
Vehicles with auxiliary heating.
– Place a catch pan for coolant under the auxiliary heating.
– Detach the coolant hoses of the auxiliary heating.
Vehicles fitted with a manual gearbox
– Remove shift mechanism from gearbox ⇒ gearbox ⇒ Rep.
gr. 34 .
– Remove pressure line from breather/slave cylinder ⇒ Gearbox
⇒ Rep. gr. 30 .

WARNING

After separating the hydraulic line, do not operate the clutch

pedal.

Vehicles with automatic gearbox

– Remove shift mechanism from gearbox ⇒ Automatic Gearbox
⇒ Rep. gr. 34 .
Continued for all vehicles
– Unclamp all remaining connecting, coolant, vacuum and suc‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
tion hoses from the
unless authorised engine.
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Release all remaining plugs at engine and gearbox and lay
aside the relevant lines.

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

-2- and screw -1- to 20 Nm.
– Insert engine/gearbox jack -V.A.G 1383 A- in the engine
mount and slightly raise.

Note

Use the double ladder to release the screws for the engine/gear‐
box mounting.

1. Removing and installing engine 15

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Successively release screws for engine mount -arrows-.

– Successively release screws for gearbox mount -arrows-.

Note

♦ Check whether all hose and line connections between engine,

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

– Carefully lower engine with gearbox. During this procedure,

turn or move the engine with the gearbox depending upon the
constriction.
– Remove the gearbox from the engine.

1.3 Securing the engine to the assembly

stand
Special tools and workshop equipment required
♦ Engine mount -MP1-202- or -VAS 6095-
♦ Hook -MP1-202/10-
♦ Assembly stand -MP9-101-
♦ Lifting device -MP9-201 (2024A)-
♦ Bushing -T30010 (VW 540/1B)-
♦ Workshop crane , e.g. -VAS 6100-
• Separate engine fromProtected
gearbox. by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
WARNING

Use securing pins on the hooks and rig pins to prevent release.

16 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Attach lifting device -MP9-201- at engine and at workshop

crane e.g. -VAS 6100- .
belt pulley side
♦ 2. Hole of the attachment in Position 1
Flywheel side
♦ 4. Hole of the attachment in Position 8

Note

The illustration shows a pump injector engine. The attachment for

the Common Rail engine occurs in the same way.

– Lift off engine with installed engine mount -T10012- with work‐
shop crane from engine/gearbox jack.
– Remove engine mount -T10012 - .

– For carrying out assembly work, attach the engine with engine
mount -MP1-202- , hooks -MP1-202/10- and sleeves -T30010-
or engine mount -VAS 6095- to the assembly stand -
MP9-101-
Protected . The
by copyright. figure
Copying shows
for private the 1.9purposes,
or commercial ltr./47inkW SDI
part or Engine.
in whole, is not permitted
The
unless fixingbysystem
authorised ŠKODA AUTOis identical.
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1.4 Installing the engine

Special tools and workshop equipment required
♦ Grease -G 000 100- for manual gearbox
♦ High temperature grease -G 052 133 A2- for automatic gear‐
box
• Fit engine with engine mount to engine/gearbox jack .
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Observe all safety measures and notes for assembly work on

the fuel and injection system, the charge air system as well as
the rules for cleanliness ⇒ page 2 .
♦ When undertaking assembly replace self-locking nuts and
screws which have been tightened to a torquing angle.
♦ Always replace gasket rings and seals.
♦ All cable straps should be fastened again in the same place
when installing.
♦ Secure all hose connections with corresponding hose clamps
⇒ Electronic Catalogue of Original Parts .

1. Removing and installing engine 17

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Caution

When undertaking all installation work, particularly in the en‐

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

Vehicles fitted with a manual gearbox

Note

♦ Clean the drive shaft serration and hub serration on a used

clutch disc, remove corrosion and only apply a very thin layer
of grease -G 000 100- on the serration. Subsequently move
the clutch disc up and down on the drive shaft until the hub fits
smoothly on the shaft. Always remove excess grease.
♦ After installing the coupling, check the centering of the clutch
disc ⇒ gearbox ⇒ Rep. gr. 30 .
♦ Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ gearbox ⇒ Rep. gr. 30 .

Vehicles with automatic gearbox

Note

♦ Check needle bearing for drive shaft pin in the crankshaft. Re‐
place bearing if worn ⇒ page 58 .
♦ Lubricate needle bearing and drive shaft pin with a thin layer
of high temperature grease -G 052 133 A2- . Do not grease
the serration of the drive shaft.

Continued for all vehicles

– Check whether the dowel sleeves for centering the engine/
gearbox are present in the cylinder block; insert if necessary.

– Ensure that the intermediate plate has been inserted on the

sealing flange and is pushed onto the dowel sleeves
-arrows-.
– Screw on gearbox to engine ⇒ gearbox ⇒ Rep. gr. 34 .
– Insert engine with gearbox
AUTO into the body.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

18 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Successively screw in by hand the screws for engine mount

-arrows-.

– Successively screw in screws for gearbox mount -arrows- at

gearbox 0A4 or ...

... at gearbox 02E -arrows- by hand.

– Align engine and gearbox mount and tighten screws
⇒ page 22 .
– Remove engine mount -T10012- from engine.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Install pre-exhaust pipe:
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Engine identification characters CFHC, CFHF ⇒ page 225

♦ Engine identification characters CLCA, CLCB ⇒ page 228

1. Removing and installing engine 19

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– First screw on pendulum support with new screws -2- and

-3- at gearbox and then screw on with new screw -1- at as‐
sembly carrier.
– Install the left and right drive shaft ⇒ Chassis ⇒ Rep. gr. 40 .
Vehicles fitted with a manual gearbox
– Connect hydraulic line to breather/slave cylinder and bleed the
clutch hydraulic ⇒ Gearbox ⇒ Rep. gr. 30 .
– Attach the shift mechanism to the gearbox and adjust ⇒ Gear‐
box ⇒ Rep. gr. 34 .
Vehicles with automatic gearbox
– Attach shift mechanism to gearbox ⇒ Automatic Gearbox ⇒
Rep. gr. 34 .
Continued for all vehicles
– Install AC compressor at the bracket for auxiliary units
⇒ page 24 .
– Install the V-ribbed belt ⇒ page 27 .
– Install radiator ⇒ page 129 .
– Install fan shroud with radiator fan ⇒ page 128 , to do so pay
attention to the clearance of the radiator fans.
– Connect all connecting, fuel, cooling fluid, vacuum and suction
hoses to the engine.
– Connect electrical connections and attach cables ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
– Carry out cohesive work when reconnecting the battery ⇒
Electrical System ⇒ Rep. gr. 27 .
– Install bulkhead plenum chamber and plenum chamber cover
⇒ Body Work ⇒ Rep. gr. 66 .
– Install wiper arms ⇒ Electrical System ⇒ Rep. gr. 92 .
– Top up coolant ⇒ page 115 .
– Checking the oil level ⇒ Maintenance ; Booklet Octavia II .
– Install the noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Install the left and right wheelhouse liner bottom part ⇒ Body
Work ⇒ Rep. gr. 66 .
– Perform a test drive.
– Interrogate the fault memory of the engine control unit, if nec‐
essary remove any faults which exist and delete the fault
memory ⇒ Vehicle diagnostic, testing and information system
VAS 5051.

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.

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

20 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Tightening torques
Component Nm
Screws or nuts M6 8 (9)1)
M7 13 (13)1)
M8 20 (20)1)
M10 40 (40)1)
M12 65 (70)1)
Engine/gearbox connecting screws ⇒
gearbox ⇒ Rep. gr. 34
1) The instruction in the brackets applies to collar screws and col‐
lar nuts.

1.5 Assembly bracket

Tightening torques
Assembly bracket
1 - 20 Nm + 90° (1/4 turn) - replace

2 - 40 Nm + 90° (1/4 turn) - replace

3 - 60 Nm + 90° (1/4 turn) - replace

Gearbox mount 0A4 (MQ 250)

A - 40 Nm + 90° (1/4 turn) - replace

B - 60 Nm + 90° (1/4 turn) - replace

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Gearbox mount 02E (MQ with250)
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1 - 40 Nm + 90° (1/4 turn) - replace

2 - 60 Nm + 90° (1/4 turn) - replace

1. Removing and installing engine 21

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Pendulum support
A - 50 Nm + 90° (1/4 turn) - replace

B - 100 Nm + 90° (1/4 turn) - replace

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

1.6 Adjusting the unit mounting

Special tools and workshop equipment required
♦ Supporting device -T30099-
♦ Surface -T30099/1-
♦ Adapter -MP9-200/3 (10-222A/3)-
or

♦ Engine mount -T10012-

♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
Precondition
• Engine with gearbox supported with supporting device -
T30099- , base -T30099/1- and adapter -MP9-200/3 - or en‐
gine with gearbox supported with engine mount -T10012- and
engine/gearbox jack -V.A.G 1383 A - .

– Slacken screws -arrows- for engine mount by approx. 1 turn.

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

22 Rep. gr.10 - Removing and installing engine

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release screws for gearbox mount at gearbox 0A4 -arrows-

or ...

... at gearbox 02E -arrows- by approx. 1 turn.

– Successively replace all the screws of the assembly bracket
(as long as it has not already been performed when installing)
and insert these loosely.

The following dimensions -a- and -x- must be maintained:

• Between engine bracket and engine support there must be a
distance -a- = 10 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.

Note

The distance -a- = 10 mm can be checked e.g. with suitable round

bars.

– Tighten the screws of the assembly bracket.

Tightening torques of the unit mounting ⇒ page 21 .

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

1. Removing and installing engine 23

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

13 – Crankshaft group
1 Removing and installing a V-ribbed
belt and a toothed belt

1.1 V-ribbed belt drive - Summary of com‐

ponents

1.1.1 Vehicles without air conditioning

1 - Crankshaft-belt pulley
❑ with vibration damper
❑ pay attention to correct
installation position
⇒ page 25
❑ removing and installing
⇒ page 29
2 - 25 Nm
3 - AC generator
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ removingunless
andauthorised
installingby ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ Electrical
withSystem ⇒ correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
respect to the
Rep. gr. 27
4 - Bracket for auxiliary units
❑ order of tightening
⇒ page 25
5 - V-ribbed belt
❑ removing and installing
⇒ page 27
❑ do not kink
❑ check for wear, replace
if damaged
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it.

24 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Fitting position of the crankshaft-belt pulley

• The hole -arrow- in the crankshaft belt pulley must be posi‐
tioned above the peg on the crankshaft timing belt sprocket.

Bracket for auxiliary units - tightening order and tightening torques

• A dowel sleeve must be located between the bracket for aux‐
iliary units and the cylinder block in the area of the screw hole
-6-.
– Insert new fixing screws for the bracket for auxiliary units as
follows:
♦ Screws -1- and -2- M10 x 52
♦ Screws -3- and -4- M10 x 30
♦ Screws -5- and -6- M10 x 60
– Gradually tighten the fixing screws for the bracket for auxiliary
units in the sequence -1…6-:
1. Screw in all the screws by hand.
2. Tighten all screws to 40 Nm.
3. Torque the screws with a rigid wrench as follows:
Torque screws -1 and 2- a further 90° (1/4 turn.)

Torque screws -3 and 4- a further 45° (1/8 turn.)

Torque screws -5 and 6- a further 90° (1/4 turn.)

1.1.2 Vehicles with air conditioning

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

1. Removing and installing a V-ribbed belt and a toothed belt 25

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Crankshaft-belt pulley
❑ with vibration damper
❑ pay attention to correct
installation position
⇒ page 26
❑ removing and installing
⇒ page 29
2 - 25 Nm
3 - AC generator
❑ removing and installing
⇒ Electrical System ⇒
Rep. gr. 27
4 - Bracket for auxiliary units
❑ order of tightening
⇒ page 27
5 - 20 Nm + torque a further
180° (1/2 turn)
❑ replace
6 - Tensioning element
❑ for the V-ribbed belt
7 - AC compressor
❑ removing and installing
⇒ Heating, Air Condi‐
tioning ⇒ Rep. gr. 87
8 - 45 Nm
9 - Fitting sleeve
❑ pay attention to correct
fit in the holder
10 - V-ribbed belt
❑ mark the direction of ro‐
tation with chalk or a felt-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
tiprespect
with pen to before removing
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ removing and installing ⇒ page 27
❑ check for wear, replace if damaged
❑ do not kink
❑ pay attention to the correct position on the belt pulley when installing it.

Fitting position of the crankshaft-belt pulley

• The hole -arrow- in the crankshaft belt pulley must be posi‐
tioned above the peg on the crankshaft timing belt sprocket.

26 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Bracket for auxiliary units - tightening order and tightening torques

• A dowel sleeve must be located between the bracket for aux‐
iliary units and the cylinder block in the area of the screw hole
-6-.
– Insert new fixing screws for the bracket for auxiliary units as
follows:
♦ Screws -1- and -2- M10 x 52
♦ Screws -3- and -4- M10 x 30
♦ Screws -5- and -6- M10 x 60
– Gradually tighten the fixing screws for the bracket for auxiliary
units in the sequence -1…6-:
1. Screw in all the screws by hand.
2. Tighten all screws to 40 Nm.
3. Torque the screws with a rigid wrench as follows:
Torque screws -1 and 2- a further 90° (1/4 turn.)

Torque screws -3 and 4- a further 45° (3/8 turn.)

Torque screws -5 and 6- a further 90° (5/4 turn.)

1.2 Removing and installing V-ribbed belt

for vehicles without air conditioning sys‐
tem

Note

The repair kit for the V-ribbed belt includes the assembly device
-T10367- and an illustrated ⇒ work procedure .
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Removing with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .

– Remove the right wheelhouse liner ⇒ Body Work ⇒ Rep. gr.
66 .
– Cut through V-ribbed belt.
Install
Installation is performed in the reverse order, pay attention to the
following points:
– The following work procedure is described in the illustrated ⇒
work procedure .
– Start engine and check ribbed V-belt run.

1.3 Removing and installing V-ribbed belt

for vehicles with air conditioning system
Special tools and workshop equipment required
♦ Locking pin -T10060 A-
Removing
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Remove the right wheelhouse liner bottom part ⇒ Body Work
⇒ Rep. gr. 66 .

1. Removing and installing a V-ribbed belt and a toothed belt 27

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Caution

Risk of damage through reversing the rotation direction of an

already used V-ribbed belt.
♦ If it is intended to re-install the V-ribbed belt, mark the di‐
rection of rotation with chalk or a felt-tip pen before re‐
moving it.

– Loosen the V-ribbed belt by swivelling the tensioning element

in -the direction of the arrow-.

– Align the holes -arrows- and lock the tensioning element using
the locking pin -T10060 A- .
– Remove the V-ribbed belt.
Install
Installation is performed in the reverse order, pay attention to the
following points:
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Note with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.

– Lay the V-ribbed belt onto the V-ribbed belt pulleys.

1- Crankshaft belt pulley with vibration damper
2- Tensioning element
3- AC generator
4- AC compressor

28 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Hold the tensioning element with the ring spanner and pull out
the locking pin -T10060 A- .
– Release the tensioning element.
– Check correct positioning of the V-ribbed belt.
– Start engine and check ribbed V-belt run.

1.4 Removing and installing crankshaft-belt

pulley
Removing
– Remove V-ribbed belt ⇒ page 24 .
– Remove the cover for the vibration damper.
– Loosen the screws -arrows- of the crankshaft belt pulley, to do
so hold the screw for the crankshaft timing belt sprocket using
the ring spanner.
– Release screws and remove crankshaft-belt pulley.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Pay attention to the fitting position of the crankshaft belt pulley

⇒ page 26 or ⇒ page 25 .
♦ Replace the screws of the crankshaft belt pulley.
♦ Tightening torques: ⇒ page 24

1.5 Removing and installing tensioning ele‐

ment for V-ribbed belt
Removing
– Remove V-ribbed belt ⇒ page 27 .
– Remove right charge air hose.
– Remove fan shroud with radiator fans ⇒ page 128 .

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

1. Removing and installing a V-ribbed belt and a toothed belt 29

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release screws -arrows-.

– Expose coolant hose -3-.
– Loosen hose clamp -2-.
– Disconnect the plug -1- at the charge pressure sender -G31-
with intake air temperature sender -G42- and remove the right
charge air pipe.

– Unscrew screw -2- and remove tensioning element -1- from V-

ribbed belt.
Install
Installation is performed in the reverse order,
Protectedpay attention
by copyright. to for
Copying theprivate or commercial purposes, in part or in whole, is not permitted
following points: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Tightening torques: ⇒ page 25
– Replace the screw of the tensioning element for the V-ribbed
belt.
– Install the V-ribbed belt ⇒ page 27 .

1.6 Timing belt drive - Summary of components

30 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Toothed belt
❑ before removing mark
running direction
❑ check for wear
❑ do not kink
❑ removing and installing
⇒ page 33

Note

If the toothed belt is replaced when

carrying out engine repair (apart
from regular change interval), it
should be entered in the ⇒ Service
Schedule !

2 - 120 Nm + torque a further

90° (1/4 turn)
❑ replace
❑ to release and tighten
use counterholder -
T30004 (3415)-
❑ Neither oil nor grease
thread or collar.
❑ tightening may occur in
successive stages
3 - Crankshaft - toothed belt
sprocket
❑ at the crankshaft
4 - 20 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
5 - Guide pulley
❑ for toothed belt
6 - 20 Nm + torque a further 45°
(1/8 turn)
7 - Tensioning pulley
❑ for toothed belt
❑ for removing and installing, remove engine support ⇒ page 33
8 - 20 Nm + torque a further 45° (1/8 turn)
9 - Toothed belt gear
❑ on the camshaft
10 - 20 Nm
11 - 100 Nm
❑ to release and tighten use counterholder -T10051-
12 - Hub
❑ for camshaft
❑ to remove use extractor -T10052-
❑ removing and installing ⇒ page 85
13 - Rear toothed belt guard
14 - 20 Nm + torque a further 45° (1/8 turn)
❑ replace
❑ Attach high pressure pump

1. Removing and installing a V-ribbed belt and a toothed belt 31

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

15 - 9 - 12 Nm
❑ replace
16 - Guide pulley
❑ for toothed belt
17 - 50 Nm + torque a further 90° (1/4 turn)
❑ replace
18 - Hub
❑ for high pressure pump
❑ to release and tighten use counterholder -T10051-
❑ to remove use extractor -T40064-
❑ removing and installing ⇒ page 187
19 - 95 Nm
20 - Toothed belt gear
❑ on the high pressure pump
21 - 20 Nm + torque a further 90° (1/4 turn)
❑ replace
22 - Coolant pump
❑ removing and installing ⇒ page 121
23 - 15 Nm
24 - Timing belt guard - top part
25 - Timing belt guard - bottom part
❑ removing and installing ⇒ page 33
26 - 9 Nm
❑ apply locking agent -D 000 600 A2- before installing
27 - 10 Nm + torque a further 90° (1/4 turn)
❑ replace
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
28 - Crankshaft-belt pulley
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ with vibration damper
29 - 5 Nm
30 - Protection plate
31 - 40 Nm + torque a further 180° (1/2 turn)
❑ replace
❑ observe the order of tightening up ⇒ page 33
32 - Engine support bracket

32 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Secure the engine support

Note

Replace screws for engine support.

– Tighten screws in 3 stages in the following sequence:

Stage Tightening order Torque/torquing angle
1. -2, 1, 3-, 7 Nm
2. -2, 1, 3- 40 Nm
3. -2, 1, 3- 180° (1/2 turn)

Attach toothed belt guard - bottom part

– Insert screws with locking agent -D 000 600 A2- .
– Tighten screws -arrows- to 9 Nm ⇒ Item 26 (page 32) .

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

1.7 Removing and installing toothed belt

Special tools and workshop equipment required
♦ Rig pin for diesel injection pump -3359- (2x)
♦ Crankshaft arrester -T10050-
♦ Locking pin -T10060 A-
♦ Counterholder -T10172 - with bolts -T10172/4- and bolts -
T10172/9-
♦ Offset screwdriver -T10264-
♦ Rig tool -T10265 -
♦ Socket insert -T10385-
♦ Pliers for spring strap clamps

1. Removing and installing a V-ribbed belt and a toothed belt 33

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.7.1 Removing

Caution

When undertaking all installation work, particularly in the en‐

gine compartment because of its cramped construction, please
observe the following:
♦ If the toothed belt is replaced when carrying out engine
repair (apart from regular change interval), it should be
entered in the ⇒ Service Schedule !
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.

Note

♦ Observe safety measures when working on the fuel system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .
♦ The engine support does not have to be removed in order to
remove the camshaft sprocket.
♦ For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must be disconnected additionally.

– Put the shift lever into Neutral or the selector lever into position
„N“ in order to turn the crankshaft.
– Switch off ignition and withdraw ignition key.
– Remove engine cover ⇒ page 7 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove noise insulation ⇒ Body Work ⇒withRep.
respectgr.
to the66 .
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Detach fuel feed line -2- and fuel return-flow line -1-, to do so
press in securing ring.
Vehicles with engine identification characters CFHC, CFHF

34 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect plug -2- at differential pressure indicator -G505- .

– Screw out screw -3- and remove bracket with differential pres‐
sure indicator -G505- from the bracket of the additional fuel
pump in -direction of arrow-.
– Place the bracket with the differential pressure indicator -
G505- to the rear.

Caution

Risk of damage!
♦ The differential pressure indicator -G505- is very sensitive
and must not touch somewhere when laying it down with
the bracket.

Continued for all vehicles

– Unscrew bolt -1-.

– Push the filler tube with the filler neck -2- for the washer-fluid
reservoir to the side.

Note

For reasons of clarity the fuel filter is not shown.

– Unhook the fuel hose -2- from the bracket.

– Remove the bracket for the fuel lines upwards in
-direction of arrow- and place it to the side.
– Disconnect plug -1- from the additional fuel pump -V393- .
– Unscrew bolts -3-.

– Loosen screw -1- by 2 turns.

– Release screw -2- and nut -3-.
– Unclip bracket for coolant line at fuel filter.
– Lay the compensation bottle with the hoses connected and the
fuel filter with the hoses connected onto the engine.

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

1. Removing and installing a V-ribbed belt and a toothed belt 35

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect plug -3- at the coolant temperature sender at ra‐

diator outlet -G83- .
– Release nut -1- and screw -2-.
– Press the right coolant pipe with the hoses connected
-arrows- to the side.

– Remove top part of toothed belt guard; to do so release re‐

taining clips -arrows-.
– Remove crankshaft belt pulley.

Note

Do not lock tensioning element for V-ribbed belt.

– Release screws -arrows-.

– Remove bottom part of toothed belt guard.

– Rotate the crankshaft in direction of rotation of engine at top

dead centre and remove the crankshaft toothed belt sprocket
with the crankshaft arrester -T10050- . To do so, slide the
crankshaft arrester from the front side of the timing belt sprock‐
et into its teeth.

Note

The markings on the crankshaft timing belt sprocket -2- and the
crankshaft arrester -T10050- -1- must be positioned opposite
each other. While doing so, the stud of the crankshaft arrester -
T10050- must engage in the hole of the sealing flange.

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

36 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

While doing so, the arrow on the camshaft sprocket must be close
to the »12 o'clock« position.
– Successively release the screws -1- of the camshaft sprocket,
replace these screws and do not fully screw in the new screws
by hand.

– Successively release the screws -2- of the toothed belt sprock‐

et at the high pressure pump, replace these screws and do not
fully screw in the new screws.

– Loosen nut -1- for tensioning pulley.

– Turn the eccentric of the tensioning pulley with the offset
screwdriver -T10264- in Protected
-direction of arrow- (anti-clockwise)
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
until the tensioning pulley can
unless be interlocked
authorised by ŠKODA AUTO with the
A. S. rig tool
ŠKODA AUTO A. S. does not guarantee or accept any liability
-T10265- . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Afterwards, turn the eccentric of the tensioning pulley with the

offset screwdriver -T10264- in -direction of arrow- up to the
stop and tighten nut -1- by hand.

Caution

Risk of damage through reversing the rotation direction of an

already used toothed belt.
♦ If the toothed belt is re-installed, mark the direction of ro‐
tation with chalk or a felt-tip pen before removing it.

– First of all remove the toothed belt from the large guide pulley
and then from the remaining toothed belt gears.

1. Removing and installing a V-ribbed belt and a toothed belt 37

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.7.2 Installing (set the timing)

Note

♦ Adjusting work on the timing belt must only be performed on

a cold engine, as the position of the pointer at the tensioning
element is temperature dependent.
♦ If it is intended to replace the tensioning pulley, the engine
support must be removed.

Conditions

• Tensioning pulley locked with rig tool -T10265- and fixed with
nut up to right stop.
• Lock the crankshaft with the crankshaft arrester -T10050- .
• The screws for the camshaft sprocket and the toothed belt
gear on the high pressure pump are replaced and loosely
tightened. It must still be possible to just turn the timing belt
gears, however they must not tilt.

Note

If necessary, turn the hub of the camshaft using the counterholder

-T10172- with adapters -T10172/4- until it can be locked. To do
so tighten at least one fixing screw -1- by hand.

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

38 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Lock the hub of the camshaft with the rig pin for injection pump
-3359- . To do so, insert rig pin through the open elongated
hole in the cylinder head bore.
– Loosen again the screws which were tightened by hand.

– Lock the hub of the high pressure pump with the rig pin for
injection pump -3359- . To do so, insert the rig pin into the hole
of the timing belt gear from the outside.

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

Note

If necessary, use a screwdriver to turn the hub of the high pres‐

sure pump at the screw heads -1- until the hub can be locked with
the rig pin.

1. Removing and installing a V-ribbed belt and a toothed belt 39

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Turn the camshaft sprocket -3- and the toothed belt sprocket
on the high pressure pump -5- clockwise in their elongated
holes as far as the stop.
– Fit the toothed belt in the following order:
1- Crankshaft - toothed belt sprocket
2- Tensioning pulley
3- Camshaft sprocket
4- Timing belt gear on the coolant pump
5- Toothed belt gear on the high pressure pump
6- Guide pulley

– Loosen nut -1- for tensioning pulley and remove rig tool -
T10265- .

Note

Pay attention to correct fitting of the tensioning pulley in the rear

timing belt cover -arrow-.

– Fit counterholder -T10172- with adapters -T10172/4 - onto

camshaft sprocket.
– Push the counterholder in -direction of arrow- and keep it pre‐
tensioned.
– First of all tighten the screws -1- for the camshaft sprocket and
the screws -2- for the toothed belt gear on the high pressure
pump in this position to 20 Nm.

Note

The screws must be further turned after the setting and testing of
the timing have been carried out ⇒ page 43 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
40 Rep. gr.13 - Crankshaft group
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Turn the eccentric of the tensioning pulley with the offset

screwdriver -T10264- clockwise -arrow- until the pointer -2- is
in the centre of the base plate in front of the gap.
• The nut -1- must not turn along.
– Hold tensioning pulley in this position and tighten nut.
Tightening torque: 20 Nm + torque a further 45° (1/8 turn)
– Remove locking pins -3359- and the crankshaft arrester -
T10050- .
Test timing
– Turn the crankshaft at the central screw for the crankshaft
toothed belt sprocket 2 turns in the direction of rotation of the
engine until the crankshaft is positioned shortly before „TDC“.

– Position the crankshaft arrester -T10050- on the crankshaft

toothed belt sprocket.
– Turn the crankshaft in the direction of rotation of the engine
until the bolt -arrow- of the crankshaft arrester engages during
this rotary movement into the hole in the sealing flange.

Note

The removal of the crankshaft and camshaft is limited in the fol‐

lowing test. The removal point of the hub of the high pressure
pump is always difficult to find again. A slight difference -arrow-
does not influence the engine running.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

41
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1. Removing and installing a V-ribbed belt and a toothed belt
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Conditions
• The hub of the camshaft must be locked with the rig pin for
injection pump -3359- .
• The pointer of the tensioning pulley -2- must be in the area
-a- of the base plate -1-.
If the conditions are not fulfilled:
– Correct timing ⇒ page 42 .
If the conditions are fulfilled:
– Continued if the timing is correctly set ⇒ page 43 .
Correct timing
– Push the crankshaft arrester -T10050- until its locking bolt
pushes out of the hole in the sealing flange.
– Turn the crankshaft against the running direction of the engine
slightly before the „TDC“.
– Now slowly turn with the crankshaft in the running direction of
the engine, until the hub of the camshaft can be locked during
this rotary movement with the rig pin for the injection pump
-3359- .
– Slacken the fixing screws for the camshaft sprocket on the
locked hub of the camshaft sprocket.
– unless
Check the position
authorised of the
by ŠKODA AUTO bolt
A. S. ŠKODAof the
AUTOcrankshaft arrester
A. S. does not guarantee -
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
or accept any liability
T10050-
with respectto thecorrectness
to the hole inofthe sealing
information flange:
in this document. Copyright by ŠKODA AUTO A. S.�

42 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

If the bolt of the crankshaft arrester -T10050- is positioned to the

left of the hole:
– Slowly turn the crankshaft in the direction of rotation of the
engine until the bolt of the crankshaft arrester -T10050- en‐
gages into the hole in the sealing flange.
– First tighten the fixing screws for the camshaft sprocket to 20
Nm.

