Service

Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
1.2/63; 77 kW TSI engine
Engine ID CJZB CJZA

Edition 11.2014
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Service Department. Technical Information

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

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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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.
 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety measures for working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . 3
2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 4
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when working on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Assembly of radiators and capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Additional instructions when undertaking assembly work on the air-conditioning system . . 8
3.7 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.9 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.10 Reduce pressure in the high-pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Unit mounting - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 V-ribbed belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3 Removing and installing tensioning device for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Removing and installing ribbed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Gearbox side cylinder block - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Crankshaft mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Contents i
 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.3 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.5 Removing and installing oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Summary of components - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.4 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.3 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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3.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.5 Removing and installing N205 the camshaft adjustment valve 1 . . . . . . . . . . . . . . . . . . . . 119
3.6 Removing and installing valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Oil sump and oil pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.4 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 134
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.1 Summary of components - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.1 Summary of components - crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.1 Summary of components - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 141
4.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 Summary of components - coolant pump/coolant thermostat . . . . . . . . . . . . . . . . . . . . . . 154

ii Contents
 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

2.3 Summary of components - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.5 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 162
2.6 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 167
2.9 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 168
3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.1 Radiator version 1 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.2 Radiator version 2 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.3 Radiator version 3 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.4 Fan shroud with a radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 178
4.5 Fan shroud with two radiator fans - Summary of components . . . . . . . . . . . . . . . . . . . . . . 179
4.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.7 Removing and installing fan shroud for radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.8 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.9 Removing and installing radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1 Fuel tank and fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.1 Fuel tank - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.2 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.3 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.4 Summary of components - fuel delivery unit and sender for fuel gauge display . . . . . . . . 200
1.5 Fuel delivery unit with sender for fuel gauge display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.6 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 204
1.7 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.8 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2 Separating push-on couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.3 Disconnect connector for accelerator pedal module and fit on . . . . . . . . . . . . . . . . . . . . . . 216
4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.3 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.3 Removing and installing charge pressure regulator V465 . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.2 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.4 Checking the charge-air system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Contents iii
 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

1.1 Injection system - Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 234

2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.3 Removing and installing the throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . 244
3.4 Clean throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.2 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.4 Clean injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
5.1 Removing and installing intake manifold pressure sender GX9 . . . . . . . . . . . . . . . . . . . . 257
5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
5.3 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
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6.3 Removing and installing high pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7.2 Removing and installing lambda probe GX10 / GX7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
8.1 Removing and installing engine control unit J623 without protective housing . . . . . . . . . . 268
8.2 Removing and installing engine control unit J623 , engine control unit with protective
housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

1 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.1 Catalytic converter and component parts - Summary of components . . . . . . . . . . . . . . . . 272
1.2 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.3 Removing and installing catalytic converter with pre-exhaust pipe . . . . . . . . . . . . . . . . . . 275
1.4 Removing and installing or replacing the middle and rear silencer . . . . . . . . . . . . . . . . . . 277
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.6 Align exhaust tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.7 Inspecting the exhaust system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 282
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

iv Contents
 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

00 – Technical data
1 Identification
(SRL000738; Edition 11.2014)
⇒ “1.1 Engine number, engine data”, page 1

1.1 Engine number, engine data

“The engine identification characters” and the “serial number” are
located on the sticker -arrow- at the top timing belt guard.
The “engine identification characters” and “serial numbers” are
also indicated on the engine above the engine connection with
the gearbox, on the vehicle data sticker and on the engine control
unit.
♦ Starting with the letter “C”, new four digit engine codes have
been introduced.
♦ 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 on the cylinder block including
the serial number.
♦ The 4th digit refers to the output and torque of the engine and
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depends upon the engine - J623- control unit.

Note

Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet

Octavia III .

Engine codes CJZA CJZB

Manufactured 01.2013 ► 11.2012 ►
Emission standards EU5 EU5
Capacity cm3 1197 1197
Output kW at rpm 77/4500-5500 63/4300-5300
Torque Nm at rpm 175/1400-4000 160/1400-3500
Bore ∅ mm 71.0 71.0
Stroke mm 75.6 75.6
Compression ratio 10.5 10.5
Cylinder/valves per cylinder 4/4 4/4
RON min. 95 unleaded 95 unleaded
Ignition system, fuel injection Motronic MED17 Motronic MED17
Firing order 1-3-4-2 1-3-4-2

1. Identification 1
 Octavia III 2013 ➤ , Octavia III 2014 ➤
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2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 2
⇒ “2.2 Safety measures for working on vehicles with start/stop
system”, page 3
⇒ “2.3 Safety precautions during road tests in which testing and
measuring equipment is used”, page 4
⇒ “2.4 Safety precautions when working on cooling system”, page
4
⇒ “2.5 Safety precautions when working on the injection system”,
page 5
⇒ “2.6 Safety precautions when working on ignition system”, page
6

2.1 Safety precautions when working on

fuel supply system

WARNING

Fuel under high pressure creates a risk of injury.

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Leaking fuel creates a fire hazard.

♦ The fuel system is under pressure! Before opening the
high-pressure system, the fuel pressure must be reduced
to residual pressure
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .
♦ The safety measures for the pressure reduction in the high
pressure system must be observed.
♦ To reduce the residual pressure (about 0.7 MPa or 7 bar),
the connection point must be opened »immediately« after
the pressure has been reduced. Place a cleaning cloth
around the connection point.
♦ Wear protective gloves.
♦ Wear safety goggles.

♦ Fuel pump is activated by switching on ignition and via driver

door contact switch. Before opening the fuel system and for
reasons of safety, if the battery is not disconnected, the con‐
nector must be disconnected from the fuel pump.
♦ Take out fuse for fuel pump control unit - J538- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.

Caution

There is a risk of destruction of electronic components when

disconnecting the battery.
♦ Observe notes on procedure for disconnecting the battery.

Disconnect the battery only when the ⇒ Electrical System; Rep.

gr. 27 battery is disconnected.

2 Rep. gr.00 - Technical data

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is adequate free access to all moving or
hot components.

♦ Clean connection points and their environment thoroughly with

engine or brake cleaner and dry the cleaned area thoroughly
before loosening.
♦ Open closed lines and connections immediately with suitable
screen caps.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths!
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes etc.).
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♦ When the system is open: Do not work with compressed air.

Avoid moving the vehicle.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Prevent skin contact with fuel!
♦ Wear fuel-resistant gloves!

2.2 Safety measures for working on vehi‐

cles with start/stop system
When working on vehicles with start/stop system, please observe
the following:

WARNING

There is risk of injury from automatic engine starting on vehi‐

cles with start/stop system.
♦ In vehicles with an activated start-stop system (indicated
by a message in the dash panel insert), the engine can
start automatically if necessary.
♦ It is therefore necessary to ensure that the start-stop sys‐
tem is deactivated when carrying out work on the vehicle
(switch ignition off, if required switch ignition on again).

2. Safety instructions 3
 Octavia III 2013 ➤ , Octavia III 2014 ➤
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2.3 Safety precautions during road tests in

which testing and measuring equipment
is used
Note the following if testers and measuring instruments must be
used during a road test:

WARNING

There is a risk of accident from deflection and insufficient se‐

curing of testers and measuring instruments.
There is also a hazard from the release of the passenger airbag
in the event of an accident.
• Using testers and measuring instruments during driving
operation creates a risk of deflection.
• Increased risk of injury from unsecured testers and meas‐
uring instruments must be prevented.
♦ Testers and measuring instruments must always be se‐
cured on the rear seat using a seat belt and by a 2nd
person on the rear seat.
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2.4 Safety precautions when working on

cooling system

WARNING

Steam may escape when expansion tank is opened.

♦ Wear eye protection and protective clothing to avoid eye
injuries and scalding.
♦ Cover cap with cloth and open carefully.

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.

4 Rep. gr.00 - Technical data

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Note

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

sure. If necessary, release pressure before beginning repair
work.
♦ Secure all hose connections with hose clips, allocation ⇒
electronic parts catalogue “ETKA” .
♦ Hose clip pliers - VAS 6362- are recommended to install
spring-type clips.
♦ Renew gaskets and seals.
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection and hose).

2.5 Safety precautions when working on the

injection system

WARNING

The fuel system is under pressure! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
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tions. Reduce pressure by carefully removing the hose.

The safety measures for the pressure reduction in the high
pressure system must be observed
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .

To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure, re‐
move the fuse for the voltage supply of the injection valves and
the ignition coils from the fuse holder ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger could be injured by the release of
the passenger airbag in the event of an accident.

2. Safety instructions 5
 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

2.6 Safety precautions when working on ig‐

nition system

WARNING

To prevent injuries to persons and/or damage to the injection

and ignition system, please observe the following:
Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Fuel pump is activated by switching on ignition and via driver
door contact switch. Therefore, if the battery power hasn't been
disconnected, for safety reasons the plug of the fuel delivery
unit must be disconnected, or the fuel pump fuse must be re‐
moved before opening the fuel system.
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6 Rep. gr.00 - Technical data

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 7
⇒ “3.2 Foreign bodies in the engine”, page 7
⇒ “3.3 Contact corrosion”, page 7
⇒ “3.4 Cable routing and securing”, page 8
⇒ “3.5 Assembly of radiators and capacitors”, page 8
⇒ “3.6 Additional instructions when undertaking assembly work
on the air-conditioning system”, page 8
⇒ “3.7 General instructions for charge air system”, page 8
⇒ “3.8 General notes on the ignition system”, page 9
⇒ “3.9 General notes on the injection system”, page 9
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10

3.1 Rules of cleanliness

Carefully observe the following “rules” for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
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before releasing.
♦ Place removed parts on a clean surface and cover. Use only
lint-free 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 fitting. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean
the hoses immediately.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.

3.2 Foreign bodies in the engine

To prevent the penetration of foreign bodies, open channels of
the inlet connection and exhaust tract must be sealed with suita‐
ble plugs during assembly works on the engine, for example from
the screw plug set for engine - VAS 6122- .

3.3 Contact corrosion

The use of unsuitable connection elements causes contact cor‐
rosion (screws, nuts, washers, ...).
This is why only connection elements with a special surface coat‐
ings are fitted.
Therefore, the rubber or plastic parts and the adhesives are made
from electrically non-conductive materials.
If you have any doubts about the suitability of parts, please use
new parts in general ⇒ Electronic Catalogue of Original Parts“ET‐
KA” .

3. Repair instructions 7
 Octavia III 2013 ➤ , Octavia III 2014 ➤
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3.4 Cable routing and securing

♦ To ensure the original installation position, e.g. lines for fuel,
hydraulics, vacuum, activated charcoal filter system lines or
electric cables must be marked before removal. Make sketch‐
es or take photographs if necessary.
♦ Sufficient clearance from all moving or hot components must
be ensured in the engine compartment due to its cramped
construction. This prevents damage to lines.

3.5 Assembly of radiators and capacitors

The radiator, capacitor and charge air cooler may have minor in‐
dentations on the fins, even if assembly is correct. This is not a
case of damage. Radiator, capacitors or charge air cooler must
not be replaced because of these indentations.

3.6 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system

WARNING

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

tem.
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Note

To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.

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

engine without opening the refrigerant circuit:
– Remove the holding clamp(s) of the refrigerant lines.
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

3.7 General instructions for charge air sys‐

tem

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (for example, 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-established.
♦ Ensure that there is adequate free access to all moving or
hot components.

8 Rep. gr.00 - Technical data

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Caution

In case a mechanical damage to the exhaust gas turbocharger

is found, for example, damage to the compressor wheel, it is
not sufficient to only replace the turbocharger. In order to avoid
consequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
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.

♦ Renew self-locking nuts.
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.
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♦ Only use approved clamps for securing the hose connections

⇒ Electronic Catalogue of Original Parts“ETKA” .
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Before connecting the oil feed line, fill the exhaust turbocharg‐
er via the connection fitting with engine oil.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.

3.8 General notes on the ignition system

♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the engine control unit.
♦ The engine control unit and further components are equipped
with self-diagnosis; inspect ⇒ Vehicle diagnostic tester
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety measures
⇒ “2.6 Safety precautions when working on ignition system”, page
6.
Setting data, spark plugs ⇒ Maintenance ; Booklet Octavia III .

3.9 General notes on the injection system

Repairing ignition ⇒ “1 Ignition system”, page 281 .
♦ The engine control unit is equipped with self-diagnosis. Before
repairs and also for fault finding, first of all interrogate the event
memory. Also check the vacuum hoses and connections (un‐
metered air).

3. Repair instructions 9
 Octavia III 2013 ➤ , Octavia III 2014 ➤
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♦ Fuel hoses in the engine compartment must only be secured

with spring-type clips ⇒ electronic catalogue of original
parts“ETKA” . The use of clamp or screw-type clips is not per‐
missible.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety precautions when working on the injection system
⇒ “2.5 Safety precautions when working on the injection system”,
page 5 .

3.10 Reduce pressure in the high-pressure

system

Caution

The injection system consists of a high pressure part (max.

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pressure of 12 MPa = 120 bar) and a low pressure part (pres‐

sure of approx. 0.7 MPa = 7 bar).
Before opening the high pressure system, e.g. removing the
high pressure pump, the fuel distributor, the injection valves,
the fuel pipes or the fuel pressure sender - G247- , the fuel
pressure in the high pressure system with a remaining pres‐
sure of approx. 0.7 MPa (7 bar) must be reduced.

– Connect the ⇒ Vehicle diagnostic tester and carry out the tar‐
geted function “remove high fuel pressure”.
• The fuel pressure drops to a predetermined value.
– Switch off ignition.
– Before opening the fuel system, disconnect the plug from the
fuel pump control unit.
– Before opening the high pressure system, lay cleaning cloths
around the connection point.
– Open fuel system carefully to reduce the residual pressure of
0.7 MPa (7 bar) and when doing so collect fuel that is flowing
out.

Note

♦ If the high-pressure system is not opened immediately the

pressure increases again as a result of the reheating effect.
♦ The ignition system must no longer be switched on, since oth‐
erwise the pressure will increase again.
♦ Interrogate the event memory of the engine control unit at the
end of the following work and delete all the event memory en‐
tries.
♦ The readiness code must be generated if the event memory
has been cleared ⇒ Vehicle diagnostic tester.

10 Rep. gr.00 - Technical data

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 11
⇒ “1.2 Securing the engine to the assembly stand”, page 21
⇒ “1.3 Installing engine”, page 22

1.1 Removing engine

Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel - MP8-602/1-
♦ Extension - 2024 A /1- of lifting device - MP9-201 (2024A)-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine bracket - T10497-
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Hose clip pliers, e.g. - VAS 6362-
♦ Locking pin - T10060 A-
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♦ Double ladder , e. g. -VAS 5085-

♦ Grease - G 000 100-

♦ Protective goggles
♦ Protective gloves
Work procedure

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 reuse or proper
disposal.

WARNING

There is risk of injury from high fuel pressure.

♦ Before opening the high-pressure system, the fuel pres‐
sure must be reduced to residual pressure.

– Reduce the fuel pressure in the high pressure system

⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .

1. Removing and installing engine 11

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– Open cap -arrow- for coolant expansion tank.

WARNING

There is risk of injury due to hot steam and hot coolant.

♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.

– Remove both front wheels ⇒ Chassis; Rep. gr. 44 .

– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
– Remove the front left and right wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Disconnect electrical plug connection -2- at the coolant tem‐
perature sender at the radiator outlet - G83- -3-.
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .

Caution
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There is a risk of destruction through reversing the rotation di‐

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

Vehicles with air conditioning

WARNING

Risk of injury through refrigerant.

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

– Remove V-ribbed belt

⇒ “1.2 Removing and installing poly V-belt”, page 37 .

– Disconnect electric plug connection -1- on the control valve for

the air conditioning system - N280- compressor.
– Release screws -arrows- for AC compressor.

Caution

Risk of damaging refrigerant lines and hoses.

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

– Remove AC compressor with connected refrigerant hoses and

strap up to the right side.
Continued for all vehicles
– Loosen hose clamp -1- and remove air guide hose.

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– Release screw left and right arrow -2-.

– Unclip and remove the air guide on the lock carrier.

– Raise holding clamp -arrow- and remove top left coolant hose
from radiator.

Note

Depending on the vehicle version, 3 radiator versions are instal‐

led.

♦ Radiator Version 1
⇒ “4.1 Radiator version 1 - Summary of components”,
page 173 .
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♦ Radiator Version 2
⇒ “4.2 Radiator version 2 - Summary of components”,
page 175 .
♦ Radiator Version 3
⇒ “4.3 Radiator version 3 - Summary of components”,
page 176 .

Vehicles with radiator version 1

– Raise holding clamp -arrow- and disconnect coolant hose right
above radiator for charge air circuit.

Vehicles with radiator versions 2 and 3:

– Raise holding clamps -1- and remove coolant hose from
charge air circuit cooler.
Continued for all vehicles
– Removing fan shroud
⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .

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– Unlock catch -arrow- and remove vacuum hose -1-.

– Expose vacuum hose on the air guide pipe -2-.

Vehicles without auxiliary heating

– Raise holding clamps -arrows- and remove coolant hoses
from heat exchanger for heating.
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Vehicles with auxiliary heating

– Loosen holding clamp and holding clamps and pull off both
coolant hoses -arrows-.
Continued for all vehicles

– Unscrew screw -2- and remove screw clamp.

– Unscrew screws -1- and nuts -arrows-, strap up catalytic con‐
verter.

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– Release screws -arrows- and remove holder.

Note

Collect leaking coolant by placing a cloth under it.

– Loosen hose clamp -1- and remove coolant hose.

WARNING

There is risk of injury from fuel.

♦ To relieve the fuel pressure, place a clean cloth around
the connection point and loosen the connection point care‐
fully before opening the fuel system.
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Caution

Risk of contamination.
♦ Rules of cleanliness when working on the fuel supply sys‐
tem ⇒ “3.1 Rules of cleanliness”, page 7 .

– First press the hose coupling -1- down, then press release
buttons -arrows-
⇒ “2 Separating push-on couplings”, page 211 .

– Remove hose coupling with pressed release buttons.

– Press release buttons on the hose -2- to the activated charcoal
filter.
– Disconnect and expose hose.

– Pull off air guide hose -2-.

– Pull off -1- air filter housing upwards from the ball pin.
– Loosen hose clamps -3- and -4- and remove air guide pipes.

Note

For the following clip unclipping procedure use the removal tool
for inner door trim panel - MP8-602/1- .

1. Removing and installing engine 15

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– Disconnect the plug electrical plug connection -1- at the en‐

gine control unit - J623- .

Note

On vehicles with an engine control unit with protective cover, first

remove the protective cover
⇒ “8 Engine control unit”, page 268 .

– Take electrical plug connections -2- and -3- out of the holder
and disconnect.
– Expose electric cables.

– Separate electrical plug connection -2-.

– Press back pole protection -1- and unscrew cable from the
starter magnet switch.
– Unscrew the earth cable on the body.
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– Unlock catches -arrows-, remove cover-1- for engine com‐

partment E-box.

– Unlock catch with a screwdriver -arrow-, pull cover -1- for E-

box engine compartment upwards.

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– Unscrew nut -arrow-, remove and expose electric cable.

– Disconnect plug connections -1- and -2-.

For vehicles with manual gearbox
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.
34 .
– Remove slave cylinder ⇒ Gearbox; Rep. gr. 30 .
For models with automatic gearbox
– Remove selector lever linkage, pull off mechatronics plug and
remove all holders from the gearbox ⇒ Gearbox; Rep. gr. 37 .
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Continued for all vehicles

– Screw out screws -arrows- on engine mount by approximately

2 turns.

– Screw out screws -arrows- on gearbox mount by approxi‐

mately 2 turns.

1. Removing and installing engine 17

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– Disconnect electrical plug connection -1- at the oil level and

temperature sender - G266- .
– Unhook electric cable on the holder -2-.

– Unscrew nuts -1- for coupling rod -3- at anti-roll bar -2- left and
right.
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– Undo screws -1-, -2-, -3- and remove the pendulum support
-4-.

– Release screws -1- and remove heat shield for right drive
shaft, if present.