Note

The screws must be further turned according to the setting of the

timing ⇒ page 43 .

If the bolt of the crankshaft arrester -T10050- is positioned to the

right behind the hole:
– First of all turn the crankshaft slightly against the direction of
rotation of engine until the bolt is positioned to the left in front
of the hole.
– Slowly turn the crankshaft in the direction of rotation of the
engine until the bolt of the crankshaft arrester -T10050- en‐
gages into the hole in the sealing flange.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– respect
with Firsttotighten the fixing
the correctness screws
of information in this for the camshaft
document. sprocket
Copyright by ŠKODA AUTO to 20
A. S.�
Nm.

Note

The screws must be further turned according to the setting of the

timing ⇒ page 43 .

Continued if the timing is correctly set

– Remove the locking pin -3359- and the crankshaft arrester -
T10050- .
– Once again test timing ⇒ page 41 .
If the hub of the camshaft sprocket can now be removed:
– Tighten the fixing screws of the toothed belt sprockets with a
rigid wrench as follows:
♦ Camshaft sprocket:

– 45° (torque a further 45° (1/8 turn). Counterhold counterholder

-T10172- with adapters -T10172/4- .
♦ Toothed belt sprocket on the high pressure pump:

1. Removing and installing a V-ribbed belt and a toothed belt 43

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– 90° (torque a further 45° (1/4 turn). Counterhold counterholder

-T10172- with adapters -T10172/9- .
Further installation occurs in reverse order to removal.
Tightening torques: ⇒ page 30

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

44 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2 Removing and installing sealing

flange and two-mass flywheel

Note

Repairs to the clutch ⇒ gearbox ⇒ Rep. gr. 30 .

1 - Sealing ring
❑ replace ⇒ page 46
❑ do not oil or grease
2 - Sealing flange
❑ on belt pulley side
❑ must be positioned on
dowel sleeves
❑ removing and installing
⇒ page 47
3 - Cylinder block
4 - The two-mass flywheel
❑ removing and installing
⇒ page 55
❑ assembly is only possi‐
ble in one position
through offset holes
5 - 60 Nm + torque a further 90°
(1/4 turn)
❑ replace
6 - Intermediate plate
❑ must be positioned on
dowel sleeves
❑ do not damage/bend
during assembly work
❑ hang on the sealing
flange ⇒ page 46
7 - 15 Nm
❑ replace
8 - Sealing flange
❑ on gearbox side
❑ can only be replaced
complete with gasket
Protected ring and
by copyright. with
Copying for rotor ofcommercial
private or engine purposes,
speed insender -G28-
part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ replace ⇒ page with49
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

9 - Engine speed sender -G28-

❑ removing and installing ⇒ page 184
10 - 5 Nm

2. Removing and installing sealing flange and two-mass flywheel 45

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Installing intermediate plate

– Insert intermediate plate on sealing flange -top arrow- and
push onto the dowel sleeves -side arrows-.

2.1 Replacing crankshaft seal on belt pulley

side
Special tools and workshop equipment required
♦ Counterholder -T30004 (3415)- or Counterholer -MP1-310
(3099)-
♦ Gasket ring extractor -MP1-226 (3203)-
♦ Assembly device -T10053-
Removing
• Engine installed.
– Removing toothed belt ⇒ page 33 .
– Remove crankshaft - toothed belt sprocket, to this end lock
toothed belt sprocket with counterholder -T30004- or counter‐
holder -MP1-310- .

– To guide the gasket ring extractor -MP1-226- screw the central

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

46 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Turn inner part of gasket ring extractor -MP1-226- two turns

(approx. 3 mm) out of the outer part and secure with knurled
screw.
– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Release knurled screw and turn the inner side against the
crankshaft until the gasket ring is pulled out.
– Clamp gasket ring extractor into the vice and remove gasket
ring with pliers.
– Clean the contact and sealing surfaces.
Install

Note

Do not oil the sealing lip and the outer surface of the new gasket
ring before the pressing in procedure.

– Remove oil residue on the crankshaft journal with a clean

cloth.

– Insert guide bushing -T10053/1- on the crankshaft journal.

– Slide gasket ring over the guide bushing.

– Press in the gasket ring flush with the central screw for the
crankshaft toothed belt sprocket and with the pressure bush‐
ing of the assembly device -T10053- .

Note

♦ There must not be any oil present on the contact surface be‐
tween toothed belt sprocket and crankshaft.
♦ Replace central screw for crankshaft toothed belt sprocket.
♦ Do not oil central screw for crankshaft toothed belt sprocket.
♦ Tighten central screw ⇒ page 30 .

– Install crankshaft - toothed belt sprocket, to this end lock tooth‐

Protected byed belt sprocket
copyright. with orcounterholder
Copying for private commercial purposes,. in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Installing the timing belt ⇒ page 38 .
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2.2 Removing and installing the sealing

flange on the belt pulley side
Special tools and workshop equipment required
♦ Counterholder -T30004 (3415)- or Counterholer -MP1-310
(3099)-

2. Removing and installing sealing flange and two-mass flywheel 47

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

♦ Assembly device -T10053-

♦ Protective goggles and gloves
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Silicone sealant -D 176 404 A2-
Removing
• Engine installed.
– Removing toothed belt ⇒ page 33 .
– Remove crankshaft - toothed belt sprocket, to this end lock
toothed belt sprocket with counterholder -T30004- or counter‐
holder -MP1-310- .
– Drain engine oil ⇒ Maintenance ; Booklet Octavia II .
– Removing the oil pan ⇒ page 103 .
– Unscrew the fixing screws of the sealing flange on the belt
pulley side and remove sealing flange, if necessary release by
applying slight blows with a rubber-headed hammer.
– Drive out the gasket ring from the removed sealing flange.
Install
Installation is performed in the reverse order, pay attention to the
following points:

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Wear protective gloves andauthorised
unless goggles whenAUTO
by ŠKODA working with AUTO
A. S. ŠKODA gasketA. S. does not guarantee or accept any liability
remover and degreasing agent!
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Remove residual sealant from the sealing surfaces on sealing

flange, cylinder block and on the oil pan with chemical sealant
remover.
– Degrease the sealing surfaces.

Note

Pay attention to the use by date on the silicone sealant.

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

3 mm).

48 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Apply silicone sealant bead -arrow- to the clean sealing sur‐

face of the upper part of the sealing flange, as shown.
• Thickness of sealant bead -arrow-: 2…3 mm

Note

♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clog the strainer
in the intake manifold of the oil pump.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ When installing the sealing flange with the gasket ring fitted
place a guide sleeve -T10053/1- on the crankshaft journal.

– Carefully push the sealing flange onto the dowel sleeves at the
cylinder block and tighten new fixing bolts by hand.
– Tighten the screws of the sealing flange alternately and cross‐
wise to 15 Nm.
– Installing the oil
Protected pan ⇒Copying
by copyright. page for
103 . or commercial purposes, in part or in whole, is not permitted
private
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Install the new
with gasket
respect ring forofthe
to the correctness crankshaft
information on theCopyright
in this document. belt pulley
by ŠKODA AUTO A. S.�
side ⇒ page 46 .
– Installing the timing belt ⇒ page 38 .
– Top up with engine oil and check the oil level ⇒ Maintenance ;
Booklet Octavia II .

2.3 Replace sealing flange on the gearbox

side
Special tools and workshop equipment required
♦ Assembly tool -T10134-
♦ Feeler gauge
♦ Steel straightedge
♦ Screw M6 x 35 (3x)
♦ Screw M7 x 35 (2x)

2.3.1 Removing
• Gearbox is removed.
– Remove the two-mass flywheel ⇒ page 55 .
– Remove the intermediate plate from the dowel sleeves and
unhook from sealing flange -arrows-.
– Position crankshaft to TDC for cylinder 1 ⇒ page 33 .
– Removing the oil pan ⇒ page 103 .

2. Removing and installing sealing flange and two-mass flywheel 49

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Remove engine speed sender -G28- -1-.

– Unscrew the fixing screws of the sealing flange.

– Screw 3 screws M6 x 35 mm into the threaded bores of the

sealing flange -arrows-.
– Remove the sealing flange together with rotor from the crank‐
shaft by alternately screwing in the press-off screws.

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

2.3.2 Install

Note

♦ The sealing flange with PTFE gasket ring is provided with

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

50 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

A - Mounting sealing flange with rotor on the assembly tool -

T10134-
A - Hexagon nut
B - Clamping surface
C - Assembly cup
D - Allan screw
E - Guide bolts for petrol engine - with red handle
F - Positioning pin
G - Guide bolts for diesel engine - with black handle

– Grip the assembly tool -T10134- on the clamping surface -B-

of the threaded spindle in a vice.
– Push assembly cup -C- down so that it rests on the hexagon
nut -A- -arrow-.
• The inner part of the assembly tool and the assembly cup must
be flush.

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

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

Note

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

– Lay the front side of the sealing flange on a clean and level
surface.
– Press down sealing lips supporting ring -A- in
-direction of the arrow-, until it rests on the level surface.

Note

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

2. Removing and installing sealing flange and two-mass flywheel 51

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

The locating hole -B- on the rotor -C- must be flush with the mark‐
ing -A- on the sealing flange.

– Lay the sealing flange with the front side on the assembly tool
-T10134- in such a way that the positioning pin -A- engages
into the hole -B- of the rotor.

Note

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

– When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly tool -
T10134- in such a way that the positioning pin can no longer
slide out of the rotor hole.
B - Mounting the assembly tool -T10134- with sealing flange on
the crankshaft flange
• The crankshaft flange must be free of grease and oil
• Crankshaft is at TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.

– Screw assembly tool -T10134- with Allan screws -A- up to the

stop onto the crankshaft flange.

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

52 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

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

for the sealing flange guide into the cylinder block.

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

-direction of the arrow- until the rotor -B- rests on the crank‐
shaft flange -A-. Subsequently insert the guide bolt for diesel
engines with black handle -D- fully into the threaded bore of
the crankshaft. If the guide bolt is correctly positioned, then the
handle has a distance of approx. 10 mm from the assembly
cup -C-. This gives the rotor its final fitting location.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.

Note

The guide bolt for petrol engines (red handle) -F- must not be fitted
into the threaded hole of the crankshaft. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
C - Pressing the rotor onto the crankshaft flange

– Tighten the hexagon nut of the assembly tool -T10134- using

a torque wrench with adapter.
Tightening torque: 35 Nm

Note

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

gap between the cylinder block and the sealing flange.

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

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

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

2. Removing and installing sealing flange and two-mass flywheel 53

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

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

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

– Position the steel striaghtedge onto the crankshaft flange.

– Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
– Press down rotor ⇒ page 54 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing alternately cross‐
wise.
Tightening torque: 15 Nm

– Install engine speed sender -G28- -1-.

Tightening torque: 5 Nm
– Installing the oil pan ⇒ page 103 .
– Installing intermediate plate.
– Install two-mass flywheel with new screws. Tighten fixing
screws to 60 Nm + torque a further 90°by(1copyright.
Protected /4 turn). Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
E - Pressing down the rotor with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Screw assembly tool -T10134- with Allan screws up to the stop

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

54 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

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

wrench with adapter.
Tightening torque: 40 Nm
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 53 .
If the dimension -a- is again too small:
– Tighten the hexagon nut of the assembly tool to 45 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 53 .

2.4 Removing and installing the two-mass

flywheel
Special tools and workshop equipment required
♦ Counterholder -MP1-223 (3067)-
or

♦ Engine mount -MP1-202 (VW 540)-

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

Engine removed
– Position the flywheel lock -MP1-504- on the starter ring gear
of the flywheel disk and turn crankshaft until it rests against
the sleeve -T30010 - .

2. Removing and installing sealing flange and two-mass flywheel 55

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Continued for all engines

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

Caution

When unscrewing the screws -B-, ensure that no screw head

catches on the secondary side -A- of the two-mass flywheel,
otherwise the flywheel will be damaged.

– Release screws -B- and remove two-mass flywheel.

Install
Installation occurs in reverse order to removal. Pay attention to
the following:

Note

Use new screws for attaching.

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

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

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

56 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

3 Crankshaft, Piston and Conrod

3.1 Removing and installing crankshaft

Note

The engine should be attached to the engine repair stand with the engine holder -MP1-202- for carrying out
removal and installation work.

1 - 65 Nm + torque a further 90°

(1/4 turn)
❑ replace
2 - Bearing caps
❑ Bearing cap 1: belt pul‐
ley side
❑ Bearing cap 3: with re‐
cesses for thrust wash‐
ers
❑ retaining lugs of the
bearing shells of the cyl‐
inder block/bearing cap
must be on top of one
another
3 - Bearing shell 3
❑ for cylinder block with lu‐
bricating groove
❑ for bearing cap without
lubricating groove
❑ do not mix up used bear‐
ing shells (mark)
4 - Thrust washers
❑ pay attention to locating
element
5 - Needle bearing
❑ only vehiclesProtected
with auto‐
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
matic gearbox
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ replace ⇒ page 58
6 - Crankshaft
❑ with timing belt sprocket
for oil pump drive
❑ Axial play when new:
0.07…0.17 mm
Wear limit: 0.37 mm
❑ Crankshaft bearing pins: ∅ 54.00 mm
❑ Conrod bearing pin: ∅ 50,90 mm
7 - Bearing shells 1, 2, 4 and 5
❑ for cylinder block with lubricating groove
❑ for bearing cap without lubricating groove
❑ do not mix up used bearing shells (mark)

3. Crankshaft, Piston and Conrod 57

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

3.2 Replace needle bearing for crankshaft

Only on vehicles equipped with automatic gearbox.
Special tools and workshop equipment required
♦ Centering mandrel -T30029 (3176)-
♦ Interior extractor -Kukko 21/2-
♦ Countersupport -Kukko 22/1-

Note

For installing an engine in a vehicle with automatic gearbox,

check whether the needle bearing is built on the gearbox side in
the crankshaft. Install the needle bearing as required.

Removing
– Pull out needle bearing with interior extractor -Kukko 21/2- and
countersupport -Kukko 22/1- .
Install
• Fitting position: The marked side of the needle bearing should
be legible when in its installed condition.

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

Depth of installation of the needle bearing.

• Dimension -a- = 1.5 up to 1.8 mm

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

3.3 Disassembling and assembling pistons and conrods

58 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Piston rings
❑ Offset joint 120°
❑ use piston ring pliers for
removing and installing
❑ marking „TOP“ faces
piston crown
❑ Inspect gap clearance
⇒ page 60
❑ Inspect end clearance
⇒ page 60
2 - Piston
❑ with combustion cham‐
ber
❑ mark installation posi‐
tion and matching cylin‐
der
❑ Installation position and
assignment of piston/
cylinder ⇒ page 61
❑ arrow on the piston
crown faces towards the
belt pulley side
❑ replace piston if there is
any sign of crack forma‐
tion on the piston body
❑ Inspecting piston
⇒ page 61
❑ Piston dimension: ∅
80,95 mm
❑ use piston ring tension‐
ing strap for installing
❑ inspect piston projection
at TDC ⇒ page 62
3 - Piston pin
❑ if stiff, heat piston to 60°C
❑ use drift -VW 222A- for removing and installing
4 - Circlip
❑ replace
5 - Conrod
❑ with a split bearing cap
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Markings -B- point towards the belt pulley side
❑ separate new conrod ⇒ page 63
❑ Axial clearance: Wear limit 0.37 mm
6 - Bearing shell
❑ Fitting position ⇒ page 62
❑ do not mix up used bearing shells (mark)
❑ Observe
Protected version:
by copyright. Copying top bearing
for private or commercialshell (towards
purposes, in part or the piston)
in whole, must be made from a long lasting material, rec‐
is not permitted
ognition
unless authorised feature
by ŠKODA AUTOfor new
A. S. ŠKODA bearing
AUTO A. shells:
S. does notblack
guaranteemarking on liability
or accept any the contact surface near the separation point
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ insert in middle ⇒ page 62
❑ pay attention to correct position
7 - Cylinder block
❑ Inspect cylinder ⇒ page 61

3. Crankshaft, Piston and Conrod 59

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011
❑ Cylinder dimension: ∅ 81,01 mm
8 - Conrod bearing cap
❑ Check fitting position
❑ cracked cover fits only in one position at the relevant conrod
❑ separate new conrod ⇒ page 63
9 - Oil injection nozzle
❑ for piston cooling
❑ removing and installing ⇒ page 62
10 - Pressure valve, 27 Nm
❑ replace without sealant
❑ removing and installing ⇒ page 62
11 - 30 Nm + torque a further 90° (1/4 turn)
❑ replace
❑ Oil thread and contact surface

Inspecting piston ring gap clearance

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

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

Special tools and workshop equipment required

60 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

♦ Feeler gauge
– Clean before inspecting the annular grooves of the piston.
Piston ring new Wear limit
(dimensions in mm)
1. Compression ring 0,06 … 0,09 0,25
2. Compression ring 0,05 … 0,08 0,25
Oil scraper ring 0,03 … 0,06 0,15
Inspecting pistons

Special tools and workshop equipment required

♦ External micrometer
– Measure about 10 mm from the lower edge, offset at right an‐
gles to the piston pin shaft.
• Max. deviation from specified dimension: 0,04 mm
Installation position and assignment of piston/cylinder
• The arrow on the piston crown -arrows- faces towards the belt
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
pulley side.unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Inspecting cylinder bore

3. Crankshaft, Piston and Conrod 61

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Special tools and workshop equipment required

♦ Internal precision measuring instrument
– Measure cylinder at 3 points crosswise in transverse direction
-A- and lengthwise -B-.
• Max. deviation from specified dimension: 0.10 mm
Fitting position of the bearing shells in the conrods
– Insert bearing shell in the conrod or in the center of the conrod
bearing cap.
• Dimension -a- = 2.5 mm

Oil spray nozzle and pressure valve

1- Screw with pressure valve
2- Oil spray nozzle (for cooling piston)
• Fitting position: Align the guide edge of the oil spray nozzle to
the edge of the cylinder block being worked on.

Note

♦ The oil injection nozzles must not be bent.

♦ Replace the oil injection nozzles if they are bent.

3.4 Checking piston projection in TDC

Special tools and workshop equipment required
♦ Measuring tool for liner pretension -MP1-107-
Test sequence
– Attach theProtected
measuring tool Copying
by copyright. for liner pretension
for private -MP1-107-
or commercial purposes, into the
part or in whole, is not permitted
cylinder block as shown
unless authorised in the
by ŠKODA illustration.
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Measure the projection for each cylinder at 2 points.
When fitting new pistons or a partial engine, check the piston pro‐
jection in TDC on all pistons.
If different values are measured during the projection measure‐
ment of the piston, the greatest dimension applies for the seal
assignment.
Depending on the piston projection fit the relevant cylinder head
seal in accordance with the table below.
Piston projection over cylinder Marking of
block top side bores
mm
0,91 … 1,00 1
1,01 … 1,10 2
1,11 … 1,20 3

62 Rep. gr.13 - Crankshaft group

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Identification of the cylinder head gasket

♦ Part number -arrow 1-
♦ Bores -arrow 2-
♦ Notches -arrow 3- (ignore)

Note

If different values are measured during the projection measure‐

ment of the piston, the greatest dimension applies for the seal
assignment.

3.5 Separating new conrod

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

Note

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

the conrod.
♦ The conrod is clamped beyond the breaking point, which is
shown in the figure with a broken line.

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

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Carefully knock against the conrod bearing cap with a plastic
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
hammer in -direction of arrow- in order to loosen it.

3. Crankshaft, Piston and Conrod 63

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

15 – Cylinder head, valve gear

1 Removing and installing the cylinder
head

Note

♦ Cylinder heads with cracks between the valve seats may con‐
tinue to be used without any reduction in the life time provided
the cracks are slight and max. 0.5 mm wide.
♦ It is not permissible to rework the cylinder heads of diesel en‐
gines.
♦ Replace O-rings and gaskets.
♦ Replace cylinder head bolts and screws which have been
tightened to a torquing angle.
♦ When installing an exchange cylinder head with the camshafts
installed, it is necessary to oil the contact surfaces between
the roller arms and the cams after installing the head.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ When replacing the cylinder head, replace all the coolant
⇒ page 115 .
♦ Change contaminated engine oil ⇒ Maintenance ; Booklet
Octavia II .

1.1 Cylinder head cover - Summary of components

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

64 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Gasket
❑ replace if damaged or
leaking
2 - Cylinder head cover
❑ removing and installing
⇒ page 66
3 - O-ring
❑ replace
4 - Hose
❑ for crankcase ventila‐
tion
❑ to remove, press re‐
lease buttons
5 - Sealing bush
❑ for fixing screw of fuel
high pressure reservoir
❑ replace if damaged or
leaking
6 - Support
❑ for electrical cables
7 - Grommet
8 - Clamping claw
❑ together with 2 injection
units
9 - 8 Nm
10 - Fuel high pressure reser‐
voir
❑ Observe rules for clean‐
liness ⇒ page 4
❑ Do not change the
bending form of the high
pressure pipes
❑ Install high pressure pipes ⇒ page 199
11 - 22 Nm
12 - 8 Nm + torque a further 180° (1/2 turn)
❑ replace
13 - Fuel return-flow line
14 - O-ring
❑ replace
15 - Injection unit (Piezo injector)
❑ Observe rules for cleanliness ⇒ page 4
❑ removing and installing ⇒ page 196
16 - O-ring
❑ replace
17 - Heat-protection seal
❑ replace
18 - Protected
Sealing by ring
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑unless
with respect to units
Injection
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ replace ⇒ page 68

1. Removing and installing the cylinder head 65

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

19 - Screw cap
20 - Gasket
❑ for cap
21 - Grommet
22 - Support
❑ for electrical cables
23 - Screw, 10 Nm
❑ Replace seal if damaged
❑ tightening order and tightening torque ⇒ page 66

Cylinder head cover - tightening torque and tightening order

– Tighten the screws for the cylinder head cover in the sequence
-1 ... 6- to 10 Nm.

1.2 Removing and installing cylinder head

cover
Removing
– Remove engine cover ⇒ page 7 .
Engine with identification characters CFHC, CFHF
– Disconnect plug -2- at differential pressure indicator -G505- .
– Screw outbyscrew
Protected copyright.-3-, remove
Copying bracket
for private withpurposes,
or commercial differential
in part orpressure
in whole, is not permitted
sender -G505-
unless authorised byfrom
ŠKODAthe AUTObracket
A. S. ŠKODAof the
AUTO additional
A. S. does notfuel pump
guarantee in any liability
or accept
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
-direction of arrow- and place it to the side.
Continued for all engines

– Release the clamps -arrows- and press the toothed belt guard
- top part to the right side.
– Remove the injection units ⇒ page 196 .
– Remove high pressure reservoir ⇒ page 200 .

66 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Remove the hose -1- for the crankcase ventilation from the
cylinder head cover, to do so press the release buttons.

– Disconnect the plug -arrow- on the position sender for charge

pressure regulator -G581- .
– Remove the vacuum lines from the bracket at the cylinder
head cover.

– Slacken the screws for the cylinder head cover in the se‐
quence -6 … 1- and release them.

– Unclip the cylinder head cover at the catch pegs -arrows- of

the rear toothed belt guard and remove it from the cylinder
head.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Replace gasket and screws for cylinder head cover if dam‐

aged or leaking.
Replace grommets and gasket rings for injection units if dam‐
♦unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

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

1. Removing and installing the cylinder head 67

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Tighten the screws for the cylinder head cover in the sequence
-1 ... 6- to 10 Nm.

– Make sure that the cylinder head cover is correctly clipped with
the rear toothed belt guard, -arrows-.

Note

To provide a clearer illustration, the fitting position is shown with

the hub removed and the toothed belt sprocket removed at the
camshaft.

– Check the clearance between the hub and the rear toothed
belt guard.
– Install coolant return-flow line.
Engine with identification characters CFHC, CFHF
– Install differential pressure indicator -G505- .

1.2.1 Replacing gasket rings for injection units

Special tools and workshop equipment required
♦ Driver -3390-
Work procedure
– Remove cylinder head cover ⇒ page 66 .
– Press out the old gasket ring for the injection unit using the
driver -3390- and a short extension -1- fromProtected
the inside of the
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
cover outwards. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

68 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Press in the new gasket ring for the injection unit using the
driver -3390- and a short extension -1- from the outside of the
cover up to the stop.
– Install cylinder head cover ⇒ page 66 .

1.3 Cylinder head - summary of compo‐

nents

Note

♦ Do not remove the plastic bases supplied as a protection for

the open valves until just before fitting on the cylinder head.
♦ When replacing the cylinder head, replace all the coolant
⇒ page 115 .

1 - Cylinder head gasket

❑ replace
❑ Pay attention to theunless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

marking ⇒ page 71 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
2 - 10 Nm
❑ insert using locking
agent ⇒ Electronic
Catalogue of Original
Parts
3 - Hall sender -G40-
❑ for camshaft position
❑ removing and installing
⇒ page 79
4 - Cylinder head
❑ removing and installing
⇒ page 71
❑ check for distortion
⇒ page 71
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
5 - Washer
❑ for cylinder head screw
⇒ Item 6 (page 69)
6 - Cylinder head bolt
❑ replace
❑ pay attention to se‐
quence for loosening
and tightening

1. Removing and installing the cylinder head 69

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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⇒ page 71
❑ before fitting insert washers ⇒ Item 5 (page 69) in the cylinder head
7 - Oil pressure switch -F1- , 22 Nm
❑ Marking: green
❑ 0.05 MPa (0.5 bar)
❑ Cut open gasket ring if leaking and replace
❑ removing and installing ⇒ page 107
❑ check ⇒ page 108
8 - Sealing ring
❑ replace
9 - 20 Nm
10 - Lifting eye
❑ at rear left of cylinder head
11 - Sealing ring
❑ replace
12 - Screw plug, 14 Nm
❑ the oil duct
13 - Gasket
❑ replace
14 - Vacuum pump

WARNING
The vacuum pump must
on no account be disas‐
sembled, otherwise the
proper operation of the
pump vacuum part is no
longer assured. This will
result in a failure of the
brake booster.

❑ removing and installing ⇒ page 80

15 - 10 Nm
16 - Connection fittings
❑ for coolant with coolant temperature sender -G62-
❑ Replace coolant temperature sender -G62- ⇒ page 119
17 - 9 Nm
18 - Gasket
❑ replace
19 - 20 Nm
20 - Lifting eye
❑ atunless
front
Protected left of cylinder
by copyright. Copying head
for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

70 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Inspecting the cylinder head for distortion

– Inspect cylinder head at several points for distortion using a
knife-edge straightedge and feeler gauge.
• Max. permissible distortion: 0.1 mm

Note

It is not permissible to rework the cylinder heads of diesel engines.

Identification of the cylinder head gasket

♦ Part number -arrow 1-
♦ Control code -arrow 2- (ignore)
♦ Bores -arrow 3-

Note

♦ Differing thicknesses of cylinder head gaskets are inserted

according to the piston projection. If only the gasket is re‐
placed, it must be replaced with a new gasket with the same
marking.
♦ When fitting new pistons or a partial engine, check the piston
projection in TDC on all pistons ⇒ page 62 .

1.4 Removing and installing the cylinder

head
Special tools and workshop equipment required
♦ Guide bolt -MP1-208 (3070)-
♦ Rig pin for the diesel injection pump -3359- or -MP1-301- (2x)
♦ Crankshaft arrester -T10050-
♦ Counterholder -T10051 -
♦ Extractor -T10052-
♦ Socket insert XZN 10 -T10385-
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Locking agent -D 000 600 A2-
♦ Protective goggles and gloves

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

1. Removing and installing the cylinder head 71

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Caution

When undertaking all installation work, particularly in the en‐

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

Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .

1.4.1 Removing
Requirements
• Engine temperature should not exceed 35 °C, because the
cylinder head could be twisted when slackening the screws.
• The pistons must not be in TDC.
– Remove air filter with air mass meter -G70- and inlet hose
⇒ page 214 .
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
gr. 27 .
– Remove fan shroud for radiator fan -V7- and -V35-
⇒ page 128 .
– Remove cylinder head cover ⇒ page 66 .
– Disconnect the plug -2- from the throttle valve control unit -
J338 - .
– Screw out the fixing screw of the oil dipstick -4-.
– Detach the vacuum line byfrom
Protected theCopying
copyright. vacuum pump.
for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

72 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unscrew screws -2, 5- and -arrows-.

– Expose electrical cables and hoses on the left charge air pipe.
– Release hose clamp -3- and remove left charge air pipe.

– Screw out screws -arrows- and remove pulsation dampener

-2-.
– Drain coolant ⇒ page 115 .

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

– Disconnect plug -4- at the coolant temperature sender -G62- .

– Remove the coolant hoses from the connection fitting, to do
so slacken the hose clamps -1- and -2-

– Disconnect plug -1- at oil pressure switch -F1- .

– Release screw -arrow-.
– Disconnect vacuum hose -2-.

1. Removing and installing the cylinder head 73

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Pull the plug connection -3- out of the fixture and disconnect.
– Expose electrical cables at exhaust gas turbocharger.

– Release screws -arrows-.

– Expose coolant hose -3-.
– Loosen hose clamp -2-.
– Disconnect the plug -1- at the charge pressure sender -G31- /
intake air temperature sender -G42- and remove the right
charge air pipe.

Caution

Pay attention that the bellows of the connection pipe is not bent
or overstretched. There is a risk of crack formation.

– Remove connection pipes for exhaust gas recirculation -A-

with the socket insert XZN 10 -T10385- .

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

74 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unscrew the nuts -2- of the bracket for the pre-exhaust pipe
at the cylinder block.

– Screw out screws -5- and -10-.

– Unscrew the union nut -2- and place the oil feed line -1- to the
rear.
– Release screw -4- and remove bracket -3-.

– Unscrew the screw -arrow- on the rear timing belt guard.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Slacken the screw with
-1-respect
of theto fixing clampof between
the correctness information in the exhaust
this document. Copyright by ŠKODA AUTO A. S.�
gas turbocharger and the pre-exhaust pipe.
Engines with identification characters CFHC, CFHF and CLCB

1. Removing and installing the cylinder head 75

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Release the screw -arrow- from the bracket at the cylinder

head and push the pre-exhaust pipe to the side.
Continued for all engines

– Disconnect plug at Hall sender -G40- -arrow-.

– Remove the toothed belt from the camshaft ⇒ page 33 .
– Remove camshaft sprocket and pull off the hub of the cam‐
shaft with the extractor -T10052- .
– Release the fixing nut of the timing belt tensioning pulley.

– Follow the sequence -1…10- for loosening the cylinder head

screws.

Note

♦ The assistance of a second mechanic is required for removing

the cylinder head.
♦ The timing belt tensioning pulley is removed from the pin screw
when lifting out the cylinder head.
♦ The oil return-flow line for the exhaust gas turbocharger is de‐
tached from the support when removing the cylinder head.

– First of all raise the cylinder head on the gearbox side and
thread it out of the rear toothed belt guard. Make sure that the
timing belt tensioning pulley does not fall down.

Caution

Risk of damage
Protected by copyright. to the for
Copying glow plugs
private whenpurposes,
or commercial placing down
in part the cyl‐
or in whole, is not permitted
inder head.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ If the cylinder head is removed with installed glow plugs,
do not place it down on the sealing surface since the glow
plugs protrude slightly beyond the sealing surface.

– Place down the cylinder head in such a way that the oil return
flow line does not bend, if necessary place a wooden wedge
under the exhaust manifold.

76 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.4.2 Install

Note

♦ There must not be any oil or coolant present in the threaded

holes for the cylinder head bolts.
♦ Replace cylinder head screws, self-locking nuts and all the
screws which have been tightened to a torquing angle.
♦ Always replace gasket rings and seals.
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the seal with the utmost care. Damage to the silicone
layer and in the area of the bead results in leakages.
♦ When installing an exchange cylinder head with the camshafts
installed, it is necessary to oil the contact surfaces between
the roller arms and the cams after installing the cylinder head.
♦ Secure all hose connections with corresponding hose clips.

WARNING

Wear protective gloves when working with sealant and grease

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

Note

Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder, the oil and cool‐
ant galleries or into the threaded holes.

– Carefully remove old sealant residue from the cylinder head

and cylinder block using a chemical sealant remover.
– Remove the crankshaft arrester -T10050- before placing on
the cylinder head and turn the crankshaft in the opposite di‐
rection of rotation of engine until all the pistons are almost
evenly positioned at the same height.
– Pay attention to the identification of the cylinder head seal.
♦ Part number -arrow 1-
♦ Control code -arrow 2- (ignore)
♦ Bores -arrow 3-

Note

♦ Install a new cylinder head gasket with the same marking, ir‐
respective of whether or not the cylinder head was replaced.
♦ If parts of the crankshaft drive were replaced, then the new
cylinder head gasket must be redefined by measuring the pro‐
trusion of the piston in TDC ⇒ page 62 .

– Position the cylinder head gasket with the marking to the top.

1. Removing and installing the cylinder head 77

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– For centering, screw in guide bolts -MP1-208 (3070)- into the

outer holes on the suction side.

Note

The tensioning pulley for timing belt must be fitted onto the pin
screws when placing on the cylinder head.

– Fit on cylinder head, insert all 8 cylinder head bolts and tighten
by hand.
– Screw the guide bolts out of the screw holes with a bolt tight‐
ener from -MP1-208 (3070)- and screw in the 2 remaining
cylinder head screws.

– Tighten cylinder head screws in the order -1 ... 10- in 3 stages

as follows:
Stage Procedure
I – Pre-tighten with the torque wrench to 30 Nm.
II – Pre-tighten with the torque wrench to 50 Nm.
III – Using a rigid wrench torque a further 180° (1/2
turn).

Note

Tightening up the cylinder head bolts after doing repair work is

not necessary.

Further installation occurs in reverse order, while paying attention

to the following:
– Attach rear toothed belt guard at cylinder head.
– Install the hub and the camshaft sprocket.
– Lock the camshaft and the high pressure pump with the rig
pins for diesel injection pump -3359- .

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

78 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Rotate the crankshaft on TDC in direction of rotation of the

engine, interlock with the crankshaft arrester -T10050- .
– Fit on the toothed belt ⇒ page 38 .
– Install cylinder head cover ⇒ page 66 .

Note

If the cylinder head was replaced, refill the entire system with
coolant.

– Top up coolant ⇒ page 115 .

– Perform a test drive, interrogate fault memory of engine control
unit and erase ⇒ Vehicle diagnostic, testing and information
system VAS 5051.

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be checked, if necessary re-generated ⇒ Vehicle
diagnostic, testing and information system VAS 5051.

1.5 Removing and installing Hall sender -

G40-
– Remove engine cover ⇒ page 7 .
– Removing toothed belt ⇒ page 33 .
– Disconnect plug from Hall sender -G40- -arrow-.
– Disconnect the plug from its bracket.

– Unscrew Hall sender -G40- -arrow-.

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

1. Removing and installing the cylinder head 79

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Remove the lands and the cover of the repair opening

-arrows- using a screwdriver.
– Unscrew the Hall sender -G40- from the cylinder head and
guide its plug through the repair hole in the toothed belt guard.
Install
Installation is carried out in the reverse order. Pay attention to the
following:
♦ Close the repair opening in the toothed belt guard with a rubber
plug ⇒ Electronic Catalogue of Original Parts .
– install toothed belt and set the timing ⇒ page 38 .

1.6 Removing and installing the vacuum

pump

WARNING

The vacuum pump must on no account be disassembled, oth‐

erwise the proper operation of the pump vacuum part is no
longer assured. This will result in a failure of the brake booster.

Removing
– Remove air filter ⇒ page 214 .
– Detach the vacuum line to the brake servo unit from the nozzle
-1- of the vacuum pump -2-.
– Release the fixing screws of the left charge air pipe, afterwards
press the left charge air pipe slightly downwards in order to
reach the rear fixing screw of the vacuum pump.

– Unscrew fixing screws -arrows-.

– Remove vacuum pump -2- from cylinder head.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Pay attention to the correct position of the coupling for the
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
vacuum pump in the camshaft.
♦ Always replace the vacuum pump seals.

– Install vacuum pumps and tighten fixing screws to 9 Nm.

– Connect the vacuum line of the brake servo unit to the nozzle
-1- of the vacuum pump.

80 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.7 Testing the compression

Note

♦ A rough test of the compression pressure can be carried out

in the targeted fault finding ⇒ Vehicle diagnostic, testing and
information system VAS 5051.
♦ The following work sequence with the compression tester
gives more precise values.

Special tools and workshop equipment required

♦ Compression tester , e.g. -V.A.G 1763 -
♦ Adapter , e.g. -V.A.G 1381/12-
♦ Hinged wrench -3220-
Test condition
• Engine oil temperature at least 30 °C.
Test sequence
– Disconnect the plug -arrow- at the fuel pressure regulating
valve -N276- .
– Remove the glow plug for the relevant cylinder with the hinged
wrench -3220 - ⇒ page 238 .
– Screw adapter -V.A.G 1381/12 - into the threaded hole of the
glow plug.
– Check compression pressure using the compression tester -
V.A.G 1763- .

Note

Use of tester ⇒ Operating Instructions .

– Operate starter until the tester no longer indicates a pressure

rise.
Compression readings
New engine Wear limit Permissible
difference
between the cylin‐
ders
2.5…3.1 MPa 1.9 MPa max. 0.5 MPa
25…31 bar 19 bar max. 5 bar
Work procedure after the compression pressure test
– Re-install the glow plug of the relevant cylinder ⇒ page 238 .

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

1. Removing and installing the cylinder head 81

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Connect the plug -arrow- to the fuel pressure regulating valve

-N276- .
– Interrogating and erasing fault memory of engine control unit
⇒ Vehicle diagnostic, testing and information system
VAS 5051.

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.

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

82 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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2 Valve gear

2.1 Summary of components

Note

♦ After installing the camshafts, the engine must not be cranked or started for about 30 minutes. The hydraulic
clearance compensation elements must settle (otherwise the valves would strike the pistons).
♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no
valve touches the piston when the engine is started.
♦ Always replace gasket rings and seals.

1 - Valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ mark the fitting position
for re-installation
❑ Valve dimensions
⇒ page 94 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ inspecting valve guidesunless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ page 94
2 - Cylinder head
❑ pay attention to the
notes ⇒ page 69
❑ check for distortion
⇒ page 71
❑ removing and installing
⇒ page 71
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
3 - Valve stem seal
❑ replace ⇒ page 91
4 - Valve spring
5 - Valve spring retainer
6 - Valve collets
7 - Screw cap
❑ replace
❑ removing: plunge into
the installed bearing
frame using a screw‐
driver and lever out
❑ installing: drive in with‐
out sealant using a suitable thrust piece until flush
8 - Sealing ring
❑ Do not additionally lubricate or grease sealing lip of the gasket ring
❑ Remove oil residue on the camshaft stud with a clean cloth
❑ before fitting, cover slot on the camshaft cone with adhesive tape (e.g. Scotch tape)
❑ removing and installing ⇒ page 84

2. Valve gear 83
 Octavia II 2004 ➤ , Octavia II 2010 ➤
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9 - Camshaft
❑ for exhaust valves
❑ removing and installing ⇒ page 85
❑ Measure axial play ⇒ page 89
10 - 10 Nm
❑ order of tightening ⇒ page 85
11 - Bearing frame
❑ pay attention to sequence for loosening and tightening ⇒ page 85
❑ seal with silicone sealant -D 176 501 A1-
12 - Camshaft
❑ for inlet valves
❑ removing and installing ⇒ page 85
❑ Measure axial play ⇒ page 89
13 - Roller rocker arm
❑ Mark installation position
❑ do not interchange
❑ inspect roller bearings for smooth operation
❑ oil contact surfaces
14 - Locking clip
❑ Protected
check byforcopyright.
firm seating
Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
15 - Hydraulic balancing element
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ Mark installation position

❑ oil the contact surfaces before installing
❑ check ⇒ page 90

2.2 Replacing camshaft gasket ring

Special tools and workshop equipment required
♦ Insertion tool -MP1-214 (10-203)-
♦ Gasket ring extractor -T30003 (3240)-
♦ Screw M12 x 1.5 x 75 from the insertion tool -MP1-214
(10-203)-
Removing
– Pull toothed belt off camshaft sprocket and from toothed belt
gear on the high pressure pump ⇒ page 85 .
– Remove camshaft sprocket and hub ⇒ page 85 .
– Insert thrust piece -3240/1- into the camshaft.
– Unscrew inner part of the gasket ring extractor -3240- two
turns (approx. 3 mm) out of the outer part and lock with knurled
screw.

84 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Release knurled screw and turn the inner side against the
camshaft until the gasket ring is pulled out.
Install

Note

The sealing lip of the new gasket ring must neither be oiled nor
greased additionally.

– Fit the guide bushing from -MP1-214 (10-203)- onto the cam‐
shaft as shown in the illustration.
– Carefully slide the gasket ring -1- over the guide bushing onto
the camshaft.

– Press in the gasket ring with the thrust piece of the insertion
tool -MP1-214 (10-203)- and the screw M12 x 1.5 x 75 up to
the stop.
– Install the hub and the camshaft sprocket ⇒ page 85 .
– Installing the timing belt ⇒ page 38 .

2.3 Removing and installing camshafts

Special tools and workshop equipment required
♦ Counterholder -T10051 -
♦ Extractor -T10052-
♦ Camshaft-insertion tool -T40094-
♦ Camshaft-insertion tool -T40095-
♦ Tensioning tool -T40096/1-
♦ Silicone sealant -D 176 501 A1-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing
• Cylinder head fitted.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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2. Valve gear 85
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Pull toothed belt off camshaft sprocket and from toothed belt
gear on the high pressure pump ⇒ page 33 .
– Remove cylinder head cover ⇒ page 66 .
– Remove camshaft sprocket.
– Slacken screw -1- for the hub of the camshaft, to do so coun‐
terhold with counterholder -T10051- .
– Release screw by about 2 turns.

– Position the extractor -T10052- at the hub of the camshaft and

screw the screws -1- into the hub.
– Slacken the hub of the toothed belt sprocket from the camshaft
cone by uniformly tightening the screw of the extractor -2-.

Note

While doing so, hold the extractor firmly using a wrench SW 30.

– Remove hub of toothed belt sprocket from cone of camshaft.

– Remove vacuum pump ⇒ page 80 .

– Release the bearing frame screws in the order -24...1-.

– Unscrew screws and carefully separate the bearing frame
from the cylinder head.
– Mark the camshafts for reinstalling and remove.
Install

WARNING

Wear protective gloves and goggles when working with gasket

remover and degreasing agent!

– Remove residual sealant on the bearing frame and cylinder

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

Caution

The camshafts must only be installed using the camshaft-in‐

sertion tool -T40094- as described in the following, otherwise
the axial bearing in the bearing frame can be destroyed and
the cylinder head must be replaced.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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86 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Set up the camshaft-insertion tool -T40094- as follows:

– Tighten the support bearing -T40094/9- and -T40094/10- (with
the bearing bracket -T40094/11- ) to the boundary points of
the base plate, as shown in the illustration. If necessary, re‐
move any other support bearings screwed on these points.

– Position the support -T40094/1- onto the plug location -F- and
the support -T40094/2- onto the plug location -A-.
– Insert the inlet camshaft in the supports -T40094/1- and -
T40094/2- .

The protrusion -arrow- of the cylinder head bolt must point to the
outside.
– Fit on a feeler gauge of 0.50 mm and slide the support -
T40094/8- into the groove of the inlet camshaft.

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2. Valve gear 87
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Insert the outlet camshaft in the supports -T40094/9 - and -

T40094/11- and lock with serration of detent bracket -
T40094/11-
• The serration -1- of the detent bracket must engage into the
groove -2- in the outlet camshaft.
– Position the tensioning tool -T40096/1- on the pinions of the
outlet camshaft in such a way that each clamping arm engages
in a pinion.
• The wider clamping arm must engage in the wider pinion.
– Tension the tensioning tool -T40096/1- with the knurled wheel
until the tooth flanks of both wheels are aligned.
– Slide the inlet camshaft -arrows- to the outlet camshaft until
the serrations engage.

– Position the bearing frames onto the camshafts.

• All of the camshaft bearings must rest on the camshafts.
– Position the camshaft-insertion tool -T40095- , as shown in the
figure, and fix the camshafts in the bearing frame.
– Remove the locking bracket -T40094/11- and pull the support
-T40094/8 - out of the groove of the inlet camshaft.

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

Pay attention to the use by date on the silicone sealant.

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

2 mm).

Caution

Risk of contamination of the camshaft bearings through excess

sealant.
♦ The sealant bead must not be thicker than specified.

88 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Apply sealant onto the clean sealing surface of the cylinder

head as shown in the illustration.
• Thickness of the sealant beads: 2…3 mm
• The oil duct for the bearing frame -arrow- must not be clogged
with excess sealant.

Note

The bearing frame with camshafts must be installed within 5 mi‐

nutes after applying the silicone sealant.

– Remove the camshafts together with the bearing frame, the

camshaft-insertion tool -T40095- and the tensioning tool -
T40096/1- from the camshaft-insertion tool -T40094- and
carefully insert into the bearings in the cylinder head.

– Insert the screws of the bearing frame and first tighten in the
sequence -1 … 24- by hand.
• The bearing frame must rest on the cylinder head with its com‐
plete contact surface.
– Tighten the screws of the bearing frame in the sequence
-1…24-.
Tightening torque:
unless 10 Nm by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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authorised
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove the camshaft-insertion tool -T40095- and the ten‐
sioning tool -T40096/1- .
The further assembly is carried out in the reverse order, while
paying attention to the following:
– Replacing camshaft gasket ring ⇒ page 84 .
– Drive in new screw cap ⇒ Item 7 (page 83) .
– Install vacuum pump ⇒ page 80 .
– Install cylinder head cover ⇒ page 66 .

Note

♦ After installing the camshafts, the engine must not be cranked

or started for about 30 minutes. The hydraulic clearance com‐
pensation elements must settle (otherwise the valves would
strike the pistons).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.

2.4 Measuring the axial play of the cam‐

shafts
Special tools and workshop equipment required
♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Dial gauge , e.g. -VAS 6079-
Work procedure
– Remove bearing frame ⇒ page 85 .

2. Valve gear 89
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Attach the dial gauge with the universal dial gauge holder -
MP3-447 (VW 387)- to the bearing frame as shown in the
illustration.
– Press the camshaft by hand against the dial gauge.
– Position dial gauge to „0“.
– Press the camshaft off the dial gauge and read the value.
Axial play of inlet camshaft and outlet camshaft:
• Wear limit 0.17 mm

2.5 Checking hydraulic balancing elements

Note

♦ The hydraulic balancing elements cannot be repaired.

♦ Irregular valve noises when starting engine are normal.
♦ If the irregular valve noises disappear but occur regularly dur‐
ing short journeys, then the oil pressure must be checked
⇒ page 108 .
♦ The valve for oil pressure control is integrated in the oil pump.

Special tools and workshop equipment required

♦ Feeler gauge
Work procedure
– Start engine and allow to run until the radiator fan starts.
– Increase speed to about 2500 rpm for 2 minutes and under‐
take a test drive if necessary.
If the valve noises occur irregularly, determine the defective hy‐
draulic balancing element as follows:
– Remove cylinder head cover ⇒ page 66 .
– Turn the crankshaft until the cam of the hydraulic balancing
element to be tested is positioned on top.

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90 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Press down the hydraulic balancing element using a wooden

or plastic wedge.
– Determine the play between the cam and the roller of the valve
lever.
If a 0.20 mm feeler gauge can be slipped between the cam and
the roller of the valve lever, the hydraulic balancing element is
defective:
– Replace the hydraulic balancing element. To do so, remove
camshafts ⇒ page 85 .

Note

♦ After installing the camshafts, the engine must not be started

for about 30 minutes. The hydraulic clearance compensation
elements must settle (otherwise valves would strike the pis‐
tons).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.

2.6 Replacing valve stem seals

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Special tools and workshop equipment required
♦ Valve stem seal extractor -MP1-230 (3364)-
♦ Valve stem seal insertion tool -MP 1-233 (3365)-
♦ Disassembly and assembly device for valve collets -VAS
5161- with knurled spacer ring -VAS 5161/23-1- and guide
plate -VAS 5161/23-
♦ Screw M6 x 30 (2 pieces)
Work procedure
– Remove all glow plugs ⇒ page 238 .
– Remove the camshafts ⇒ page 85 .
– When installing again, mark the assignment of the roller rocker
arms and the hydraulic clearance compensation elements.
– Remove the roller rocker arms together with the hydraulic bal‐
ancing elements and lay aside on a clean surface.
– Put the piston of the relevant cylinder at „bottom dead centre“.
– Position the guide plate -VAS 5161/23 - onto the cylinder head.
– Screw the guide plate at the side of the intake manifold with
the knurled screw -VAS 5161/12- to the cylinder head and with
2 screws M6 x 30 -1- by hand until it fits on tightly.

2. Valve gear 91
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Screw the sealing bolt -VAS 5161/10- into the guide plate.
– Screw adapter -VAS 5161/11 - into the threaded hole of the
glow plug by hand.

– Insert the impact drift -VAS 5161/3 - into the guide plate and
slacken the tightly fitted valve collets using a plastic hammer.

– Screw the detent part -VAS 5161/6- and the interlocking fork
-VAS 5161/5- into the guide plate.
– Slide the knurled spacer ring -VAS 5161/23-1- onto the as‐
sembly cartridge -VAS 5161/8- .
– Connect the adapter -VAS 5161/11 - to the compressed air
with a commercially available intermediate piece and apply
constant pressure.
• Minimum pressure: 0.6 MPa (6 bar)
– Hook the pressure fork -VAS 5161/2 - onto the detent part and
push the assembly cartridge Protected
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Turn simultaneously the knurled withscrew
respect toof
thethe assembly
correctness car‐ in this document. Copyright by ŠKODA AUTO A. S.�
of information
tridge to the right, until the tips click into the valve collets.
– Rotate the knurled screw to the left and to the right, by doing
so the valve collets are pressed apart and are installed in the
assembly cartridge.
– Release the pressure fork.
– Remove the assembly cartridge with the knurled spacer ring.
– Remove the valve spring with the valve spring retainer.

92 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Pull off valve stem seal with extractor for valve stem seal
-3364- .

– Fit the plastic protective sleeve -A-, which is attached to the

new valve stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the new valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool -3365 - onto the valve guide.
– Remove plastic sleeve.

If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the device -VAS 5161/18- .
• The large diameter of the valve collets points to the top.
– Insert the valve spring and the valve spring retainer.
– Press assembly cartridge -VAS 5161/8- from the top onto the
disassembly and assembly device -VAS 5161/18- and lift up
the valve collets.

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2. Valve gear 93
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Re-insert the assembly cartridge into the guide plate -

VAS 5161/23- .
– Press down the pressure fork and turn the knurled screw to
the left and to the right while pulling it upwards, by doing so
the valve collets are inserted.
– Release the pressure fork on tightened knurled screw.
– Repeat the procedure for each valve.
Assembling together
Installation is performed in the reverse order, pay attention to the
following points:

Note

Ensure that all the roller arms are correctly positioned on the valve
stem ends and are clipped in place on the relevant hydraulic bal‐
ancing elements.

– Install camshafts ⇒ page 85 .

– Install glow plugs ⇒ page 238 .

2.7 Valve dimensions

Dimension Inlet valve Exhaust valve
∅a mm 26,6 26,0
∅b mm 5,975 5,965
c mm 99,3 99,1
α ∠° 45 45

Note

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

2.8 Inspect valve guides

Special tools and workshop equipment required
♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Dial gauge , e.g. -VAS 6079-

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94 Rep. gr.15 - Cylinder head, valve gear

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Test sequence

Note

♦ If the valves are replaced when carrying out repair work, use
new valves for the measurement.
♦ Because of the different stem diameters only use inlet valve
in inlet guide or outlet valve in outlet guide.

– Insert valve into valve guide. The end of valve stem must be
flush with guide.
• Valve rock: max. 1.3 mm

Note

If the wear limit is exceeded, repeat measurement with new

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

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2. Valve gear 95
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

17 – Lubrication
1 Removing and installing parts of the
lubrication system

Note

♦ If considerable quantities of metal swarf as well as abrasion is

found in the engine oil when carrying out engine repairs, care‐
fully clean the oil galleries in order to avoid consequential
damage and additionally replace the engine oil cooler as well
as the oil filter element.
♦ The oil level must not be above the max. marking - risk of
damage to catalytic converter!

Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Booklet Octavia II .

1.1 Removing and installing parts of the lubrication system - Summary of com‐
ponents

1 - 15 Nm
2 - Sealing flange
❑ on belt pulley side
❑ must be positioned on
dowel sleeves
❑ removing and installing
⇒ page 47
❑ Replace crankshaft seal
on belt pulley side
⇒ page 46
3 - Toothed belt
❑ for oil pump drive
❑ check for wear and
damage, replace if nec‐
essary.
❑ mark the fitting position
for re-installation
4 - 10 Nm
5 - Dipstick
❑ Oil level must not ex‐
ceed the max. marking
6 - Guide tube
7 - Clip
8 - Fitting sleeve
9 - O-ring
❑ replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
10 - 10 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

11 - Oil pump
❑ with pressure control
valve 0.45 MPa (4.5 bar)

96 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011
❑ with safety valve 1.0 MPa (10.0 bar)
❑ removing and installing ⇒ page 106
❑ before installing, check whether both dowel sleeves are present
❑ if there is any scoring on the contact surfaces of the gears, replace
❑ Tighening torque of oil pump cover at oil pump housing: 10 Nm
If the toothed belt or the oil pump must be removed:
♦ Check smooth operation of oil pump:
♦ It must be possible to easily turn the toothed belt sprocket with the finger
♦ if the oil pump is sluggish, it must be replaced
❑ removing and installing ⇒ page 106
12 - Intake manifold
❑ Clean strainer if dirty
13 - Baffle
14 - 15 Nm
15 - 15 Nm
16 - Oil pan
❑ removing and installing ⇒ page 103
❑ install with silicone sealant -D 176 404 A2-
17 - 15 Nm
18 - Drain plug, 30 Nm
❑ with integrated gasket ring
❑ replace
19 - 10 Nm
❑ replace
20 - Oil level and oil temperature sender -G266-
❑ check ⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ removing and installing ⇒ page 97
21 - O-ring
❑ replace
22 - Line
❑ to oil level and temperature sender
23 - Pressure valve, 27 Nm
❑ opens at 0.25..0.32 MPa (2.5..3.2 bar) overpressure
❑ replace without sealant
❑ removing and installing ⇒ page 58
24 - Oil injection nozzle
❑ for piston cooling
❑ removing and installing ⇒ page 58

1.2 Removing and installing oil level and oil

temperature sender -G266-
Removing
– Drain engine oil ⇒ Maintenance ; Booklet Octavia II .
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1. Removing and installing parts of the lubrication system 97

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect plug connection -3-.

– Unscrew screw -1- and remove oil level and oil temperature
sender -G266- -4-.
Install
Installation is performed in the reverse order, pay attention to the
following points:
• Tightening torque ⇒ Item 19 (page 97) .

Note

Replace gasket ring -2- and screws -1-.

– Top up with engine oil and check the oil level ⇒ Maintenance ;
Booklet Octavia II .

1.3 Oil filter with engine oil cooler - Summary of components

1 - Screw cap, 25 Nm
❑ with hexagon 32 mm
2 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ replace with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3 - O-ring
❑ replace
4 - O-ring
❑ replace
5 - Oil filter element
❑ remove from the cap
⇒ Item 1 (page 98)
❑ replace O-rings
⇒ Item 2 (page 98) ,
⇒ Item 3 (page 98) and
⇒ Item 4 (page 98) when
replacing the oil filter el‐
ement
❑ Check fitting position
❑ pay attention to change
intervals ⇒ Mainte‐
nance ; Booklet Octavia
II
6 - Engine oil cooler
❑ with connection of oil
and coolant circuit via oil
filter holder
❑ removing and installing
⇒ page 101
7 - 11 Nm
❑ gradually tighten cross‐
wise:
♦ 1. Stage: only by hand
♦ 2. Stage: 5 Nm

98 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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♦ 3. Stage: 11 Nm
8 - Gasket
❑ to engine oil cooler
❑ replace
9 - 14 Nm + torque a further 90° (1/4 turn)
❑ replace
❑ tighten crosswise
10 - Oil filter holder
❑ with integrated connection to the engine lubrication and cooling system for the engine oil cooler
❑ removing and installing ⇒ page 99
11 - Gasket
❑ to cylinder block
❑ replace

Note

♦ The oil pressure switch -F1- is located on the cylinder head.

Therefore it is listed in the summary of components
⇒ page 69 .
♦ Remove and install oil pressure switch -F1- ⇒ page 107 .
♦ Test oil pressure switch -F1- ⇒ page 108 .

1.4 Removing and installing the oil filter

holder with the engine oil cooler
Special tools and workshop equipment required
♦ Assembly device -T10118-
♦ Removal tool for inner lining of the door panel -MP8-602/1-
♦ Catch pan e.g. -VAS 6208-
♦ Old oil collecting and suction equipment , e.g. -V.A.G 1782-
Removing
– Drain coolant ⇒ page 115 .
– Remove fan shroud for radiator fan ⇒ page 128 .
– Remove air filter ⇒ page 214 .