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– Release nut -arrow- on left and right for swivel hub.

– Unscrew the nut -arrow- from the left track control arm - G78-
if the front left vehicle level sensor is present.
– Unhook swivel hub from track control arm on left and right for
swivel hub.
– Unscrew left and right cardan shaft from the gearbox ⇒ Chas‐
sis; Rep. gr. 40 and strap up.

Note

Ensure that the surface protection of the cardan shaft is not dam‐
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aged.

– Swivel suspension strut left towards the outside and support

with extension -2024 A /1- , as shown in the illustration.

WARNING

There is a risk of accidents caused by loose parts of the sup‐

port.
♦ Secure rig pin with plug-in lock and swivel hub -arrow- with
nut -1-.

– Screw swivel hub -2- right at the track control arm -1- tight
using the nut -arrow-, as shown in the illustration.
Continued for all vehicles

1. Removing and installing engine 19

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– Position adapter T10497/2 on the housing fin of the cylinder

block, as shown in the illustration.
– Position engine mount T10497 with bolts T10497/1 at the cyl‐
inder block.
– Screw adapter T10497/2 with screw -1- onto the engine mount
T10497 and tighten it to 20 Nm.

– Fit the adapter - T10497/3- to the engine mount - T10497- and

tighten screw -1- to 20 Nm.
– Insert engine and gearbox jack - V.A.G 1383 A- at engine
mount T10497 and raise the engine/gearbox unit somewhat.
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Note

Use double ladder , -VAS 5085- for example, to release the

screws for the assembly bracket.

– Screw out engine mount screws -arrows- fully.

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– Screw out gearbox mount screws -arrows- fully.

Caution

There is a risk of damage from vacuum lines or electric cables.

♦ Check that all vacuum lines and electric cables between
engine, gearbox, assembly bracket and body have been
loosened.
♦ Guide the engine/gearbox unit out of the engine compart‐
ment carefully when lowering.

– Drain engine/gearbox unit a little.

– Push the gearbox side of the engine/gearbox unit forwards
and drain it slowly and carefully.
– Remove the gearbox from the engine ⇒ gearbox; Rep. gr.
34 .

1.2 Securing the engine to the assembly

stand
Special tools and workshop equipment required
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♦ Lifting device - MP9-201 (2024A)-

♦ Engine and gearbox support - VAS 6095-
♦ Workshop crane, e.g. - VAS 6100-
Work procedure
• Gearbox disconnected from engine.
– Suspend lifting device - MP9-201 (2024A)- from the engine
and workshop crane - VAS 6100- as shown in the illustration.

Note

For coordination with the unit centre of gravity position the perfo‐
rated rails must be placed as shown in the illustration.

WARNING

There is a risk of accident from loose parts of the lifting device.

♦ The suspension hooks and rig pin on the lifting must be
secured using plug-in locks -arrows-.

– Lift off engine with installed engine mount T10497 with work‐
shop crane - VAS 6100- from engine/gearbox jack - V.A.G
1383 A- .
– Remove engine mount T10497 .

1. Removing and installing engine 21

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– Secure engine with bolts -arrows- at engine and gearbox

mount - VAS 6095- as shown in the illustration.

1.3 Installing engine

Work procedure
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
– Installing intermediate plate ⇒ page 48 .
For vehicles with manual gearbox
– Clean the serration of the drive shaft and if the clutch disc has
been used clean the hub serration, remove any corrosion
present and only apply a very thin layer of grease - G 000 100-
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to the serration of the drive shaft.

– Subsequently move the clutch disc up and down on the drive
shaft until the hub fits smoothly on the shaft. Always remove
excess grease.
– 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 .

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For models with automatic gearbox

– Replace the needle bearing -arrow- in the crankshaft
⇒ “3.3 Replace needle bearing for crankshaft”, page 57 .
– Attach the selector lever control cable at the gearbox ⇒ Gear‐
box; Rep. gr. 34 .
Continued for all vehicles
– Installing the gearbox ⇒ Gearbox; Rep. gr. 34 .
– Install gearbox support bracket.
– Take up engine/gearbox unit with the engine mount T10497 .
– Position engine/gearbox unit with the engine mount - T10497-
on the engine and gearbox jack - V.A.G 1383 A- .

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ Replace self-locking nuts and screws as well as gasket rings,
gaskets and O-rings.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
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Parts“ETKA.”
♦ All cable straps should be fastened again in the same place
when installing.

– Insert engine/gearbox unit into the body.

– Initially insert screws -arrows- for engine mount by hand as far

as the stop.

1. Removing and installing engine 23

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– Initially insert screws -arrows- for gearbox mount by hand as

far as the stop.

Note

The screws must not be permanently tightened until the assembly

bracket is adjusted
⇒ “2.5 Adjusting the assembly bracket”, page 31 .

– Remove engine mount T10497 from engine.

– Install the starter motor ⇒ Electrical System; Rep. gr. 27 .
– Install pump for coolant recirculation - V188-
⇒ “2.6 Removing and installing electric coolant pump”,
page 163 .
– Install air guide pipe
⇒ “2.1 Summary of components - charge air system”,
page 228 .
– Install air guide
For vehicles with manual gearbox
– Install slave cylinder ⇒ Gearbox; Rep. gr. 30 .
– Install linkages with linkage support ⇒ Gearbox; Rep. gr. 34 .
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For models with automatic gearbox

– Install the assembly carrier ⇒ Chassis; Rep. gr. 40 .
– Install selector lever linkage, attach mechatronics plug and all
holders to the gearbox ⇒ Gearbox; Rep. gr. 37 .
Continued for all vehicles
– Install high catalytic converter
⇒ “1.3 Removing and installing catalytic converter with pre-
exhaust pipe”, page 275 .
– Install drive shafts ⇒ Chassis; Rep. gr. 40 .
– Install track control arm, swivel hub and coupling rod ⇒ Chas‐
sis; Rep. gr. 40 .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr.
87 .
– Install the V-ribbed belt
⇒ “1.2 Removing and installing poly V-belt”, page 37 .
– Electrical connections and proper routing ⇒ Electrical System;
Rep. gr. 97 and ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
– Installing the engine control unit - J623-
⇒ “8 Engine control unit”, page 268 .
– Connect coolant hoses with quick coupling ⇒ page 174 .
– Install pendulum support
⇒ “2.1 Unit mounting - summary of components”, page 26 .
– Install wheelhouse liners ⇒ Body Work; Rep. gr. 66 .
– Attach the right front wheel ⇒ Chassis; Rep. gr. 44 .
– Adjust the assembly bracket
⇒ “2.5 Adjusting the assembly bracket”, page 31 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .

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– Install air filter housing

⇒ “2.2 Removing and installing air filter housing”, page 239 .

Caution

There is a risk of destruction of control units as a result of over‐

voltage.
♦ Do not use charger for jump starting!

– Top up and bleed cooling system ⇒ page 148 .

– Interrogate all event memories and delete all event entries
which are caused by removing and installing the engine ⇒ Ve‐
hicle diagnostic tester.
After deleting the event memory of the engine control unit the
readiness code must be re-generated.

Note

♦ Only re-use drained coolant if the cylinder head or cylinder

block has not been replaced.
♦ Dirty coolant must not be used again.
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Tightening torques

Note

♦ Tightening torques apply only for lightly greased, oiled,

phosphatized or blackened nuts and screws.
♦ Other lubricants such as engine and gearbox oil are allowed,
but no lubricants containing graphite.
♦ Do not use degreased parts.

Component Nm
Screws and nuts M6 9 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. gr. 34
Screws for assembly bracket:
♦ Assembly bracket
⇒ “2.1 Unit mounting - summary of components”,
page 26 .

1. Removing and installing engine 25

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2 Assembly bracket
⇒ “2.1 Unit mounting - summary of components”, page 26
⇒ “2.2 Removing and installing engine mount”, page 28
⇒ “2.3 Removing and installing gearbox mount”, page 28
⇒ “2.4 Check assembly bracket setting”, page 31
⇒ “2.5 Adjusting the assembly bracket”, page 31

2.1 Unit mounting - summary of components

1 - Bolt
❑ replace after removal
❑ Tightening torque and
tightening order
⇒ page 27
2 - Engine support bracket
❑ Tightening torque and
tightening order
⇒ page 27
3 - Engine mounting
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❑ with supporting arm

❑ installing and removing
⇒ “2.2 Removing and in‐
stalling engine mount”,
page 28
4 - Bolt
❑ replace after removal
❑ 40 Nm + torque a further
90° (1/4 turn)
5 - Bolt
❑ replace after removal
❑ 20 Nm + torque a further
90° (1/4 turn)
6 - Bolt
❑ 8 Nm
7 - Mounting bracket
8 - Bolt
❑ replace after removal
❑ 60 Nm + torque a further
90° (1/4 turn)
9 - Pendulum support
❑ removing and installing ⇒ page 27
10 - Bolt
❑ replace after removal
❑ Tightening torque and tightening order ⇒ page 27
11 - Bolt
❑ replace after removal
❑ Tightening torque and tightening order ⇒ page 27

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12 - Bolt
❑ replace after removal
❑ Tightening torque and tightening order ⇒ page 27
13 - Bolt
❑ replace after removal
❑ 60 Nm + torque a further 90° (1/4 turn)

14 - Bolt
❑ replace after removal
❑ 60 Nm + torque a further 90° (1/4 turn)

15 - Bolt
❑ replace after removal
❑ 50 Nm + torque a further 90° (1/4 turn)

16 - Gearbox mount
❑ with supporting arm
❑ installing and removing ⇒ “2.3 Removing and installing gearbox mount”, page 28

Engine support bracket - tightening torque and tightening order

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Note

Replace screws which have been tightened firmly to a torque an‐

gle.

– Tighten screws in steps in the given sequence:

Stage Screws Tightening torque/torque angle
1st -1 … 3- 7 Nm
2nd -1 … 3- 40 Nm
3rd -1 … 3- 90° (torque a further 90° (1/4 turn)

Removing and installing pendulum support

– Unscrew screw -1-.

– Remove screws -2- and -3- and remove support -4-.
Installation is carried out in the reverse order.

Note

Screws which have been tightened firmly to a torque angle must

be replaced.

– Tighten screws in steps in the given sequence:

Stage Bolts Tightening torque/torque angle
1st -2-, -3- 50 Nm
2nd -1- 130 Nm
3rd -1 … 3- 90° (torque a further 90° (1/4 turn)

2. Assembly bracket 27
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2.2 Removing and installing engine mount

Special tools and workshop equipment required
♦ Supporting device - T30099-
♦ Surface - T30119-
♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Removing
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Separate electrical plug connection -1-.
– Open locking device -3- and undo hoses -2- from the activated
charcoal filter.
– Unlock catches using a screwdriver -arrow- and lay coolant
expansion tank to the side.
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– Connect supporting device - T30099- as shown in the illustra‐

tion.
– Attach snap hook to the engine suspension eye, right.
– Slightly pre-tension engine/gearbox unit with the spindle, do
not raise.

– Release screws -arrows- and remove engine mount -1-.

Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Check assembly bracket setting
⇒ “2.4 Check assembly bracket setting”, page 31 .
Tightening torques
♦ ⇒ “2.1 Unit mounting - summary of components”, page 26

2.3 Removing and installing gearbox mount

Special tools and workshop equipment required
♦ Supporting device - T30099-

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♦ Surface - T30119-
♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Removing
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Loosen hose clamps -1- and -2- and remove air guide pipe.
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 239 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Remove engine control unit
⇒ “8 Engine control unit”, page 268 .
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– Unscrew screws -arrows- and remove holder -1-.

Note

Holders are installed differently according to build version.

– Unscrew screw -1-, unclip upwards -arrows- and push slightly

to the side.
– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
50 .
– Remove caps of screwed connections for front suspension
strut domes.

2. Assembly bracket 29
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– Connect support bracket - T30099- together with the other el‐

ements, as shown in the illustration.
– Attach spindle snap hook to the engine suspension eye.
– Pre-tension engine/gearbox unit with the spindle, do not raise.

– Release screws -arrows- and remove gearbox mount -1-.

Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

Screws which have been tightened firmly to a torque angle must

be replaced.
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Caution

There is a risk of damaging the thread in the gearbox support

bracket by positioning the bolts obliquely.
♦ Before screwing in the screws -arrows 1- the gearbox
support bracket and supporting arm of the gearbox mount
must be absolutely parallel to each other. If necessary,
push up gearbox at the rear using a hydraulic trolley jack.
♦ Do not remove support bracket - 10-222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.

– Lift gearbox with the support bracket spindle until the gearbox
support bracket is touching the supporting arm of the gearbox
mount.
– Check assembly bracket setting
⇒ “2.4 Check assembly bracket setting”, page 31 .
– Disconnect support bracket - 10-222 A- from engine.
Tightening torques
♦ ⇒ “2.1 Unit mounting - summary of components”, page 26
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 238
♦ ⇒ “8 Engine control unit”, page 268
♦ Battery tray ⇒ Electrical system; Rep. gr. 27

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2.4 Check assembly bracket setting

Work procedure
The following dimensions must be reached:
• A distance of -a- = 10 mm must be present between engine
support -1- and engine mount -2-.
• The cast edge on the engine support -2- must be parallel -b-
with the engine mount supporting arm -1-.
• The dimension -a- must be the same on the front and rear.

Note

The distance -a- = 10 mm can be checked, for example with suit‐

able round bars.

– If the measured distance is too great or too small, adjust the

assembly bracket
⇒ “2.5 Adjusting the assembly bracket”, page 31 .

2.5 Adjusting the assembly bracket

Special tools and workshop equipment required
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♦ Supporting device - T30099-

♦ Surface - T30119-
♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Work procedure
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Loosen hose clamps -1- and -2- and remove air guide pipe.
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 239 .
– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
50 .
– Remove caps of screwed connections for front suspension
strut domes.

2. Assembly bracket 31
 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Connect supporting device - T30099- as shown in the illustra‐

tion.
– Attach snap hook to the engine suspension eyes.
– Slightly pre-tension engine/gearbox unit with the spindles, do
not raise.

– Unscrew screws -arrows- for engine mount one after another

and replace (if not already done during engine installation).
– Loosely insert the screws.
ProCarManuals.com

– Unscrew screws -arrows- for gearbox mount -1- after another

and replace (if not already done during engine installation).
– Loosely insert the screws.

– Move engine/gearbox unit with an assembly lever until the fol‐

lowing dimensions are set:
A distance of -a- = 10 mm must be present between engine sup‐
port -2- and engine mount -1-.
The cast edge on the engine support -2- must be parallel with the
engine mount supporting arm -1-.
Dimension -b- = dimension -b-.

Note

The distance -a- = 10 mm can be checked, for example with suit‐

able round bars.

– Tighten engine mount screws.

32 Rep. gr.10 - Removing and installing engine

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Make sure that on the gearbox side the edges of the support‐
ing arm -2- and gearbox support -1- are parallel.
• Dimension -x- = dimension -x-.
– Tighten gearbox mount screws.
Installation is carried out in the reverse order.
Tightening torques
♦ ⇒ “2.1 Unit mounting - summary of components”, page 26
♦ ⇒ “2.1 Summary of components - charge air system”,
page 228
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 238
♦ Battery tray ⇒ Electrical system; Rep. gr. 27
ProCarManuals.com

2. Assembly bracket 33
 Octavia III 2013 ➤ , Octavia III 2014 ➤
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13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 V-ribbed belt - Summary of components”, page 34
⇒ “1.2 Removing and installing poly V-belt”, page 37
⇒ “1.3 Removing and installing tensioning device for V-ribbed
belt”, page 39
⇒ “1.4 Removing and installing ribbed belt pulley”, page 40
⇒ “1.5 Removing and installing engine support”, page 41
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 44

1.1 V-ribbed belt - Summary of components

⇒ “1.1.1 Summary of components - Vehicles without air condi‐
tioning”, page 34
⇒ “1.1.2 Summary of components - Vehicles with air condition‐
ing”, page 36

1.1.1 Summary of components - Vehicles without air conditioning

ProCarManuals.com

1 - Bolt
❑ replace after removal
❑ to release and tighten
use counterholder -
T10475-

Caution
There is a risk of destruc‐
tion of the engine.
So
♦ as not to adjust the
timing the crankshaft
must not be turned while
the screws are removed.

❑ 150 Nm + torque a fur‐

ther 180° (1/2 turn)
2 - Crankshaft-belt pulley
❑ with vibration damper
❑ installing and removing
⇒ “1.4 Removing and in‐
stalling ribbed belt pul‐
ley”, page 40

Caution
There is a risk of destruc‐
tion of the engine.
So
♦ as not to adjust the
timing the crankshaft
must not be turned while
the vibration damper is
removed.

34 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

3 - Poly V-belt
❑ check for wear
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ do not kink
❑ Routing of the ribbed V-belt ⇒ page 38
❑ installing and removing ⇒ “1.2 Removing and installing poly V-belt”, page 37
❑ pay attention to the correct position on the belt pulley when installing it
4 - Bolt
❑ replace after removal
❑ 20 Nm + torque a further 90° (1/4 turn)

5 - Tensioning device for V-ribbed belt

❑ Swivel tensioning device for V-ribbed belt with socket insert to slacken the V-ribbed belt
❑ lock with locking pin - T10060 A-
❑ installing and removing ⇒ “1.3 Removing and installing tensioning device for V-ribbed belt”, page 39
6 - Bolt
❑ 23 Nm
7 - AC generator
❑ removing and installing ⇒ Electrical System; Rep. gr. 27
❑ depending on the model of the alternator, different separation V-ribbed belt pulleys can be fitted with
ProCarManuals.com

freewheel -A- and -B- ⇒ page 35

❑ depending on the model of the belt pulley for alternator, the correct length of the V-ribbed belt must be
assigned ⇒ ETKA - Electronic Catalogue of Original Parts

Model of the V-ribbed belt pulley with freewheel

1. Cylinder block (pulley end) 35

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1.1.2 Summary of components - Vehicles with air conditioning

1 - Poly V-belt
❑ check for wear
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ do not kink
❑ Routing of the ribbed V-
belt ⇒ page 39
❑ installing and removing
⇒ “1.2.1 Removing and
installing V-ribbed belt -
Vehicles without air con‐
ditioning ”, page 37
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it
2 - Bolt
❑ replace after removal
❑ to release and tighten
use counterholder -
ProCarManuals.com

T10475-

Caution
There is a risk of destruc‐
tion of the engine.
So
♦ as not to adjust the
timing the crankshaft
must not be turned while
the screws are removed.

❑ 150 Nm + torque a fur‐

ther 180° (1/2 turn)
3 - Crankshaft-belt pulley
❑ with vibration damper
❑ installing and removing ⇒ “1.4 Removing and installing ribbed belt pulley”, page 40

Caution
There is a risk of destruc‐
tion of the engine.
So
♦ as not to adjust the
timing the crankshaft
must not be turned while
the vibration damper is
removed.

4 - Tensioning device for V-ribbed belt

❑ Swivel tensioning device for V-ribbed belt with socket insert to slacken the V-ribbed belt
❑ lock with locking pin - T10060 A-
❑ installing and removing ⇒ “1.3 Removing and installing tensioning device for V-ribbed belt”, page 39
5 - Bolt
❑ 20 Nm + torque a further 90° (1/4 turn)

6 - Bolt
❑ 23 Nm

36 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

7 - AC generator
❑ removing and installing ⇒ Electrical System; Rep. gr. 27
❑ depending on the model of the alternator, different separation V-ribbed belt pulleys can be fitted with
freewheel -A- and -B- ⇒ page 37
❑ depending on the model of the belt pulley for alternator, the correct length of the V-ribbed belt must be
assigned ⇒ ETKA - Electronic Catalogue of Original Parts
8 - Fitting sleeve
❑ for the AC compressor
9 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
10 - Screw
❑ Tightening torques ⇒ Heating, Air Conditioning; Rep. gr. 87

Model of the V-ribbed belt pulley with freewheel

ProCarManuals.com

1.2 Removing and installing poly V-belt

⇒ “1.2.1 Removing and installing V-ribbed belt - Vehicles without
air conditioning ”, page 37
⇒ “1.2.2 Removing and installing V-ribbed belt - Vehicles with air
conditioning ”, page 38

1.2.1 Removing and installing V-ribbed belt -

Vehicles without air conditioning
Special tools and workshop equipment required
♦ Locking pin - T10060 A-

1. Cylinder block (pulley end) 37

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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Removing
– To release the tension of the V-ribbed belt, turn the tensioning
device anticlockwise -arrow-.
– Lock tensioning device with locking pin - T10060 A- .