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1. Removing and installing parts of the lubrication system 99

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Remove oil filter insert -3- ⇒ Maintenance ; Booklet Octavia

II .

– Remove the charge air hose, to do so slacken the hose clamps

-1- and -2-.

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– Release screws -arrows-. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Expose coolant hose -3-.

– Loosen hose clamp -2-.
– Disconnect the plug -1- at the charge pressure sender -G31- /
intake air temperature sender -G42- and remove the right
charge air pipe.

100 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Slightly pull out oil dipstick, unscrew screw -1-.

– Press off clip -2- with removal tool -MP8-602/1- .
– Pull out the oil dipstick guide pipe upwards out of the cylinder
block and push it to the side.
– Position the catch pan , e.g. -VAS 6208- , under the engine.

– Slacken hose clamp -1- and detach the coolant return hose
from the oil filter holder.
– Place an old oil collecting and suction equipment -V.A.G 1782-
under the engine.
– Screw out screws -arrows- and remove oil filter holder and
engine oil cooler.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Replace all the gaskets and O-rings.

♦ Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Secure all hose connections with screw
unlessclamps
authorised ⇒
by page 177 A.
ŠKODA AUTO . S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Tightening torques: ⇒ page 98

– Install oil filter insert, fill with engine oil and check the oil level
⇒ Maintenance ; Booklet Octavia II .
– Top up coolant ⇒ page 115 .

1.5 Removing and installing engine oil cool‐

er
Special tools and workshop equipment required
♦ Catch pan e.g. -VAS 6208-
♦ Old oil collecting and suction equipment , e.g. -V.A.G 1782-
Removing
– Drain coolant ⇒ page 115 .
– Remove air filter ⇒ page 214 .

1. Removing and installing parts of the lubrication system 101

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Remove oil filter insert -3-.

– Release screws -arrows-.

– Remove engine oil cooler from holder.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Replace all the gaskets and O-rings.

♦ Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
♦ Observe the mounting sequence for hose connections with
screw clamps ⇒ page 177 .

– Insert new gasket -1- ⇒ Item 8 (page 99) in the guides at the
oil filter holder.
– Carefully position the engine oil cooler onto the dowel sleeves.

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

102 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Press in the engine oil cooler at the flange of the oil filter holder
in such a way that it rests on the complete surface and the
extremities of the dowel pins -1- protrude out of the openings
of the guide.

– Insert screws -arrows-, first of all screw in by hand up to the

stop, then gradually tighten crosswise ⇒ Item 7 (page 98) .
– Install oil filter insert, fill with engine oil and check the oil level
⇒ Maintenance ; Booklet Octavia II .

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
If the engine oil
with cooler
respect to was replaced,
the correctness refill the
of information entire
in this system
document. Copyrightwith
by ŠKODA AUTO A. S.�
coolant.

– Top up with coolant, if necessary replace ⇒ page 115 .

1.6 Removing and installing oil pan

Special tools and workshop equipment required
♦ Socket insert -T10058-
♦ Old oil collecting and suction equipment , e.g. -V.A.G 1782-
♦ Silicone sealant -D 176 404 A2-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Remove the right wheelhouse liner bottom part ⇒ Body Work
⇒ Rep. gr. 66 .
– Remove right charge air hose.

1. Removing and installing parts of the lubrication system 103

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unscrew screws -arrows-, push the right charge air pipe slight‐
ly to the side and secure.

– Unscrew screw -arrow- and push the coolant recirculation

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
pump 2 -V178- to thebyside.
unless authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Unscrew screw -arrow- on the left charge air pipe.

– Disconnect plug from oil level and oil temperature sender -
G266- .

– Remove noise insulation of oil pan, to do so slacken the fixing

parts -arrows-.
Front: 1x clip, 2-part
Rear: 2x screw clip, 2-part
– Suction off engine oil -V.A.G 1782- with old oil collecting and
suction equipment ⇒ Maintenance ; Booklet Octavia II .

104 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Unscrew connecting screws of oil pan/gearbox -arrows-.

– Loosen bolts -1...20- crosswise and release.
– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.
Install
Installation is performed in the reverse order, pay attention to the
following points:

WARNING

Wear protective gloves and goggles when working with gasket

remover and degreasing agent!

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

inder block and on the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).

– Apply silicone sealant -D 176 404 A2- to the clean sealing

surface of the oil pan, as shown -arrows-.
• Thickness of sealant bead: 2…3 mm.

Note

♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clogg the strainer
in the oil suction pipe.
♦ Take particular care when applying the sealant bead in the
area of the sealing flange on the gearbox side -arrows-.
♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant -D 176 404 A2- .

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

1. Removing and installing parts of the lubrication system 105

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Fit on oil pan and tighten the screws as follows:

1. Tighten screws -1...20- crosswise to 5 Nm.
2. Tighten the connecting screws of the oil pan/gearbox
-arrows- to 40 Nm.

Note

When installing the oil pan on a removed engine, this work step
is not carried out. Make sure however that the pan is flush with
the cylinder block on the flywheel side.

3. Tighten screws -1...20- crosswise to 15 Nm.

Note

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

– Fill with engine oil and check the oil level ⇒ Maintenance ;
Booklet Octavia II .

1.7 Removing and installing oil pump

Removing
– Removing the oil pan ⇒ page 103 .
– Release screws -4- and remove oil suction pipe -3-.
– Release screws -arrows- and remove baffle -2-.
– Unhook the oil pump -1- from the toothed belt and remove it.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

Replace O-ring.

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

106 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Check the dowel sleeves at the oil pump housing -arrows- for
centering the oil pump, insert the dowel sleeves if they are not
present.
– Check smooth operation of oil pump, to do so turn the toothed
belt sprocket with a finger.

Note

A sluggish oil pump must be replaced.

– Check toothed belt for oil pump.

Note

♦ Replace damaged toothed belt.

♦ After long duration the toothed belt can sag, this is not a fault.

– Hook the oil pump with the toothed belt sprocket into the tooth‐
ed belt and tighten together with the baffle.
– Installing the oil pan ⇒ page 103 .

1.8 Removing and installing oil pressure

switch -F1-
Removing
– Remove engine cover ⇒ page 7 .
– Remove the hose for the crankcase ventilation -1-, to do so
press together the release buttons.
– Release vacuum hoses -arrows-.
– Release hose clamp -3- and separate the intake hose from the
air mass meter -G70- .
– Release screw -2-, swivel suction hose with connection fitting
towards the rear and detach from exhaust gas turbocharger.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Unscrew screws -2- and -3- and remove engine lifting eye
-1-.
– Unplug connector -arrow-.
– Screw out oil pressure switch -F1- .
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

Replace gasket ring.

Tightening torque: ⇒ page 69

– Install vacuum line.

1. Removing and installing parts of the lubrication system 107

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.9 Testing oil pressure switch -F1- and oil

pressure
Special tools and workshop equipment required
♦ Oil pressure tester , e.g. -V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
Test conditions
• Oil level o.k.
• Coolant temperature approx. 80°C.

1.9.1 Test after removal of the oil pressure

switch -F1-

Note

The test is carried out after removing the oil pressure switch -F1-
from the cylinder head ⇒ page 107 .

Test preparations
– Remove oil pressure switch -F1- ⇒ page 107 .

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

108 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Screw the connection of the oil pressure tester -V.A.G 1342-

with positioned gasket into the threaded hole for the oil pres‐
sure switch.
– Screw the oil pressure switch -2- into the oil pressure tester.
Test oil pressure switch -F1-
– Connect brown cable -1- of oil pressure tester to earth (-).
– Connect the voltage tester with the auxiliary cables from the
measuring tool set to the oil pressure switch -F1- and to battery
positive (+).
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch.
If the LED does not light up:
– Start the engine.

Note

Observe the testing equipment and the LED while actuating the
starter since the switching point of the oil pressure switch -F1- can
already be reached when starting up.

• At a pressure of 0.03...0.06 MPa (0.3...0.6 bar) the LED should

light up.
If the LED does not light up:
– Replace oil pressure switch -F1- ⇒ page 107 .
Testing oil pressure
– Start the engine.
• Oil pressure when engine idling: at least 0.05 MPa (0.5 bar)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
• Oil pressure at 2000 rpm: min. 0.2 MPa
unless (2.0bybar)
authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
If the specified values are not reached, the oil pump is defective.
– Replace oil pump ⇒ page 96 .
• Oil pressure at a higher engine speed: max. 0,4 MPa (4,0 bar)
If the specified value is exceeded, the pressure control valve in
the oil pump is defective.
– Replace oil pump ⇒ page 96 .

Note

♦ After testing the oil pressure switch -F1 - or after checking the
oil pressure, remove the oil pressure tester -V.A.G 1342- and
install the oil pressure switch -F1- with a new gasket ring
⇒ page 107 .
♦ The tightening torque of the oil pressure switch -F1- is 22 Nm.

1. Removing and installing parts of the lubrication system 109

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.9.2 Test without removal of the oil pressure

switch -F1-

Note

The oil pressure switch -F1- remains installed and only the screw
plug of the oil duct at the left of the cylinder head, which is more
easily accessible, is unscrewed.

Test preparations
– Clean the surroundings and unscrew the screw plug of the oil
duct at the left of the cylinder head.
– Screw the connection of the oil pressure tester -V.A.G 1342-
with positioned gasket into the threaded hole for the screw
plug.
– Close the hole for the oil pressure switch in the oil pressure
tester by means of the removed screw plug of the oil duct with
gasket.
– Disconnect the plug from the oil pressure switch -F1- at the
rear of the cylinder head.
Test oil pressure switch -F1-
– Connect the voltage tester with the auxiliary cables from the
measuring tool set to the oil pressure switch -F1- at the cylin‐
der head and to battery positive (+).
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch -F1- ⇒ page 107 .
If the LED does not light up:
– Start the engine.

Note

Observe the testing equipment and the LED while actuating the
starter since the switching point of the oil pressure switch -F1- can
already be reached when starting up.

• At a pressure of 0.03...0.06 MPa (0.3...0.6 bar) the LED should

light up.
If the LED does not light up:
– Replace oil pressure switch -F1- ⇒ page 107 .
Testing oil pressure
– Start the engine.
• Oil pressure when engine idling: at least 0.05 MPa (0.5 bar)
• Oil pressure at 2000 rpm: min. 0.2 MPa (2.0 bar)
If the specified values are not reached, the oil pump is defective.
– Replace oil pump ⇒ page 96 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
• Oil pressure at a higher unless
engine speed: max. 0.45 MPa (4.5
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
bar)
If the specified value is exceeded, the pressure control valve in
the oil pump is defective.

110 Rep. gr.17 - Lubrication

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Replace oil pump ⇒ page 96 .

Note

♦ After testing the oil pressure switch -F1 - or after checking the
oil pressure, remove the oil pressure tester -V.A.G 1342- and
install the screw plug of the oil duct with a new gasket ring.
♦ Tightening torque of plug is 14 Nm.

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

1. Removing and installing parts of the lubrication system 111

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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19 – Cooling
1 Cooling system

WARNING

Hot steam or hot coolant may escape when the compensation

bottle is opened. Cover the cap with a cloth and open carefully.

Note

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

sure. If necessary reduce pressure before repairs.
♦ Secure all hose connections with spring strap clamps.
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ The arrows affixed to the coolant pipes and the coolant hoses
must stand opposite to each other.

1.1 Parts of cooling system engine side

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

112 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Grommet
❑ not available separately
2 - Bushing
❑ not available separately
3 - 3 Nm
4 - 40 Nm
5 - Support
❑ for coolant recirculation
pump 2 -V178-
6 - Coolant pipe - front
7 - O-ring
❑ replace
8 - 8 Nm
9 - Coolant pipe - right
10 - O-ring
❑ replace
11 - Retaining clip
❑ check tightness
12 - Coolant temperature
sender at radiator outlet -G83-
❑ replace ⇒ page 119
13 - 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
14 - 9 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

15 - 9 Nm
16 - Coolant pipe - top
17 - Gasket
❑ replace
18 - Connection fittings
❑ for cylinder head
19 - O-ring
❑ replace
20 - Coolant temperature sender -G62-
❑ replace ⇒ page 119
21 - Double screw, 9 Nm
22 - 9 Nm
23 - Retaining clip
❑ check tightness

1. Cooling system 113

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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24 - Coolant pipe - left

25 - 9 Nm
26 - 9 Nm
27 - 9 Nm
28 - 13 Nm
29 - Coolant pipe - front top
30 - Coolant recirculation pump 2 -V178-
❑ removing and installing ⇒ page 117

1.2 Connection diagram for coolant hoses

1 - Expansion reservoir
❑ with cap
❑ Test the pressure valve
in the cap ⇒ page 131
2 - Radiator for exhaust gas re‐
circulation
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
❑ removing and installing
⇒ page 236
3 - to auxiliary heating
4 - from the auxiliary heating
5 - Cylinder block
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6 - Heat exchanger of heating
system
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
7 - Throttle valve
❑ integrated into the cool‐
ant hose, not visible
from the outside
❑ The fitting position is not
defined, therefore the
coolant hose must not
be unclipped with the
hose clamp (Risk of
damage!)
8 - ATF radiator
❑ only for automatic gearbox
9 - Coolant regulator
❑ only for automatic gearbox
10 - Engine oil cooler
❑ after replacing fill entire system with fresh coolant ⇒ page 115
❑ removing and installing ⇒ page 98

114 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

11 - Coolant recirculation pump 2 -V178-

❑ removing and installing ⇒ page 117
12 - Radiator
❑ for coolant
❑ removing and installing ⇒ page 129
❑ after replacing fill entire system with fresh coolant ⇒ page 115
13 - Coolant temperature sender at radiator outlet -G83-
14 - 4/2 way valve with coolant regulator
❑ removing and installing ⇒ page 122
15 - Coolant pump
❑ removing and installing ⇒ page 121
16 - Cylinder head
❑ after replacing fill entire system with fresh coolant ⇒ page 115

1.3 Draining and filling up coolant

Special tools and workshop equipment required
♦ Catch pan e.g. -VAS 6208-
♦ Pliers for spring strap clamps
♦ antifreeze tester
Draining
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

Collect drained coolant in a clean container for proper disposal or

reuse.

WARNING

Hot steam or hot coolant may escape when the compensation

bottle is opened. Cover the cap with a cloth and open carefully.

– Open the cap of the coolant expansion reservoir.

– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Remove right charge air hose.

WARNING

Shut off the opening of the charge air cooler, e.g. with a clean
foam piece, so that no coolant can penetrate.

– Place a catch pan under the engine.

1. Cooling system 115

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Remove the right coolant hose from the radiator; to do so pull

the retaining clip -arrow-.

– Detach the coolant hoses -3- from the coolant recirculation

pump 2 -V178- .

– Remove the coolant hose from the oil filter holder -arrow- and
drain residual coolant. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Filling up with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

Replace O-rings.

– Connect right coolant hose at radiator -arrow-.

116 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Connect the coolant hoses -3- at the coolant recirculation

pump 2 -V178- .

– Connect coolant hose at oil filter holder -arrow-.

Select the appropriate coolant additive from the Electronic Cata‐
logue of Original Parts Škoda or from the list of allowed coolant
additives ⇒ Maintenance ; Booklet Octavia II .
– Mix water with coolant in the correct ratio in a clean reservoir
⇒ Maintenance ; Booklet Octavia II .

– Top up coolant through the connection of the expansion res‐

ervoir, until the max. marking of the coolant level is reached.
– Switch off the heating, and if present, the air conditioning sys‐
tem.
– Start engine, run for not more than 2 minutes at approx. 1500
rpm and while doing so continuously top up coolant in the ex‐
pansion reservoir.
– Seal expansion reservoir.
– Run engine until radiator fan starts.

WARNING

Hot steam or hot coolant may escape

Protectedwhen the Copying
by copyright. compensation
for private or commercial purposes, in part or in whole, is not permitted
bottle is opened. Cover the cap with
unless a cloth and
authorised open
by ŠKODA carefully.
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Check the level of coolant when the expansion reservoir is

closed and top up if necessary when the engine is cooled
down.
• When engine is at operating temperature the coolant level
must be at the maximum marking, when engine is cold be‐
tween the minimum and the maximum markings.

1.4 Remove and install coolant recirculation

pump 2 -V178-
Special tools and workshop equipment required
♦ Hose clamps up to a diameter of 25 mm -MP7-602 (3094)-
♦ Pliers for spring strap clamps
Removing
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .

1. Cooling system 117

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Remove right charge air hose.

– Release screws -arrows-.

– Expose coolant hose -3-.
– Slacken the hose clamp -2- and push the charge air pipe to
the right.

Note

In order to collect flowing out coolant, place a cloth below the

coolant recirculation pump 2 -V178- .

– Pinch off the coolant hoses with hose clamps up to a diameter

of 25 mm -MP7-602- , slacken spring strap clamps -3- and
detach the hoses.
– Unplug connector -2-.
– Release screws -1- and remove coolant recirculation pump 2
-V178- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Install unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Connections as well as charge air pipes and charge air hoses

must be free of oil and grease before being installed.
♦ Observe the instructions for installing the charge air hoses and
tightening torques of the screw clamps ⇒ page 177 .

– Inspect coolant level, top up with coolant if necessary

⇒ page 115 .

118 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.5 Replace coolant temperature sender -

G62-
• Engine is cold
– Briefly open the cap for the coolant expansion reservoir in or‐
der to adjust the pressure in the coolant system.
– Remove air filter ⇒ page 214 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Screw out screws -arrows- and screw -5-.
– Expose electrical cables and hoses on the left charge air pipe.
– Release hose clamp -3- and push charge air pipe to the side.

– Disconnect plug -2- at the coolant temperature sender -G62- .

Note

♦ In order to collect flowing out coolant, place a cloth below the

connection fitting.
♦ Have a new coolant temperature sender -G62- with a new
gasket ring ready.

– Remove the retaining clip -1-, pull the coolant temperature

sender -G62- out of the connection fitting and install a new
coolant temperature sender -G62- .
Further installation occurs in reverse order to removal.
– Inspect coolant level, top up with coolant if necessary
⇒ page 115 .

1.6 Replace coolant temperature sender at

radiator outlet -G83-
• Engine is cold Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Briefly open the cap forrespect
the coolant expansion
to the correctness reservoir
of information in or‐ Copyright by ŠKODA AUTO A. S.�
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with in this document.
der to adjust the pressure in the coolant system.
– Remove engine cover ⇒ page 7 .

1. Cooling system 119

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release screw -1-.

– Release screw -2- and nut -3-.
– Remove bracket -4- with fuel filter -7- and lay to the side with
the connected fuel hoses.

– Disconnect plug -2- at the coolant temperature sender at ra‐

diator outlet -G83- .

Note

♦ In order to collect flowing out coolant, place a cloth below the

right coolant pipe.
♦ Have a new coolant temperature sender at radiator outlet -
G83- with a new gasket ring ready.

– Pull off the retaining clip -1-, remove the coolant temperature
sender at radiator outlet -G83- from the connection of the right
coolant pipe and install new coolant temperature sender -
G83- .
Further installation occurs in reverse order.
– Install fuel filter ⇒ page 140 .
– Inspect coolant level, top up with coolant if necessary
⇒ page 115 .

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

120 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2 Coolant pump and 4/2 way valve with

coolant regulator

2.1 Coolant pump and 4/2 way valve with coolant regulator - Summary of com‐
ponents

1 - Coolant pump
❑ removing and installing
⇒ page 121
2 - 15 Nm
3 - O-ring
❑ replace
4 - O-ring
❑ replace
5 - 4/2 way valve with coolant
regulator
❑ unless
Theauthorised
coolant regulator
AUTOis
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
integrated in the
with respect to the 4/2 way
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
valve and cannot be re‐
placed separately
❑ removing and installing
⇒ page 122
❑ Testing coolant thermo‐
stat ⇒ page 125
6 - 15 Nm

2.2 Removing and installing coolant pump

Removing
– Drain coolant ⇒ page 115 .
– Removing toothed belt ⇒ page 33 .

2. Coolant pump and 4/2 way valve with coolant regulator 121
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release screws -1- and remove coolant pump -2-.

– Remove O-ring -3-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

Replace O-ring.

– Clean sealing surface for O-ring, if necessary smoothen.

– Moisten the new O-ring -3- with coolant.

– Attach the coolant pump -2-.
• Fitting position: Plug in housing points down.
– Insert screws -1- of coolant pump and tighten to ⇒ page 121 .
– Installing the timing belt ⇒ page 38 .
– Top up coolant ⇒ page 115 .

2.3 Removing and installing 4/2 way valve

with coolant regulator
Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel -MP8-602/1-
♦ Pliers for spring strap clamps
Removing
– Drain coolant ⇒ page 115 .
– Remove air filter with air mass meter -G70- and inlet hose
⇒ page 212 .
– Remove battery with battery tray ⇒ Electrical System ⇒ Rep.
gr. 27 .
– Unclip the wiring loom from the holder -arrow-.

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

122 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Expose the wiring looms -arrows- and the plug connection

-1- on the bracket.

– Unscrew screws -2, 5- and -arrows-.

– Expose electrical cables and hoses on the left charge air pipe.
– Release hose clamp -3- and remove left charge air pipe.

– Remove the coolant hoses, to do so slacken the hose clamps

-1-.

– Remove the plug connection -1- for the hall sender -G40- from
the bracket and disconnect.
– Release the screws -arrows-, press off and detach the front
coolant pipe from the 4/2 way valve to the left-hand side and
leave it in the fitting position.

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

2. Coolant pump and 4/2 way valve with coolant regulator 123
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release screws -arrows-.

– Expose coolant hose -3-.
– Loosen hose clamp -2-.
– Disconnect the plug -1- at the charge pressure sender -G31- /
intake air temperature sender -G42- and remove the right
charge air pipe.

– Slightly pull out the oil dipstick and release the screw -1-.
– Press off clip -2- with removal tool for inner lining of the door
panel -MP8-602/1- .
– Pull out the oil dipstick guide pipe upwards out of the cylinder
block and push it to the side.

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

124 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Unscrew bolts -2-.

– Remove the coolant hoses, to do so slacken the hose clamps
-1, 3, 4-.
– Remove 4/2 way valve with coolant regulator.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Replace O-ring.
♦ Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
♦ Observe the instructions for installing the charge air hoses and
tightening torques of the screw clamps ⇒ page 177 .
♦ Secure all hose connections with prescribed hose clamps ⇒
Electronic Catalogue of Original Parts .

– Install the oil dipstick guide pipe ⇒ page 96 .

– Top up coolant ⇒ page 115 .

2.4 Testing coolant thermostat

– Heat up the removed 4/2 way valve with coolant regulator in
a water bath.
Start of opening Full opening Stroke
approx. 87°C approx. 102 °C 1) min. 8 mm
1) Cannot be tested.

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

2. Coolant pump and 4/2 way valve with coolant regulator 125
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

3 Radiator and fan

3.1 Radiator with a radiator fan - Summary of components

1 - Radiator
❑ removing and installing
⇒ page 129
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
2 - Screw cap
❑ Test pressure
0.14...0.16 MPa
(1.4...1.6 bar)
❑ check ⇒ page 131
3 - Connector
4 - 3 Nm
5 - Expansion reservoir
6 - O-ring
❑ replace if damaged
7 - Bottom coolant hose Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ to connection fitting of unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
4/2 way valve with cool‐ with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

ant regulator at cylinder

block
❑ connection diagram for
coolant hoses
⇒ page 114
8 - Radiator fan -V7-
❑ with radiator fan control
unit -J293-
❑ removing and installing
⇒ page 128
9 - Fan shroud
10 - 5 Nm
11 - Connector
12 - 5 Nm
13 - Top coolant hose
❑ To connection fitting at cylinder head
❑ connection diagram for coolant hoses ⇒ page 114

126 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

3.2 Radiator with two radiator fans - Summary of components

1 - Top coolant hose

❑ To connection fitting at
cylinder head
❑ connection diagram for
coolant hoses
⇒ page 114
2 - O-ring
❑ replace if damaged
3 - Radiator
❑ removing and installing
⇒ page 129
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 115
4 - Screw cap
❑ Test pressure
0.14...0.16 MPa
(1.4...1.6 bar)
❑ check ⇒ page 131
5 - Connector
6 - 3 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
7 unless
- Expansion
authorised byreservoir
ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
8 - 5 Nm
9 - 5 Nm
10 - Bottom coolant hose
❑ to connection fitting of
4/2 way valve with cool‐
ant regulator at cylinder
block
❑ connection diagram for
coolant hoses
⇒ page 114
11 - Right radiator fan -V35-
❑ removing and installing ⇒ page 128
12 - Connector
13 - Connector
14 - Radiator fan -V7-
❑ with radiator fan control unit -J293-
❑ removing and installing ⇒ page 128
15 - Fan shroud

3. Radiator and fan 127

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

3.3 Removing and installing fan shroud and

radiator fan
Removing
For vehicles with a fan
– Unscrew top screws -top arrows- of the fan shroud.

For vehicles with two fans

– Unscrew top screws -top arrows- of the fan shroud.
Continued for all vehicles
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .

– Remove the left charge air hose, to do so slacken the hose

clamps -1 and 2-.

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

For vehicles with a fan

– Disconnect plug connection -1-.
– Unscrew bottom screw -bottom arrows- of the fan shroud.
– Remove fan shroud with radiator fan downwards.
– Release the screws of the fan ⇒ Item 10 (page 126) and re‐
move the radiator fan from the shroud.

128 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

For vehicles with two fans

– Disconnect plug connection -1-.
– Unscrew bottom screw -bottom arrows- of the fan shroud.
– Remove fan shroud with radiator fans downwards.

– Separate plug connection -1- and expose cables.

– Unscrew the nuts -arrows- and remove the radiator fan from
the fan shroud.
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ Tightening torques ⇒ page 126 and ⇒ page 127 .

3.4 Removing and installing radiator

Special tools and workshop equipment required
♦ Catch pan e.g. -VAS 6208-
♦ Pliers for spring strap clamps
Removing
– Drain coolant ⇒ page 115 .
– Pull off left coolant hose from radiator -arrow-.
– Remove fan shroud with radiator fans ⇒ page 128 .
On vehicles with air conditioning

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

3. Radiator and fan 129

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect plug -A- on the high pressure sender -G65- -B-.

Continued for all vehicles

– Remove cover for connection fitting, to do so release lateral

retaining clasps -arrows-.

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

– Release screws -arrows- for the inlet connection -1- and re‐
move connecting hose -2-.

– Press in catches -1- and -3- and pull off connecting hose -4-
from air filter -2-.

130 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Screw out screws -arrows- and remove the radiator upwards.

Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Replace gasket rings and O-rings.

♦ Secure all hose connections with spring strap clamps.

– Top up coolant ⇒ page 115 .

3.5 Checking the coolant system for leak‐

tightness

3.5.1 Checking with the cooling system test‐

ing device -V.A.G 1274-
Special tools and workshop equipment required
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter , e.g. -V.A.G 1274/8-
♦ Adapter , e.g. -V.A.G 1274/9-
Test condition
• Engine is at operating temperature.
Test sequence

WARNING

Hot steam or hot coolant may escape when the compensation

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

– Open the cap of the coolant expansion reservoir.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Position
unless authorised by ŠKODAtester
AUTO-V.A.G 1274-
A. S. ŠKODA AUTOwith adapter
A. S. does -V.A.G
not guarantee 1274/8-
or accept on
any liability
the compensation bottle.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Generate a pressure of approx. 0.1 MPar (1.0 bar) for testing

the cooling system.
If the pressure drops:
– Search position of the leak and repair fault.
Test the pressure valve in the cap

3. Radiator and fan 131

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

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

adapter -V.A.G 1274/9- on the cap.
– Generate a pressure for testing the pressure valve in the screw
cap.
• The pressure valve should open at a pressure of 0.14...0.16
MPa (1.4...1.6 bar).
If the valve does not open in the prescribed pressure range:
– Replace cap.

3.5.2 Checking with the cooling system test‐

ing device -V.A.G 1274 B-
Special tools and workshop equipment required
♦ Cooling system testing device , e.g. -V.A.G 1274 B-
♦ Adapter , e.g. -V.A.G 1274/8-
♦ Adapter , e.g. -V.A.G 1274/9-
Test condition
• Engine is at operating temperature.
Test sequence

WARNING

Hot steam or hot coolant may escape when the compensation

bottle is opened. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Wear safety goggles and safety clothing,
with respect to the in order to
correctness avoid in this document. Copyright by ŠKODA AUTO A. S.�
of information
eye injuries and scalding.
♦ Cover the cap with a cloth and open carefully.

– Open the cap of the coolant expansion reservoir.

– Screw the adapter -V.A.G 1274/8- into the coolant expansion
reservoir.
– Connect the connecting piece -V.A.G 1274 B/1- to the adapter
-V.A.G 1274/8- .

132 Rep. gr.19 - Cooling

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Using the hand pump of the testing device generate a pressure
of approx. 0.1 MPa (1.0 bar).

WARNING

Risk of scalding!
♦ Before the cooling system testing device -V.A.G 1274 B-
is separated from the connecting hose or the connecting
piece -V.A.G 1274 B/1- , the existing pressure must ab‐
solutely be released.
♦ For this step, press the pressure relief valve on the cooling
system testing device -V.A.G 1274 B- until the pressure
gauge indicates the value »0«.

If the pressure drops:

– Search position of the leak and repair fault.
Test the
Protected pressure
by copyright. valve
Copying in the
for private cap purposes, in part or in whole, is not permitted
or commercial
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Screw the screw cap into the adapter -V.A.G 1274/9- .
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Connect the connecting piece -V.A.G 1274 B/1- to the adapter

-V.A.G 1274/9- .

– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Generate a pressure for testing the pressure valve in the screw
cap.
• The pressure valve should open at a pressure of 0.14...0.16
MPa (1.4...1.6 bar).
If the valve does not open in the prescribed pressure range:
– Replace cap.

3. Radiator and fan 133

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

20 – Fuel supply system

1 Removing and installing parts of the
fuel supply system

Note

♦ Fuel lines are secured with quick-release couplings.

♦ Fuel hoses at the engine must only be secured with spring-
type clips ⇒ electronic catalogue of original parts .
♦ Use pliers for spring strap clips to fit the spring strap clips.

Observe safety measures ⇒ page 3 .

Observe rules for cleanliness ⇒ page 4 .

1.1 Behaviour in case of misfuelling

Caution

Fueling with incorrect fuel can result in irreversible damage to

the high pressure components, in particular to the high pres‐
sure pump, because of inadequate fuel lubricity and the dirt
contained in the fuel.
♦ The damage is caused by seizures and the formation of
abrasion.
♦ This abrasion damages the fuel pressure regulating valve
and the injection units.

Here are 2 examples which show the consequences of misfuel‐

ing.
Example 1
Misfueling was noticed BEFORE starting the engine, the engine
was NOT started.
Example 2
Misfueling was noticed AFTER starting the engine. Contaminated
or incorrect fuel was already drawn in and is present in the high
pressure parts.

Note

Collect the incorrect fuel which was drained from the fuel tank and
the diesel fuel which was used for cleaning the fuel tank and dis‐
pose.

Behaviour in case of example 1

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

Do not switch on the ignition.

The engine must not be started.

134 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect the plug -1- at the additional fuel pump -V393- in

the engine compartment.
– Completely empty the fuel tank ⇒ page 142 .
– Fill the fuel tank with 5 ltr. of diesel fuel and empty it again.
– Completely fill up the fuel tank with diesel fuel.
– Fit the plug on the additional fuel pump -V393- in the engine
compartment.
– Perform a test drive.
Behaviour in case of example 2
– Completely empty the fuel tank ⇒ page 142 .
– Remove fuel delivery unit ⇒ page 143 .
– Check the fuel tank for dirt and fine metal swarf, if necessary
clean with great care.
– Install fuel delivery unit ⇒ page 143 .
– Fill the fuel tank with 5 ltr. of diesel fuel and empty it again.
– Replace the fuel filter ⇒ page 140 .
– Replace all of the following parts:
♦ High pressure pump ⇒ page 187 .
♦ High pressure lines ⇒ page 199 .
♦ Fuel high pressure reservoir ⇒ page 200 .
♦ Fuel pressure regulating valve -N276 - ⇒ page 205 .
♦ Fuel pressure sender -G247- ⇒ page 202 .
♦ Injection units ⇒ page 196 .
♦ Fuel return-flow lines ⇒ page 184 .
♦ Additional fuel pump -V393- in engine compartment
⇒ page 160 .
– Completely fill up the fuel tank with diesel fuel.
– Fill up the fuel system ⇒ page 189 .
– Perform a test drive.

1.2 Summary of components of fuel tank with attached parts - Vehicles with
front-wheel drive

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

1. Removing and installing parts of the fuel supply system 135

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Mounting part
2 - Screw cap
❑ replace the O-ring if it is
damaged
3 - Earth connection
❑ check for firm seating
4 - 11 Nm
5 - Guide
6 - 25 Nm
❑ replace
7 - Fuel tank
❑ when removing, support
using the engine/gear‐
box jack , e.g. -V.A.G
1383 A-
❑ removing and installing
⇒ page 151
8 - Circlip
9 - Support
❑ for exhaust pipe
10 - Tensioning strap
❑ Check fitting position
11 - Heat shield
12 - Sealing ring
❑ replace if damaged
❑ insert dry into the open‐
ing of the fuel tank
❑ must be moistened on
the inside with fuel be‐
fore assembly of the fuel
delivery unit
13 - Fuel delivery unit
❑ with sender for fuel gauge display
❑ removing and installing ⇒ page 143
❑ note the correct installed position of the fuel tank ⇒ page 137
❑Protected
inspecting fuel
by copyright. pump
Copying ⇒ page
for private 156 purposes, in part or in whole, is not permitted
or commercial
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ withClean
respectstrainer if dirty
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ removing and installing the sender for fuel gauge ⇒ page 148
14 - Lock ring, 110 Nm
❑ slacken and tighten with wrench -T30101 (3087)-
❑ pay attention to correct position
15 - Return-flow line
❑ from fuel filter
❑ clipped in place on fuel tank
❑ pay attention to correct position
❑ blue
16 - Feed line
❑ to fuel filter
❑ clipped in place on fuel tank

136 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011
❑ pay attention to correct position
❑ black
17 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work ⇒ Rep. gr. 55

Fitting location of the fuel delivery unit

The marking -3- on the flange of the fuel delivery unit points
against the direction of travel.

Note

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

Return line -1- blue.

Feed line -2- black.

Note

After installing the fuel delivery unit, check whether the feed line
and return-flow line are correctly clipped in place on the fuel tank.

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

1. Removing and installing parts of the fuel supply system 137

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.3 Summary of components of fuel tank with attached parts - Vehicles with
four-wheel drive

1 - Fuel tank lid unit

❑ with rubber bowl
❑ removing and installing
⇒ Body Work ⇒ Rep.
gr. 55
2 - Screw cap
❑ replace the O-ring if it is
damaged
3 - Mounting part
4 - Earth connection
❑ check for firm seating
5 - 10 Nm
6 - Suction spray pump
❑ connected to fuel gauge
sender 2 -G169-
❑ removing and installing
7 - Lock ring, 110 Nm
❑ use wrench -T30101
(3087)- for removing
and installing
❑ check for firm seating
8 - Fuel gauge sender 2 -
G169-
❑ note the installed posi‐
tion of the fuel tank
⇒ page 139
❑ removing and installing
⇒ page 149
9 - Sealing ring
❑ insert dry into the open‐
ing of the fuel tank
❑ replace if damaged
❑ only moisten from the inside the seal of the flange with fuel for installation purposes
10 - Fuel tank
❑ when removing, support with the engine/gearbox jack e.g. -V.A.G 1383 A -
❑ removing and installing ⇒ page 153
11 - Tensioning strap
❑ Check fitting position
12 - 25 Nm
❑ replace
13 - 25 Nm
14 - Heat shield
15 - Fuel delivery unit
❑ with sender for fuel gauge display -G-
❑ removing and installing ⇒ page 145
❑ note the installed position of theProtected
fuel tank ⇒ page
by copyright. 139for private or commercial purposes, in part or in whole, is not permitted
Copying
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

138 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011
❑ inspecting fuel pump ⇒ page 156
❑ Clean strainer if dirty
❑ Removing and installing the sender for fuel gauge display -G- ⇒ page 148
16 - Feed line
❑ to fuel filter
❑ clipped in place on fuel tank
❑ check for firm seating
❑ black
17 - Return-flow line
❑ from fuel filter
❑ clipped in place on fuel tank
❑ check for firm seating
❑ blue

Fitting position of the flange of the fuel delivery unit with ( sender
for fuel gauge display -G- ) and the flange of the fuel gauge sender
2 -G169-
The markings on the flanges must be aligned with markings on
the fuel tank -arrows-.

Note

♦ The markings on the fuel tank are hardly visible.

♦ After installing the fuel delivery unit, check whether the feed
line and return-flow line are correctly clipped in place on the
fuel tank.

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

1. Removing and installing parts of the fuel supply system 139

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.4 Fuel filter - Summary of components

1.4.1 Fuel filter for engine with identification characters CFHC, CFHF

Note

Before disconnecting the fuel hoses, mark assignment to the supports.

1 - Return-flow hose
❑ to fuel tank
❑ blue marking and blue
inscription
❑ is connected on the blue
line on the separation
point in the engine com‐
partment on the right
2 - Intake hose
❑ from fuel tank
❑ white marking and white
inscription
❑ is connected on the
black line on the sepa‐
ration point in the engine
compartment on the
right
3 - Fuel filter - top part
❑ raise at the assembly
groove using the offset
screwdriver -VAS 6543-
⇒ Maintenance ; Book‐
let Octavia II
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
4 - 5 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
5 - Return-flow hose
❑ of engine
❑ blue marking and blue
inscription
6 - Intake hose
❑ to additional fuel pump
❑ white marking and white
inscription
7 - Sealing ring
❑ replace
8 - Fuel filter element
❑ pay attention to change intervals ⇒ Maintenance ; Booklet Octavia II
9 - 8 Nm
10 - 8 Nm
❑ to remove the fuel filter only slacken the screw
11 - Fuel filter - bottom part with integrated bracket

140 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.4.2 Fuel filter for engines with identification characters CLCA, CLCB

Note

Before disconnecting the fuel hoses, mark assignment to the supports.

1 - Return-flow hose
❑ to fuel tank
❑ blue marking and blue
inscription
❑ is connected on the blue
line on the separation
point in the engine com‐
partment on the right
2 - Intake hose
❑ from fuel tank
❑ white marking and white
inscription
❑ is connected on the
black line on the sepa‐
ration point in the engine
compartment on the
right
3 - Water drain plug, 7 Nm
❑ Drain fuel filter ⇒ Main‐
tenance ; Booklet Octa‐
via II
4 - Fuel filter - top part
❑ raise at the assembly
groove using the offset
screwdriver -VAS 6543-
⇒ Maintenance ; Book‐
let Octavia II
5 - 5 Nm
6 - Return-flow hose
❑ of engine
❑ blue marking and blue
inscription
7 - Intake hose
❑ to additional fuel pump -V393-
❑ white marking and white inscription
8 - Sealing ring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ replace
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
9 - Fuel filter element
❑ Change intervals ⇒ Maintenance ; Booklet Octavia ll
10 - 8 Nm
11 - 8 Nm
❑ to remove fuel filter only slacken screw and do not release
12 - Fuel filter - bottom part
❑ with integrated bracket

1. Removing and installing parts of the fuel supply system 141

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.5 Extract fuel from the fuel tank

Special tools and workshop equipment required
♦ Hose adapter , e.g. -V.A.G 1318/16-
♦ Adapter , e.g. -V.A.G 1318/17-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Battery
♦ Fuel tank

Note

If the fuel pump is defective, suction off fuel using a fuel suction
device , e.g. -VAS 5190- .

Work procedure

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Switch off ignition and withdraw ignition key.

– Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 .
– Unclip retaining catches -arrows- of cover for the fuel delivery
unit and remove cover.

Note

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

WARNING

The fuel feed line is pressurized! Wear safety goggles and

safety clothing, in order to avoid injuries and skin contact with
fuel. Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by carefully
removing the wiring.

Note

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

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

142 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unplug the 5-pin connector -1- and the black feed line -2-.

– Connect the adapter set -V.A.G 1318/17- and the hose adapt‐
er -V.A.G 1318/16- and fit the resulting „drain pipe“ onto the
feed support of the fuel delivery unit.
– Hold the „drain pipe“ in a suitable fuel tank.
– Connect the battery and the contacts of the fuel pump with
adapter cables -A- from the adapter cable set as follows:
♦ Battery positive terminal (+) to contact -1- of the fuel pump.
♦ Battery negative terminal (-) to contact -5- of the fuel pump.
The fuel pump runs and suctions off fuel.

WARNING

In order to prevent an overflow of fuel, the fuel pump must not

run unattended.

1.6 Removing and installing the fuel delivery

unit on vehicles with front-wheel drive
Special tools and workshop equipment required
♦ Key -T30101 (3087)- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Protective gloves with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Removing
• The fuel tank must not be more than 3/4 full.

Note

♦ If necessary drain the fuel tank ⇒ page 142 .

♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Switch off ignition and withdraw ignition key.

– Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 .

1. Removing and installing parts of the fuel supply system 143

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unclip retaining catches -arrows- of cover for the fuel delivery

unit and remove cover.

Note

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

– Unplug the 5-pin plug -1-, the black feed line -2- and blue re‐
turn-flow line -3- abziehen.

Note

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

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

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Slacken lock ring with the wrench -T30101-
with respect to the.correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

When removing and installing, ensure that the float arm of the
sender for fuel gauge display -G- is not bent.

– Pull the fuel delivery unit and the gasket ring out of the opening
of the fuel tank.

Note

You must empty the old fuel delivery unit before disposing of it if
you wish to replace it.

Install
– Installation is performed in the reverse order, pay attention to
the following points:

144 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Note

♦ Insert new dry gasket ring into the opening of the fuel tank.
♦ The gasket ring must only be moistened on the inside with fuel
before assembly of the fuel delivery unit.
♦ When installing, do not bend the sender for fuel gauge display.
♦ Observe the fitting location of the fuel delivery unit. The mark‐
ing -3- on the flange must point against the direction of travel.
The fuel delivery unit can only be installed in this position.
♦ Do not interchange feed line and return-flow line.
♦ Tighten the lock ring to a tightening torque ⇒ page 135 .
♦ Make sure the line connections fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
line and return-flow line are correctly clipped in place on the
fuel tank.

1.7 Removing and installing the fuel delivery

unit on vehicles with four-wheel drive
Special tools and workshop equipment required
♦ Key -T30101 (3087) -
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
• The fuel tank must not be more than 3/4 full.

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Switch off ignition and withdraw ignition key.

– Empty the fuel tank if necessary ⇒ page 142 .
– Fold up rear seat.
– Unclip retaining catches -arrows- of cover for the fuel delivery
unit and remove cover.

Note

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

1. Removing and installing parts of the fuel supply system 145

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unplug the 5-pin plug -1-, the black feed line -2- and blue re‐
turn-flow line -3- abziehen.

Note

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

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

– Open lock ring with the wrench -T30101- .

– Slightly raise the closing flange and check if the spring -2- is
still fastened on the flange -1-.
If the spring -2- is loose on the guide pipe -3-, hold it with your
fingers while removing the closing flange.
– Pull out closing flange and gasket ring of the fuel delivery unit
from the opening of the fuel tank and place to the side with the
connected lines.

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

146 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Separate through the opening of the fuel tank the fuel line
-1- to the suction jet pump, to do so press the release button.
– Separate the fuel delivery line -2- from the fuel delivery unit.

Note

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

– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
The fuel delivery unit is installed in the reverse order. However,
pay attention to the following:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Insert the fuel delivery unit into theunless
fuel tank with
authorised the closing
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
flange placed to the side. Thus, do not bend the float arm of
the fuel gauge sender unit -G- .
– Install the fuel delivery unit and the fuel line.
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.

• The spring -2- must be fastened to the retaining lugs -1- of the
closing flange.
– First of all guide the guide pipe -3- into the guide bore -4-.
– Then lower the closing flange in such a way that the guide pipe
-6- locks into the guide bore -5-.

1. Removing and installing parts of the fuel supply system 147

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Note

Pay attention that the electrical cables -1- and the fuel feed line
-3- are routed according to the illustration and the float arm -2- is
not blocked.

– Press the closing flange down and bring it into the installation
position.
Further information:

♦ Fitting position of the fuel delivery unit: The peg -2- at the clos‐
ing flange must be located between the pegs -1- and -3-. The
-thick arrow- points in the direction of travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
line and the return-flow line are still clipped
Protected in place
by copyright. on for
Copying the fuelor commercial purposes, in part or in whole, is not permitted
private
tank. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1.8 Removing and installing the sender for

fuel gauge display -G-
Removing
– Remove fuel delivery unit ⇒ page 143 .
– Unlock the catches -arrows- using a screwdriver and pull out
the sender for the fuel gauge display -G- towards the top.

148 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unlatch and disconnect the plugs of the electrical cables -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the wiring and check correct installation of the plug.
– Insert the sender for fuel gauge display -G- in the guides at the
fuel delivery unit and press downwards until it latches into po‐
sition.
– Install fuel delivery unit ⇒ page 143 .

1.9 Removing and installing fuel gauge

sender 2 -G169-
• The fuel tank must not be more than 1/2 full.

Note

♦ Empty the fuel tank if necessary ⇒ page 142 .

♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Observe the regulations concerning cleanliness when working
on the fuel supply/injection system ⇒ page 4 .
♦ Make sure that the fuel gauge sender is not tilted.

Removing
Switch off ignition and withdraw ignition key.
– Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 .
– Remove left cover and disconnect plug from fuel gauge sender
2 -G169- .
– Unlock lock ring from flange with wrench -T30101- .

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

1. Removing and installing parts of the fuel supply system 149

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Slightly pull fuel gauge sender 2 -G169- out of the opening of

the fuel tank, unlock securing tabs -arrows- and disconnect
suction jet pump.
Install
– Installation is carried out in the reverse order. Pay attention to
the following:

WARNING

When installing do not bend the float arm of the fuel gauge
sender 2 -G169 - .

– Insert the fuel gauge sender 2 -G169- into the fuel tank.

– Fit the suction jet pump in the fuel tank onto the fuel gauge
sender 2 -G169- and push it in until the securing tabs
-arrows- latch into position.
– Insert new dry gasket ring of the flange into the opening of the
fuel tank and only moisten the inside (towards flange) with fuel.
– Check the fitting position ⇒ page 139 and insert the flange of
the fuel gauge sender 2 -G169- into the opening of the fuel
tank.
– Check correct seating of the gasket ring.

– Tighten the lock ring with wrench -T30101- to 110 Nm.

– Fit on plug and install left cover.

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

150 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.10 Removing and installing suction jet

pump

Note

♦ The fuel tank consists of a left and right chamber. In order to

pump the fuel out of the left chamber -3- of the fuel tank into
the right chamber to the housing of the fuel delivery unit -2-, a
suction jet pump -1- is required.
♦ The version of the fuel tank requires that the fuel is pumped
from the area of the fuel gauge sender 2 -G169- with a suction
jet pump to the fuel delivery unit.
♦ A check is only to be carried out, if the engine stops because
of fuel shortage, although the fuel gauge still indicates a fuel
tank which is 1/4 full.

Work procedure
– Remove fuel delivery unit ⇒ page 143 .
– Remove fuel gauge sender 2 -G169- ⇒ page 149 .
– Now the suction jet pump can be pulled out from the side of
the fuel gauge sender 2 -G169- (on left in direction of travel).
– Check if the fuel lines are firmly connected to the suction jet
pump and are not damaged.
– Check the suction jet pump additionally for possible contami‐
nation.

1.11 Remove and install the fuel tank for ve‐

hicles with front-wheel drive
Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
Removing
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 142 .

Note

♦ Drain the fuel tank ⇒ page 142 .

♦ Safety precautions when working on the fuel supply system
⇒ page 3 .
♦ Observe the regulations concerning cleanliness when working
on the fuel supply/injection system ⇒ page 4 .

– Switch off ignition and withdraw

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

1. Removing and installing parts of the fuel supply system 151

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Unclip retaining catches -arrows- of cover for the fuel delivery

unit and remove cover.

Note

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

– Unplug the 5-pin plug -arrow- from the fuel delivery unit.
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew the cap from the fuel filler neck.
– Close the opening of the fuel filler neck with a clean foam
piece, so that no dirt can penetrate.
– Remove right rear wheel ⇒ Chassis ⇒ Rep. gr. 44 .
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
gr. 66 .

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

152 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

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

– Unclip the wiring loom from the holder -2- at the top and bottom
of the filler neck.
– Remove rear tunnel bridge ⇒ page 222 .
– Slacken front double clamp at exhaust pipe and push to the
rear.
– Loosen the middle and rear part of the exhaust system from
all the retaining straps.
– Slightly lower the middle and rear part of the exhaust system
and tie with wire to the body.
– Disconnect the fuel feed line and the fuel return-flow line on
the front right of the fuel tank.

Note

♦ For vehicles with auxiliary heating, the fuel line of the dosing
pump -V54- must also be disconnected.
♦ Press down the securing rings in order to unlock the connec‐
tions of the fuel lines.

– Unscrew tensioning strap.

– Support fuel tank using the engine/gearbox jack -V.A.G 1383
A- .
– Unscrew securing bolts.
– Lower the fuel tank.
Install
Installation occurs in reverse order to removal. Pay attention to
the following:
♦ Lay the fuel lines avoiding any kinks.
♦ Do not mix-up the fuel feed line (black) and the fuel return-flow
line (blue).
♦ Make sure the line connections fit tightly.
♦ Check feed line and return-flow line at fuel tank for firm seating.
♦ Check earth connection of fuel tank/body at filler neck.

1.12 Removing and installing fuel tank for ve‐

hicles with four-wheel drive
Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
• The fuel tank must be empty for weight reasons when remov‐
ing it, if necessary suction the fuel out of the fuel tank
⇒ page 142 .
Removing
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

1. Removing and installing parts of the fuel supply system 153

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Switch off all electrical components and withdraw key from ig‐
nition lock.
– Remove rear seat bench with brackets ⇒ Body Work ⇒ Rep.
gr. 72 .
– Remove floor covering under the rear seat bench.
– Remove the cover from the fuel delivery unit and the cover for
the flange with the fuel gauge sender 2 -G169- .

Note

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

– Disconnect the plug for the fuel delivery unit and the flange
with the fuel gauge sender 2 -G169- -arrows-.
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew the cap from the fuel filler neck.
– Close the opening of the fuel filler neck with a clean foam
piece, so that no dirt can penetrate.
– Remove right rear wheel ⇒ Chassis ⇒ Rep. gr. 44 .
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
gr. 66 .

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

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

Note

♦ For vehicles with auxiliary heating, the fuel line of the dosing
pump -V54- must also be disconnected.
♦ Press down the securing rings in order to unlock the connec‐
tions of the fuel lines.

– Remove tunnel bridge -arrows-.

– Remove rear part of exhaust system ⇒ page 231 .
– Remove propshaft ⇒ Gearbox ⇒ Rep. gr. 39 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

154 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Disconnect plug -arrow- at four-wheel drive control unit -

J492- .

– First unscrew screws -2, 5- and -6-.

– Support the fuel tank using the engine/gearbox jack -V.A.G
1383 A- .
– Screw out the screws for the tensioning straps -1, 3, 4- and
-7-.

– Lower slightly the fuel tank using the engine/gearbox jack -

V.A.G 1383 A- .
– Then remove the fuel tank from the engine/gearbox jack -
V.A.G 1383 A- and pull through the filler neck between the
body and the rear axle with the help of a second mechanic.
Install
Installation occurs in reverse order to removal. Pay attention to
the following:

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

♦ Do not mix-up the fuel feed line (black) and the fuel return-flow
line (blue).
♦ Make sure the line connections fit tightly.
♦ Check feed line and return-flow line at fuel tank for firm seating.

– Check earth connection of fuel tank/body at filler neck and if

necessary remove corrosion.
• The plug -1- on the metal plate ring -2- must be pushed on
firmly.
• The contact tab -4- must be hung on the fuel tank -3- and se‐
cured with the spacer bush -5-.
– Pull through the filler neck between the body and the rear axle
with the help of a second mechanic. Then position the fuel tank
onto the engine/gearbox jack -V.A.G 1383 A- .
Tightening torques: ⇒ page 138

1. Removing and installing parts of the fuel supply system 155

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.13 Testing fuel pump

1.13.1 Checking function and voltage supply of

fuel pump
Special tools and workshop equipment required
♦ Measuring tool set , e.g. -V.A.G 1594 C-
Test conditions
• Battery voltage at least 12 V.
• Fuses o.k. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
• All electrical consumers such as the light and rear window
heater must be switched off.
Test sequence

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 .

– Unclip retaining catches -arrows- of cover for the fuel delivery
unit and remove cover.unless
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

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

– Switch on ignition.
• The fuel pump must be heard to start running.
– Switch off ignition.
If the fuel pump does not run:
– Continuing searching for faults using a multimeter ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.

1.13.2 Test feed pressure of fuel pump

Special tools and workshop equipment required
♦ Pressure gauge , e.g. -V.A.G 1318-
♦ Adapter , e.g. -V.A.G 1318/17A-
Test conditions
• Battery voltage at least 12 V.
• Fuses o.k. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
• All electrical consumers such as the light and rear window
heater must be switched off.

156 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Test sequence

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Separate fuel feed line -2-, to do so press in securing ring.

– Connect the pressure gauge -V.A.G 1318- with the adapter

set -V.A.G 1318/17A- to the open ends of the fuel feed line
(the illustration shows a different engine).
– Open shut-off cock of the pressure gauge.
– Start engine and run in idle.
– Read the pressure on the pressure gauge -V.A.G 1318- .
• Specified value: min. 0,05 MPa (0,5 bar)
– Ïncrease the engine speed to 2 500 rpm and read the pressure
on the pressure gauge -V.A.G 1318- .
• Specified value: min. 0,025 MPa (0,25 bar)
If the specified value is not reached or the pressure fluctuates:
– Replace fuel delivery unit.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
If the specified value is reached:
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Replace the fuel filter in order to prevent a fuel filter from being
blocked.
– Check the fuel flow rate of the fuel pump ⇒ page 157 .

1.13.3 Check the fuel flow rate of the fuel pump

Special tools and workshop equipment required
♦ Remote control , e.g. -V.A.G 1348/3A-
♦ Measuring tool set , e.g. -V.A.G 1594C-
♦ Adapter , e.g. -V.A.G 1318/16-
♦ Adapter , e.g. -V.A.G 1318/17-
♦ Measuring vessel
Test conditions
• Battery voltage at least 12 V.
• Fuel temperature 15…30°C.
• Fuel tank must be at least 1/4 full.

1. Removing and installing parts of the fuel supply system 157

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Test sequence

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Unscrew the cap from the fuel filler neck.

– Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 .
– Unclip retaining catches -arrows- of cover for the fuel delivery
unit and remove cover.

Note

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

– Unplug the 5-pin plug from the fuel delivery unit.

– Connect remote control -V.A.G 1348/3A- with connection lines

from measuring tool set to contact -1- of the fuel pump and to
battery positive terminal.
– Use connection lines from the measuring tool set to connect
the contacts -5- to the plug and to the fuel pump.
– Pull off the fuel feed line from the flange of the fuel delivery
unit.
– Connect adapter -V.A.G 1318/17- and adapter -
V.A.G 1318/16- , fit onto the feed support and hold the other
end in a measuring glass.
– Activate the remote control -V.A.G 1348/3A- for 30 seconds.
– Measure the battery voltage.

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

158 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Compare the fuel rate with the specified value.

Note

♦ The amount of the fuel pumped is dependent on the voltage

at the fuel pump.
♦ The diagram refers to the existing voltage at the fuel pump
which is about 2 V less than the battery voltage.

If the minimum delivery volume is not reached:

– Remove the fuel pump and check whether the pump strainer
is not clogged up.
If no fault was detected:
– Replace fuel delivery unit ⇒ page 143 .

1.13.4 Check voltage consumption of the fuel

pump
Special tools andbyworkshop
Protected equipment
copyright. Copying for private or required
commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Vehicle diagnosis, measurement
with respect to the and information
correctness of information systemby-ŠKODA AUTO A. S.�
in this document. Copyright
VAS 5051-
– Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 .
– Unclip retaining catches -arrows- of cover for the fuel delivery
unit and remove cover.

Note

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

– Connect the current probe -A- of the vehicle diagnosis, meas‐

urement and information system -VAS 505X- on the line -B- to
contact 1 of the 5-pin plug.
– Start engine and run in idle.
– Measure voltage consumption of the fuel pump.
Specified value: max. 7.5 A
If the power consumption is exceeded, the fuel pump is defective.
– Replace fuel delivery unit ⇒ page 143 .

1. Removing and installing parts of the fuel supply system 159

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.14 Removing and installing additional fuel

pump -V393-

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .
♦ The additional fuel pump -V393- is only supplied as a spare
part complete with the bracket.

Removing
Engine with identification characters CFHC, CFHF
– Disconnect plug -2- at differential pressure indicator -G505- .
– Screw out screw -3- and remove bracket with differential pres‐
sure indicator -G505- from the bracket of the additional fuel
pump in -direction of arrow-.

Caution

Risk of damage!
♦ The differential pressure indicator -G505- is very sensi‐
tive. It must not touch somewhere when laying it down.

– Place the bracket with the differential pressure indicator -

G505- to the rear.

– Unhook the fuel hoses -1, 2, 3- on the bracket and remove the
bracket -4-.
Continued for all engines

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

160 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unplug connector -1-.