Caution

There is a risk of destruction through reversing the rotation di‐

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

– Remove poly V-belt.

Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Lay the V-ribbed belt as shown in the illustration.
1- Vibration damper
2- Tensioning device for V-ribbed belt
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3- Generator

– Turn the tensioning element in the -direction of the arrow- and

pull out the locking pin - T10060 A- .
– Release pressure on tensioning device.
– Check that the V-ribbed belt is positioned correctly.
– Start end and check that the V-ribbed belt is running correctly.

1.2.2 Removing and installing V-ribbed belt -

Vehicles with air conditioning
Special tools and workshop equipment required
♦ Locking pin - T10060 A-

38 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Removing
– To release the tension of the V-ribbed belt, turn the tensioning
device anticlockwise -arrow-.
– Lock tensioning device with locking pin - T10060 A- .

Caution

There is a risk of destruction through reversing the rotation di‐

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

– Remove poly V-belt.

Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Lay the V-ribbed belt as shown in the illustration:
1- Vibration damper
2- Tensioning device for V-ribbed belt
ProCarManuals.com

3- Generator
4- Air conditioner compressor

– Turn tensioning device anticlockwise -arrow-, pull out locking

pin - T10060 A- .
– Release pressure on tensioning device.
– Check that the V-ribbed belt is positioned correctly.
– Start end and check that the V-ribbed belt is running correctly.

1.3 Removing and installing tensioning de‐

vice for V-ribbed belt
Removing
– Remove the V-ribbed belt from the tensioning device .
Vehicles without air conditioning system
⇒ “1.2.1 Removing and installing V-ribbed belt - Vehicles without
air conditioning ”, page 37 .
Vehicles with air conditioning system
⇒ “1.2.2 Removing and installing V-ribbed belt - Vehicles with air
conditioning ”, page 38 .

1. Cylinder block (pulley end) 39

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– Release screws -arrows- and pull off tensioning device -1- for
V-ribbed belt.
Install
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
– Install the V-ribbed belt.
Vehicles without air conditioning system
⇒ “1.2.1 Removing and installing V-ribbed belt - Vehicles without
air conditioning ”, page 37 .
Vehicles with air conditioning system
⇒ “1.2.2 Removing and installing V-ribbed belt - Vehicles with air
conditioning ”, page 38 .
Tightening torque
Component Nm
Screw for tensioning device 20 Nm + tor‐
que a further
90° (1/4 turn)

1.4 Removing and installing ribbed belt pul‐

ley
ProCarManuals.com

Special tools and workshop equipment required

♦ Counterholder - T10475-
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
– Remove V-ribbed belt
⇒ “1.2 Removing and installing poly V-belt”, page 37 .
– Undo the screw -arrow-; to do so, use the counterholder -
T10475- .
– Unscrew bolt and remove V-ribbed belt pulley crankshaft.

Caution

There is a risk of destruction of the engine.

♦ So as not to adjust the timing the crankshaft must not be
turned while the vibration damper is removed.

Install

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ All contact surfaces between screws, V-ribbed belt pulley
crankshaft and crankshaft toothed belt sprocket must be free
of oil and grease.

40 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Place V-ribbed belt pulley crankshaft, insert screw with the

oiled thread manually until into the system.
– Tighten the screw -arrow-; to do so, use the counterholder -
T10475- .
Continued installation is carried out in the reverse order. When
installing, note the following:
– Install the V-ribbed belt
⇒ “1.2 Removing and installing poly V-belt”, page 37 .
Tightening torque
Component Nm
Screw for belt pulley 150 Nm + tor‐
que a further
180° (1/2 turn)

1.5 Removing and installing engine support

Special tools and workshop equipment required
♦ Supporting device - T30099-
♦ Surface - T30119-
♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)-
ProCarManuals.com

♦ Adapter - MP9-200/18 (10-222A/18)-

♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Removing
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .
– Loosen hose clamps -1- and -2- and remove air guide pipe.
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 239 .
– Remove ribbed V-belt tensioning device
⇒ “1.3 Removing and installing tensioning device for V-ribbed
belt”, page 39 .

– Expose vacuum hose on the holder -3-.

– Release screw -2-.
– Loosen clips -arrows- and remove toothed belt guard -1- up‐
wards.

1. Cylinder block (pulley end) 41

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Release screw -1-.

– Loosen hose clamp -2- and remove coolant hose.

– Unscrew screws -1- and remove the catalytic converter holder

-2-.
ProCarManuals.com

– Pull off plug connection -1-.

– Open locking device -3- and undo hoses -2- from the activated
charcoal filter.
– Unlock catches using a screwdriver -arrow- and lay coolant
expansion tank to the side.
– Open holding clamps on the air conditioning system pipes.

– Loosen screw -1- but do not unscrew it.

– Unscrew screw -2-.
– Swivel generator -3- forward in -direction of the arrow-.

42 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Release screws -arrows- at holder for pre-exhaust pipe.

– Remove pendulum support
⇒ “2.1 Unit mounting - summary of components”, page 26 .
– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
50 .
– Remove caps of screwed connections for front suspension
strut domes.

– Connect supporting device - T30099- as shown in the illustra‐

tion.
– Attach snap hook to the engine suspension eye, right.
– Slightly pre-tension engine/gearbox unit with the spindle, do
not raise.
– Remove engine mounts
⇒ “2.2 Removing and installing engine mount”, page 28 .
ProCarManuals.com

– Remove bolts -arrows-.

– Unscrew screws -1-, -2-, -3-.

1. Cylinder block (pulley end) 43

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Remove bolts -arrows-.

– Press engine/gearbox unit slightly to the left and remove en‐
gine support.
Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Check assembly bracket setting
⇒ “2.4 Check assembly bracket setting”, page 31 .
Tightening torques
♦ ⇒ “2.1 Unit mounting - summary of components”, page 26
♦ ⇒ “1.1 V-ribbed belt - Summary of components”, page 34
♦ Fixing screws for generator ⇒ Electrical System; Rep. gr. 27
♦ ⇒ “2.1 Summary of components - toothed belt guard”,
page 79
♦ ⇒ “3.1 Summary of components”, page 170
♦ ⇒ “2.1 Summary of components - charge air system”,
page 228
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 238
♦ ⇒ “1.1 Catalytic converter and component parts - Summary of
ProCarManuals.com

components”, page 272

♦ Battery tray ⇒ Electrical system; Rep. gr. 27
♦ Wiper arms ⇒ Electrical system; Rep. gr. 96

1.6 Renewing crankshaft oil seal - belt pul‐

ley end
Special tools and workshop equipment required
♦ Assembly tool - T10485-
♦ Extractor tool - T20143-
Work procedure
– Remove toothed belt
⇒ “2.5 Removing and installing toothed belt”, page 99 .
– Remove crankshaft toothed belt pulley -1- -arrow-.

Caution

There is a risk of destruction of the engine.

♦ So as not to adjust the timing the crankshaft must not be
turned while the vibration damper is removed.

44 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Lift out sealing ring using the extractor hook -T20143/2-

-arrow-.
– Clean the contact and sealing surfaces.

Note

Do not oil new sealing ring.

– Push new sealing ring in -direction of the arrow- over the as‐
sembly sleeve - T10485/3- onto the assembly sleeve -
T10485/2- .
• Fitting position: Closed side of sealing ring points to the re‐
ceiver tube.
ProCarManuals.com

– Pull off assembly sleeve - T10485/3- in -direction of arrow-.

– Fit guide bushing -T10485/2- with seal -1- onto crankshaft

journal.

1. Cylinder block (pulley end) 45

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Pull sealing ring -2- in to the stop using the thrust piece -
T10485/1- and the belt pulley screw -1-.

– Fit crankshaft toothed belt pulley onto the crankshaft.

• The contact surface between the V-ribbed belt pulley crank‐
shaft and crankshaft toothed belt sprocket must be free of oil
and grease.
• Milled surface -arrow- on the crankshaft toothed belt must be
positioned on the crankshaft stub.
– install (set the timing) ⇒ page 105 .
ProCarManuals.com

46 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

2 Cylinder block, gearbox end

⇒ “2.1 Gearbox side cylinder block - Summary of components”,
page 47
⇒ “2.2 Removing and installing flywheel”, page 48
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 49

2.1 Gearbox side cylinder block - Summary of components

Note

For assembly work, secure the engine to the engine and gearbox support -VAS 6095-
⇒ “1.2 Securing the engine to the assembly stand”, page 21 .

1 - Bolt
❑ replace after removal
❑ 60 Nm + torque a further
90° (1/4 turn)
2 - Flywheel
ProCarManuals.com

❑ installing and removing

⇒ “2.2 Removing and in‐
stalling flywheel”,
page 48
❑ can be installed only in
one position
3 - Engine speed sender -
G28-
❑ installing and removing
⇒ “1.5 Removing and in‐
stalling engine speed
sender G28 ”,
page 284
4 - Bolt
❑ Tightening torque
⇒ “1.1 Assembly over‐
view - ignition system”,
page 281
5 - Fit pin
❑ 2 pieces
6 - Intermediate plate
❑ do not damage or bend
during assembly work
❑ installing ⇒ page 48
7 - Screw
❑ Tightening torque and
tightening order
⇒ page 48
8 - Sealing flange with sender wheel and oil seal
❑ Renew sealing flange complete with oil seal and sender wheel only
❑ installing and removing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 49

2. Cylinder block, gearbox end 47

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Sealing flange on the gearbox side - tightening torque and tight‐

ening order
– Tighten screws in steps as follows:
Stage Screws Tightening torque
1st -1 … 6- by hand as far as the stop
2nd -1 … 6- tighten crosswise in steps up to 10 Nm

Installing intermediate plate

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

2.2 Removing and installing flywheel

Special tools and workshop equipment required
♦ Counterholder - MP1-223 (3067)-
Removing
• Gearbox removed
– Insert the counterholder - 3067- into the hole on the cylinder
block -B-.
– Loosen and remove all flywheel bolts.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ Assembly of flywheel with rotor is only possible in one position.

– Insert the counterholder - 3067- into the hole on the cylinder

block -A-.
Tightening torque
Component Nm
Screw for flywheel 60 Nm + tor‐
que a further
90° (1/4 turn)

48 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

2.3 Removing and installing sealing flange

on gearbox side
Special tools and workshop equipment required
♦ Depth gauges - VAS 6082-
♦ Assembly tool - T10134-
♦ Fixing screw - T10340-
♦ 3x screw M6x35.
Work procedure
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 .

Note

For a clearer illustration, see the work sequences while the engine
is removed.

– Remove the flywheel

⇒ “2.2 Removing and installing flywheel”, page 48 .
Set the crankshaft to “OT”:
– Remove ignition coil with power output stage 1 ⇒ page 282 .
ProCarManuals.com

– Remove ignition plug cylinder 1 with spark plug socket

wrench , e. g. -3122 B- .
Set the correct position of the crankshaft for screwing in the fixing
screw.
– Carefully insert a screwdriver into the opening of the ignition
plug, minimum length of shaft 250 mm, in -direction of arrow-
so that it touches the piston head.
– Rotate the crankshaft in direction of rotation of engine on
“TDC” for cylinder 1.

2. Cylinder block, gearbox end 49

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Turn engine shaft further in direction of arrow so that the

screwdriver just out at the top by approx. 35 mm in the
-direction of the arrow-.
– Unscrew locking screw for “TDC” bore at the cylinder block
⇒ page 81 .

Caution

Risk of engine damage.

If the fixing screw - T10340- cannot be screwed in up to the
stop, the crankshaft is not in the correct position.
In this case, proceed as follows:
♦ Unscrew the fixing screw.
♦ Set the correct position of the crankshaft for screwing in
the fixing screw ⇒ page 49 .

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

block and tighten to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
• The crankshaft sprocket now lies on the fixing screw and the
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“TCD” position is set.

Note

The crankshaft is only locked in direction of rotation of engine

using the fixing screw - T10340- .

– Removing the oil pan

⇒ “1.2 Removing and installing oil sump”, page 128 .

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

⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 284 .

– Unscrew screws -arrows- on sealing flange -1-.

50 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Note

The sealing flange -1- is pressed together with the sensor rotor
-2- from the crankshaft -3-.

– To press out, insert 3 screws M6x35 -arrows- into the sealing

flange -1- alternately by a maximum of 1/2 turns each.
– Remove sealing flange -1- with sensor rotor -2-.
Press in sealing flange with rotor

Note

♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
♦ The rotor is held in its installation position on the assembly
device - T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
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renewed together with the sender wheel.

♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin, which is inserted into a hole
in the crankshaft.

Assembly of the assembly device - T10134- :

A - Clamping surface
B - Nut
C - Assembly housing
D - Locating pin
E - Allan screws (2 pieces)
F - Guide bolts (for petrol engines)
G - Guide bolts (for diesel engines)
H - Knurled screws (3 pieces)
I - Inner part

A - Assemble sealing flange with rotor on the assembly device -

T10134- :
– Untwist nut -B- until just before it touches the clamping surface
-A- of the threaded spindle.

2. Cylinder block, gearbox end 51

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

– Grip assembly device - T10134- on clamping surface -A- of

the threaded spindle in a vice -1-.
– Push assembly cup -C- down so that it rests on the nut -B-
-arrow-.
• The inside of the assembly device and assembly cup must be
at the same level.

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

Note

Do not twist rotor or take it out of the sealing flange.

ProCarManuals.com

• Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.

– Place sealing flange with front side facing down on a clean

level surface.
– Press down sealing lips supporting ring -1- in
-direction of the arrow-, until it rests on the level surface.

52 Rep. gr.13 - Crankshaft group

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.

– Lay the sealing flange -1- with the front side on the assembly
device - T10134- in such a way that the positioning pin -D-
engages into the hole -3- of the sensor rotor -2-.
• The sealing flange must lie flat on the assembly device.
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– Press the sealing flange -1- and sealing lip supporting ring
-2- during tightening of 3 knurled screws -H- onto the surface
of the assembly device - T10134- to ensure that the positioning
pin is no longer able to slip out of the bore of the sensor rotor.

Note

When installing sealing flange, ensure that sender wheel remains

fixed in assembly tool.

B - Mount assembly tool - T10134- with sealing flange on crank‐

shaft flange:
• Crankshaft flange free from oil and grease.
• Engine on “TDC”.
– Screw nut -B- on until it reaches end of threaded spindle.
– Press the threaded spindle on the assembly tool - T10134- in
-direction of arrow- until the nuts -B- rest against the assembly
cup -C-.
– Align flat side of assembly housing to the cylinder block sealing
surface on the oil sump side.

2. Cylinder block, gearbox end 53

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– Secure the assembly device - T10134- onto the crankshaft

flange -2-. Screw in Allan screws -E- into the crankshaft flange
by approx. five thread turns.

– Insert 2 screws M6x35 Pos. -2- into the cylinder block for the
sealing flange guide -1-.
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C - Bolt assembly tool - T10134- onto the crankshaft flange:

– Push the assembly cup -C- by hand in the
-direction of the arrow- until the sealing lip supporting ring -1-
rests on the crankshaft flange -2-.
– Push guide pin for petrol engines (red knob) -F- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.

Note

The guide pin for diesel engines must not be inserted in threaded
hole of crankshaft.

– Tighten both hexagon socket head bolts of the assembly de‐

vice hand-tight.
– Screw nut -B- onto threaded spindle by hand until it lies against
assembly housing -C-.

D - Press sender wheel onto crankshaft flange using assembly

device - T10134- :
– Tighten nuts -B- on the assembly device - T10134- to 35 Nm.
• After hexagon nut is tightened to 35 Nm, a small air gap must
still be present between cylinder block and sealing flange -1-.

54 Rep. gr.13 - Crankshaft group

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E - Inspect the installation position of the rotor on the crankshaft

– Screw nut -B- on until it reaches end of threaded spindle.
– Unscrew both bolts-2- from the cylinder block.
– Unscrew knurled screws -H- from the sealing flange -1-.
– Unscrew assembly device - T10134- from the crankshaft
flange - to do so, unscrew the hexagon socket head bolts -E-
from the crankshaft flange.
– Remove sealing lip support ring.

– Mount depth gauge - VAS 6082- onto the crankshaft flange

-2-.
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– Measure distance -a- between crankshaft flange -2- and sen‐

sor rotor -1-.
• Specified value: Dimension -a- = 0.5 mm.
– If the specified value is too small, press rotor down
⇒ page 55 .
– When the specified value has been reached, perform the re‐
maining assembly ⇒ page 56 .

F - Pressing down the rotor:

– Screw assembly tool - T10134- with Allan screws -E- up to the
stop onto the crankshaft flange.
– Screw three knurled screws -H- into the sealing flange -1-.
– Screw nuts -B- onto threaded spindle by hand until it lies
against assembly device - T10134- .

2. Cylinder block, gearbox end 55

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– Tighten nuts -B- on the assembly device - T10134- to 40 Nm.

– Checking sender wheel installation position on crankshaft
again ⇒ page 55 .
– If the specified value is too small, tighten assembly device -
T10134- hexagon nut to 45 Nm.
– Checking sender wheel installation position on crankshaft
again ⇒ page 55 .
Assembling together:
– Tighten screws for sealing flange crosswise.
– Installing the oil pan
⇒ “1.2 Removing and installing oil sump”, page 128 .
– Installing intermediate plate ⇒ page 48 .
– Install flywheel
⇒ “2.2 Removing and installing flywheel”, page 48 .
Tightening torques
♦ ⇒ Fig. ““Sealing flange on the gearbox side - tightening torque
and tightening order”“ , page 48
♦ ⇒ “1.1 Assembly overview - ignition system”, page 281
♦ ⇒ Fig. ““Unscrew locking screw TDC bore at the cylinder block
ProCarManuals.com

- tightening torque”“ , page 81

♦ ⇒ “2.1 Gearbox side cylinder block - Summary of compo‐
nents”, page 47

56 Rep. gr.13 - Crankshaft group

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3 Crankshaft
⇒ “3.1 Crankshaft mass”, page 57
⇒ “3.2 Measuring axial play of crankshaft”, page 57
⇒ “3.3 Replace needle bearing for crankshaft”, page 57

3.1 Crankshaft mass

Caution

There is a risk of bearing seat deformation.

♦ The crankshaft must not be removed. Merely releasing the
crankshaft bearing cover screws will result in deforma‐
tions of the bearing seats of the cylinder block.
♦ If the bearing cover screws have been released, replace
the complete cylinder block together with the crankshaft.
♦ Measuring the main bearing clearance is not possible with
normal workshop equipment.

3.2 Measuring axial play of crankshaft

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Caution

There is a risk of bearing seat deformation.

♦ The crankshaft must not be removed. Merely releasing the
crankshaft bearing cover screws will result in deforma‐
tions of the bearing seats of the cylinder block.
♦ If the bearing cover screws have been released, replace
the complete cylinder block together with the crankshaft.
♦ Measuring the main bearing clearance is not possible with
normal workshop equipment.

Special tools and workshop equipment required

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge , e.g. -VAS 6079-
Work procedure
– Secure dial gauge - VAS 6079- with the universal dial gauge
bracket to the camshaft housing - VW 387- , as shown in the
illustration.
– Place dial gauge against the crankshaft cheek.
– Press crankshaft against the dial gauge and set dial gauge to
“0”.
– Press the crankshaft off the dial gauge and read the measured
value.
• Axial clearance: 0.066…0.233 mm.

3.3 Replace needle bearing for crankshaft

Only for vehicles with an automatic Gearbox
Special tools and workshop equipment required

3. Crankshaft 57
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♦ Centering mandrel -T30029 (3176)-

♦ Interior extractor -Kukko 21/2-
♦ Countersupport -Kukko 22/1-
Removing
– Pull out needle bearing with interior extractor -Kukko 21/2-
and countersupport -Kukko 22/1- .
Install

Note

Labelled side of needle bearing must be legible in the installed

condition.
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– Drive in needle bearing with centring mandrel -T30029 (3176)-

flush with the crankshaft face.