– Unscrew screws -3- and -4- and remove bracket -2- with ad‐
ditional fuel pump.

– Open the spring strap clamps and remove the fuel hoses -2-
and -4-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

– Tighten screws -3- and -4- to 20 Nm.

– After replacing the additional fuel pump -V393- , fill up the fuel
system ⇒ page 189 .

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

1. Removing and installing parts of the fuel supply system 161

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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2 Accelerator control

2.1 Accelerator pedal module - Summary of components

1 - Connector
❑ black
❑ 6-pin
❑ disconnect and fit on
⇒ page 164
2 - Accelerator pedal module
❑ with accelerator pedal
position sender -G79-
and accelerator pedal
position sender 2 -
G185-
❑ -A- openings for release
tool -T10238- or -
T10240-
❑ not adjustable
❑ removing and installing
⇒ page 162
❑ when replacing, the en‐
gine control unit must be
adapted ⇒ Vehicle diag‐
nostic, testing and infor‐
mation system
VAS 5051 on vehicles
with automatic gearbox
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
3 - 10unless
Nmauthorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4 - Cap

2.2 Removing and installing accelerator

pedal module
Special tools and workshop equipment required
♦ Release tool -T10238- (for left-hand drive vehicle)
♦ Release tool -T10240- (for right-hand drive vehicle)

162 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Removing
– Remove steering column cover -arrows-.
– Disconnect connector at accelerator pedal module
⇒ page 164 .
– Lever out the cap ⇒ Item 4 (page 162) with a screwdriver.
– Unscrew the fixing screw ⇒ Item 3 (page 162) .

– Push the release tool -T10238- (for right-hand drive vehicles

release tool -T10240 - ) as shown up to the stop into the pro‐
vided openings.
– Remove accelerator pedal module.
Install

– Fit the connector -2- onto the accelerator pedal module -5-
⇒ page 164 .
– Push again rubber grommet -1- onto the connector -2-.
– Push accelerator pedal module onto the retaining bolts -6-.
– Insert the centering pin -7- into the hole in the underbody.
– Fasten accelerator pedal module with screw -3- (10 Nm) and
fit on cap -4-.
– Re-install steering column cover. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

If the accelerator pedal module was replaced on vehicles with

automatic gearbox, the engine control unit must be adapted ⇒ Ve‐
hicle diagnostic, testing and information system VAS 5051.

2. Accelerator control 163

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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2.3 Disconnect connector for accelerator

pedal module and fit on

Note

The plugs for the accelerator pedal module which are inserted,
must be disconnected and fit on in a different manner.

Disconnect connector 1K0 973 706

– Slightly press the piston slide valve -A- (grey) in
-direction of arrow 1- and push it up to the stop in
-direction of arrow 2-.
– Hold the piston slide valve in this position and disconnect the
socket housing -B- in -direction of arrow 3-.
The piston slide valve -A- remains in the bottom position.

Fit on connector 1K0 973 706

– Push the socket housing -B- in -direction of arrow- until the
piston slide valve can be heard to lock in place.
The piston slide valve -A- moves automatically upwards.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.

Disconnect connector 8K0 973 706

– Pull out the piston slide valve -A- (red) up to the stop in
-direction of arrow-.
– Press the piston slide valve in -direction of by
Protected arrow 2- Copying
copyright. and dis‐
for private or commercial purposes, in part or in whole, is not permitted
connect the socket housing -B- in -direction of arrow
unless authorised by ŠKODA3-.AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
The piston slide valve -A- remains in the top position.

Fit on connector 8K0 973 706

– Push the socket housing -B- up to the stop in
-direction of arrow 1-.
– Slightly press the piston slide valve in -direction of arrow 2-
and push it in -direction of arrow 3-.
The piston slide valve -A- can only be pushed down if the
socket housing was pushed up to the stop.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.

164 Rep. gr.20 - Fuel supply system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

21 – Turbocharging/supercharging
1 Charge-air system - exhaust gas tur‐
bocharger

Note

♦ Observe rules for cleanliness ⇒ page 5 .

♦ Observe general instructions for charge-air system
⇒ page 5 .

1.1 Exhaust gas turbocharger with component parts - Summary of components

The exhaust turbocharger and the exhaust manifold are one com‐
ponent part.

1 - Connecting pipe
❑ to radiator for exhaust
gas recirculation
2 - Gasket
❑ replace
3 - 20 Nm
4 - 10 Nm
❑ at bracket
⇒ Item 33 (page 167)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
5 - 15 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6 - Heat shield
7 - Exhaust gas turbocharger
❑ only complete with ex‐
haust manifold
❑ removing and installing
⇒ page 167
❑ Remove and install the
connection pipe for the
suction hose
⇒ page 214
8 - Retaining loop
❑ can only be installed in
one position
9 - O-ring
❑ replace
10 - Pulsation dampener
11 - 9 Nm
12 - 9 Nm
❑ captive in the inlet con‐
nection
⇒ Item 13 (page 165)
13 - Inlet connection
❑ with fixing screw ⇒ Item 12 (page 165)

1. Charge-air system - exhaust gas turbocharger 165

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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14 - O-ring
❑ replace
15 - 15 Nm
16 - Support
❑ for electrical cables
17 - Heat shield
18 - Gasket
❑ replace
19 - 25 Nm
❑ replace
20 - Exhaust gas temperature sender 1 -G235- ( Temperature sender upstream turbocharger -G507- ), 45 Nm
❑ the thread of a new sender must be coated with assembly paste
❑ coat thread with hot bolt paste -G 052 112 A3- before installing a used sender
❑ removing and installing ⇒ page 171
21 - 20 Nm
22 - Support for exhaust gas turbocharger
❑ for oil return-flow line
23 - 10 Nm
24 - Gasket rings
❑ different diameters, observe fitting position
❑ replace
25 - Hollow screw, 60 Nm
26 - Gasket rings
❑ replace
27 - Hollow screw, 30 Nm
28 - O-ring
❑ replace
29 - Oil feed line
❑ Tighten the union nut using the socket wrench insert -T40055- , tightening torque 22 Nm
❑ check continuity
❑ before installing, fill the exhaust gas turbocharger on the connection fitting with engine oil
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
30 - 24 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
31 - Gasket
❑ replace
32 - Oil return pipe

Caution
Before installing, check
whether the bellows of
the oil return pipe is not
bent or overstretched. If
this is the case, micro‐
cracks might occur
which can result in leaks.
Replace damaged oil re‐
turn pipe or support for
exhaust gas turbocharg‐
er.

166 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

33 - Support
❑ for oil feed line

1.2 Removing and installing exhaust gas

turbocharger
Special tools and workshop equipment required
♦ Socket insert XZN 10 -T10385-
♦ Pliers for spring strap clamps
Removing

Caution

In case of mechanical damage to the exhaust gas turbocharg‐

er, e.g. damage of the compressor wheel, it is not sufficient to
only replace the exhaust gas turbocharger. In order to prevent
consequential damage to the engine, perform the following
tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter,byair
Protected filter Copying
copyright. insert for
and charge
private air hoses
or commercial asinwell
purposes, part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
as chargewithairrespect
pipes for soiling.
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Check all the air guides and the charge air cooler for for‐
eign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.

Note

♦ Observe rules for cleanliness ⇒ page 5 .

♦ Observe general instructions for charge-air system
⇒ page 5 .

– Remove pre-exhaust pipe:

♦ Engine identification characters CFHC, CFHF ⇒ page 225
♦ Engine identification characters CLCA, CLCB ⇒ page 228
– Remove air filter with air mass meter -G70- and inlet hose
⇒ page 214 .
– Disconnect plug -2- from position sender for charge pressure
regulator -G581- at exhaust gas turbocharger.
– Detach vacuum line -3- at exhaust gas turbocharger.

1. Charge-air system - exhaust gas turbocharger 167

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Disconnect plug connection -3- for exhaust gas temperature

sender 1 -G235- ( temperature sender upstream turbocharger
-G507- ) and expose electrical cable.

– Release screws -arrows-.

– Slacken hose clamp -1- and remove pulsation dampener -2-.

Caution

Pay attention that the bellows of the connection pipe is not bent
and therefore is not overstretched. There is a risk of crack for‐
mation.

– Remove connection pipes for exhaust gas recirculation -A-

with the socket insert XZN
unless10 -T10385-
authorised by ŠKODA. AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Vehicles with front-wheel-drive
– Unscrew the union nut -2- of the oil feed line -1-.

– Screw out screws -4- and -9-.

– Release hollow screws -7- and -8-.
– Remove the support for exhaust gas turbocharger -6- with oil
return pipe and oil feed pipe -1-.
Vehicles with four-wheel drive
– Remove the right flange shaft from the angle gearbox ⇒ Gear‐
box ⇒ Rep. gr. 39 ⇒ Chapter „Gasket ring in separated
version for right flange shaft“ .

168 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Screw out screws -5- and -10-.

– Unscrew the union nut -2- and place the oil feed line -1- to the
rear.
– Screw out screws -4- and -9-.
– Release hollow screw -7-.
– Remove support for exhaust gas turbocharger -6- with oil re‐
turn pipe.
Continued for all vehicles

– Release screws -arrows- and remove heat shield.

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

1. Charge-air system - exhaust gas turbocharger 169

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unscrew the fixing nuts of the exhaust manifold -arrows-.

– Remove exhaust turbocharger with exhaust manifold down‐
wards.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Caution

Before installing, check whether the bellows of the oil return

pipe is not bent or overstretched. If this is the case, microcracks
might occur which can result in leaks. Replace damaged oil
return pipe or support for exhaust gas turbocharger.

Note

♦ Replace the gaskets, the sealing rings and the self-locking

nuts.
♦ Fill exhaust turbocharger with engine oil through the connec‐
tion fitting of the oil feed line.
♦ Remove oil and grease from the charge
unlessair pipesbyand hoses
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authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
and from their connections before installing.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Secure all hose connections with screw clamps.

♦ Only install approved clamps for securing the hose connec‐
tions ⇒ Electronic Catalogue of Original Parts .
♦ Tightening torques: ⇒ page 165

– Checking the oil level ⇒ Maintenance ; Booklet Octavia II .

Note

After installing the exhaust turbocharger, run engine at idling

speed for about 1 minute to ensure that oil is supplied to the tur‐
bocharger bearing.

170 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.3 Removing and installing exhaust gas

temperature sender 1 -G235- ( temper‐
ature sender upstream turbocharger -
G507- )
Removing
– Disconnect plug connection -3- for exhaust gas temperature
sender 1 -G235- ( temperature sender upstream turbocharger
-G507- ) and expose electrical cable.
Vehicles with four-wheel drive
– Remove propshaft ⇒ Gearbox ⇒ Rep. gr. 39 .
Continued for all vehicles

– Unscrew exhaust gas temperature sender 1 -G235- ( temper‐

ature sender upstream turbocharger -G507 - ) -1- from the
exhaust manifold.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ The thread of the new temperature sender must be coated with

assembly paste.
♦ Before installing, grease only the thread with hot bolt paste -
G 052 112 A3- for a re-used temperature sender.
♦ All cable straps should be fastened again in the same place
when installing.
♦ Tightening torque: 45 Nm

1.4 Connection diagram for vacuum hoses

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

1. Charge-air system - exhaust gas turbocharger 171

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1 - Vacuum setting element

❑ for change-over flap for
exhaust gas recircula‐
tion
2 - Non-return valve
❑ Check fitting position
3 - Changeover valve for radi‐
ator of exhaust gas recircula‐
tion -N345-
❑ Check change-over
⇒ page 236
4 - Cylinder head cover
❑ with integrated vacuum
reservoir
5 - Vacuum setting element
❑ at exhaust gas turbo‐
charger
❑ with position sender for
charge pressure regula‐
tor -G581-
6 - Solenoid valve for charge
pressure control -N75-
7 - Vacuum pump
8 - Air filter
❑ with connecting piece
for vent line

1.5 Inspect the vacuum system

Caution

When routing the vacuum lines, make sure that the lines are
not kinked, twisted or crimped. Otherwise this can lead to
breakdown.

Special tools and workshop equipment required

♦ Hand vacuum pump , e.g. -VAS 6213-
– Remove engine cover ⇒ page 7 .
Check vacuum supply line, vacuum reservoir and non-return
valve
– Unclip the unless
changeover valve
Protected by copyright. for for
Copying radiator
private or of exhaust
commercial gas inrecir‐
purposes, part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
culation -N345- fromtothe
with respect front bracket
the correctness at the
of information intake
in this manifold.
document. Copyright by ŠKODA AUTO A. S.�

172 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Detach the vacuum hose on the bottom connection of the ex‐

haust gas recirculation radiator change-over valve -N345-
-arrow in I-.
– Detach the vacuum hose on the bottom connection of the
charge pressure control solenoid valve -N75- -arrow in II-.
– Close off the open hose ends with suitable plugs.

Note

Do not use any thread screws or thread bolts.

– Detach the vacuum hose -arrow in l- on the connecting piece

of the vaccum pump.

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

1. Charge-air system - exhaust gas turbocharger 173

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Note

In order to generate „vacuum“, push the ring -1- for the hand vac‐
uum pump -VAS 6213- into position -A-.

– Attach the hand vacuum pump -VAS 6213- to the detached

hose and generate a vacuum of 0.06 MPa (0.6 bar).
– Observe the pressure gauge of the hand vacuum pump for
approx. 30 seconds.
• The vacuum must not drop.
If the vacuum drops:
– Search for damage, for example a leaky connection in the
hose line, and replace the corresponding part.
If the vacuum does not drop:
– First of all, detach the hose at the hand vacuum pump -VAS
6213- .
– Remove one of the plugs from the hose ends.
If the non-return valve is functional, a significant spluttering can
now be heard when the pressure is compensated for in the vac‐
uum reservoir.
If no spluttering can be heard:
– Replace non-return valve.
– Re-connect all vacuum hoses.
Check the control vacuum line to the exhaust turbocharger

– Detach the hose -arrow in I- from the middle connection of the

charge pressure control solenoid valve -N75- .
– Detach the hose from the vacuum setting element of the ex‐
haust turbocharger -arrow in II-.
– Close one opening of the hose with a suitable plug.

Note

Do not use any thread screws or thread bolts.

– Attach the hand vacuum pump -VAS 6213- to the other end of
the Protected
hose and generate
by copyright. aforvacuum
Copying of 0.06 purposes,
private or commercial MPa (0.6 bar).
in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Observe the pressure
with respect gauge
to the correctness of theinhand
of information vacuum
this document. pump
Copyright for AUTO A. S.�
by ŠKODA
approx. 30 seconds.
• The vacuum must not drop.
If the vacuum drops:
– Replace vacuum hose.
Check the control vacuum line to the vacuum setting element for
the change-over flap for radiator of exhaust gas recirculation

174 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Detach the hose on the middle connection of the exhaust gas

recirculation radiator change-over valve -N345- -arrow-.
– Attach the hand vacuum pump -VAS 6213- to the detached
hose and generate a vacuum of 0.06 MPa (0.6 bar).
– Observe the pressure gauge of the hand vacuum pump for
approx. 30 seconds.
• The vacuum must not drop.
If the pressure drops:
– Detach the vacuum hose on the vacuum setting element for
the change-over flap for radiator of exhaust gas recirculation.
– Attach the hand vacuum pump -VAS 6213- with the factory-
delivered test hose to the vacuum setting element and gener‐
ate a vacuum of 0.06 MPa (0.6 bar).

Note

♦ The adjustment on the vacuum setting element must be no‐

ticeable and the vacuum must not drop. If this is not the case,
replace the radiator for exhaust gas recirculation
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ page 236 .
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ If no defect can be found on the vacuum setting element, re‐
place the vacuum line of the changeover valve for radiator of
exhaust gas recirculation -N345- .

1. Charge-air system - exhaust gas turbocharger 175

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2 Charge-air system - radiator, leak‐

tightness

2.1 Charge air cooling - Summary of com‐

ponents

Note

♦ Observe general instructions for charge-air system

⇒ page 5 .
♦ Observe tightening torques of screw clamps for hose connec‐
tions ⇒ page 177 .

1 - Charge air cooler

❑ removing and installing
⇒ page 177
2 - Right charge air hose
3 - Screw clamp
❑ Tightening torque
⇒ page 177
4 - to throttle valve control unit
-J338-
5 - Connecting hose
6 - 5 Nm
7 - Charge pressure sender -
G31- with intake air tempera‐
ture sender -G42-
8 - Rubber grommet
❑ replace if damaged
9 - 10 Nm
10 - Right charge air pipe
11 - Connecting hose
12 - from exhaust turbocharger
13 - Left charge air pipe
14 - Left charge air hose
15 - Support
❑ Check fitting position
16 - 5 Nm

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

176 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2.2 Hose connections with screw clamps

Note

♦ Connections, charge air pipes and hoses of charge air system

must be free of oil and grease before being installed.
♦ Only install approved screw clamps for securing the hose con‐
nections ⇒ Electronic Catalogue of Original Parts .
♦ In order to secure the charge air hoses on their connection
fittings, the threads must be treated with rust solvent if the
screw clamps have been used beforehand.
♦ After a repair, check all the charge air pipes, charge air hoses
and vacuum lines for tight connection and leaktightness.

Caution

The screw clamps -A- on the charge air hoses must definitely
be precisely tightened in accordance with the specifications
⇒ page 177 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ A unless
too
withlow ortoon
respect the the contrary,
correctness a tooin high
of information tightening
this document. torque
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Copyright by ŠKODA AUTO A. S.�
of the screw clamps, may result in the charge air hose
slipping off the fluted pipe or the charge air pipe while
driving.

Tightening torques of screw clamps

1- Screw clamp -a- = 12 mm: 5.5 Nm
2- Screw clamp -b- = 9 mm: 3 Nm

2.3 Removing and installing charge air cool‐

er
Removing
– Remove radiator ⇒ page 129 .
– Remove front bumper ⇒ Body Work ⇒ Rep. gr. 63 .
– Remove the charge air hoses on the left and right from the
charge air cooler.
Vehicles with air conditioning

WARNING

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

tem.

2. Charge-air system - radiator, leaktightness 177

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Caution

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

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

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

Continued for all vehicles
– Unscrew fixing screws for charge air cooler
⇒ Item 16 (page 176) on right and left side.
Vehicles with air conditioning

– Press off the charge air cooler from the lock carrier with the
assistance of a 2nd mechanic so that the screw -1- for attach‐
ing the pipes of the air conditioning system is accessible.
– Unscrew bolt -1-.
Continued for all vehicles
– Carefully remove radiator downwards.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Replace O-rings.
Observe the mounting
AUTO sequence for hose connections
not guarantee or with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ unless authorised by ŠKODA A. S. ŠKODA AUTO A. S. does accept any liability
screw clamps
with respect ⇒ pageof177
to the correctness . in this document. Copyright by ŠKODA AUTO A. S.�
information

2.4 Checking the charge-air system for

leaktightness
Special tools and workshop equipment required
♦ Charge-air system testing device , e. g. -V.A.G 1687-
♦ Adapter , e.g. -V.A.G 1687/10-

178 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Test sequence
– Remove the intake hose -1- from the air filter.
– Fit adapter -1687/10- into the intake hose -1- and secure with
a hose clamp.
Prepare tester for charge air system -V.A.G 1687- as follows:

– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.

Note

The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.

– Connect tester for charge air system

Protected-V.A.G 1687-
by copyright. asforshown
Copying private or commercial purposes, in part or in whole, is not permitted
to adapter -1687/10 - . unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Charge-air system - radiator, leaktightness 179

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Connect the feed hose for the compressed air -1- to the tester.

Note

If there is water in the inspection glass, drain water via the drain
plug -6-.

– Open valve -3-.

– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.

Caution

The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.

– Open valve -4- and wait until the test circuit is filled. If neces‐
sary regulate the pressure to 0.05 MPa (0.5 bar).
– Charge-air system:
♦ by looking,
♦ by listening,
♦ by touching,
♦ with a commercially available leak search spray, or
♦ with ultrasonic measuring device , e.g. -V.A.G 1842- ,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
check for leak points. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

♦ Minor leaks are permissible on the suction side of the turbo‐

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

180 Rep. gr.21 - Turbocharging/supercharging

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

23 – Mixture preparation - injection

1 Diesel direct injection system - fitting
locations, system overview
The control unit is equipped with a fault memory. Before repairs,
setting operations and fault finding, interrogate the fault memory
and execute a self-diagnosis ⇒ Vehicle diagnostic, testing and
information system VAS 5051.

Note

♦ Faults can be detected by the control unit as checking and

adjustment work is being undertaken and then saved. It is
therefore absolutely necessary to read and delete the fault
memory after completing all checking and adjustment work
⇒ Vehicle diagnostic, testing and information system
VAS 5051.
♦ Observe the safety precautions when working on the diesel
direct injection system ⇒ page 3 .

1.1 Overview of fitting locations

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

1. Diesel direct injection system - fitting locations, system overview 181

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Differential pressure sender

-G505-
❑ only installed on engine
with identification char‐
acters CFHC, CFHF
2 - Hall sender -G40- (cam‐
shaft position sensor)
3 - lambda probe -G39- with
heating for lambda probe -Z19-
❑ only on engine with
identification characters
CFHC, CFHF
4 - Engine control unit -J623-
5 - Injection units
❑ Injection valve for cylin‐
der 1 -N30-
❑ Injection valve for cylin‐
der 2 -N31-
❑ Injection valve for cylin‐
der 3 -N32-
❑ Injection valve for cylin‐
der 4 -N33-
6 - Exhaust gas return valve -
N18-
❑ consists of:
♦ mechanical valve (electri‐
cally operated)
♦ EGR control motor -V338-
♦ EGR potentiometer -G212-
7 - Position sender for charge
pressure regulator -G581-
8 - Control valve for fuel pres‐
sure -N276-
9 - Solenoid valve for charge pressure control -N75-
10 - Connector
❑ for exhaust gas temperature sender 4 -G648- (only on engine with identification characters CFHC, CFHF)
❑ for exhaust gas temperature sender 1 -G235- ( Temperature sender upstream turbocharger -G507- )
❑ for lambda probe -G39- (only on engine with identification characters CFHC, CFHF)
11 - Air mass meter -G70-
12 - Coolant temperature sender -G62-
13 - Engine speed sender -G28-
❑ removing and installing ⇒ page 184
14 - Changeover valve for radiator of exhaust gas recirculation -N345-
15 - Throttle valve control unit -J338-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
16 - Glow plugs by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Glow plug 1 -Q10-
❑ Glow plug 2 -Q11-
❑ Glow plug 3 -Q12-
❑ Glow plug 4 -Q13-

182 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

17 - Coolant recirculation pump 2 -V178-

18 - Charge pressure sender -G31-
19 - Connection of high pressure line
❑ to fuel high pressure reservoir
20 - Connection of high pressure line
❑ from fuel filter
21 - Fuel temperature sender -G81-
22 - High pressure pump with fuel dosage valve -N290-
23 - Coolant temperature sender at radiator outlet -G83-
24 - Additional fuel pump -V393-
25 - Fuel pressure sender -G247-
26 - Fuel filter

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

1. Diesel direct injection system - fitting locations, system overview 183

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.2 System overview

WARNING

Absolutely observe the safety precautions when working on

the diesel direct injection system ⇒ page 3 .

1 - Fuel dosage valve -N290-

❑ do not open
2 - High pressure pump
❑ removing and installing
⇒ page 187
3 - Fuel pressure sender -
G247-
❑ removing and installing
⇒ page 202
4 - Fuel high pressure reservoir
5 - Control valve for fuel pres‐
sure -N276-
❑ removing and installing
⇒ page 205
❑ check ⇒ page 205
6 - Injection unit
❑ removing and installing
⇒ page 196
7 - Fuel return-flow line
❑ from the injection units
❑ with pressure holding
valve approx. 0.2 MPa
(2.0 bar)
8 - Fuel tank
9 - Fuel filter
10 - Additional fuel pump -
V393-
11 - Fuel temperature sender -
G81-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1.3 Removing and installing engine speed

sender -G28-
Special tools and workshop equipment required
♦ Socket insert -T10370-
♦ Assembly device -T10118-
Removing
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .

184 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect the plug -1- on the engine speed sender -G28- with
the assembly device -T10118- and lay the electrical cable to
the side.

Note

To unlock the plug without using the assembly device -T10118- ,

the unlock button must be pressed at the plug using a screwdriver
and at the same time unlock the unlock button with a thin wire
hook.

– Unscrew the fixing screw -arrow- of the engine speed sender

-G28- and pull out the sender.
Install
Installation is performed in the reverse order, pay attention to the
following points:
Tightening torque
Component Nm
Engine speed sender -G28- on the flange 5

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

1. Diesel direct injection system - fitting locations, system overview 185

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2 Fuel system, engine side

2.1 High pressure pump - Summary of components

1 - Bracket for auxiliary units

2 - 20 Nm + torque a further
180° (1/2 turn)
❑ replace
3 - Hub
❑ with transmitter ring
❑ to release and tighten
use counterholder -
T10051-
❑ to remove use extractor
-T40064-
4 - Toothed belt gear
❑ for high pressure pump
5 - 20 Nm + torque a further 90°
(1/4 turn)
❑ replace
6 - 95 Nm
7 - 20 Nm + torque a further 45°
(1/8 turn)
❑ replace
8 - High pressure pump
❑ removing and installing
⇒ page 187
❑ with fuel dosage valve - Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
N290- (do not open) unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ an initial fuel filling must
be carried out after the
replacement (absolutely
avoid it to run dry)
⇒ page 189
9 - Fuel intake hose
10 - Fuel return-flow hose
11 - Fuel high pressure pipe, 15 Nm + torque a further 60° (1/6 turn)
❑ between high pressure pump and fuel high pressure reservoir
❑ do not install under tension
❑ Tighten union nuts in one work step without time delay between tightening and torquing angle (max. 1
min)
❑ first of all tighten the union nut on the side of the high pressure pump
❑ only tighten the fixing screw after tightening both union nuts

Note

♦ The high pressure line can be re-

used after the following tests:

186 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

♦ Check the sealing cones and the

union nuts for damage, deforma‐
tions and tears.
♦ The inner line boring must not be
deformed, constricted or dam‐
aged.
♦ A corroded high pressure line
must not be reinstalled.

2.2 Removing and installing the high pres‐

sure pump
Special tools and workshop equipment required
♦ Counterholder -T10051 -
♦ Extractor -T40064-
♦ Thrust piece -T40064/1-
♦ Cylinder head screws -T40064/2-
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Pull toothed belt off camshaft sprocket and from toothed belt
gear on the high pressure pump ⇒ page 33 .
– Release screws -2- and remove timing belt gear from the high
pressure pump.

– Hold the hub of the high pressure pump with the counterholder
-T10051- and unscrew the securing nut -1-.

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

2. Fuel system, engine side 187

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Note

Replace the basic pressure plate with the pressure plate -

T40064/1- on the extractor -T40064- .

– Position extractor -T40064- with thrust piece -T40064/1 - and

cylinder head screws (bolts) -T40064/2- as shown.
– Detach the hub from the high pressure pump, if necessary
counterhold with a lateral wrench SW 24.

– Release screws -arrows-.

– Lay the coolant return-flow line and the fuel return-flow line to
the side.

– Release screw -2- and union nuts -1- and -3- and
Protected remove
by copyright. highfor private or commercial purposes, in part or in whole, is not permitted
Copying
pressure line. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Disconnect plugs -1- and -3-.

– Remove fuel intake hose -2- and fuel return-flow hose -4-.

188 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release the fixing screws -arrows- of the high pressure pump.

– Carefully remove the high pressure pump.
Install

Caution

Risk of damage to the high pressure pump through running dry.

♦ After reinstalling the high pressure pump: carry out the
basic setting „check fuel pump“ »3 times« before the first
engine start ⇒ Vehicle diagnostic, testing and information
system VAS 5051.
♦ After installing a new high pressure pump: fill up the high
pressure pump with fuel before the first engine start
⇒ page 189 .

Installation is performed in the reverse order, pay attention to the

following points:

Note

♦ When installing the high pressure pump, ensure that no dirt

penetrates the fuel system.
♦ Only remove the screw plug immediately before installing the
fuel lines.
♦ The fixing screws for the high pressure pump must be re‐
placed.

Tightening torques: ⇒ page 186

2.3 Filling and bleeding the high pressure

pump/fuel system
Special tools and workshop equipment required
♦ Cleaning and
Protected by degreasing
copyright. Copying for agent
private or,commercial
e.g. -D purposes,
000 401 04-or in whole, is not permitted
in part
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Vehicle Diagnosis,
with respect Measurement
to the correctness of information and
in this Information System
document. Copyright - AUTO A. S.�
by ŠKODA
VAS 505X-

Caution

Risk of damage to the high pressure pump through running dry.

♦ After installing a new high pressure pump, the high pres‐
sure pump must be filled up with fuel before the first engine
start. Avoid the high pressure pump to run dry.

Note

♦ When installing the high pressure pump, ensure that no dirt

penetrates the fuel system.
♦ Only remove the screw plug immediately before installing the
fuel lines.

• On vehicles with automatic gearbox the selector lever must be

in position „P“.

2. Fuel system, engine side 189

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

• The vehicle must be filled up.

• Temperature of the fuel system ≥ 15 °C.
In order to fill up the high pressure pump with fuel, proceed as
follows:
– Connect vehicle diagnosis, measurement and information
system -VAS 505X- .
– Switch on ignition.
– Select the „Engine electronics“ in the self-diagnosis.
– Then select „006 - Basic setting“.
– Then select „Test of fuel pump for predelivery“.
– Subsequently press on „Start“.
♦ The fuel pumps start running for approx. 60 seconds.
– Repeat this work procedure 3x.
This ensures that the high pressure pump is adequately filled
up with fuel.
– Degrease the union nuts -1- and -3- of the high pressure line
and their surrounding area at the high pressure pump and at
the fuel high pressure reservoir.
– Start the engine and let it run at an average speed for a few
minutes.
– Carry out a visual inspection of the fuel system for leaks after
switching off the engine.
If there is leakage despite the correct tightening torque:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Replace the related component part and
unless authorised by repeat
ŠKODA AUTOtheA.filling/
S. ŠKODA AUTO A. S. does not guarantee or accept any liability
bleeding procedure. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Then carry out a test drive with minimum one full load accel‐
eration up to max. speed.
– Then once again carry out a visual inspection of the fuel sys‐
tem for leaks.
If there is leakage despite the correct tightening torque:
– Replace the related component part and repeat the filling/
bleeding procedure.
– Interrogate and if necessary erase fault memory of engine
control unit ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.
– Check readiness code, if necessary re-generate ⇒ Vehicle di‐
agnostic, testing and information system VAS 5051.

2.4 Check the fuel system for tightness

Special tools and workshop equipment required
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Vehicle Diagnosis, Measurement and Information System -
VAS 505X-
– Degrease all fuel connections.
– Let the engine run at idling speed for a few minutes.
– Carry out a visual inspection of the complete fuel system for
leaks after switching off the engine.
If there is leakage despite the correct tightening torque:

190 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Replace the related component part and repeat the procedure.

– Then carry out a test drive with minimum one full load accel‐
eration up to max. speed.
– Then once again carry out a visual inspection of the complete
fuel system for leaks.
If there is leakage despite the correct tightening torque:
– Replace the related component part and repeat the procedure.
– Interrogate and if necessary erase fault memory of engine
control unit ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be checked, if necessary re-generated ⇒ Vehicle
diagnostic, testing and information system VAS 5051.

2.5 Injection units (solenoid injectors) - Summary of components

1 - Sealing ring
❑ in the cylinder head cov‐
er
❑ replace ⇒ page 68
2 - Copper seal
❑ replace
3 - O-ring
❑ replace
4 - Injection unit (solenoid in‐
jector)
❑ do not mix up - when re‐
moving, mark the fitting
position of the pair of in‐
jection units (injectors)
and the clamping claw
❑ When slackening the
union nut of the high
pressure lines, hold the
connection fitting with
an open-end wrench
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ removing and installing
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ page 196
❑ when installing, the fol‐
lowing must be replaced
each time: copper seals
of injectors, O-rings for
bores of injection valve
heads, O-rings for con‐
nections of fuel return-
flow line and the screw
of the clamping claw
❑ when replacing, also re‐
place the clamping claw
and the relevant high
pressure line
❑ when replacing, the adaptation according to the code „injector quantity adjustment IQA“ must also be
carried out ⇒ page 194

2. Fuel system, engine side 191

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Note

Observe the instructions when re-

using the injection units (injectors)
⇒ page 197 .

5 - O-ring
❑ replace
6 - Fuel return-flow line
❑ from the injection units
❑ with pressure holding valve approx. 0.2 MPa (2.0 bar)
❑ removing and installing ⇒ page 196
❑ must not be kinked, damaged or blocked
❑ do not disassemble
❑ after an exchange, the engine must run at idling speed for approx. 2 minutes in order to vent the fuel
system; afterwards check the fuel return-flow line for tightness
7 - 8 Nm + torque a further 180° (1/2 turn)
❑ together with 2 injection units
❑ replace
❑ before tightening, first of all tighten the union nuts of the high pressure lines
8 - Clamping claw
❑ together with 2 injection units
❑ do not exchange - when removing, mark fitting position
❑ check fitting position ⇒ page 193
❑ replace, when installing new injection units (injectors)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
9 - High pressure line, 15 Nm + torquewith
a further
respect to 60° (1/6AUTO
unless authorised by ŠKODA
turn)
the correctness
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ between fuel high pressure reservoir and injection unit

❑ do not exchange - when removing, mark
❑ when slackening the union nut at the injection unit, counterhold the connection fitting with a lateral wrench
❑ do not install under tension
❑ Tighten union nuts in one work step without time delay between tightening and torquing angle (max. 1
min)
❑ first of all tighten the union nut on the side of the injection unit (injector)

Note

♦ Pay attention to the cylinder spe‐

cific marking when re-using the
high pressure lines.
♦ The high pressure lines can be
re-used after the following tests:
♦ Check the sealing cones and the
union nuts for damage, deforma‐
tions and tears.
♦ The inner line boring must not be
deformed, constricted or dam‐
aged.
♦ The corroded injection lines
must not be re-used.

192 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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10 - 22 Nm
11 - Fuel high pressure reservoir
❑ removing and installing ⇒ page 200
❑ Tighten the fixing screws ⇒ Item 10 (page 193) only after tightening the union nuts for the high pressure
lines ⇒ Item 9 (page 192) and the union nut of the high pressure line ⇒ Item 15 (page 193)
12 - Fuel return-flow hose
13 - Fuel pressure regulating valve -N276- , 80 Nm
❑ cannot be re-used, replace after removal
❑ replace ⇒ page 205
14 - O-ring
❑ replace
15 - High pressure line, 15 Nm + torque a further 60° (1/6 turn)
❑ between high pressure pump and fuel high pressure reservoir
❑ do not install under tension
❑ Tighten union nuts in one work step without time delay between tightening and torquing angle (max. 1
min)
❑ first of all tighten the union nut on the side of the high pressure pump, to do so counterhold the connection
fitting
❑ Only tighten the fixing screw of the clamp ⇒ Item 16 (page 193) after tightening both union nuts

Note

♦ The high pressure lines can be

re-used after the following tests:
♦ Check the sealing cones and the
union nuts for damage, deforma‐
tions and tears.
♦ The inner line boring must not be
deformed, constricted or dam‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
aged.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ A corroded high pressure line
must not be reinstalled.

16 - 8 Nm
17 - Fuel pressure sender -G247- , 100 Nm
❑ removing and installing ⇒ page 202
18 - Grommet
❑ in the cylinder head cover

Fitting position of the clamping claw

• The clamping claw with 2 injection units.
• The thickening -arrow- of the clamping claw points down‐
wards.

2. Fuel system, engine side 193

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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2.6 Adaptation for injector quantity adjust‐

ment (IQA code)
The function „injector quantity adjustment (IQA)“ of the engine
control unit with the Common Rail system is used to correct the
injection rate for each cylinder of the engine individually in the
complete characteristic diagram area and thus to suppress the
differences in the fuel dosage of the individual injection units as
a result of manufacturing variances.
Each injection unit is factory-marked with an IQA code -1-.
View from the top of the injection unit
1 - IQA code
2 - Data matrix IQA code
3 - Part number
The specifications provided in the figure are only one example.
After replacing the injection unit, the „IQA code“ of the new injec‐
tion unit must be written into the engine control unit.
After replacing the engine control unit, the „IQA codes“ for all the
injection units must be written into the new engine control unit.
Adaptation process ⇒ Vehicle diagnostic, testing and information
system VAS 5051.

Note

At the same time check if the „IQA codes“ for all the other injection
units are correctly written. If the correct „IQA codes“ are stored in
the engine control unit, these codes must never be entered again.

2.7 Always search for injection units in open

state
Special tools and workshop equipment required
♦ Insertion tool SW 17 , e.g. -V.A.G 1331/6-
♦ Screw plug -T40204-
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Observe the rules for cleanliness and the instructions when un‐
dertaking all work on the fuel system ⇒ page 2 .
– Remove engine cover ⇒ page 7 .

Note

Pay attention to cleanliness, no dirt must get into the fuel system.

WARNING

Wear protective gloves and protective googles when working

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

194 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Clean all the connections of the high pressure lines on the fuel
high pressure reservoir and on the injection units with grease
remover and let all the cleaned parts dry off.

Note

Check the injection units of all the cylinders one after the other.

Start testing cylinder 1.

• Fit the plug of the injection unit to be checked.
Procedure
– Unscrew the union nut of the high pressure line of the cylinder
to be checked at the fuel high pressure reservoir.
– Slightly slacken the union nut of the high pressure line of the
injection unit to be checked, while doing so hold the connection
fitting with an open-end wrench.
– Close the open connection of the high pressure line with a
suitable screw plug.
– Close the open connection fitting at the fuel high pressure res‐
ervoir with the screw plug -T40204- .
– Delete all the entries stored in the fault memory for the engine
control unit ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.
– Perform a test drive.

Note

♦ If the correct injection unit is found, no event log entry related

to the „positive control deviation“ must be stored.
♦ It is possible that other event log entries are made. Do not pay
attention to these new event log entries (follow-up fault).

– After the test drive, read out all the entries stored in the fault
memory for the engine control unit ⇒ Vehicle diagnostic, test‐
ing and information system VAS 5051.
If an entry related to the „positive control deviation“ is present in
the fault memory:
– Reconnect the high pressure line to the checked injection unit
⇒ page 199 .
– Repeat the work procedure for the next injection unit
⇒ page 195 .
If no event entry „positive control deviation“ is stored in the fault
memory after the test drive, the correct injection unit was found.
– Replace injection unit ⇒ page 196 .

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be checked, if necessary re-generated ⇒ Vehicle
diagnostic, testing and information system VAS 5051.

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

2. Fuel system, engine side 195

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2.8 Removing and installing the injection

units
Special tools and workshop equipment required
♦ Extractor -T10055-
♦ Assembly sleeve -T10377-
♦ Extractor -T10415-
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Remove engine cover ⇒ page 7 .

Caution

♦ Mark the assignment of the injection units to the cylinders.

They must only be re-used on the same cylinder.
♦ Immediately close the open connections with suitable
caps.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Detach the return-flow line
unless authorised connections
by ŠKODA AUTO A. S.at the injection
ŠKODA units.
AUTO A. S. does not guarantee or accept any liability
To do so, presswith
down the clamps -1- and -2- and at the same
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

time pull up the unlocking bolt -arrow-.

– Disconnect the plug -arrows- at the injection units.

Caution

When slackening the union nuts for the high pressure lines,
counterhold the connection fitting with a lateral wrench. If the
connection fitting loosens, this can cause leakage.

– Unscrew the union nuts of the relevant high pressure line

-1, 2, 3- or -4- and remove the corresponding high pressure
line.

196 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Release the screw -1- of the clamping claw for the injection
unit to be removed.
– Position the extractor -T10055- with the extractor -T10415-
and pull out the injection unit towards the top by tapping it.

Note

♦ In order not to damage the sealing lip, pull out the injection unit
with rotary movements.
♦ Place the removed injection units on a clean cloth.

Important instructions for the replacement of parts

When reinstalling the injection unit, the following parts must be
replaced:
♦ Copper seal
♦ O-ring for gasket of bore in cylinder head
♦ O-ring for fuel return-flow line
♦ Screw for clamping claw
When installing the new injection unit (the injector), the following
must also be replaced:
♦ Clamping claw
♦ High pressure line of cylinder
Instructions for reinstalling the injection units (injectors)

Note

♦ When reinstalling, the removed injection units, the high pres‐

sure lines and the clamping claws must only be installed again
at the same point.
♦ The reinstalled injection units (injectors) or high pressure lines
must not be damaged.

– Spray the tip of the injection unit with a rust solvent spray. Re‐
move the soot and grease particles with a cloth after approx.
5 minutes.
– Remove the old copper seal from the injection unit; to do so,
carefully tighten the copper seal in a vice until the copper seal
does no longer turn. Then pull the injection unit out of the cop‐
perunless
sealauthorised
with slight turning
AUTO and
A. S.pulling movements
ŠKODA AUTO A. S. does notofguarantee
the hand.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
• Check the injection units and the fitting positions for cleanli‐
ness before installing.
Mounting sequence

Note

♦ All the O-rings must be coated with engine oil before installing.
♦ Carefully check all the parts and the fitting positions for clean‐
liness before installing.

– Clean the channel with a cloth soaked in engine oil or rust

solvent in order to remove the soot particles on the contact
surface of the injection unit in the cylinder head.

2. Fuel system, engine side 197

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Caution

Make sure the sealing surfaces are not damaged in the proc‐
ess.

– Insert the new copper gasket ring at the injection unit (injector)
using a plastic bush.

– Replace the O-ring for the channel of the injection unit (injec‐
tor), to do so use the assembly sleeve -T10377- .
– Carefully slide the new and oiled O-ring onto the fuel return-
flow connection.

Caution

Pay particular attention in order to avoid unnecessary installa‐

tion work or consequential damage.
Avoid damage and contact of the injection units (injectors) with
the cylinder head.

– Always insert 2 injection units (injectors) with clamping claw

carefully into the holes of the cylinder head,bywhile
Protected doing
copyright. Copyingsofor private or commercial purposes, in part or in whole, is not permitted
observe the fitting position. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Screw in the new fixing screw of the clamping claw and only
slightly tighten to tightening torque of maximum 1 - 2 Nm.

Note

In order to install the high pressure line free of stress, it must be

possible to align the injection unit (the injector) by turning it slight‐
ly.

– Install the high pressure line free of stress, to do so, align the
position of the injection unit (the injector) by turning it slightly.
Only tighten the union nuts by hand.
– Tighten the fixing screw of the clamping claw. Tightening tor‐
que and tightening order ⇒ page 191 .
– Tighten the union nuts of the high pressure lines. Tightening
torque and tightening order ⇒ page 191 .
– Carefully press the connection of the fuel return-flow line via
the gasket ring onto the injection unit.
• The cap must click audibly into place.
– Afterwards carefully press the unlocking bolt downwards.

Note

After replacing one or several injection units (injectors), carry out

the adaptation „injector quantity adjustment IQA“ and „injector
voltage adjustment IVA“ ⇒ Vehicle diagnostic, testing and infor‐
mation system VAS 5051.

– Fill up the fuel system ⇒ page 189 .

198 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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2.9 Installing the high pressure lines

Special tools and workshop equipment required
♦ Socket wrench insert -T40055-

Caution

♦ Slacken the fuel high pressure reservoir for improved and

stress-free positioning of the high pressure line. If neces‐
sary, slightly move the fuel high pressure reservoir.
♦ Slacken the fuel high pressure reservoir as well as the
clamping claws of the injection units for improved and
stress-free installation of the high pressure lines. If nec‐
essary, slightly move the fuel high pressure reservoir and
if necessary slightly twist the relevant injection unit.
♦ The high pressure lines must on no account be bent or
installed under tension. Tensions would eventually lead to
a fracture of the corresponding high pressure line.

Note

The installation of new high pressure lines is described in the fol‐

lowing. If previously installed high pressure lines are re-used, they
must not be damaged. Before the installation, they must be care‐
fully checked ⇒ Item 15 (page 193) and ⇒ Item 9 (page 192) , the
work procedure is otherwise the same.

– Slacken the fixing screws of the fuel high pressure reservoir

in order to push it.
– Loosen the fixing screws of the clamping claws in order to turn
the injection units.
– Remove the new high pressure lines from their wrapping. Re‐
move the screw plugs and install the high pressure lines at the
connection fittings without placing them down.

Note

First of all, install the high pressure lines between the injection
units and the fuel high pressure reservoir, then install the high
pressure lines between the high pressure pump and the fuel high
pressure reservoir.

– First tighten the union nuts of the high pressure lines in the
prescribed order ⇒ page 200 by hand up to the „stop“. When
doing this, ensure that the Protected
pipe cones are correctly seated in
the connection fittings. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

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

Note

Tighten the union nuts of the high pressure lines using the socket
wrench insert -T40055- .

– Tighten the fixing screws and the union nuts of the high pres‐
sure lines according to the prescribed work procedure
⇒ page 200 .
– Carefully press the connection of the fuel return-flow line via
the new gasket rings onto the injection unit.

2. Fuel system, engine side 199

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

• The cap must click audibly into place.

– Press down the unlocking bolts.
– Fill up the fuel system ⇒ page 189 .
Mounting sequence
Tightening order Tightening torque
1. Screws of clamping claws for injection units 8 Nm + torque a further 180° (1/2 turn)
2.1. Union nuts of the high pressure lines at the connection 15 Nm + torque a further 60° (1/6 turn) 1)
fittings of the injection units
2.2. Union nuts of the high pressure lines at the connection 15 Nm + torque a further 60° (1/6 turn) 1)
fittings of the fuel high pressure reservoir
3.1. Union nuts of the high pressure line at the connection 15 Nm + torque a further 60° (1/6 turn) 1)
fitting of the high pressure pump
3.2. Union nuts of the high pressure line at the connection 15 Nm + torque a further 60° (1/6 turn) 1)
fitting of the fuel high pressure reservoir
4. Fixing screws of the fuel high pressure reservoir 22 Nm
5. The screws of the clamp for the high pressure line 8 Nm
1) Tighten union nuts in one work step without time delay between
tightening and torquing angle (max. 1 min).

2.10 Removing and installing fuel high pres‐

sure reservoir
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Remove engine cover ⇒ page 7 .

– Disconnect the plug -arrow- at the fuel pressure regulating
valve -N276- .

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

200 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect plug -B- at fuel pressure sender -G247- .

– Detach the vacuum hose -A- from the cylinder head cover.

– Remove the fuel return hose from the fuel high pressure res‐
ervoir, to do so slacken the hose clamp -arrow-.
– Disconnect the plugs at the glow plugs ⇒ page 238 .

– Release screw -2- and union nuts -1- and -3-.

– Remove high pressure line.
– Remove the cable line from the fuel high pressure reservoir
and lay it to the side.

Caution

When slackening the union nuts of the high pressure line, hold
the connection fitting with an open-end wrench. If the connec‐
tion fitting loosens, this can cause leakage.

– Unscrew the union nuts -1- of the high pressure lines from the
injection units.

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

2. Fuel system, engine side 201

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release fixing screws -arrows- and remove the fuel high pres‐
sure reservoir.
Install
Installation is performed in the reverse order, pay attention to the
following points:
• Tightening torques ⇒ page 191 and ⇒ page 186 .
– Install high pressure lines free of stress ⇒ page 199 .

2.11 Removing and installing fuel pressure

sender -G247-
The fuel pressure sender -G247- is located in the fuel high pres‐
sure reservoir. It measures the current fuel pressure in the high
pressure system and delivers a voltage signal to the engine con‐
trol unit -J623- .
If the sender fails, the pressure regulation is controlled by the en‐
gine control unit via a characteristic diagram; in case of emer‐
gency, the maximum engine speed is limited to approx. 3000 rpm.
Special tools and workshop equipment required
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Remove engine cover ⇒ page 7 .

WARNING

Wear protective gloves and protective googles when working

with grease remover!

Note

No grease remover must get into the plug connection, carefully

clean.

– Before removing the fuel pressure sender -G247- , clean the

thread area with a grease remover. (No dirt must get into the
hole of the fuel high pressure reservoir).
– Dry the fuel pressure sender -G247- .
– Disconnect plug at fuel pressure sender -G247- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

202
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Rep. gr.23 - Mixture preparation - injection
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Caution

Do not slacken the fuel pressure sender using the open-end

wrench or the open ring spanner - Risk of damage!
Use lengthened socket insert.

– Unscrew the fuel pressure sender -G247- .

– Remove dirt from thread hole and sealing surface on the fuel
high pressure reservoir. To do so do not use any mechanical
tools.

Note

Close the hole in the fuel high pressure reservoir immediately with
a suitable screw plug in order to prevent dirt from penetrating.

Install

Note

♦ The fuel pressure sender -G247- has no gasket ring but a bit‐
ing edge for sealing.
♦ Pay attention to damage of the biting edge and the thread of
the new fuel pressure sender -G247- . It is possible to use the
fuel pressure sender -G247- again.
♦ Also check the sealing surface of the hole at the fuel high
pressure reservoir.

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

Do not tighten the fuel pressure sender using the open-end

wrench or the open ring spanner - Risk of damage!
Use lengthened socket insert.

– Screw in fuel pressure sender -G247- by hand.

Tightening torque: ⇒ page 186

– Check fuel system for tightness ⇒ page 190 .

2.12 Check the low pressure fuel system

Special tools and workshop equipment required
♦ Pressure gauge , e.g. -V.A.G 1318-
Test conditions
• Battery voltage at least 12.5 V.
• Fuel filter o.k.
• Fuel tank at least 1/2 full.
Test holding pressure
Observe the rules for cleanliness and the instructions when un‐
dertaking all work on the fuel system ⇒ page 2 .

2. Fuel system, engine side 203

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Remove engine cover ⇒ page 7 .

– Remove the fuel feed line -arrow- from the high pressure
pump, to do so slacken the hose clamp.

– Connect the pressure gauge -V.A.G 1318- with the suitable

adapter -2- to the fuel feed line -1-.
– Connect the second hose -3- to the pressure gauge -V.A.G
1318- at the open connection of the high pressure pump as
shown in the following figure.

Note

The pressure gauge -V.A.G 1318- is interposed in the fuel feed

line.

– Connect vehicle diagnosis, measurement and information

system -VAS 505x- .
– Switch on ignition.
– Select the „Engine electronics“ in the self-diagnosis.
– Then select „Basic setting“.
– Select „Test of fuel pump“ in the selection list.
– Leave the fuel pumps running until the highest fuel pressure
has built up.
• Specified value: min. 0.35 MPa (3.5 bar)
If the specified value is not reached, this may be due to the fol‐
lowing causes:
♦ The fuel filter is clogged.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ The battery voltage
unlessis low. by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
authorised
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Check the fuel flow rate of the fuel pump ⇒ page 157 .

Note

Check fuel system for cable damage and leaks.

204 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2.13 Check fuel pressure regulating valve -

N276-

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Remove engine cover ⇒ page 7 .

– Remove the fuel return hose from the fuel high pressure res‐
ervoir, to do so slacken the hose clamp -arrow-.
– Close the detached fuel return flow hose with a suitable plug.

– Connect the auxiliary hose -2- to the return-flow connection of

the fuel high pressure reservoir -3-.
– Hold the auxiliary hose in a measuring vessel -4- in order to
measure the return flow quantity.
– Start engine and run for 30 seconds at idling speed.
• Specified value: 90 ... 110 ml
If the specified value is not reached, the fuel pressure regulating
valve -N276- is defective.
– Replace fuel pressure regulating valve -N276- ⇒ page 205 .

2.14 Replace fuel pressure regulating valve -

N276-
The fuel pressure regulating valve -N276 - is installed in the fuel
high pressure reservoir and provides a constant pressure in the
high-pressure fuel circuit.
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens and some of the fuel from the fuel high
pressure reservoir flows back into the fuel tank via the fuel return-
flow line.
The pressure control valve closes if there is too low a pressure in
the high-pressure fuel circuit and thus seals the high-pressure
side from the low-pressure side.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Fuel system, engine side 205

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Note

The fuel pressure regulating valve -N276- is not reusable.

Special tools and workshop equipment required

♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Remove engine cover ⇒ page 7 .

WARNING

Wear protective gloves and protective googles when working

with grease remover!

Note

No grease remover must get into the plug connection, carefully

clean.

– Also clean the thread area of the fuel pressure regulating valve
-N276- with a grease remover - no dirt must get into the hole
of the fuel high pressure reservoir.
– Dry fuel pressure regulating valve -N276-
– Disconnect the plug at the fuel pressure regulating valve -
N276- .
– Counterhold the fuel pressure regulating valve -N276- on the
hexagon and slacken the screwed connection using a wrench.
– Unscrew the screwed connection by hand and remove the fuel
pressure regulating valve -N276- from the fuel high pressure
reservoir.
– Remove dirt from the thread, the sealing surface and the hole
in the fuel high pressure reservoir. To do so do not use any
mechanical tools.

Note

Close the hole in the fuel high pressure reservoir immediately with
a suitable screw plug in order to prevent dirt from penetrating.

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

206
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Rep. gr.23 - Mixture preparation - injection
 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

Install

Note

♦ The fuel pressure regulating valve -N276- does not have a

gasket ring but a biting edge.
♦ The fuel pressure regulating valve -N276- is not reusable.
♦ The O-ring seals the high-pressure side from the low-pressure
side and must be replaced.
♦ Before installing, moisten the O-ring and the hole in the fuel
high pressure reservoir with diesel fuel.
♦ Pay attention to damage of the biting edge and the thread of
the new fuel pressure regulating valve -N276- .
♦ Also check the sealing surface at the fuel high pressure res‐
ervoir.

– Screw in the screwed connection and tighten by hand.

– Align the fuel pressure regulating valve -N276- in such a way
that the connecting line is routed tension-free after fitting on
the plug.
– Counterhold the fuel pressure regulating valve -N276- on the
hexagon and tighten the screwed connection using a wrench.
Tightening torque: ⇒ page 186
– Check fuel system for tightness ⇒ page 190 .

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

2. Fuel system, engine side 207

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

3 Intake manifold, air filter

3.1 Intake manifold with component parts - Summary of components

1 - Dipstick
❑ with guide pipe
2 - Sealing ring
❑ replace
3 - Gasket
❑ replace
4 - 8 Nm
5 - Fuel return-flow line
6 - 9 Nm
7 - Intake manifold
❑ removing and installing
⇒ page 210
8 - Support
❑ for changeover valve for
radiator of exhaust gas
recirculation -N345-
9 - 9 Nm
10 - Changeover valve for ra‐
diator of exhaust gas recircu‐
lation -N345-
11 - Gasket
❑ replace
12 - 20 Nm
13 - Connecting pipe
❑ to radiator for exhaust Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
gas recirculation unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Caution
Pay attention that the
bellows of the connec‐
tion pipe is not bent or
overstretched. There is a
risk of crack formation.

14 - Warm-type clamp, 5 Nm
❑ replace
15 - Supports
❑ for exhaust gas recirculation
16 - 8 Nm
17 - Sealing ring
❑ replace
18 - Throttle valve control unit -J338-
❑ removing and installing ⇒ page 209

208 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

19 - 8 Nm
20 - 10 Nm
21 - Clip
❑ for oil dipstick guide pipe

3.2 Removing and installing the throttle

valve control unit -J338-
Removing
– Remove engine cover ⇒ page 7 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Remove the charge air hose, to do so slacken the screw
clamps -1 and 2-.

– Release screws -arrows-.

– Expose coolant hose -3-.
– Loosen hose clamp -2-.
– Disconnect the plug -1- at the charge pressure sender -G31- /
intake air temperature sender -G42- and remove the right
charge air pipe.

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

3. Intake manifold, air filter 209

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Disconnect the plug -2- from the throttle valve control unit -
J338 - .
– Release screw -1- of guide pipe for oil dipstick.
– Release screws -arrows- and remove throttle valve control unit
-J338- .
Install
Installation is performed in the reverse order, pay attention to the
following points:
• Tightening torques ⇒ page 208 .

Note

Replace O-ring.

3.3 Removing and installing intake manifold

Special tools and workshop equipment required
♦ Socket insert T30 with spherical head -T10405-
Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .

– Remove engine cover ⇒ page 7 .

– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Remove the charge air hose, to do so slacken the screw
clamps -1 and 2-.

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

210 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Release screws -arrows-.

– Slacken the hose clamp -2- at the throttle valve control unit -
J338 - , detach the right charge air pipe and leave it in the fitting
position.
– Disconnect the plugs at the glow plugs ⇒ page 238 .

– Take the changeover valve for radiator of exhaust gas recir‐

culation -N345- -left arrow- out of the bracket and place it to
the side.

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

– Release screw -2- and union nuts -1- and -3- for the high pres‐
sure line and remove the high pressure line.
– Remove fuel high pressure reservoir ⇒ page 200 .

– Disconnect the plug -2- from the throttle valve control unit -
J338 - .
– Release screw -1- of guide pipe for oil dipstick.

3. Intake manifold, air filter 211

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Open clamp -1- and remove.

– Release the screws -arrows- for the intake manifold using the
socket insert T30 with spherical head -T10405- from outside
to inside and crosswise.
– Carefully remove the intake manifold.
Install
Installation is performed in the reverse order, pay attention to the
following points:
• Tightening torques ⇒ page 208 .

Note

Replace gasket.

– Tighten fixing screws for intake manifold crosswise from the

inside to the outside.