58 Rep. gr.13 - Crankshaft group

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4 Pistons and conrods

⇒ “4.1 Assembly overview - piston and conrod”, page 59
⇒ “4.2 Separating new conrod”, page 61
⇒ “4.3 Removing and installing the piston”, page 61
⇒ “4.4 Checking piston and cylinder bore”, page 63
⇒ “4.5 Removing and installing oil injection nozzles”, page 64

4.1 Assembly overview - piston and conrod

1 - Bolt
❑ replace after removal
❑ Oil threads and contact
surface
❑ 30 Nm + torque a further
90° (1/4 turn)
2 - Conrod bearing cap
❑ as a result of the con‐
rods separated in the
cracking process, the
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conrod bearing cap fits

only in one position and
only to the relevant con‐
rod
❑ Mark assignment to the
cylinder and to the con‐
rod in colour -B-
❑ Fitting position: Peg -A-
on the conrod bearing
cap points to the belt
pulley side
3 - Bearing shells
❑ Fitting position
⇒ page 60
❑ replace used bearing
shells
❑ check for firm seating
4 - Conrod
❑ with cracked conrod
bearing cap
❑ Renew as set only
❑ Mark assignment to the
cylinder and to the con‐
rod bearing cap in col‐
our -B-
❑ separate new conrod ⇒ “4.2 Separating new conrod”, page 61
❑ Fitting position: Peg -A- on the conrod bearing cap points to the belt pulley side
5 - Circlip
❑ 2 pieces
❑ replace after removal
6 - Piston pin
❑ removing and installing ⇒ “4.3 Removing and installing the piston”, page 61

4. Pistons and conrods 59

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7 - Piston
❑ with combustion chamber
❑ Mark the installation position and the assignment to cylinder ⇒ page 60
❑ installing and removing ⇒ “4.3 Removing and installing the piston”, page 61
❑ Check piston and cylinder bore ⇒ “4.4 Checking piston and cylinder bore”, page 63
8 - Piston rings
❑ Compression rings
❑ Measure end gap ⇒ page 63
❑ Measure vertical gap ⇒ page 63
❑ use commercially available piston ring pliers for removing and installing
❑ Fitting position: Identification “TOP” or labelled side for piston crown
❑ Offset gaps by 120°
9 - Piston ring
❑ Oil scraper ring
❑ Measure end gap ⇒ page 63
❑ Measure vertical gap ⇒ page 63
❑ use piston ring pliers for removing and installing
❑ Fitting position: Identification “TOP” or labelled side for piston crown
❑ Offset joint 120° to bottom compression ring
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Fitting position of piston and assignment of piston to cylinder

Caution

Risk of damaging the piston crown.

♦ For re-installation: Mark the assignment in colour on the
piston crown of cylinders that have already been used.
Piston crown not by centre punch, scratch, nick or similar
mark.

• Arrow on the piston crown to the belt pulley side -arrow-.

Bearing shell installation position

– Insert bearing shells centrally in the conrod and conrod bear‐
ing cap.
• Dimension -a- = 2.5 mm.

60 Rep. gr.13 - Crankshaft group

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Oil spray nozzle and pressure relief valve

1- Screw with pressure relief valve - 27 Nm
2- Oil spray nozzle (for cooling piston)
• Fitting position: Align guide edge of the oil spray nozzle -2- to
the cylinder block surface.

Caution

Risk of damaging the oil injection nozzles.

♦ Do not bend oil injection nozzles.
♦ Check clearance of pistons from oil injection nozzles after
reinstalling the piston and nozzles.
♦ Replace the oil injection nozzles if they are bent.

4.2 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. If the conrod bearing cap cannot be removed by hand,
proceed as follows:
– Slightly clamp the conrod in a vice provided with aluminium
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protective jaws, as shown in the illustration.

Note

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

the conrod.
♦ The conrod is clamped below the broken line.

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

– Knock against the conrod bearing cap carefully with a plastic

hammer -arrow- in order to loosen it.

4.3 Removing and installing the piston

Special tools and workshop equipment required
♦ Drift - VW 222 A-
♦ Commercially available piston ring tensioning strap
Removing
• Engine attached to engine and gearbox mount - VAS 6095-
⇒ “1.2 Securing the engine to the assembly stand”, page 21 .

4. Pistons and conrods 61

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– Remove cylinder head

⇒ “1.3 Removing and installing cylinder head”, page 69 .
– Remove oil sump
⇒ “1.2 Removing and installing oil sump”, page 128 , remove
baffle.
– Mark installation position and assignment of the piston to the
cylinder.
– Mark the installation position and assignment of the conrod to
the cylinder and to the conrod bearing cap Pos. -4-
⇒ “4.1 Assembly overview - piston and conrod”, page 59 .
– Remove conrod bearing cap and pull out piston with conrod
upwards.

Note

In case of tightness of the piston pin, heat piston to approximately

60 °C.

– Remove securing rings from the piston pin eye.

– Drive off piston pin with a drift - VW 222 A- .
Install
ProCarManuals.com

Installation is carried out in the reverse order. When installing,

observe the following:

Note

Replace screws which have been tightened firmly to a torque an‐

gle.

– Oil the contact surfaces of the bearing shells.

– Install piston with commercially available piston ring tension‐
ing strap, check installation position ⇒ page 60 .
– Install conrod bearing cap, check installation position Pos.
-2- ⇒ “4.1 Assembly overview - piston and conrod”, page 59 .
– Install cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 69 .
– Installing the oil pan
⇒ “1.2 Removing and installing oil sump”, page 128 .
Tightening torques
Component Nm
Conrod with conrod bearing cap 30 Nm + tor‐
que a further
90° (1/4 turn)

62 Rep. gr.13 - Crankshaft group

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4.4 Checking piston and cylinder bore

Checking piston
– Using an external micrometer, measure pistons approx.
10 mm from the lower edge of skirt, at 90° to the piston pin
axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Piston ∅ mm
Nominal dimension 70.92 1)
• 1)Dimensions without coating (thickness 0.015 mm on each
side)

Measure piston ring end gap

– Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder.
– Push a commercially available feeler gauge into the piston ring
opening to check the end gap.
Piston ring new Wear limit
mm mm
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Compression ring 0.20 + 0.15 1.0

Oil scraper ring 0.20 + 0.20 3.0

Measure piston ring vertical gap

– Clean before inspecting the annular groove of the piston.
Piston ring new Wear limit
mm mm
1st Compression ring 0.05 … 0.09 0.15
2nd Compression ring 0.03 … 0.07 0.15
Oil scraper rings (2 part) 0.04 ... 0.08 0.15
Oil scraper rings (3 part) Not measurable

4. Pistons and conrods 63

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Measure cylinder bore

Caution

There is risk of damaging the cylinder bore surface.

♦ Do not use normal workshop equipment to work on cylin‐
der bore (boring, honing, grinding).

– Using the internal precision instrument - VAS 6078- , measure

crosswise at 3 points in the transverse direction -A- and lon‐
gitudinal direction -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore ∅ mm
Nominal dimension 71.0 + 0.015 1)
+0.005

Note

Cylinder bores must not be measured when cylinder block is

mounted on engine and gearbox support - VAS 6095- , as meas‐
urements may be incorrect.
ProCarManuals.com

4.5 Removing and installing oil injection

nozzles
Special tools and workshop equipment required
♦ Socket - T10545-
Removing
– Remove the noise insulation ⇒ General body repairs, exterior ;
Rep. gr. 66Noise insulation .
– Removing the oil pan
⇒ “1.2 Removing and installing oil sump”, page 128 .
– Rotate crankshaft on the fixing screw of the crankshaft belt
pulley in the engine's running direction -arrow- until the asso‐
ciated screw can be reached.

64 Rep. gr.13 - Crankshaft group

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– Unscrew relief valve -1- with socket insert - T10545- .

– Remove oil spray nozzles -2-.
Installing
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:

Caution

There is a risk of damage to the oil spray nozzles.

♦ Do not bend oil injection nozzles.
♦ Check oil injection nozzles after reinstalling the pistons.
♦ Replace the oil injection nozzles if they are bent.

1- Pressure relief valve

2- Oil spray jet
• Fitting position: Align guide edge of the oil spray nozzle -2- to
the cylinder block surface.
Tightening torques
ProCarManuals.com

Component Nm
Pressure relief valve 27 Nm

4. Pistons and conrods 65

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15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 66
⇒ “1.2 Summary of components - camshaft housing”, page 68
⇒ “1.3 Removing and installing cylinder head”, page 69
⇒ “1.4 Removing and installing camshaft housing”, page 73
⇒ “1.5 Checking compression”, page 77

1.1 Summary of components - cylinder

head

Caution

The camshafts must not be removed individually.

When carrying out repairs the camshaft housing must be com‐
pletely replaced.
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1 - Cylinder head gasket

❑ Renew
⇒ “1.3 Removing and in‐
stalling cylinder head”,
page 69 .
❑ check fitting position:
Cylinder head part num‐
ber
2 - Fitting sleeve
❑ 2 pieces
3 - Cylinder head
❑ installing and removing
⇒ “1.3 Removing and in‐
stalling cylinder head”,
page 69
❑ check for distortion
⇒ page 67
4 - Dowel pins
5 - Gasket
❑ With oil strainer
❑ inserted into the cylinder
head
❑ For vehicles up to
05.2013
6 - Gasket
❑ replace after removal
7 - Camshaft housing
❑ installing and removing
⇒ “1.4 Removing and in‐
stalling camshaft hous‐
ing”, page 73

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

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8 - Bolt
❑ Tightening torque and tightening order ⇒ page 69
9 - Bolt
❑ replace after removal
❑ Loosening order ⇒ page 72
❑ Tightening torque and tightening order ⇒ page 67

Cylinder head - tightening torque and tightening order

Note

Replace screws which have been tightened firmly to a torque an‐

gle.

– Tighten screws in steps in the given sequence:

Stage Screws Tightening torque/torque angle
1st -1 … 10- 40 Nm
2nd -1 … 10- 90° (torque a further 90° (1/4 turn)
3rd -1 … 10- 90° (torque a further 90° (1/4 turn)
ProCarManuals.com

4th -1 … 10- 90° (torque a further 90° (1/4 turn)

Checking cylinder head for distortion

– Inspect cylinder head at several points for distortion using a
500 mm knife-edge straightedge - VAS 6075- and feeler
gauge.
• Maximum permitted distortion: 0.05 mm.

1. Cylinder head 67
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1.2 Summary of components - camshaft housing

1 - Fit pin
2 - Gasket
❑ With oil strainer
❑ inserted into the cylinder
head
❑ For vehicles up to
05.2013
3 - Sealing ring
❑ For inlet camshaft
❑ Renew
⇒ “3.4.1 Removing and
installing the camshaft
sealing ring on the belt
pulley side”, page 115 .
4 - Sealing ring
❑ For exhaust camshaft,
belt pulley side
❑ Renew
⇒ “3.4.2 Removing and
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installing the camshaft

sealing ring for the ex‐
haust camshaft”,
page 116 .
5 - Camshaft housing
❑ installing and removing
⇒ “1.4 Removing and in‐
stalling camshaft hous‐
ing”, page 73
6 - Bolt
❑ Tightening torque and
tightening order
⇒ page 69
7 - O-ring
❑ replace after removal
8 - Inlet camshaft control valve 1 - N205-
❑ installing and removing
⇒ “3.5 Removing and installing N205 the camshaft adjustment valve 1”, page 119
❑ with integrated seal with oil strainer
9 - Bolt
❑ 8 Nm
10 - Gasket
❑ for cap
11 - Screw cap
12 - O-ring
❑ replace after removal
13 - Hall sender - G40-
❑ installing and removing ⇒ “1.4 Removing and installing Hall sender G40 ”, page 284
14 - Bolt
❑ 8 Nm

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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15 - Sealing ring
❑ For exhaust camshaft, gearbox side
❑ Renew
⇒ “3.4.3 Removing and installing the camshaft sealing ring for exhaust camshaft on the gearbox side”,
page 118 .
16 - Toothed belt pulley
❑ For coolant pump
❑ installing and removing
⇒ “2.5 Removing and installing toothed belt pulley for coolant pump”, page 162
17 - Bolt
❑ Tightening torque ⇒ “2.1 Summary of components - coolant pump/coolant thermostat”, page 154
18 - Bolt
❑ 8 Nm
19 - Screw cap
20 - O-ring
❑ replace after removal
21 - Gasket
❑ replace after removal
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Camshaft housing - tightening torque and tightening order

Note

Replace screws which have been tightened firmly to a torque an‐

gle.

– Tighten screws in steps in the given sequence:

Stage Bolts Tightening torque/torque angle
1st -1 … 15- 10 Nm
2nd -1 … 15- 180° (torque a further 180° (1/2 turn)

1.3 Removing and installing cylinder head

Special tools and workshop equipment required
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
Removing
Requirements
• Engine temperature should not exceed 35 °C, because the
cylinder head could be twisted when slackening the screws.

Note

Fit all heat protection sleeves on again in the same place when
installing.

1. Cylinder head 69
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– Remove camshaft housing

⇒ “1.4 Removing and installing camshaft housing”,
page 73 .
– Removing the intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 241 .
– Disconnect electrical plug connections:
1- On the oil pressure switch for reduced oil pressure - F378-
2- On the fuel pressure sender - G247-
3- on the injection valves -N30- to -N33-

– Unscrew screw -2- and remove screw clamp.

– Unscrew screw -1- and nuts -arrows- and strap up catalytic
converter.
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– Release screws -1- and remove heat shield for right drive
shaft, if present.

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Screw out the screws -arrows-, remove oil feed line -1- and oil
return pipe -2-.

– Disconnect electrical plug connections:

1 - for coolant temperature sender - G62-
2 - For charge pressure regulator - V465-
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– Unscrew screw -1- at the engine support.

1. Cylinder head 71
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– Slacken the screws for the cylinder head in the sequence

-1…10- and release them.
– Remove cylinder head and place it on a clean base (foam).
Install

Caution

Risk of damaging sealing surfaces.

♦ Carefully remove residual sealant from the cylinder head
and cylinder block.
♦ Make sure this does not cause any extended scoring or
scratching.
Risk of damaging the cylinder block.
♦ There must be no oil or coolant in the blind holes for the
cylinder head bolts in the cylinder block.
There is a risk of leakage on the cylinder head gasket.
♦ Remove the new cylinder head gasket from its wrapping
immediately before fitting.
♦ To prevent the silicon layer and the area of the bead from
being damaged, handle the gasket with the utmost care.
ProCarManuals.com

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ Replace self-locking nuts, gasket rings, gaskets and O-rings.
♦ If a replacement cylinder head must be installed, the contact
surfaces between hydraulic balancing elements, roller rocker
fingers and camshaft slideways must be oiled before the cam‐
shaft housing is installed.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts“ETKA.”
♦ When the cylinder head or the cylinder head gasket is re‐
placed, all the coolant and engine oil must be replaced.

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

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
– Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.

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

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– Fit on cylinder head gasket -1-.

♦ Pay attention to centring pins in cylinder block -arrows-.
♦ Check installation position of the cylinder head gasket, identi‐
fication: Part number must be legible from the inlet side.
– If the crankshaft has been turned in the meantime: Put piston
of 1st. relevant cylinder at top dead centre. Turn the crank
shaft back again slightly.
– Insert the cylinder head.
– Insert cylinder head bolts and tighten hand-tight.
– Tighten cylinder head bolts ⇒ page 67 .

Note

Tightening up the cylinder head bolts after doing repair work is

not necessary.

Continued installation is carried out in the reverse order. When

installing, note the following:
– Install camshaft housing
⇒ “1.4 Removing and installing camshaft housing”,
page 73 .
ProCarManuals.com

– Installing the intake manifold

⇒ “3.2 Removing and installing intake manifold”, page 241 .
– Change engine oil ⇒ Maintenance ; Booklet Octavia III .
– Replace coolant
⇒ “1.2 Draining and filling coolant”, page 147 .
Tightening torques
♦ ⇒ Fig. ““Engine support bracket - tightening torque and tight‐
ening order”“ , page 27
♦ ⇒ “1.1 Summary of components - cylinder head”, page 66
♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger ”,
page 221
♦ ⇒ “1 Injection system”, page 234
♦ ⇒ Fig. ““Installing catalytic converter - tightening torque and
tightening order”“ , page 277
♦ Drive shaft screening ⇒ Chassis; Rep. gr. 40

1.4 Removing and installing camshaft hous‐

ing
Removing
– Remove coolant pump
⇒ “2.4 Removing and installing coolant pump”, page 158 .
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 239 .
– Removing ignition coils
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 282 .
– Remove the toothed belt from the camshafts
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .

1. Cylinder head 73
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– Remove high pressure pipe -3-

⇒ “6.3 Removing and installing high pressure pipe”,
page 263 .
– Separate electrical plug connection -1-.
– Loosen hose clamp -2- and disconnect hose.
– Separate electrical plug connection -2-.

– Release screws -arrows- and remove connection piece -1-.

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– Loosen hose clamp -2- and remove coolant hose.

– Unscrew -arrows- screws and swivel coolant lines -1- to the
right side.

– Release screws -arrows- and remove mount with heat shield

-1-.

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– Remove connector -arrow- from manifold pressure sender -

GX9- .

– Disconnect electrical plug connections:

2 - For valve 1 for camshaft control - N205- .
4 - For Hall sender - G40- .
– Unscrew screw -3- and expose the wiring loom and lay it to
the left-hand side.
– Pull out oil dipstick -1-.
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– Loosen the screws for the camshaft housing in the sequence

-15…1- and unscrew them.
– Carefully unscrew the camshaft housing and remove from the
bonding.
– When installing again, mark the assignment of the roller rocker
finger and the balancing elements.
– Remove the roller rocker finger together with the balancing
elements and lay aside on a clean surface.
Install

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ Replace gasket with oil strainer.

– “Check TDC” position of camshaft and crankshaft:

• Attach camshaft clamp -T10494- to camshaft housing using

screw -arrow-.

Caution

Risk of damaging the valve gear.

♦ When turning, the camshafts must not be moved axially.

1. Cylinder head 75
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• Fixing screw - T10340- turned up to the stop in the cylinder

block and tightened to 30 Nm.
• Crankshaft in engine direction of rotation applied to the fixing
screw - T10340- = “TDC” position.
– Check that all roller rocker fingers are lying flat correctly on the
end of the valve stem and are clipped into the respective bal‐
ancing element.
For vehicles up to 05.2013

– Insert gasket with oil strainer -2- into the cylinder head -1-.
Continued for all vehicles
– Fit gasket onto dowel pins -arrows-.
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– Screw 2 threaded bolts Pos. -2- and -4-, for example , -

T10288/4- into the cylinder head.
– Carefully place camshaft housing -3- vertically from above on‐
to the threaded bolts in the cylinder head.

Note

Make sure that the camshaft housing does not tilt.

– Tighten camshaft housing screws ⇒ page 69 .

Installation is carried out in the reverse order. When installing,
note the following:
– Install high pressure pipe
⇒ “6.3 Removing and installing high pressure pipe”,
page 263 .
– install (set the timing)
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .
– Install ignition coils
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 282 .
– Install coolant pump
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⇒ “2.4 Removing and installing coolant pump”, page 158 .

– Electrical connections and proper routing ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.

Caution

Risk of damaging valves and piston crowns after work on the

valve gear.
♦ To ensure that no valve is set during starting, turn the en‐
gine carefully by at least 2 turns.

Tightening torques
♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger ”,
page 221
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 238

1.5 Checking compression

Special tools and workshop equipment required
♦ Spark plug wrench , e.g. -3122 B-
♦ Compression tester - V.A.G 1763-
Work procedure
• Engine oil temperature at least 30 ℃.
• Battery voltage at least 12.5 V.
– Remove fuse for fuel pump control unit from the fuse holder.
Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations

1. Cylinder head 77
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Note

Removing fuse interrupts the voltage supply of the fuel pump

control unit.