3.4 Air filter - Summary of components

Removing and installing air filter ⇒ page 214

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

212 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - Air intake hose

❑ to exhaust gas turbo‐
charger
2 - Pipe support for ventilation
❑ with heating
❑ only vehicles for cold cli‐
matic zones
3 - Connecting pipe
❑ for crankcase ventila‐
tion
❑ to remove, press re‐
lease buttons
4 - 2 Nm
5 - Air mass meter -G70-
6 - O-ring
❑ replace if damaged
7 - 2 Nm
❑ Fixing screws for air fil‐
ter top part
8 - 8 Nm
❑ Fixing screw for air filter
(air filter bottom part)
9 - Bushing
10 - Washer
11 - Air filter top part
12 - Air filter element
❑ pay attention to change
intervals ⇒ Mainte‐
nance ; Booklet Octavia
II
13 - Air filter bottom part
14 - Connecting piece
❑ for drain pipe
15 - Overflow valve
16 - Hose
❑ for waterProtected
drainageby copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
17 - Connectingwith
hoserespect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

18 - Inlet connection
❑ screwed onto lock carrier
❑ with pinhole on engines BS-4 (»monsoon hole«)
19 - 2 Nm
20 - Intake air duct
21 - Cover
❑ for intake air duct

3. Intake manifold, air filter 213

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

22 - Spring strap clamp

23 - Spring strap clamp
24 - Inlet connection
❑ Observe fitting position to exhaust gas turbocharger
❑ with fixing screw, 9 Nm
25 - O-ring
❑ replace

3.5 Removing and installing air filter

Special tools and workshop equipment required
♦ Pliers for spring strap clamps
Removing
– Remove engine cover ⇒ page 7 .
– Remove cover for intake air duct, to do so release lateral se‐
curing tabs -arrows-.

– Release screws -arrows- for connection fitting -1- and take

connecting hose -2- out of the guide.

– Press in catches -1- and -3- and pull off connecting hose -4-
from air filter -2-.

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

214 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Unplug connector -1- from air mass meter -G70- .

– Detach vacuum hose -3- and suction hose -2-.
– Release screw -4- and remove air filter with air mass meter -
G70- .
Remove suction hose

Note

Due to the poor access of the pliers for spring strap clamps to the
bottom suction hose it is preferable to remove the inlet connection
from the exhaust turbocharger.

– Unclip vacuum lines -2- and -3- from suction hose.

– Remove connecting pipe for crankcase ventilation -1-.

– Fully release screw of inlet connection -2-.

– Swivel the inlet connection -3- in the
-direction of the arrow A- and remove it with the suction hose
-1-.
Install
Installation is performed in the reverse order, pay attention to the
following points:
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

♦ Replace O-ring.
♦ When installing the inlet connection -3- at the exhaust gas tur‐
bocharger, make sure that the inlet connection is correctly
seated on the bolt -arrow B-.

3. Intake manifold, air filter 215

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

4 Engine control unit

4.1 Removing and installing engine control

unit

Note

If the engine control unit should be replaced, connect the vehicle

diagnosis, measurement and information system -VAS 5051- and
in the targeted fault finding carry out „replace engine control unit“.

Special tools and workshop equipment required

♦ Body saw e.g. -V.A.G 1523 A-
Removing
– Switch off ignition.
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.
gr. 66 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Removeunless
bulkhead
authorisedplenum
by ŠKODA chamber -arrows-.
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove windscreen wiper and washer system ⇒ Electrical
System ⇒ Rep. gr. 92 .
For vehicles with protective cover

– Cut with body saw -1- a slot for the cross-head screwdriver in
the heads of the pull-off screws -2-.

Note

♦ It must be sawed twice with the body saw, so that the slot is
wide enough, in order to be able to unscrew the screws with
a suitable screwdriver.
♦ The pull-off screws until are inserted with locking agent.

– Unscrew bolts -2-.

216 Rep. gr.23 - Mixture preparation - injection

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Lift locking tab of protective cover with a cross-head screw‐

driver.
– Push the protective cover in the -direction of the arrow- out of
the bracket for engine control unit.
Continued for all vehicles
– Disconnect front plug -1- and remove from engine control unit.

– Lever off retaining bracket -2- slightly.

– Push engine control unit out of the bracket -arrow-.
– Disconnect rear plug and remove from engine control unit.
Install
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

For vehicles with protective cover, the metal swarfs must be suc‐
tioned out of the plenum chamber before installing the engine
control unit.

– Connect rear plug to engine control unit and lock.

– Push engine control unit into the bracket and lock the retaining
bracket -2-.
– Connect front plug to engine control unit and lock.
For vehicles with protective cover
– Fasten protective cover with new pull-off screws (before tight‐
ening align the protective cover in such a way that it does not
come into contact with the surrounding components)
Continued for all vehicles
– Install windscreen wiper and washer system ⇒ Electrical Sys‐
tem ⇒ Rep. gr. 92 .
– Install bulkhead plenum chamber and plenum chamber cover
⇒ Body Work ⇒ Rep. gr. 66 .

4. Engine control unit 217

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

26 – Exhaust system
1 Removing and installing parts of the
exhaust system

Note

♦ The decoupling element in the pre-exhaust pipe should not be

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

1.1 Pre-exhaust pipe

1.1.1 Summary of components for enigne with identification characters CFHC,

CFHF

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

218 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - 8 Nm
2 - Support
❑ for hoses
3 - 5 Nm
4 - 8 Nm
5 - Differential pressure sender
-G505-

Caution
Risk of damage!
The
♦ differential pressure
sender -G505- is very
sensitive and therefore
requires the utmost care.
It must not touch some‐
where when laying it
down.
Only
♦ detach the hoses
from the differential pres‐
sure sender -G505- if it
must be replaced.

❑ replace ⇒ page 223

6 - Support
❑ for differential pressure
sender -G505-
7 - Spring strap clamps
8 - Hose
9 - 9 Nm
10 - Heat shield
11 - Lambda probe -G39- , 50 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ the thread of new lambda probes must be coated with assembly paste
❑ when installing an already used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3- ;
the hot bolt paste -G 052 112 A3- must not get into the slots of the probe body
❑ use wrench set 17 mm -T10395- for removing and installing
12 - Exhaust gas temperature sender 4 -G648- , 45 Nm
❑ the thread of new temperature senders must be coated with assembly paste
❑ coat thread with hot bolt paste -G 052 112 A3- before installing a used sender
❑ use wrench set 17 mm -T10395- for removing and installing
13 - Gasket
❑ replace
❑ Check fitting position
14 - Warm-type clamp, 7 Nm
❑ replace
15 - 25 Nm
16 - to middle part of exhaust system
17 - Hanger
❑ replace if damaged

1. Removing and installing parts of the exhaust system 219

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

18 - Pre-exhaust pipe
❑ with diesel particle filter and oxidation catalytic converter
❑ after replacing, the adaptation of the ash mass balance must be set to „0“ ⇒ Vehicle diagnostic, testing
and information system VAS 5051
❑ removing and installing ⇒ page 225
19 - Support
❑ screwed onto the cylinder block
20 - Exhaust gas temperature sender 3 -G495- , 45 Nm
❑ the thread of new temperature senders must be coated with assembly paste
❑ coat thread with hot bolt paste -G 052 112 A3- before installing a used sender
❑ use wrench set 17 mm -T10395- for removing and installing
21 - Support
❑ screwed onto the cylinder head

1.1.2 Summary of components for engine with identification characters CLCA

1 - Gasket
❑ replace
❑ Check fitting position
2 - Warm-type clamp, 7 Nm
❑ replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
3 - 25 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4 - to middle part of exhaust

system
5 - Retaining strap
❑ replace if damaged
6 - Pre-exhaust pipe
❑ with oxidation catalytic
converter
❑ removing and installing
⇒ page 228
7 - 25 Nm
8 - Support
❑ screwed onto the cylin‐
der block
❑ Replace bracket with
riveted threaded bolts
(the required tightening
torque can only be ap‐
plied in this way)

220 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.1.3 Summary of components for engine with identification characters CLCB

1 - Gasket
❑ replace
❑ Check fitting position
2 - Warm-type clamp, 7 Nm
❑ replace
3 - 25 Nm
4 - to middle part of exhaust
system
5 - Retaining strap
❑ replace if damaged
6 - Pre-exhaust pipe
❑ with diesel particle filter
with unregulated regen‐
eration (PMS)
❑ removing and installing
⇒ page 228
❑ after replacing, the
adaptation of the ash
mass balance must be
set to „0“ ⇒ Vehicle di‐
agnostic, testing and in‐
formation system
VAS 5051
7 - 25 Nm
8 - Support
❑ screwed onto the cylin‐
der block
❑ Replace bracket with
riveted threaded bolts
(the required tightening
torque can only be ap‐
plied in this way)
9 - Support
❑ screwed onto the cylinder head

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

1. Removing and installing parts of the exhaust system 221

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.2 Middle or rear part of the exhaust sys‐

tem - Summary of components

1.2.1 Summary of components for vehicles with front-wheel drive

1 - Double clamp
❑ align the exhaust sys‐
tem free of stress before
tightening ⇒ page 231
❑ Tighten bolted connec‐
tions evenly
2 - Middle part of exhaust sys‐
tem
❑ for first equipment build‐
ing unit with rear part,
replace individually
when carrying out re‐
pairs ⇒ page 231
❑ Align exhaust system
free of stress
⇒ page 231
❑ Separation point
⇒ page 231
3 - Retaining strap
❑ replace if damaged
❑ Pay attention to the part
number Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4 - Tunnel bridge
❑ rear
5 - 23 Nm
❑ replace
6 - Rear part of exhaust system
❑ for first equipment build‐
ing unit with middle part,
replace individually
when carrying out re‐
pairs ⇒ page 231
❑ Align exhaust system
free of stress ⇒ page 231
❑ Separation point ⇒ page 231
7 - Retaining strap
❑ replace if damaged
❑ Pay attention to the part number
8 - Tunnel bridge
❑ front
9 - Hanger

222 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.2.2 Summary of components for vehicles with four-wheel drive

1 - Middle and rear part of the

exhaust system
❑ for first equipment a
building unit, replace in‐
dividually when carrying
out repairs ⇒ page 231
❑ Align exhaust system
free of stress
⇒ page 231
❑ Separation point
⇒ page 231
2 - Retaining strap
❑ replace if damaged
❑ Pay attention to the part
number
3 - 23 Nm
4 - Double clamp
❑ align the exhaust sys‐
tem free of stress before
tightening ⇒ page 231
❑ Tighten bolted connec‐
tions evenly
5 - Hanger
6 - 23 Nm
7 - Tunnel bridge
❑ front
8 - Retaining strap
❑ replace if damaged
❑ Pay attention to the part
number
9 - Tunnel bridge
❑ rear
10 - Retaining strap
❑ replace if damaged
❑ Pay attention to the part number
11 - Separation point
❑ Separation point ⇒ page 231

1.3 Replacing differential pressure sender -

G505- (for engine with engine identifica‐
tion characters CFHC, CFHF)
The differential pressure sender -G505- determines the volumet‐
ric efficiency of the particle filter volume. It is connected to the
measuring point behind the diesel particle filter via a pressure line
and to the diesel particle filter via another control line.
• If the lines or hoses are clogged with soot, which significantly
constricts their cross section, then the sender together with the
bracket and the connected
Protectedhoses must
by copyright. be for
Copying completely re‐ purposes, in part or in whole, is not permitted
private or commercial
placed. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Removing and installing parts of the exhaust system 223

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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Caution

The differential pressure sender -G505 - is very sensitive to

shock load and leaks.
♦ Therefore the hoses of the sender must only be removed
if the sender is damaged.
♦ Furthermore there is the risk that the hose connections
break off when the hoses are removed.

Removing
– Remove engine cover ⇒ page 7 .
– Disconnect the plug -2- at the differential pressure sender -
G505- -1-.
– Screw out screw -6- and the bracket -3- with the differential
pressure sender -G505- from the bracket of the additional fuel
pump -V393- in -direction of arrow-.
– Release screw -5- and remove bracket -8-.
– Release spring strap clamps -7- and detach the hoses from
the connection fittings of the differential pressure sender -
G505- -1-.
– Release screw -4- and unclip the differential pressure sender
-G505- -1- from the bracket -3-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

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

♦ Before installing, blow through the pressure lines to the differ‐

ential pressure sender -G505- in order to avoid blockage.
♦ Pay attention to the tight fit and leaktightness of the connec‐
tions.

Tightening torques: ⇒ page 218

– An adaptation must be carried out after replacing the differen‐
tial pressure sender -G505- ⇒ Vehicle diagnostic, testing and
information system VAS 5051.
The work procedure for the adaptation is described in the „Tar‐
geted fault finding“. It is also described under „Targeted func‐
tions“.
– Select the correct vehicle in the targeted fault finding.
– Press button „Skip“.
– Press „Selected Functions/Components“.
– Select „Drive“.
– Select „01 - Self-diagnosable systems“.
– Select „01 - Engine electronics J623“.
– Select „01 - Engine electronics, functions“.
– Select „01 - Erase initialisation values (Rep. Gr. 21 - 28)“.

224 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.4 Removing and installing pre-exhaust

pipe with diesel particle filter (for engine
with identification characters CFHC,
CFHF)
Special tools and workshop equipment required
♦ Ratchet ring wrench -T10384-
♦ Ring spanner set for lambda probe
♦ Set of tools SW 17 -T10395-
♦ Transport security -T10404-
♦ Hot screw paste -G 052 112 A3-
Removing
– Remove assembly carrier with steering gear ⇒ Chassis ⇒
Rep. gr. 40 .
– Unbolt heat shield for right drive shaft.
– Remove right drive shaft ⇒ Chassis ⇒ Rep. gr. 40 .
– Remove engine cover ⇒ page 7 .
– Remove warm-type clamp -1- between diesel particle filter and
exhaust turbocharger.

– Disconnect the following plug connections:

♦ Position 2: exhaust gas temperature sender 4 -G648- (orange)
♦ Position 4: lambda probe -G39- (black)
♦ Position 5: exhaust gas temperature sender 3 -G495- (brown)

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

1. Removing and installing parts of the exhaust system 225

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Remove lambda probe -G39- -3-.

– Unscrew the exhaust gas temperature sender 4 -G648- -1-

from the pre-exhaust pipe using the set of tools SW 17 -
T10395- .

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

– Disconnect plug -2- at differential pressure indicator -G505- .

– Screw out screw -3- and remove bracket with differential pres‐
sure indicator -G505- from the bracket of the additional fuel
pump in -direction of arrow-.
– Remove the differential pressure sender -G505- from the
bracket with the hoses connected ⇒ page 223 .

Caution

Risk of damage!
♦ The differential pressure sender -G505- is very sensitive
and therefore requires the utmost care. It must not touch
somewhere when laying it down.

– Attach the differential pressure sender -G505- to the diesel

particle filter with the hoses connected.
– Release screw -1- at bracket on cylinder head.
– Slacken the double clamp and slide it backwards.

226 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unscrew nuts -1- using the ratchet ring wrench -T10384- .

– Release nuts -2- and remove bracket for pre-exhaust pipe.

Note

♦ The assistance of a second mechanic is required for removing

the pre-exhaust pipe.
♦ The decoupling element in the pre-exhaust pipe should not be
bent by more than 10° - risk of damage.
♦ Secure the decoupling element with the transport security -
T10404- against overtensioning -arrow-.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Remove tunnel bridge -arrows-.

– Remove diesel particle filter downwards.
Install

Note

♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° and over-tensioned - risk of damage.
♦ Secure the decoupling element against damage by means of
the transport security -T10404- .

Installation is performed in the reverse order, pay attention to the

following points:
♦ Replace gasket and fixing clamp for pre-exhaust pipe.
♦ Tightening torques ⇒ page 218 .
– First fasten the pre-exhaust pipe loosely to the exhaust gas
turbocharger and then fasten to the bottom bracket.
– Align exhaust system free of stress ⇒ page 231 .
After replacing the diesel particle filter, the adaptation of the ash
mass balance must be set to „0“ ⇒ Vehicle diagnostic, testing and
information system VAS 5051.

1. Removing and installing parts of the exhaust system 227

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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1.5 Removing and installing pre-exhaust

pipe (for engines with engine identifica‐
tion characters CLCA, CLCB)
Special tools and workshop equipment required
♦ Lifting device -MP9-201 (2024A)-
♦ Ratchet ring wrench -T10384-
♦ Hot screw paste -G 052 112 A3-
♦ Pliers for spring strap clamps
♦ Transport security -T10403-
♦ Bolt M10 x 30
Removing
– Switch off ignition and withdraw ignition key.
– Remove engine cover ⇒ page 7 .
– Remove fixing clamp -1- between pre-exhaust pipe and ex‐
haust turbocharger.
On engine with identification characters CLCA
– Release upper screw of bracket for catalytic converter.
On engine with identification characters CLCB
– Release the screw for the top attachment of the diesel particle
filter.
Continued for all engines
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .

– Unscrew screws -1- of protective plate for right drive shaft, if

present.
– Remove right drive shaft ⇒ Chassis ⇒ Rep. gr. 40 .

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

– Disconnect plug -1- from oil level and oil temperature sender
-G266- .
– Remove bracket -2- for the wiring harness of the oil level and
oil temperature sender -G266- from the assembly carrier.
– Slacken the double clamp and slide it backwards.

228 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Screw out screws -2- and -3- of the pendulum support.

– Push the engine forwards approx. 35 mm and fasten it with the

hanger from -MP 9-201- and the screw -2- (M10 x 30) at the
pendulum support -1- -arrow-.

– Unbolt bracket for exhaust system -arrows-.

– Unscrew the front cross member -arrows-.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1. Removing and installing parts of the exhaust system 229
 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Unscrew nuts -1- using the ratchet ring wrench -T10384- .

– Unscrew nuts -2- and remove the bracket for the pre-exhaust
pipe.

Note

♦ The assistance of a second mechanic is required for removing

the pre-exhaust pipe.
♦ The decoupling element in the pre-exhaust pipe should not be
bent by more than 10° - risk of damage.
♦ Secure the decoupling element with the transport security -
T10403- against overtensioning -arrow-.

– Turn diesel particle filter -1- by 180° -in direction of arrow- and
pull out.

Note

If the bracket should Protected

obstruct when pulling out -arrow-, slightly
push aside the heat unless
shield -2- if by
necessary.
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authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Install

– Insert the pre-exhaust pipe -1- with the bracket -2- upwards as
shown and turn to the left by 180°.
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
♦ Replace gasket and fixing clamp for pre-exhaust pipe.
♦ Tightening torques ⇒ page 218 .
– First fasten the pre-exhaust pipe loosely to the exhaust gas
turbocharger and then fasten to the bottom bracket.
– Align exhaust system free of stress ⇒ page 231 .
After replacing the diesel particle filter, the adaptation of the ash
mass balance must be set to „0“ ⇒ Vehicle diagnostic, testing and
information system VAS 5051.

230 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1.6 Replacing middle or rear part of the ex‐

haust system
Special tools and workshop equipment required
♦ Body saw , e.g. -V.A.G 1523 A- or chain pipe cutter , e.g. -VAS
6254-
♦ Protective goggles
Work procedure

Note

♦ For individually replacing the middle or rear part of the exhaust

system, a separation point is provided in the connecting pipe.
♦ The separation point is marked by indentation on the circum‐
ference of the exhaust pipe.

WARNING

In order to avoid injuries because of metal swarfs,bywear safety

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

– Separate exhaust pipe at right angles at the separation point

-arrow 2-.
– When installing, position double clamp -4- at the side markings
-arrow 1- and -arrow 3-.
– Rotate the double clamp -4- in such a way that the ends of the
screws are as far upwards as possible.
– Align rear part of exhaust system horizontally and tighten dou‐
ble clamp to 25 Nm.
– Align exhaust system free of stress ⇒ page 231 .

1.7 Aligning exhaust system free of stress

• The exhaust system is aligned when cold.
– Slacken front double clamp -1- and align to pre-exhaust pipe
-2- (-arrow- points in direction of travel).
-a- = 5 mm
The fixing screws must be on the right. They must not protrude
beyond the bottom edge of the double clamp.
– Tighten the front nut by hand.
Vehicles with front-wheel-drive

1. Removing and installing parts of the exhaust system 231

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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– Push the exhaust system so far forward until the initial load on
the rear retaining strap at the middle part of the exhaust sys‐
tem -a- = 9...11 mm.
Vehicles with four-wheel drive

– Push the exhaust system so far forward until the initial load on
the rear retaining strap at the middle part of the exhaust sys‐
tem -a- = 7...9 mm.
Continued for all vehicles
– Tighten the nuts of the front double clamp evenly to 23 Nm.
Align exhaust tailpipes

– Align rear part of exhaust system:

• There must be an equal distance -a- between bumper opening
and exhaust tailpipe.
• The distance -b- from the bumper opening to the exhaust tail‐
pipes is equal.
For aligning, loosen the hangers of the exhaust gas system.

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

1.8 Inspecting the exhaust system for leak‐

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

232 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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2 Exhaust gas recirculation system

Note

♦ The exhaust gas recirculation system is operated by the en‐

gine control unit -J623- for EGR valve -N18- .
♦ The EGR valve -N18- consists of the mechanical valve, the
EGR control motor -V338- and the EGR potentiometer -
G212- .
♦ The electrically controlled valve with cone-shaped valve
plunger makes it possible to achieve a uniform modification of
the passage diameter depending on the stroke.
♦ Always replace self-locking nuts.

2.1 Exhaust gas recirculation with radiator - Summary of components

Part I

1 - 9unless
Nmauthorised
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by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
2 - Connecting pipe
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ to cylinder head

Caution
Pay attention that the
bellows of the connec‐
tion pipe is not bent or
overstretched. There is a
risk of crack formation.

3 - 9 Nm
4 - Gasket
❑ replace
5 - Vacuum line
❑ do not change bending
form
❑ Connection diagram for
vacuum hoses
⇒ page 171
6 - 9 Nm
7 - Gasket
❑ replace
8 - Connecting pipe
❑ To intake manifold

Caution
Pay attention that the
bellows of the connec‐
tion pipe is not bent or
overstretched. There is a
risk of crack formation.

2. Exhaust gas recirculation system 233

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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9 - 9 Nm
10 - Warm-type clamp, 5 Nm
11 - Radiator
❑ for exhaust gas recirculation
❑ with exhaust gas recirculation valve -N18-
❑ with bypass flap
❑ removing and installing ⇒ page 236
12 - 9 Nm
13 - Gasket
❑ replace
14 - Gasket
❑ replace
15 - Connecting pipe
❑ from exhaust manifold

Caution
Pay attention that the
bellows of the connec‐
tion pipe is not bent or
overstretched. There is a
risk of crack formation.

16 - 22 Nm
17 - 9 Nm
18 - Gasket
❑ replace

Part II

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

234 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

1 - 20 Nm
2 - Connecting pipe
❑ to cylinder head
❑ Replace gasket

Caution
Pay attention that the
bellows of the connec‐
tion pipe is not bent or
overstretched. There is a
risk of crack formation.

3 - Connector
❑ for exhaust gas recircu‐
lation valve -N18-
4 - 20 Nm
5 - 10 Nm
6 - 20 Nm
7 - Connecting pipe
❑ from exhaust manifold
❑ Replace gasket

Caution
Pay attention that the
bellows of the connec‐
tion pipe is not bent or
overstretched. There is a
risk of crack formation.

8 - 20 Nm
9 - Hose
❑ for coolant
❑ with clamp
10 - Radiator
❑ for exhaust gas recirculation
❑ with exhaust gas recirculation valve -N18-
❑ with bypass flap
❑ removing and installing ⇒ page 236
11 - Vacuum setting element
❑ Change-over of bypass flap
12 - Vacuum line
❑ Connection diagram for vacuum hoses ⇒ page 171
13 - Hose
❑ for coolant
❑ with clamp
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
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2. Exhaust gas recirculation system 235

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

2.2 Removing and installing radiator for ex‐

haust gas recirculation with exhaust gas
recirculation valve -N18-
Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-
♦ Catch pan e.g. -VAS 6208-
♦ Pliers for spring strap clamps
♦ Socket insert XZN 10 -T10385-
♦ Old oil collecting and suction equipment , e.g. -V.A.G 1782-
Removing
– Remove engine cover ⇒ page 7 .
– Remove air filter with air mass meter -G70- ⇒ page 214 .
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
gr. 27 .
– Remove pre-exhaust pipe:
♦ Engine identification characters CFHC, CFHF ⇒ page 225
♦ Engine identification characters CLCA, CLCB ⇒ page 228
– Remove connection pipes -A- from cylinder head and from
exhaust manifold using the socket insert XZN 10 -T10385- .
– Remove oil feed and oil return-flow line with support for ex‐
haust turbocharger ⇒ page 165 .
– Collect escaping engine oil with the old oil collecting and suc‐
tion equipment -V.A.G 1782- .
– Remove vacuum line to vacuum setting element
⇒ Item 11 (page 235) .
– Disconnect the plug from the exhaust gas recirculation valve
-N18- .
– Pinch off the coolant feed hose and the coolant return hose of
the radiator for exhaust gas recirculation with hose clamps -
MP7-602 (3094)- and detach the hoses.
– Collect escaping coolant with the catch pan -VAS 6208- .

– Release screws -arrows- and remove radiator for exhaust gas

recirculation with exhaust gas recirculation valve -N18- .
Install
Installation is performed in the reverse order, pay attention to the
following points:
♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
♦ Secure all hose connections with spring strap clamps.
♦ Tightening torques ⇒ page 233 .
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– Inspect coolant level, top up bywith
unless authorised ŠKODAcoolant
AUTO A.ifS.necessary
ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ page 115 .

2.3 Checking change-over flap for radiator

for exhaust gas recirculation
Special tools and workshop equipment required

236 Rep. gr.26 - Exhaust system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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♦ Hand vacuum pump , e.g. -VAS 6213-

Work procedure

Note

The vacuum setting element for change-over flap is accessible

from below.

– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .

– Unbolt heat shield for right drive shaft.
– Detach vacuum hose from vacuum setting element.
– Connect hand vacuum pump to vacuum setting element.
– Actuate the hand vacuum pump in order to generate negative
pressure.
• The vacuum setting element must open the change-over flap
up to the stop at max. 0.08 MPa (0.8 bar) negative pressure
and in case of ventilation close it up to the stop -arrows-.

Note

♦ For this test the opening of the change-over flap can be per‐
formed in jolts. In driving mode the change-over flap opens
due to the larger negative pressure.
♦ The closing of the change-over flap must be carried out sud‐
denly when ventilating (e.g. detach vacuum hose).

If the vacuum setting element does not open or close the change-
over flap up to the stop:
– Replace radiator for exhaust gas recirculation with vacuum
setting element ⇒ page 236 .

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

2. Exhaust gas recirculation system 237

 Octavia II 2004 ➤ , Octavia II 2010 ➤
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28 – Glow plug system

1 Glow Plug System

1.1 Removing and installing glow plugs

Note

Metal glow plugs are installed in this engine.

Special tools and workshop equipment required

♦ Flexible-head wrench SW 10 , e.g. -3220-
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Protective goggles and gloves
Removing
Observe all safety measures and notes for assembly work on the
fuel and injection system as well as the rules for cleanliness
⇒ page 2 .
– Switch off ignition and withdraw ignition key.
– Remove engine cover ⇒ page 7 .
– If present, remove the noise insulation at the injection units.
– Disconnect plug -1- at fuel pressure sender -G247- .
– Release fixing screws -arrows- of top coolant pipe and the fuel
return-flow pipe.
– Detach the hose -2- from the pipe of the fuel return-flow line.

– Open the catches -arrows- of the cable guide and slacken the
wiring loom.

Caution

♦ Carefully disconnect the plug from the glow plugs.

♦ If the plug is damaged when disconnecting it, the complete
wiring loom including the plugs must be replaced (plugs
cannot be replaced separately).

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238 Rep. gr.28 - Glow plug system

 Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011

– Carefully disconnect the plug from the glow plugs. Use the
assembly spanner SW 12 for help.

WARNING

Wear protective gloves and protective googles when working

with grease remover!

– Clean the glow plug and the hole in the cylinder head with
great care.

Note

No dirt must get into the cylinder.

When cleaning, for example:

1. Suction off heavy dirt using a vacuum cleaner.
2. Spray grease remover and cleaning agent onto the glow
plug and into the hole around the plug, let it take effect for a
short period of time and blow out with compressed air.
3. Clean the glow plug and the channel around the plug with a
cloth soaked in oil.
– Slacken the glow plug with a flexible-head wrench 10 -3220-
and release.
Install
Installation is carried out in the reverse order; pay attention to the
following points:
– Screw in the glow plug with a flexible-head wrench 10 -3220-
and tighten.
♦ Tightening torque: 16 - 18 Nm
– Fit the plug again onto the relevant glow plugs and check for
firm seating.
– Interrogating and erasing fault memory of engine control unit
⇒ Vehicle diagnostic, testing and information system
VAS 5051.

Note

After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.

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

1. Glow Plug System 239