– Start engine and allow to run until the engine has cut out.
– Switch off ignition.
– Loosen hose clamps -1- and -2- and remove air guide pipes.

– Disconnect plug -2- and remove screw -1-.

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– Pull out ignition coils at power output stage

⇒ “1.2 Removing and installing ignition coils with output stage”,
page 282 .
– Unscrew spark plugs with spark plug wrench , e. g. -3122 B- .
– Check the compression pressure using the compression test‐
er - V.A.G 1763- ; handling, ⇒ Operating Manual .
– A 2nd. mechanic depresses the accelerator pedal fully and at
the same time actuates the starter until the tester shows no
further pressure rise.
– Repeat the procedure for each cylinder.
Compression readings
New part 1.0 ... 1.5 MPa
(10.0…15.0 bar)
Wear limit 0.7 MPa
(7.0 bar)
Maximum difference between cylinders 0.3 MPa
(3.0 bar)
Assembling
Assembling is performed in the reverse order, while paying at‐
tention to the following:
– Install spark plugs, tightening torque 22 Nm.
– Install ignition coils at power output stage
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 282 .
Because the electrical plug connections were disconnected and
the engine started, faults are stored in the event memory of the
engine control unit.
– Clear event memory and re-generate the readiness
code ⇒ Vehicle diagnostic tester.

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

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2 Toothed belt drive

⇒ “2.1 Summary of components - toothed belt guard”,
page 79
⇒ “2.2 Summary of components - toothed belt”, page 80
⇒ “2.3 Checking valve timing”, page 81
⇒ “2.4 Remove the toothed belt from the camshaft”, page 86
⇒ “2.5 Removing and installing toothed belt”, page 99

2.1 Summary of components - toothed belt guard

1 - Bottom toothed belt guard

2 - Bolt
❑ 8 Nm
3 - Engine support bracket
❑ Tightening torque and
tightening order
⇒ page 27
4 - Screw
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❑ Tightening torque and

tightening order
⇒ page 27
5 - Top toothed belt guard
6 - Bolt
❑ 8 Nm

2. Toothed belt drive 79

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2.2 Summary of components - toothed belt

1 - Toothed belt
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear

Caution
Risk of damage to the
toothed belt!
The bending radius of
the toothed belt must not
fall below 50 mm (ap‐
proximate Ø of the
crankshaft sprocket).
A larger bending radius
has a negative effect on
the life of the toothed
belt.

❑ removing
ProCarManuals.com

⇒ “2.5 Removing and in‐

stalling toothed belt”,
page 99
❑ install (set the timing)
⇒ page 93
2 - Bolt
❑ When setting the tight‐
ening torque on the tor‐
que wrench - VAS 6583-
the actual dimension
specified on the tool in‐
sert - T10500- must be
put into the torque
wrench!
❑ 25 Nm
3 - Tensioning roller
❑ for removing and installing, remove engine support
⇒ “1.5 Removing and installing engine support”, page 41
4 - Bolt
❑ replace after removal
❑ 50 Nm + torque a further 90° (1/4 turn)

5 - Toothed belt pulley, exhaust camshaft

❑ installing and removing ⇒ “2.4 Remove the toothed belt from the camshaft”, page 86
6 - Toothed belt pulley, inlet camshaft
❑ With camshaft control
❑ Removing and installing camshaft control ⇒ “3.3 Removing and installing camshaft control”, page 114
7 - Guide sleeve
8 - Bolt
❑ replace after removal
❑ 50 Nm + torque a further 135° (3/8 turn)

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9 - O-ring
❑ replace after removal
10 - Plug
❑ 20 Nm
11 - Idler roller
❑ 45 Nm
12 - Crankshaft - toothed belt sprocket
❑ there must not be any oil present on the contact surface between the toothed belt sprocket and the
crankshaft
❑ can be installed only in one position

Unscrew locking screw “TDC” bore at the cylinder block - tight‐

ening torque

Note

Replace the O-ring if it is damaged.

– Tighten bolts -arrows- to 30 Nm.

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2.3 Checking valve timing

Special tools and workshop equipment required
♦ Fixing screw - T10340-
♦ Camshaft clamp - T10494-
♦ Assembly tool - T10487-
♦ Spark plug wrench , e.g. -3122 B-
♦ Release tool - T10527-
♦ Release tool - T10527/1-
Work procedure
– Loosen hose clamps -1-, -2- and remove air guide pipes.
– Expose air guide hoses at the air guide pipe.

2. Toothed belt drive 81

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– Undo hose clamps -arrows-, remove air guide hose -1-.

– Disconnect plug -1- at charge pressure sender - GX26- .

ProCarManuals.com

– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

– Press release buttons and remove hose -1- to the activated

charcoal filter.
– Unscrew screws -arrows- and remove hose for crankcase
ventilation.

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– Expose wiring loom -arrows-.

– Unscrew screws -1-, -3- and remove toothed belt guard -2- for
coolant pump toothed belt.

– Release screws -arrows- and remove cap -1-.

– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .
ProCarManuals.com

– Unscrew screws -A...D- and push thermostat cover -1- to the

side.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
Position crankshaft to “TDC”
– Remove ignition coil with power output stage 1 ⇒ page 282 .
– Remove ignition plug cylinder 1 with spark plug socket
wrench , e. g. -3122 B- .
Set the correct position of the crankshaft for screwing in the fixing
screw.

– Carefully insert a screwdriver into the opening of the ignition

plug, minimum length of shaft 250 mm, in -direction of arrow-
so that it touches the piston head.
– Rotate the crankshaft in direction of rotation of engine on
“TDC” for cylinder 1.

2. Toothed belt drive 83

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– Turn engine shaft further in direction of arrow so that the

screwdriver just out at the top by approx. 35 mm in the
-direction of the arrow-.
– Unscrew locking screw for “TDC” bore at the cylinder block
⇒ page 81 .

Caution

Risk of engine damage.

If the fixing screw - T10340- cannot be screwed in up to the
stop, the crankshaft is not in the correct position.
In this case, proceed as follows:
♦ Unscrew the fixing screw.
♦ Set the correct position of the crankshaft for screwing in
the fixing screw ⇒ page 83 .

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

block and tighten to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
ProCarManuals.com

Note

The crankshaft is only locked in direction of rotation of engine

using the fixing screw - T10340- .

• The crankshaft sprocket now lies on the fixing screw and the
“TCD” position is set.
• On both camshafts the asymmetrically arranged grooves
-arrows- on the gearbox side must be above the middle of the
camshaft.
• On the exhaust camshaft -A-, the grooves -top arrows- are
accessible through the recesses in the coolant pump driving
wheel.
• On the inlet camshaft -E- the grooves -bottom arrow- are
above the camshaft centre.
If the camshafts are not as described:
– Remove fixing screw - T10340- and turn crankshaft another
turn, set back to “TDC” ⇒ page 83 .
If the camshafts are as described:

Note

♦ The camshaft clamp - T10494- must slide into position easily.

♦ The camshaft clamp must not be positioned using any kind of
hammer.

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– Insert camshaft clamp -T10494- to stop into camshafts and

tighten bolt -arrow- by hand.
If camshaft clamp - T10494- cannot be installed:
ProCarManuals.com

2. Toothed belt drive 85

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– Using the assembly tool - T10487- in -direction of arrow- press

on the toothed belt.
– At the same time, insert the camshaft clamp -T10494- up to
stop into the camshafts and fix with the screw.
If it is not possible to insert the camshaft clamp -T10494- , the
timing is NOK:
– Set timing, remove the toothed belt from the camshaft
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .
If it is possible to insert the camshaft clamp -T10494- , the timing
is OK:
– Valve timing is OK.

Caution

There is a risk of destruction of the engine.

♦ To complete the work, check to ensure that the fixing
screw - T10340- and camshaft clamp -T10494- have been
removed.

Installation is performed in a similar way in the reverse order. Pay

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attention to the following points:

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ Renew O-ring of locking screw if damaged.

Tightening torques
♦ ⇒ “2.1 Summary of components - toothed belt guard”,
page 79
♦ ⇒ “2.2 Summary of components - toothed belt”, page 80
♦ ⇒ Fig. ““Unscrew locking screw TDC bore at the cylinder block
- tightening torque”“ , page 81
♦ ⇒ “1.2 Summary of components - camshaft housing”,
page 68
♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger ”,
page 221
♦ ⇒ “2.1 Summary of components - coolant pump/coolant ther‐
mostat”, page 154
♦ ⇒ “2.1 Summary of components - charge air system”,
page 228
♦ Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .

2.4 Remove the toothed belt from the cam‐

shaft
Special tools and workshop equipment required
♦ Counterholder - T10172- with adapters -T10172/1- and -
T10172/2-

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♦ Fixing screw - T10340-

♦ Counterholder - T10475-
♦ Key - T10499-
♦ Insertion tool - T10500-
♦ Camshaft clamp - T10494-
♦ Assembly tool - T10487-
♦ Spark plug wrench , e.g. -3122 B-
♦ Torque wrench -VAS 6583- or -V.A.G 1410-
♦ Release tool - T10527-
♦ Release tool - T10527/1-
Work procedure
– Loosen hose clamps -1-, -2- and remove air guide pipes.
– Expose air guide hoses at the air guide pipe.
ProCarManuals.com

– Undo hose clamps -arrows-, remove air guide hose -1-.

– Disconnect plug -1- at charge pressure sender - GX26- .

2. Toothed belt drive 87

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– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

– Press release buttons, pull off hose -1-.

– Unscrew screws -arrows- and remove hose for crankcase
ventilation.
ProCarManuals.com

– Expose wiring loom -arrows-.

– Unscrew screws -1-, -3- and remove toothed belt guard -2- for
coolant pump toothed belt.

– Release screws -arrows- and remove cap -1-.

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

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– Expose vacuum hose on the holder -3-.

– Unscrew screw -2-.
– Loosen clips -arrows- and remove toothed belt guard -1- up‐
wards.
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .

– Unscrew screws -A...D- and push thermostat cover -1- to the

side.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
Position crankshaft to “TDC”
– Remove ignition coil with power output stage 1 ⇒ page 282 .
– Remove ignition plug cylinder 1 with spark plug socket
wrench , e. g. -3122 B- .
Set the correct position of the crankshaft for screwing in the fixing
ProCarManuals.com

screw.

– Carefully insert a screwdriver into the opening of the ignition

plug, minimum length of shaft 250 mm, in -direction of arrow-
so that it touches the piston head.
– Rotate the crankshaft in direction of rotation of engine on
“TDC” for cylinder 1.

2. Toothed belt drive 89

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– Turn engine shaft further in direction of arrow so that the

screwdriver just out at the top by approx. 35 mm in the
-direction of the arrow-.
– Unscrew locking screw for “TDC” bore at the cylinder block
⇒ page 81 .

Caution

Risk of engine damage.

If the fixing screw - T10340- cannot be screwed in up to the
stop, the crankshaft is not in the correct position.
In this case, proceed as follows:
♦ Unscrew the fixing screw.
♦ Set the correct position of the crankshaft for screwing in
the fixing screw ⇒ page 89 .

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

block and tighten to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.
ProCarManuals.com

Note

The crankshaft is only locked in direction of rotation of engine

using the fixing screw - T10340- .

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

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• The crankshaft sprocket now lies on the fixing screw and the
“TCD” position is set.
• On both camshafts the asymmetrically arranged grooves
-arrows- on the gearbox side must be above the middle of the
camshaft.
• On the exhaust camshaft -A-, the grooves -top arrows- are
accessible through the recesses in the coolant pump driving
wheel.
• On the inlet camshaft -E- the grooves -bottom arrow- are
above the camshaft centre.

Note

The camshafts have one symmetrically and one asymmetrically

arranged pair of grooves. In the “TDC” position the asymmetrically
arranged pair of grooves must by above the imaginary horizontal
centre line.

If the camshafts are not as described:

– Remove fixing screw - T10340- and turn crankshaft another
turn, set back to “TDC” ⇒ page 89 .
If the camshafts are as described:
ProCarManuals.com

Note

♦ The camshaft clamp -T10494- must move into position easily.

♦ The camshaft clamp must not be positioned using any kind of
hammer.

– Insert camshaft clamp -T10494- to stop into camshafts and

tighten bolt -arrow- by hand.
If camshaft clamp - T10494- cannot be installed:

Caution

To prevent damage to the belt, do not use sharp-edged tools!

2. Toothed belt drive 91

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– Using the assembly tool - T10487- in -direction of arrow- press

on the toothed belt.

– While doing so, insert camshaft control -T10494- to stop into

camshafts and tighten screw -arrow- hand-tight.

Caution
ProCarManuals.com

Risk of damaging the camshaft.

♦ Do not use the camshaft fixer/locator - T10494- as a coun‐
terholder.

– Unscrew locking screw -1- on the camshaft sprocket fitting

position. Use counterholder - T10172- with adapter -
T10172/1- to do this.

– Undo screws -1-, -2- by around one turn. Use counterholder -

T10172- with adapters -T10172/2- and -T10172/1- to do this.

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

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– Release screw -1- using insertion tool - T10500- .

– Slacken the tensioning pulley at the eccentric -2- using the
wrench - T10499- .
– Remove the toothed belt from the camshaft sprockets.
Installing (set the timing)

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ Renew O-ring of locking screw if damaged.

– “Check TDC” position of camshaft and crankshaft:

• Attach camshaft clamp -T10494- to camshaft housing.

Caution
ProCarManuals.com

Risk of damaging the camshafts.

♦ Do not use the camshaft clamp -T10494- as a counter‐
holder.

• Fixing screw - T10340- turned up to the stop in the cylinder

block and tightened to 30 Nm.
• Crankshaft in engine direction of rotation applied to the fixing
screw - T10340- = “TDC” position.

– Replace screws -1-, -2- for camshaft sprocket and insert them
loosely.
• It must still be possible to turn the camshaft sprockets on the
camshafts, however they must not tilt.

2. Toothed belt drive 93

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• Sheet peg -arrow- of the tensioning pulley must engage in the

cast iron recess of the cylinder head.

Observe sequence when fitting the toothed belt.

– Pull toothed belt upwards, place onto the guide pulley -1- and
the tensioning pulley -2- and the camshaft sprockets -3- and
-4-.
ProCarManuals.com

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

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– Rotate the eccentric -2- of the tensioning pulley with the

wrench - T10499- in -direction of arrow- until the adjustment
pointer -3- is located approx. 10 mm to the right from the ad‐
justment window.
– Push eccentric so far back that the adjustment pointer is posi‐
tioned exactly in the adjustment window.

Caution

Risk of engine damage.

To tighten, the torque wrench - VAS 6583- or torque wrench -
V.A.G 1410- must be used!
To tighten, no other torque wrench may be used!

Tighten with torque wrench VAS 6583

Caution

Only use the torque wrench together with insertion tool -

T10500- !
When setting the tightening torque on the torque wrench - VAS
6583- the actual dimension specified on the tool insert -
ProCarManuals.com

T10500- must be put into the torque wrench!

– Keep eccentric in this position and tighten screw -1- to 25 Nm.

To do so, use the insertion tool - T10500- with torque wrench
- VAS 6583- .
Tighten with torque wrench VAG 1410

Caution

Only use the torque wrench together with insertion tool -

T10500- !
Set the reduced tightening torque of 12 Nm on the torque
wrench - V.A.G 1410-
The required tightening torque of 25 Nm is achieved by the
extending the torque wrench - V.A.G 1410- around the tool in‐
sert - T10500- !

– Keep eccentric in this position and tighten screw -1- to the re‐
duced tightening torque 12 Nm. To do so, use the insertion
tool - T10500- with torque wrench - V.A.G 1410- .
Continued

Note

If the engine continued to turn or has run, there may be slight

deviations of the adjustment pointer -3- setting in the adjustment
window. This has no influence on the toothed belt tensioning.

2. Toothed belt drive 95

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– Pre-tighten screws -1-, -2- to 50 Nm, to do so, use the coun‐

terholder - T10172- with adapters -T10172/1- and -T10172/2- .

– Unscrew positioning screw - T10340- .

ProCarManuals.com

– Unscrew bolt -arrow- and remove camshaft clamp -T10494- .

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

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Test timing:
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the fixing screw - T10340- up to the stop in the cylinder
block and tighten to 30 Nm.
– Turn the crankshaft further in direction of rotation of engine to
the stop.
• The crankshaft sprocket now lies on the fixing screw and the
“TCD” position is set.

Note

The crankshaft is only locked in direction of rotation of engine

using the fixing screw - T10340- .

Note

♦ The camshaft clamp -T10494- must move into position easily.

♦ The camshaft clamp must not be positioned using any kind of
hammer.
ProCarManuals.com

– Insert camshaft control -T10494- to stop into camshafts and

tighten screw -arrow- hand-tight.
If camshaft clamp - T10494- cannot be installed:

– Using the assembly tool - T10487- in -direction of arrow- press

on the toothed belt.
– While doing so, insert camshaft control -T10494- to stop into
camshafts and tighten screw hand-tight.
If it is not possible to insert the camshaft clamp -T10494- , the
timing is NOK:
– Repeat control time settings.
If it is possible to insert the camshaft clamp -T10494- , the timing
is OK:

2. Toothed belt drive 97

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– Unscrew positioning screw - T10340- .

– Unscrew bolt -arrow- and remove camshaft clamp -T10494- .

ProCarManuals.com

– Pre-tighten screws -1-, -2- to final tightening torque

⇒ “2.2 Summary of components - toothed belt”, page 80 , to
do so use counterholder - T10172- with adapters -T10172/1-
and -T10172/2- .

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Tighten locking screw -1- to 20 Nm, to do so, use the coun‐

terholder - T10172- with the adapter -T10172/1- .

Caution

Risk of destruction of the engine.

♦ After completing the work, check whether the positioning
screw - T10340- and camshaft clamp -T10494- are re‐
moved.

Further installation occurs in reverse order.

Tightening torques
♦ ⇒ “2.1 Summary of components - toothed belt guard”,
page 79
♦ ⇒ “2.2 Summary of components - toothed belt”, page 80
♦ ⇒ Fig. ““Unscrew locking screw TDC bore at the cylinder block
- tightening torque”“ , page 81
♦ ⇒ “1.2 Summary of components - camshaft housing”,
page 68
♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger ”,
page 221
ProCarManuals.com

♦ ⇒ “2.1 Summary of components - coolant pump/coolant ther‐

mostat”, page 154
♦ ⇒ “2.1 Summary of components - charge air system”,
page 228
♦ Noise insulation ⇒ Body Work- Assembly; Rep. gr. 66

2.5 Removing and installing toothed belt

Special tools and workshop equipment required
♦ Counterholder - T10172- with adapters -T10172/1- and -
T10172/2-
♦ Fixing screw - T10340-
♦ Counterholder - T10475-
♦ Key - T10499-
♦ Insertion tool - T10500-
♦ Camshaft clamp - T10494-
♦ Assembly tool - T10487-
♦ Spark plug wrench , e.g. -3122 B-
♦ Torque wrench -VAS 6583- or -V.A.G 1410-
♦ Release tool - T10527-
♦ Release tool - T10527/1-

2. Toothed belt drive 99

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Removing
– Loosen hose clamps -1-, -2- and remove air guide pipes.
– Expose air guide hoses at the air guide pipe.

– Undo hose clamps -arrows-, remove air guide hose -1-.

ProCarManuals.com

– Disconnect plug -1- at charge pressure sender - GX26- .

– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Press release buttons and remove hose -1- to the activated

charcoal filter.
– Unscrew screws -arrows- and remove hose for crankcase
ventilation.

– Expose wiring loom -arrows-.

– Unscrew screws -1-, -3- and remove toothed belt guard -2- for
coolant pump toothed belt.
ProCarManuals.com

– Release screws -arrows- and remove cap -1-.

– Expose vacuum hose on the holder -3-.

– Unscrew screw -2-.
– Loosen clips -arrows- and remove toothed belt guard -1- up‐
wards.
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .

2. Toothed belt drive 101

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– Unscrew screws -A...D- and push thermostat cover -1- to the

side.
Position crankshaft to “TDC”
– Remove ignition coil with power output stage 1 ⇒ page 282 .
– Remove ignition plug cylinder 1 with spark plug socket
wrench , e. g. -3122 B- .
Set the correct position of the crankshaft for screwing in the fixing
screw.

– Carefully insert a screwdriver into the opening of the ignition

plug, minimum length of shaft 250 mm, in -direction of arrow-
so that it touches the piston head.
– Rotate the crankshaft in direction of rotation of engine on
“TDC” for cylinder 1.
ProCarManuals.com

– Turn engine shaft further in direction of arrow so that the

screwdriver just out at the top by approx. 35 mm in the
-direction of the arrow-.
– Unscrew locking screw for “TDC” bore at the cylinder block
⇒ page 81 .

Caution

Risk of engine damage.

If the fixing screw - T10340- cannot be screwed in up to the
stop, the crankshaft is not in the correct position.
In this case, proceed as follows:
♦ Unscrew the fixing screw.
♦ Set the correct position of the crankshaft for screwing in
the fixing screw ⇒ page 102 .

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

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

block and tighten to 30 Nm.
– Turn crankshaft up to the stop in direction of rotation of engine.

Note

The crankshaft is only locked in direction of rotation of engine

using the fixing screw - T10340- .

• The crankshaft sprocket now lies on the fixing screw and the
“TCD” position is set.
• On both camshafts the asymmetrically arranged grooves
-arrows- on the gearbox side must be above the middle of the
camshaft.
• On the exhaust camshaft -A-, the grooves -top arrows- are
accessible through the recesses in the coolant pump driving
wheel.
• On the inlet camshaft -E- the grooves -bottom arrow- are
above the camshaft centre.
ProCarManuals.com

Note

The camshafts have one symmetrically and one asymmetrically

arranged pair of grooves. In the “TDC” position the asymmetrically
arranged pair of grooves must by above the imaginary horizontal
centre line.

If the camshafts are not as described:

– Remove fixing screw - T10340- and turn crankshaft another
turn, set back to “TDC” ⇒ page 102 .
If the camshafts are as described:

Note

♦ The camshaft clamp -T10494- must move into position easily.

♦ The camshaft clamp must not be positioned using any kind of
hammer.

– Insert camshaft clamp -T10494- to stop into camshafts and

tighten bolt -arrow- by hand.
If camshaft clamp - T10494- cannot be installed:

Caution

To prevent damage to the belt, do not use sharp-edged tools!

2. Toothed belt drive 103

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– Using the assembly tool - T10487- in -direction of arrow- press

on the toothed belt.

– While doing so, insert camshaft control -T10494- to stop into

camshafts and tighten screw -arrow- hand-tight.
– Remove vibration damper
⇒ “1.4 Removing and installing ribbed belt pulley”, page 40 .
ProCarManuals.com

– Release screws -arrows- and remove bottom toothed belt

guard.

Caution

There is a risk of damage to the camshaft.

♦ Do not use the camshaft fixer/locator - T10494- as a coun‐
terholder.

– Unscrew locking screw -1- on the camshaft sprocket fitting

position. Use counterholder - T10172- with adapters -
T10172/1- to do so.

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

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– Undo screws -1-, -2- by around one turn, to do so use the

counterholder - T10172- with adapters -T10172/2- and -
T10172/1- .

– Release screw -1- using insertion tool - T10500- .

– Slacken the tensioning pulley at the eccentric -2- using the
wrench - T10499- .

Caution

There is a risk of destruction through reversing the rotation di‐

rection of an already used toothed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the toothed belt pulley.
ProCarManuals.com

– Remove timing belt.

– Remove crankshaft toothed belt pulley -1- -arrow-.

Installing (set the timing)

Note

♦ Replace screws which have been tightened firmly to a torque

angle.
♦ Renew O-ring of locking screw if damaged.

– “Check TDC” position of camshaft and crankshaft:

• Camshaft clamp - T10494- attached to camshaft housing.

Caution

Risk of damaging the camshafts.

♦ Do not use the camshaft clamp -T10494- as a counter‐
holder.

2. Toothed belt drive 105

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• Fixing screw - T10340- turned up to the stop in the cylinder

block and tightened to 30 Nm.
• Crankshaft in engine direction of rotation applied to the fixing
screw - T10340- = “TDC” position.

– Replace screws -1-, -2- for camshaft sprocket and insert them
loosely.
• It must still be possible to turn the camshaft sprockets on the
camshafts, however they must not tilt.
ProCarManuals.com

• The sheet peg -arrow- of the tensioning pulley must engage

in the cast iron recess of the cylinder head.

– Fit crankshaft toothed belt pulley onto the crankshaft.

• The contact surface between the V-ribbed belt pulley and the
crankshaft toothed belt pulley must be free of oil and grease.
• Milled surface -arrow- on the crankshaft toothed belt must be
positioned on the crankshaft stub.

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

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Observe sequence when fitting the toothed belt.

– Pull toothed belt upwards, place onto the guide pulley -1- and
the tensioning pulley -2- and the camshaft sprockets -3- and
-4-.
ProCarManuals.com

2. Toothed belt drive 107

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– Turn the eccentric -2- of the tensioning pulley with the wrench
-T10499- in the -direction of arrow- until the setting pointer
-3- is approx. 10 mm to the right of the setting window.
– Push eccentric so far back that the adjustment pointer is posi‐
tioned exactly in the adjustment window.

Caution

Risk of engine damage.

To tighten, the torque wrench - VAS 6583- or torque wrench -
V.A.G 1410- must be used!
To tighten, no other torque wrench may be used!

Tighten with torque wrench VAS 6583

Caution

Only use the torque wrench together with insertion tool -

T10500- !
When setting the tightening torque on the torque wrench - VAS
6583- the actual dimension specified on the tool insert -
T10500- must be put into the torque wrench!
ProCarManuals.com

– Keep eccentric in this position and tighten screw -1- to 25 Nm.

To do so, use the insertion tool - T10500- with torque wrench
- VAS 6583- .
Tighten with torque wrench VAG 1410

Caution

Only use the torque wrench together with insertion tool -

T10500- !
Set the reduced tightening torque of 12 Nm on the torque
wrench - V.A.G 1410-
The required tightening torque of 25 Nm is achieved by the
extending the torque wrench - V.A.G 1410- around the tool in‐
sert - T10500- !

– Keep eccentric in this position and tighten screw -1- to the re‐
duced tightening torque 12 Nm. To do so, use the insertion
tool - T10500- with torque wrench - V.A.G 1410- .
Continued

Note

If the engine continued to turn or has run, there may be slight

deviations of the adjustment pointer -3- setting in the adjustment
window. This has no influence on the toothed belt tensioning.

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

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– Pre-tighten screws -1-, -2- to 50 Nm, to do so, use the coun‐

terholder - T10172- with adapters -T10172/2- and -T10172/1- .

– Unscrew positioning screw - T10340- .

ProCarManuals.com

– Unscrew bolt -arrow- and remove camshaft clamp -T10494- .

– Install the bottom toothed belt guard -arrows-.

– Install the oscillation damper
⇒ “1.4 Removing and installing ribbed belt pulley”, page 40 .

2. Toothed belt drive 109

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Test timing:
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the fixing screw - T10340- up to the stop in the cylinder
block and tighten to 30 Nm.
– Turn the crankshaft further in direction of rotation of engine to
the stop.
• The crankshaft cheek must now be resting on the fixing screw.

Note

The crankshaft is only locked in direction of rotation of engine

using the fixing screw - T10340- .

Note

♦ The camshaft clamp -T10494- must move into position easily.

♦ The camshaft clamp must not be positioned using any kind of
hammer.

If camshaft clamp - T10494- cannot be installed:

ProCarManuals.com

Caution

To prevent damage to the belt, do not use sharp-edged tools!

– Using the assembly tool - T10487- in -direction of arrow- press

on the toothed belt.

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– While doing so, insert camshaft control -T10494- to stop into

camshafts and tighten screw -arrow- hand-tight.
If it is not possible to insert the camshaft clamp -T10494- , the
timing is NOK:
– Repeat control time settings.
If it is possible to insert the camshaft clamp -T10494- , the timing
is OK:

– Unscrew positioning screw - T10340- .

ProCarManuals.com

– Unscrew bolt -arrow- and remove camshaft clamp -T10494- .

– Pre-tighten screws -1-, -2- to final tightening torque

⇒ “2.2 Summary of components - toothed belt”, page 80 , to
do so use counterholder - T10172- with adapters -T10172/2-
and -T10172/1- .

2. Toothed belt drive 111

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– Tighten locking screw -1- to 20 Nm, to do so, use the coun‐

terholder - T10172- with the adapter -T10172/1- .

Caution

Risk of destruction of the engine.

♦ After completing the work, check whether the positioning
screw - T10340- and camshaft clamp -T10494- are re‐
moved.

Further installation occurs in reverse order.

Tightening torques
♦ ⇒ “1.1 V-ribbed belt - Summary of components”, page 34
♦ ⇒ “2.1 Summary of components - toothed belt guard”,
page 79
♦ ⇒ “2.2 Summary of components - toothed belt”, page 80
♦ ⇒ Fig. ““Unscrew locking screw TDC bore at the cylinder block
- tightening torque”“ , page 81
♦ ⇒ “1.2 Summary of components - camshaft housing”,
page 68
ProCarManuals.com

♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger ”,

page 221
♦ ⇒ “2.1 Summary of components - coolant pump/coolant ther‐
mostat”, page 154
♦ ⇒ “2.1 Summary of components - charge air system”,
page 228
♦ Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 113
⇒ “3.2 Measuring axial play of camshaft”, page 114
⇒ “3.3 Removing and installing camshaft control”, page 114
⇒ “3.4 Removing and installing camshaft oil seal”, page 115
⇒ “3.5 Removing and installing N205 the camshaft adjustment
valve 1”, page 119
⇒ “3.6 Removing and installing valve stem seal”, page 119

3.1 Assembly overview - valve gear

1 - Inlet valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 125
❑ inspecting valve guides
⇒ “4.1 Checking valve
ProCarManuals.com

guides”, page 125

2 - Exhaust valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 125
❑ inspecting valve guides
⇒ “4.1 Checking valve
guides”, page 125
3 - Cylinder head
4 - Valve stem seal
❑ Renew
⇒ “3.6 Removing and in‐
stalling valve stem
seal”, page 119 .
5 - Valve spring
❑ Fitting position
⇒ page 114
6 - Valve spring plate
7 - Valve collets
8 - Roller rocker finger
❑ installing and removing
⇒ “1.4 Removing and installing camshaft housing”, page 73
❑ mark the fitting position for re-installation
❑ inspect roller bearings for smooth operation
❑ oil the contact surfaces before installing
9 - Locking clip
❑ for hydraulic balancing element

3. Valve gear 113

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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10 - Hydraulic balancing element

❑ Do not interchange
❑ Oil contact surface

Fitting position of the valve spring

• The small ∅ -a- points to the valve spring plate.
• The small ∅ -b- points to the cylinder head.

3.2 Measuring axial play of camshaft

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

Checking camshaft axial clearance

– Remove camshaft housing
⇒ “1.4 Removing and installing camshaft housing”, page 73 .
– Secure dial gauge - VAS 6079- with the universal dial gauge
bracket - VW 387- to the camshaft housing, 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 clearance:
• Wear limit: 0.25 mm.

3.3 Removing and installing camshaft con‐

trol
Removing
– Remove the toothed belt from the camshafts
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .
Install
Installation is carried out in the reverse order.
Tightening torques
♦ ⇒ “1.1 V-ribbed belt - Summary of components”, page 34
♦ ⇒ “2.1 Summary of components - toothed belt guard”,
page 79
♦ ⇒ “3.1 Summary of components”, page 170
♦ ⇒ “2.4 Check assembly bracket setting”, page 31

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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3.4 Removing and installing camshaft oil

seal
⇒ “3.4.1 Removing and installing the camshaft sealing ring on the
belt pulley side”, page 115
⇒ “3.4.2 Removing and installing the camshaft sealing ring for the
exhaust camshaft”, page 116
⇒ “3.4.3 Removing and installing the camshaft sealing ring for
exhaust camshaft on the gearbox side”, page 118

3.4.1 Removing and installing the camshaft

sealing ring on the belt pulley side
Special tools and workshop equipment required
♦ Assembly tool - T10478 B- with screw -T10478/5-
♦ Extraction hook - T20143/1-
Removing
– Remove the toothed belt from the camshaft sprockets
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .
– Unscrew screw -1- and remove camshaft sprocket.
ProCarManuals.com

– Remove seal -1- using extractor hook -T20143/1- .

Install

Note

Do not oil new sealing ring.

3. Valve gear 115

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– Push sealing ring -1- over the receiver tube -T10478/3- onto
the guide bushing -T10478/2- .
• Fitting position: Closed side of sealing ring points to the re‐
ceiver tube.
– Disconnect receiver tube and guide bushing.

– Place guide bushing -T10478/2- with sealing ring -1- onto the
camshaft.
ProCarManuals.com

– Pull sealing ring with thrust piece -T10478/1A- and screw -

T10478/5- for camshaft sprocket as far as it can go.
– install (set the timing)
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .

3.4.2 Removing and installing the camshaft

sealing ring for the exhaust camshaft
Special tools and workshop equipment required
♦ Assembly tool - T10478 B- with screw -T10478/5-
♦ Extraction hook - T20143/1-
Removing
– Remove the toothed belt from the camshafts
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Unscrew screw -2- and remove camshaft sprocket.

– Remove seal -1- using extractor hook -T20143/1- .

Install

Note

Do not oil new sealing ring.

ProCarManuals.com

– Push sealing ring -1- over the receiver tube -T10478/3- onto
the guide bushing -T10478/2- .
• Fitting position: Closed side of sealing ring points to the re‐
ceiver tube.
– Disconnect receiver tube and guide bushing.

– Position guide bushing -T10478/2- with seal -1- on camshaft.

3. Valve gear 117

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Pull in -T10478/1A- with the screw -T10478/5- to the stop.

– install (set the timing)
⇒ “2.4 Remove the toothed belt from the camshaft”,
page 86 .

3.4.3 Removing and installing the camshaft

sealing ring for exhaust camshaft on the
gearbox side
Special tools and workshop equipment required
♦ Assembly tool - T10479 A-
♦ Extraction hook - T20143/1-
Removing
– Remove toothed belt pulley for coolant pump
ProCarManuals.com

⇒ “2.5 Removing and installing toothed belt pulley for coolant

pump”, page 162 .
– Carefully fit extractor hook -T20143/1- between camshaft and
seal -1-.
– Lever out sealing ring.
Install

Note

Do not oil new sealing ring.

– Push sealing ring -1- over the receiver tube -T10479/3- onto
the guide bushing -T10479/2- .
• Fitting position: Closed side of sealing ring points to the re‐
ceiver tube.
– Disconnect receiver tube and guide bushing.

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

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Fit guide bushing -T10479/2- with sealing ring -2- centrally on‐
to the camshaft.
– Fix guide bushing with screw -1- for coolant pump driving
wheel onto the camshaft.
– Push sealing ring onto camshaft, unscrew guide bushing.

– Pull sealing ring -2- into the stop using the thrust piece -
T10479/1- and the screw -1- for coolant pump driving wheel.
– Install toothed belt pulley for coolant pump
⇒ “2.5 Removing and installing toothed belt pulley for coolant
pump”, page 162 .
ProCarManuals.com

3.5 Removing and installing - N205- the

camshaft adjustment valve 1
Removing
– Disconnect plug connection -1-.
– Unscrew screw -2- and remove camshaft control valve 1 -
N205- .
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

Renew O-ring.

Tightening torques
Component Nm
Screw for camshaft control valve 1 8 Nm

3.6 Removing and installing valve stem seal

⇒ “3.6.1 Removing and installing valve stem seal with cylinder
head installed”, page 119
⇒ “3.6.2 Removing and installing valve stem seal with cylinder
head removed”, page 122

3.6.1 Removing and installing valve stem seal

with cylinder head installed
Special tools and workshop equipment required

3. Valve gear 119

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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♦ Spark plug wrench , e.g. -3122 B-

♦ Disassembly and assembly device for valve collets - VAS
5161A- with set - VAS 5161A/32-
♦ Adapter - T40012-
♦ Valve stem seal fitting tool - MP1-233 (3365)-
♦ Valve stem e. g. -VAS 6770-
Work procedure
– Remove camshaft housing
⇒ “1.4 Removing and installing camshaft housing”, page 73 .
– Release spark plugs with spark plug wrench , e.g. -3122 B- .
– Unscrew positioning screw - T10340- .
– Put the piston of the relevant cylinder at “bottom dead centre”.
ProCarManuals.com

– Place guide plate -VAS 5161A/32- on the cylinder head and

screw on using the knurled screws -VAS 5161/12- .
– Screw in adapter - T40012- with seal ring hand-tight into the
corresponding plug connector thread.
– Connect the adapter to the compressed air with a commer‐
cially available intermediate piece and apply constant pres‐
sure.
• Minimum pressure: 0.6 MPa (6 bar)
– Insert the impact drift -VAS 5161/3A- into the guide plate and
knock off the tightly fitted valve collets using a plastic hammer.

– Screw the detent part -VAS 5161/6- with the interlocking fork
-VAS 5161/5- into the guide plate.
– Insert assembly cartridge -VAS 5161A/32-1- with sleeve
mounted -VAS 5161A/32-2- into the guide plate.
– Hook the pressure fork -VAS 5161/2- onto the detent part and
push the assembly cartridge downwards.
– Turn simultaneously the knurled screw of the assembly car‐
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 assembly cartridge.
– Unscrew guide plate and turn it to the side.
• T compressed air hose remains connected.
– Remove the valve spring with the valve spring retainer.

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

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– Pull off valve stem seal with valve shaft pliers , for example -
VAS 6770- .

Caution

There is a risk of damage when installing the valve stem seals.

– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
ProCarManuals.com

– 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 5161A/
32-3- .
• The large diameter of the valve collets points to the top.
– Press the assembly cartridge from the top onto the device -
VAS 5161A/32-3- and lift up the valve collets.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ page 114 .

3. Valve gear 121

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– Screw the guide plate -VAS 5161A/32- back onto the cylinder
head.
– Insert assembly cartridge -VAS 5161A/32-1- with sleeve -VAS
5161A/32-2- into the guide plate.
– 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
Assembly is carried out in the reverse order. When installing, ob‐
serve the following.
– Install spark plugs ⇒ Maintenance ; Booklet Octavia III .
– Install camshaft housing
⇒ “1.4 Removing and installing camshaft housing”, page 73 .

3.6.2 Removing and installing valve stem seal

with cylinder head removed
Special tools and workshop equipment required
ProCarManuals.com

♦ Disassembly and assembly device for valve collets - VAS

5161A- with set - VAS 5161A/32-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Valve stem e. g. -VAS 6770-
♦ Valve stem seal fitting tool - MP1-233 (3365)-
Work procedure
– Remove cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 69 .
– Insert the cylinder head tensioning device - VAS 6419- into the
engine and gearbox jack - VAS 6095- .
– Tension the cylinder head in the cylinder head tensioning de‐
vice, as shown in the illustration.
– Connect cylinder head tensioning device to compressed air.
– Adjust the air bellows with the lever -arrow- below the com‐
bustion chamber on which the valve stem seals should be
removed.
– Allow just enough air to flow into the air bag so that it applied
to the valve disc.

– Place guide plate -VAS 5161A/32- on the cylinder head and

screw on using the knurled screws -VAS 5161/12- .
– Insert the impact drift -VAS 5161/3A- into the guide plate and
knock off the tightly fitted valve collets using a plastic hammer.

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

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– Screw the detent part -VAS 5161/6- with the interlocking fork
-VAS 5161/5- into the guide plate.
– Insert assembly cartridge -VAS 5161A/32-1- with sleeve
mounted -VAS 5161/32-2- into the guide plate.
– Hook the pressure fork -VAS 5161/2- onto the detent part and
push the assembly cartridge downwards.
– Turn simultaneously the knurled screw of the assembly car‐
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 assembly cartridge.
– Unscrew guide plate and turn it to the side.
– Remove the valve spring with the valve spring retainer.

– Pull off valve stem seal with valve shaft pliers , for example -
VAS 6770- .

Caution
ProCarManuals.com

Risk of damage when installing the valve stem seals.

– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the 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 - MP1-233 (3365)- onto the valve guide.
– Remove plastic sleeve.

3. Valve gear 123

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If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the device - VAS 5161A/
32-3- .
• The large diameter of the valve collets points to the top.
– Press the assembly cartridge from the top onto the device -
VAS 5161A/32-3- and lift up the valve collets.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ page 114 .

– Screw the guide plate -VAS 5161A/32- back onto the cylinder
head.
– Insert assembly cartridge -VAS 5161A/32-1- with sleeve -VAS
5161A/32-2- into the guide plate.
– 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.
ProCarManuals.com

– Install cylinder head

⇒ “1.3 Removing and installing cylinder head”, page 69 .

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

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4 Inlet and exhaust valves

⇒ “4.1 Checking valve guides”, page 125
⇒ “4.2 Testing valves”, page 125
⇒ “4.3 Valve dimensions”, page 125

4.1 Checking valve guides

Special tools and workshop equipment required
♦ Universal dial gauge bracket - MP3-447 (VW 387)-
♦ Dial gauge , e.g. -VAS 6079-
Test procedure
– Insert valve into guide. The end of the valve stem must be flush
with the guide. On account of differing stem diameters, only
use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine valve rock.
• Wear limit: 0.5 mm.
– If the wear limit is exceeded, repeat measurement with new
valves.
ProCarManuals.com

– If the wear limit is again exceeded, replace cylinder head.

Note

The valve guides cannot be changed.

4.2 Testing valves

– Check valves on the shank and seat surface for scoring.
– If scoring is clearly visible, change valve.

4.3 Valve dimensions

Note

Inlet and exhaust valves must not be reworked. Only lapping-in

is permitted.

Dimension Inlet valve Exhaust valve

∅a mm 26.5 23.5
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30

4. Inlet and exhaust valves 125

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17 – Lubrication
1 Lubrication system
⇒ “1.1 Oil sump and oil pump - Summary of components”,
page 126
⇒ “1.2 Removing and installing oil sump”, page 128
⇒ “1.3 Removing and installing oil pump”, page 131
⇒ “1.4 Removing and installing oil level and oil temperature send‐
er G266 ”, page 134

1.1 Oil sump and oil pump - Summary of components

Note

♦ If considerable quantities of metal swarf or abrasion is found when carrying out an engine repair, this can
be subject to damage to the crankshaft and conrod bearings. In order to prevent consequential damage,
the following tasks must be performed after the repair: Clean oil channels carefully; change oil injection
nozzles, engine oil cooler and oil filter.
♦ Oil spray nozzle and pressure relief valve ⇒ page 61 .
ProCarManuals.com

1 - Dipstick
❑ Oil capacities ⇒ Mainte‐
nance ; Booklet Octavia
III
2 - Screw cap
3 - Vent valve
❑ Check fitting position
4 - O-ring
❑ replace after removal
❑ Moisten with oil before
installing
5 - Screening
❑ For oil separator
6 - Oil pressure switch for re‐
duced oil pressure F378
❑ Screw in 3 threads by
hand
❑ check
⇒ “4.3 Checking oil
pressure and oil pres‐
sure switch”, page 142
❑ installing and removing
⇒ “4.2 Removing and
installing oil pressure
switch for reduced oil
pressure F378 ”,
page 141
❑ 20 Nm
7 - Oil sump
❑ installing and removing
⇒ “1.2 Removing and in‐
stalling oil sump”,

126 Rep. gr.17 - Lubrication

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page 128
8 - Oil filter
❑ Moisten gasket with oil before installing
❑ In case of damage to the outer skin, the oil filter must be replaced
❑ 20 Nm
9 - Sealing ring
❑ replace after removal
10 - Oil level and oil temperature sender - G266-
❑ installing and removing
⇒ “1.4 Removing and installing oil level and oil temperature sender G266 ”, page 134
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ Tightening torque and tightening order ⇒ page 128
13 - Sealing ring
❑ replace after removal
14 - Oil drain plug

Note
ProCarManuals.com

♦ Replace the oil drain plug when

it has an integrated sealing ring.
♦ Always replace the gasket ring.
❑ 30 Nm
15 - Suction line
16 - Bolt
❑ 8 Nm
17 - Bolt
❑ for the tensioning device
❑ Tightening torques ⇒ “1.1 V-ribbed belt - Summary of components”, page 34
18 - Sealing ring
❑ Renew ⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”, page 44 .
❑ for oil pump drive
19 - Screw
❑ replace after removal
❑ Tightening torques ⇒ page 133
20 - Oil pump
❑ installing and removing ⇒ “1.3 Removing and installing oil pump”, page 131
21 - Gasket
❑ replace after removal
❑ Observe positioning of runners

1. Lubrication system 127

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Oil sump - tightening torque and tightening order

– Tighten screws in steps in the given sequence:
Stage Screws Tightening torque
1st -1 … 19- by hand as far as the stop
2nd -1 … 19- 8 Nm + torque a further 90° (1/4 turn)

1.2 Removing and installing oil sump

Special tools and workshop equipment required
♦ Oil filter tool - 3417-
ProCarManuals.com

♦ Socket - T10058-
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
♦ Silicone sealant ⇒ Electronic Catalogue of Original Parts“ET‐
KA”
♦ Catch pan , e.g. -VAS 6208-
Removing
– Drain engine oil ⇒ Maintenance ; Booklet Octavia III .
– Remove oil filter with oil filter tool - 3417- .
– Remove V-ribbed belt
⇒ “1.2 Removing and installing poly V-belt”, page 37 .
Only vehicles with air conditioner

Note

♦ The air conditioning system lines must not be opened.

♦ Prevent damage to condenser and refrigerant lines and hoses.
♦ Do NOT stretch, kink or bend lines and hoses.

– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.

gr. 87 .
– Secure AC compressor to lock carrier.

128 Rep. gr.17 - Lubrication

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Continued for all vehicles

– Remove securing bolt -arrows- for gearbox.
– Disconnect connect for oil level and oil temperature sender -
G266-
⇒ “1.4 Removing and installing oil level and oil temperature
sender G266 ”, page 134 .

– Unscrew all sump securing bolts -arrows-.

ProCarManuals.com

– Unscrew sump securing bolts on gearbox side -arrows- using

Allen key, long reach - T10058- .

Note

When hardened, the sealant has a high adhesive strength.

1. Lubrication system 129

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– Carefully lever off sump from cylinder block at recess -arrow-

using assembly lever.
– Remove sump. Loosen sump with light blows of a rubber
headed hammer if necessary.

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove the remaining sealant on the cylinder block and on

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

Note

♦ Pay attention to the use by date on sealant.

♦ The oil pan must be installed within 5 minutes after applying
the sealant.
♦ The sump can be positioned more easily and with greater se‐
ProCarManuals.com

curity if M6 studs are inserted into the cylinder block flange at

two positions as guides.

130 Rep. gr.17 - Lubrication

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

3 mm).
– Apply sealant to clean sealing surface of sump as shown.
Sealant bead must be:
♦ 2…3 mm thick
♦ Run bead along inner side of bolt holes -arrows-

Note

The sealing compound bead must not be thicker, otherwise ex‐

cessive sealing compound will enter the sump and may block the
oil suction pipe strainer.

– Fit sump immediately and lightly tighten all sump securing

bolts ⇒ page 128 .
– Tighten the sump securing bolts to the prescribed torque.
Tightening torque of gearbox screws: ⇒ Gearbox; Rep. gr. 34 .

Note
ProCarManuals.com

Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.

– Install oil filter and tighten it with the oil filter wrench - 3417- .
– Fill engine oil ⇒ Maintenance ; Booklet Octavia III .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr.
87 .
Install the V-ribbed belt
⇒ “1.2 Removing and installing poly V-belt”, page 37 .
Further installation occurs in a similar way in reverse order to re‐
moval.
Tightening torques
Component Nm
Oil filter 20 Nm
Oil sump screws ⇒ page 128

1.3 Removing and installing oil pump

Removing
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove toothed belt
⇒ “2.5 Removing and installing toothed belt”, page 99 .
– Removing the oil pan
⇒ “1.2 Removing and installing oil sump”, page 128 .

1. Lubrication system 131

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– Unscrew securing bolts -arrows- and remove tensioning ele‐

ment.
– Remove the generator ⇒ Electrical System; Rep. gr. 27 .
– Removing gasket ring for crankshaft on belt pulley side
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 44 .

– Unscrew oil pump securing bolts -1- and -2-.

– Pull oil pump off dowel pins on cylinder block in a straight line.
ProCarManuals.com

– Remove gasket -1- from dowel pins -arrows-.

Install

– Fit new gasket -1- onto dowel pins -arrows-.

132 Rep. gr.17 - Lubrication

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– Rotate oil pump gear to a position where 2 opposing notches

-arrows- are aligned vertically, as shown in the illustration.
– Fit oil pump onto dowel pins.
Tightening torques

– Tighten the new fixing screws -1- to 8 Nm + torque a further

90° (1/4 turn).
– Tighten securing bolts -2- to 20 Nm.
– Install the new gasket ring for the crankshaft on the belt pulley
side
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 44 .
– Installing the oil pan
⇒ “1.2 Removing and installing oil sump”, page 128 .
– Install generator ⇒ Electrical System; Rep. gr. 27 .
ProCarManuals.com

– Mount tensioning element using new securing bolts -arrows-

and tighten to 20 Nm + 90° (1/4 turn).
– Install toothed belt
⇒ “2.5 Removing and installing toothed belt”, page 99 .

1. Lubrication system 133

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1.4 Removing and installing oil level and oil

temperature sender - G266-
Removing
• Drain engine oil ⇒ Maintenance ; Booklet Octavia III .
– Separate electrical plug connection -3-.
– Release screws -1- and remove oil level and oil temperature
sender - G266- Pos. -4-.
Install
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:

Note

Replace gasket ring -2- and oil before installing.

– Fill with engine oil and check the oil level ⇒ Maintenance ;
Booklet Octavia III .
Tightening torques
Component Nm
ProCarManuals.com

Oil level sender screw 8 Nm

134 Rep. gr.17 - Lubrication

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2 Engine oil cooler

⇒ “2.1 Summary of components - engine oil cooler”, page 135
⇒ “2.2 Removing and installing engine oil cooler”, page 135

2.1 Summary of components - engine oil cooler

1 - Engine oil cooler

❑ installing and removing
⇒ “2.2 Removing and in‐
stalling engine oil cool‐
er”, page 135
❑ fill with fresh coolant af‐
ter replacing
2 - Bolt
❑ replace after removal
❑ 8 Nm + torque a further
90° (1/4 turn)
3 - Gasket rings
❑ replace after removal
ProCarManuals.com

2.2 Removing and installing engine oil cool‐

er
Removing
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .
– Removing the intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 241 .

2. Engine oil cooler 135

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– Release screws -arrows- and remove engine oil cooler -1-.

Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Insert new O-rings.
– Installing the intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 241 .
– Replenish coolant ⇒ page 151 .
Tightening torques
Component Nm
Screw for engine oil cooler 8 Nm + torque
a further 90°
(1/4 turn)
ProCarManuals.com

136 Rep. gr.17 - Lubrication

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3 Crankcase ventilation
⇒ “3.1 Summary of components - crankcase ventilation”,
page 137
⇒ “3.2 Removing and installing oil separator”, page 137

3.1 Summary of components - crankcase ventilation

1 - Hose
❑ for crankcase ventila‐
tion
2 - Cover
❑ For oil separator
3 - Oil separator
❑ installing and removing
⇒ “3.2 Removing and in‐
stalling oil separator”,
page 137
❑ replace if damaged
4 - O-ring
❑ replace after removal
ProCarManuals.com

❑ Moisten with oil before

installing
5 - Inlet connections
❑ Ensure proper position‐
ing
6 - Hose
❑ for crankcase ventila‐
tion
7 - Bolt
❑ self-locking
❑ replace after removal
❑ 9 Nm

3.2 Removing and installing oil separator

Special tools and workshop equipment required
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
♦ Silicone sealant ⇒ Electronic Catalogue of Original Parts“ET‐
KA”
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .

3. Crankcase ventilation 137

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Undo screw -arrow- and place charge air cooler pump - V188-
to one side.

– Pull off hose -3- for crankcase ventilation.

– Unlock -1- oil separator cover at catches -2- -arrow- and re‐
move.
ProCarManuals.com

– Loosen the screws in the sequence -9…1- and unscrew them.

– Loosen oil separator carefully from the bonding.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

WARNING

Wear protective gloves when working with sealant and grease

remover!

– Remove the remaining sealant on the cylinder block and on

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

Caution

There is a risk of contamination of the lubrication system.

♦ Cover open parts of the engine.

138 Rep. gr.17 - Lubrication

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– Insert 2 commercially available pin bolts a few revolutions into

the holes -arrows-.

Note

Pay attention to the use by date on sealant.

ProCarManuals.com

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

1.5 mm).

Caution

There is risk of blockage of the lubrication system through ex‐

cess sealant.
♦ Do not apply a thicker sealant bead than indicated.

– Apply sealant bead -arrow- onto the clean sealing surface of

the oil separator, as shown in the illustration.
• Thickness of sealant bead: 1.5 mm.
After applying the sealant, you must install the oil separator within
5 minutes.

– Insert oil trap onto the pin bolts -arrows- and insert onto the
cylinder block.
– Remove the pin bolts again.

3. Crankcase ventilation 139

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Release the screws in the order -1...9-.

Continued installation is carried out in the reverse order. When
installing, note the following:
– Install the noise insulation ⇒ Body Work; Rep. gr. 66 .
Tightening torques
Component Nm
Screw for coolant pump 8 Nm
Screw for oil separator 9 Nm
ProCarManuals.com

140 Rep. gr.17 - Lubrication

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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4 Oil filter, oil pressure switch

⇒ “4.1 Summary of components - oil filter/oil pressure switch”,
page 141
⇒ “4.2 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 141
⇒ “4.3 Checking oil pressure and oil pressure switch”,
page 142
⇒ “4.4 Removing and installing oil filter housing”, page 143

4.1 Summary of components - oil filter/oil pressure switch

1 - Oil filter
❑ pay attention to note
⇒ page 126
❑ removing and installing
⇒ Maintenance ; Book‐
let Octavia III
❑ 20 Nm
2 - Oil pressure switch for re‐
duced oil pressure - F378-
ProCarManuals.com

❑ replace after removal

❑ Switching pressure
0.03 ... 0.06 MPa (0.3…
0.6 bar)
❑ Insulation green
❑ check
⇒ “4.3 Checking oil
pressure and oil pres‐
sure switch”, page 142
❑ installing and removing
⇒ “4.2 Removing and
installing oil pressure
switch for reduced oil
pressure F378 ”,
page 141
❑ 20 Nm
3 - Sealing ring
❑ not available separately

4.2 Removing and installing oil pressure

switch for reduced oil pressure - F378-
Special tools and workshop equipment required
♦ Flexible-head wrench SW 24 - T40175-

4. Oil filter, oil pressure switch 141

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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Removing
– Pull solenoid valve 1 for activated charcoal filter - N80- -3- off
the intake manifold and press downwards slightly.
– Separate electrical plug connection -2-.

Note

Place a cloth below to absorb leaking engine oil.

– Unscrew the oil pressure switch for reduced oil pressure -

F378- -1-.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

♦ Renew seal.
♦ To prevent larger quantities of oil from flowing out the new oil
pressure switch for reduced oil pressure - F378- must be in‐
serted into the bore immediately.
ProCarManuals.com

– Checking the oil level ⇒ Maintenance ; Booklet Octavia III .

Tightening torque
Component Nm
Oil pressure switch for reduced oil pressure 20 Nm

4.3 Checking oil pressure and oil pressure

switch
Special tools and workshop equipment required
♦ Oil pressure tester - V.A.G 1342-
♦ Measuring tool set , e. g. -V.A.G 1594 C-
♦ Voltage tester , e. g. -V.A.G 1527 B-
Work procedure
• Oil level OK, test ⇒ Maintenance ; Booklet Octavia III .
• Engine oil temperature at least 80 °C (radiator fan must have
run once).
– Remove oil pressure switch for reduced oil pressure - F378-
⇒ “4.2 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 141 .
– Screw oil pressure switch tester - V.A.G 1342- onto the oil
pressure switch bore.
– Screw oil pressure switch for reduced oil pressure - F378- into
the oil pressure tester - V.A.G 1342- bore to close it.
– Start the engine.
• Oil pressure in idle: at least 0.06 MPa (0.6 bar)
• Oil pressure at 2000 rpm: at least 0.15 MPa (1.5 bar)
• Oil pressure at 4500 rpm: at least 0.28 MPa (2.8 bar)

142 Rep. gr.17 - Lubrication

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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Note

Mechanical damage such as bearing damage may also be the

cause of oil pressure that is too low.

If no fault is found:
– Replace oil pump
⇒ “1.3 Removing and installing oil pump”, page 131 .
Check oil pressure switch for reduced oil pressure - F378- :
– Switch off engine.
– Connect brown wire of oil testing device - V.A.G 1342- to earth
(-).
– Connect the voltage tester - V.A.G 1527 B- with adapter set
from measuring tool set - V.A.G 1594 C- to the battery positive
pole (+) and connect oil pressure switch for reduced oil pres‐
sure - F378- (brown).
• The LED must not light up.
– If the LED is illuminated the oil pressure switch for reduced oil
pressure - F378- must be replaced.
If the LED does not light up:
ProCarManuals.com

– Start engine, at an overpressure of 0.03 .... 0.06 MPa

(0.3...0.6 bar) the LED must light up, otherwise renew oil pres‐
sure switch
⇒ “4.2 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 141 .

4.4 Removing and installing oil filter housing

Special tools and workshop equipment required
♦ Oil filter tool - 3417-
Removing
– Drain engine oil ⇒ Maintenance ; Booklet Octavia III .
– Remove oil filter -arrow- with oil filter tool - 3417- .
Install
– Fill oil filter with engine oil and moisten the gasket with oil.
– Tighten the oil filter using the oil filter tool - 3417- , tightening
torque 20 Nm.
– Fill engine oil ⇒ Maintenance ; Booklet Octavia III .

4. Oil filter, oil pressure switch 143

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19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Coolant hose schematic diagram”, page 144
⇒ “1.2 Draining and filling coolant”, page 147
⇒ “1.3 Checking cooling system for leaks”, page 151

1.1 Coolant hose schematic diagram

⇒ “1.1.1 For vehicles up to 05.2013”, page 144
⇒ “1.1.2 For vehicles as of 06.2013”, page 146

1.1.1 For vehicles up to 05.2013

Note

♦ Red = small coolant circuit.

♦ Blue = large coolant circuit.
♦ Green = charge-air coolant circuit
ProCarManuals.com

♦ brown= auxiliary heating coolant circuit (vehicles with auxiliary

heating only)
♦ The arrows point in the coolant flow direction.

144 Rep. gr.19 - Cooling

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1 - Coolant expansion tank

2 - Screw cap
❑ for coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 153
3 - Cylinder head and cylinder
block
❑ fill with fresh coolant af‐
ter replacing
4 - Exhaust gas turbocharger
5 - Integrated exhaust manifold
6 - Heat exchanger of heating
system
❑ fill with fresh coolant af‐
ter replacing
7 - Coolant temperature send‐
er - G62-
8 - Coolant pump
❑ with thermostat housing
ProCarManuals.com

9 - Engine oil cooler

10 - Coolant temperature
sender at radiator outlet - G83-
11 - Coolant radiator
❑ fill with fresh coolant af‐
ter replacing
12 - Choke
❑ 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!)
13 - Non-return valve
14 - Charge air cooler pump - V188-
15 - Cooler for charge air circuit
❑ fill with fresh coolant after replacing
16 - Charge-air cooler in intake manifold
❑ fill with fresh coolant after replacing
17 - Auxiliary heating
❑ for vehicles with auxiliary heating only

1. Cooling system, coolant 145

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1.1.2 For vehicles as of 06.2013

Note

♦ Red = small coolant circuit.

♦ Blue = large coolant circuit.
♦ Green = charge-air coolant circuit
♦ brown= auxiliary heating coolant circuit (vehicles with auxiliary
heating only)
♦ The arrows point in the coolant flow direction.

1 - Coolant expansion tank

2 - Screw cap
❑ for coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 153
3 - Cylinder head and cylinder
block
ProCarManuals.com

❑ fill with fresh coolant af‐

ter replacing
4 - Exhaust gas turbocharger
5 - Integrated exhaust manifold
6 - Heat exchanger of heating
system
❑ fill with fresh coolant af‐
ter replacing
7 - Coolant temperature send‐
er - G62-
8 - Coolant pump
❑ with thermostat housing
9 - Engine oil cooler
10 - Coolant temperature
sender at radiator outlet - G83-
11 - Coolant radiator
❑ fill with fresh coolant af‐
ter replacing
12 - Choke
❑ 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!)
13 - Non-return valve
14 - Charge air cooler pump - V188-
15 - Cooler for charge air circuit
❑ fill with fresh coolant after replacing
16 - Charge-air cooler in intake manifold
❑ fill with fresh coolant after replacing

146 Rep. gr.19 - Cooling

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17 - Auxiliary heating
❑ for vehicles with auxiliary heating only

1.2 Draining and filling coolant

Special tools and workshop equipment required
♦ Refractometer
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Pliers for spring strap clamps
♦ Cooling system charge unit e.g. -VAS 6096-
♦ Adapter for cooling system testing device, e.g. - V.A.G 1274/8-
♦ Protective goggles and gloves

Note

Depending on the vehicle version, 3 radiator versions are instal‐

led.

♦ Radiator Version 1
ProCarManuals.com

⇒ “4.1 Radiator version 1 - Summary of components”,

page 173 .
♦ Radiator Version 2
⇒ “4.2 Radiator version 2 - Summary of components”,
page 175 .
♦ Radiator Version 3
⇒ “4.3 Radiator version 3 - Summary of components”,
page 176 .
Draining

Note

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

disposal.
♦ Observe the disposal instructions.

– Open cap -arrow- for coolant expansion tank.

– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
– Place a catch pan for workshop crane - VAS 6208- under‐
neath.

1. Cooling system, coolant 147

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– Disconnect electrical plug connection -2- at the coolant tem‐

perature sender at the radiator outlet - G83- -3-.
– Raise holding clamp -1-, remove bottom left coolant hose from
radiator fan for coolant, allow coolant to drain.
Vehicles with radiator version 1

– Loosen holding clamp -arrow-, remove bottom right coolant

hose from charge air circuit cooler, allow remaining coolant to
drain.
Vehicles with radiator versions 2 and 3:
ProCarManuals.com

– Raise holding clamp -2-, remove coolant hose from charge air
circuit cooler, allow remaining coolant to drain.
Filling up
Select the appropriate coolant additive from the ⇒ Electronic
catalogue of original parts“ETKA” .
– In a clean reservoir mix drinking water and coolant additive in
the specified mixing ratio ⇒ Maintenance ; Booklet Octavia
III .
– Connect coolant hose with quick coupling to radiator bottom
left ⇒ page 174 .
Vehicles with radiator version 1

– Connect coolant hose bottom right to radiator -arrow-.

Vehicles with radiator versions 2 and 3:

148 Rep. gr.19 - Cooling

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– Connect coolant hose bottom right to charge air circuit cooler

-2-.
Continued for all vehicles

– Fill up the coolant -VAS 6096- with at least 10 litres of pre-

mixed coolant mixed to the correct ratio ⇒ Maintenance ;
Booklet Octavia III .
– For example, screw the adapter for cooling system testing de‐
vice - V.A.G 1274/8- to the coolant expansion tank.
– Connect the cooling system charge unit - VAS 6096- with the
adapter -V.A.G 1274/8- .
– Lead the air hose -1- into a small container -2-.
ProCarManuals.com

Note

A small amount of coolant, which is entrained with the exhaust

air, must be collected.

– Close the valves -A- and -B-, while doing so turn the lever at
right angles to the direction of flow.
– Connect hose -3- to compressed air.
• Pressure: 0.6 -1 MPa (6…10 bar) overpressure.

1. Cooling system, coolant 149

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– Open the valve -B-, while doing so turn the lever in the direction
of flow.
• Vacuum is generated in the cooling system by the suction jet
pump. The display instrument pointer must be in the green
area.
– In addition, briefly open the valve -A- and turn the lever in the
direction of flow, so that the hose of the coolant expansion
bottle is filled -VAS 6096- with coolant.
– Close the valve -A- again.
– Leave the valve -B- open a further 2 minutes.
• A vacuum pump is created in the cooling system by the vac‐
uum pump; the display instrument pointer must remain in the
green area.
– Close the valve -B-.
• The display instrument pointer must remain unaffected in the
green area. The vacuum in the cooling system is now sufficient
for subsequent filling.

Note

♦ If the pointer is below the green area, repeat the process.

ProCarManuals.com

♦ If the vacuum drops, check the cooling system for leak points.

– Disconnect pneumatic hose.

– Open valve -A-.
• The vacuum pump in the cooling system draws the coolant out
of the coolant reservoir -VAS 6096- and fills the cooling sys‐
tem.
– Remove the cooling system charge unit - VAS 6096- from the
coolant expansion tank.

– Fill up coolant up to “Max” marking.

– Install the noise insulation ⇒ Body Work; Rep. gr. 66 .
For vehicles with auxiliary heating
– Switch on auxiliary heating for approximately 30 seconds.
Continued for all vehicles
– Set temperature to “HI”.
– Switch off AC compressor. Press AC button to do so.
• The LED in the button must not illuminate.
– Start engine and run for not more than 2 minutes at 1500 rpm.
– With the engine running, fill coolant up to the overflow hole on
the coolant expansion tank.
– Tighten cap for coolant expansion tank tighten until it clicks
into place.
– Run engine at idling speed until the two large coolant hoses
at the radiator are hot.
– Switch off engine and allow it to cool down.

150 Rep. gr.19 - Cooling

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– Check coolant level.

• If the engine is cold the coolant level must be between the
“Min” and “Max” marking.
• When the engine is at operating temperature the coolant level
may be at the “Max” marking.
– If necessary, top up with coolant.

1.3 Checking cooling system for leaks

⇒ “1.3.1 Checking with the cooling system testing device V.A.G
1274 ”, page 151
⇒ “1.3.2 Checking with the cooling system testing device V.A.G
1274 B ”, page 152

1.3.1 Checking with the cooling system test‐

ing device - V.A.G 1274-
Special tools and workshop equipment required
ProCarManuals.com

♦ Cooling system testing device , e.g. -V.A.G 1274-

♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/9-
Test prerequisite
• Engine is at operating temperature.
Test procedure

WARNING

Hot steam may escape when the coolant expansion reservoir

is opened. Wear eye protection and protective clothing to avoid
eye injuries and scalding. Cover the cap with a cloth and open
carefully.

– Open cap -arrow- for coolant expansion tank.

1. Cooling system, coolant 151

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

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

– Fit the cooling system testing device - V.A.G 1274- with adapt‐
er - V.A.G 1274/9- onto the cap.
– Operate the handpump.
• The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).
If the pressure relief valve does not open:
– Renew cap.
ProCarManuals.com

1.3.2 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 for cooling system testing device , e.g. -V.A.G 1274/8-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/9-
Work procedure
• Engine must be warm.
– Open cap -arrow- for coolant expansion tank.

WARNING

There is risk of injury due to hot steam and hot coolant.

♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.

152 Rep. gr.19 - Cooling

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

adapter -V.A.G 1274/8- onto the coolant expansion tank.
– Using the hand pump of the testing device generate an over‐
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- and hold it pressed
until the pressure gauge indicates the value »0«.

– If the pressure drops determine leak positions and repair.

Check pressure relief valve in cap.

– Fit the cooling system testing device - V.A.G 1274 B- with
adapter -V.A.G 1274/9- onto the cap.
– Build up overpressure using hand pump on cooling system
ProCarManuals.com

tester.
♦ The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).

1. Cooling system, coolant 153

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2 Coolant pump, regulation of cooling

system
⇒ “2.1 Summary of components - coolant pump/coolant thermo‐
stat”, page 154
⇒ “2.2 Summary of components - electric coolant pump”,
page 157
⇒ “2.3 Summary of components - coolant temperature sender”,
page 158
⇒ “2.4 Removing and installing coolant pump”, page 158
⇒ “2.5 Removing and installing toothed belt pulley for coolant
pump”, page 162
⇒ “2.6 Removing and installing electric coolant pump”,
page 163
⇒ “2.7 Removing and installing thermostat”, page 164
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 167
⇒ “2.9 Removing and installing coolant temperature sender at
radiator outlet G83 ”, page 168

2.1 Summary of components - coolant pump/coolant thermostat

ProCarManuals.com

154 Rep. gr.19 - Cooling

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1 - Thermostat housing
❑ installing and removing
⇒ “2.7.2 Removing and
installing thermostat for
large coolant circuit”,
page 167
❑ Observe tightening se‐
quence when tightening
to coolant pump
⇒ “2.4 Removing and in‐
stalling coolant pump”,
page 158 .
2 - Thermostat
❑ For large coolant circuit
❑ Start of opening approx.
105 ℃
❑ different versions ⇒
Electronic Catalogue of
Original Parts“ETKA”
❑ installing and removing
⇒ “2.7.2 Removing and
installing thermostat for
large coolant circuit”,
page 167
ProCarManuals.com

3 - Gasket
❑ replace after removal
❑ Observe proper seating
of gasket
❑ before installing, slightly
moisten with coolant
4 - Coolant pump
❑ installing and removing
⇒ “2.4 Removing and in‐
stalling coolant pump”,
page 158
❑ Replace toothed belt when changing coolant pump
5 - Bolt
❑ order of tightening ⇒ page 156
❑ 8 Nm
6 - Gasket
❑ replace after removal
❑ Observe proper seating of gasket
❑ before installing, slightly moisten with coolant
7 - Toothed belt guard
❑ For coolant pump toothed belt
8 - Bolt
❑ replace after removal
❑ 20 Nm + torque a further 90° (1/4 turn)

9 - Toothed belt
❑ Replace when changing coolant pump
❑ For coolant pump drive
❑ installing and removing ⇒ “2.4 Removing and installing coolant pump”, page 158
10 - Toothed belt pulley
❑ For coolant pump drive

2. Coolant pump, regulation of cooling system 155

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❑ installing and removing
⇒ “2.5 Removing and installing toothed belt pulley for coolant pump”, page 162
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ order of tightening ⇒ page 157
❑ 7 Nm
13 - Cover
❑ for coolant regulator
14 - Gasket
❑ replace after removal
❑ before installing, slightly moisten with coolant
15 - Thermostat
❑ For small coolant circuit
❑ Start of opening approx. 87 °C
❑ installing and removing
⇒ “2.7.1 Removing and installing thermostat for small coolant circuit”, page 164
❑ Fitting position ⇒ page 156
16 - Screw
ProCarManuals.com

❑ Tightening torque and tightening order ⇒ page 161

Installation position of thermostat for large coolant circuit

• Must be fitted with the centring pin into guide -arrow- on cool‐
ant pump housing.

Tightening sequence thermostat housing at coolant pump - tight‐

ening torque and tightening sequence

Note

Self-cutting screws must be positioned by hand in such a way that

they find the old thread turn. Then tighten the screw to torque.

– Tighten screws in the sequence -A…F- to 8 Nm.

156 Rep. gr.19 - Cooling

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Tightening sequence cover for coolant thermostat at the coolant

thermostat housing - Tightening torque

Note

Self-cutting screws must be positioned by hand in such a way that

they find the old thread turn. Then tighten the screw to torque.

– Tighten cover screws -1- in the sequence -A…D- to 7 Nm.

2.2 Summary of components - electric coolant pump

1 - Charge air cooler pump -

V188-
❑ With holder
❑ installing and removing
⇒ “2.6 Removing and in‐
stalling electric coolant
pump”, page 163
2 - Coolant hose
ProCarManuals.com

3 - Bolt
❑ 8 Nm
4 - Coolant hose

2. Coolant pump, regulation of cooling system 157

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2.3 Summary of components - coolant temperature sender

1 - O-ring
❑ replace after removal
2 - Coolant temperature send‐
er at radiator outlet - G83-
❑ installing and removing
⇒ “2.9 Removing and
installing coolant tem‐
perature sender at radi‐
ator outlet G83 ”,
page 168
3 - Support ring
4 - O-ring
❑ replace after removal
5 - Coolant temperature send‐
er - G62-
❑ installing and removing
⇒ “2.8 Removing and in‐
stalling coolant temper‐
ature sender G62 ”,
page 167
ProCarManuals.com

6 - Bolt
❑ 8 Nm
7 - Retaining clip
❑ Check for secure seat‐
ing

2.4 Removing and installing coolant pump

Special tools and workshop equipment required
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Pliers for spring strap clamps
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
♦ Release tool - T10527-
♦ Release tool - T10527/1-
Removing
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .

158 Rep. gr.19 - Cooling

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– Loosen hose clamps -1-, -2- and remove air guide pipes.
– Expose air guide hoses at the air guide pipe.

– Undo hose clamps -arrows-, remove air guide hose -1-.

ProCarManuals.com

– Disconnect plug -1- at charge pressure sender - GX26- .

– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

2. Coolant pump, regulation of cooling system 159

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– Press release buttons on the hose -1- to pull off the activated
charcoal filter.
– Unscrew screws -arrows- and remove hose for crankcase
ventilation.

– Expose wiring loom -arrows-.

– Unscrew screws -1-, -3- and remove toothed belt guard -2- for
coolant pump toothed belt.
ProCarManuals.com

– Expose electric wiring loom -1- and coolant hose -2-.

– Loosen hose clamps -arrows- and remove coolant hoses.

– Loosen the screws in the sequence -5- to -1- and unscrew

them.
– Remove coolant pump with toothed belt.
– Remove thermostat housing when coolant pump is being re‐
placed
⇒ “2.7.1 Removing and installing thermostat for small coolant
circuit”, page 164 .
Install

Note

♦ Replace gaskets -arrows-.

♦ Remove toothed belt when coolant pump is being replaced.
♦ Secure hose connections with hose clamps which comply with
the series design ⇒ Electronic Catalogue of Original Parts“ET‐
KA” .

160 Rep. gr.19 - Cooling

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– Ensure proper seating of gaskets -arrows-.

– Moisten gasket for coolant pump with coolant.

Caution

Always adhere to the sequence of work steps given below

when installing the coolant pump.
This ensures that the toothed belt is correctly tensioned.
The following work steps must be carried out with the aid of a
2nd mechanic.

• Used toothed belts must always be replaced with new ones

when the coolant pump is being replaced.
– Place cylinder 1 to TDC
⇒ “2.3 Checking valve timing”, page 81
– Fit toothed belt centrally, move coolant pump to installation
position.
– Mount coolant pump on cylinder head with securing bolts.

– Initially tighten screws in the specified order:

ProCarManuals.com

Stage Screws Tightening torque

1st -1 … 5- by hand as far as the stop
2nd -1 … 5- 10 Nm
– Loosen all screws by 1 turn.

2. Coolant pump, regulation of cooling system 161

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– Fit torque wrench, e. g. - VAS 6583- with hexagon socket

SW10 insert -Pos. 6- to the coolant pump.
– Preload coolant pump with a 10 mm hexagon socket insert
-6- with extension and torque wrench e.g. - VAS 6583- to
30 Nm clockwise.
– Position the torque wrench - VAS 6583- vertically for better
handling.

Note

♦ Do not support torque wrench with the other hand.

♦ In order to avoid the belt tension being too high the torque
wrench must not be »put under excessive pressure«.

– Keep coolant pump pretensioned.

– At the same time, have a second mechanic pre-tighten the
fixing screws on the coolant pump clockwise in sequence from
right to left, beginning with screw -2-, -1- and -5- »3. Pretighten
stage« to 10 Nm.
– Then tighten the fixing screws to the »4th. stage«.
Stage Bolts Tightening torque
ProCarManuals.com

3rd -2-, -1-, -5- 10 Nm

4th -3-, -4-, -5-, -1-, 12 Nm
-2-
Continued installation is carried out in the reverse order. When
installing, note the following:
– Replenish coolant ⇒ page 151 .
Tightening torques
♦ ⇒ “1.1.2 Summary of components 2- exhaust gas turbocharger
”, page 222
♦ ⇒ “2.1 Summary of components - coolant pump/coolant ther‐
mostat”, page 154
♦ Battery tray ⇒ Electrical system; Rep. gr. 27

2.5 Removing and installing toothed belt

pulley for coolant pump
Special tools and workshop equipment required
♦ Counterholder - T10172- with adapters -T10172/2-
Removing
– Remove coolant pump
⇒ “2.4 Removing and installing coolant pump”, page 158 .

162 Rep. gr.19 - Cooling

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– Loosen screw -1-. Use counterholder - T10172- with adapter

-T10172/2- to do so.
– Unscrew screw, remove toothed belt pulley-2-.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

– Position toothed belt pulley:

• Grooves -1- and -2- in the camshaft are arranged asymmetri‐
cally.
• The recesses-arrows- in the toothed belt pulley are also ar‐
ranged asymmetrically.
– Place the toothed belt pulley on the camshaft so that the
asymmetrical grooves are exactly in the centre of the recess‐
es.
– Install coolant pump
⇒ “2.4 Removing and installing coolant pump”, page 158 .
ProCarManuals.com

Tightening torque
Component Nm
Screw for belt pulley 20 Nm + torque a fur‐
ther 90° (1/4 turn)

2.6 Removing and installing electric coolant

pump
⇒ “2.6.1 Removing and installing charge air cooler pump V188 ”,
page 163

2.6.1 Removing and installing charge air cool‐

er pump - V188-
Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm - MP7-602 (3094)-
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Pliers for spring strap clamps

2. Coolant pump, regulation of cooling system 163

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Removing
– Open cap -arrow- for coolant expansion tank.

WARNING

There is risk of injury due to hot steam and hot coolant.

♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.

– Remove the sound dampening system ⇒ Body Work; Rep.

gr. 66 .

– Separate electrical plug connection -1-.

– Place a catch pan for workshop crane - VAS 6208- under‐
neath.
– At the charge air cooler pump - V188- disconnect coolant ho‐
ses with hose clamps -3094- .
– Loosen hose clamps -3- and remove coolant hoses.
ProCarManuals.com

– Undo screw -2- and remove charge air cooler pump - V188- .
Installing
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:

Note

Secure all hose connections with hose clamps which comply with
the series design ⇒ Electronic Catalogue of Original Parts“ET‐
KA.” .

– Install the noise insulation ⇒ Body Work; Rep. gr. 66 .

– Check coolant level ⇒ page 151 .
Tightening torque
Component Nm
Screw for pump 8 Nm

2.7 Removing and installing thermostat

⇒ “2.7.1 Removing and installing thermostat for small coolant cir‐
cuit”, page 164
⇒ “2.7.2 Removing and installing thermostat for large coolant cir‐
cuit”, page 167

2.7.1 Removing and installing thermostat for

small coolant circuit
Special tools and workshop equipment required
♦ Pliers for spring strap clamps
♦ Key - T10508-
♦ Release tool - T10527-

164 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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♦ Release tool - T10527/1-

Removing
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .
– Expose air guide hoses at the air guide pipe.
– Undo hose clamps -arrows-, remove air guide hose -1-.

– Disconnect plug -1- at charge pressure sender - GX26- .

ProCarManuals.com

– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

2. Coolant pump, regulation of cooling system 165

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– Loosen hose clamp -4- and remove coolant hose -3-.

– Screw out screws -arrows- and remove cover -2- from ther‐
mostat housing -1-.

– Remove thermostat with spanner - T10508- .

– Light press the wrench - T10508- down, while doing so, turn
in the -direction of the arrow-.
Install
ProCarManuals.com

– Insert thermostat. Fit the centring pin in into the

guide-arrow-.

– Install thermostat with spanner - T10508- .

– Light press the wrench - T10508- down, while doing so, turn
in the -direction of the arrow- as far as it can go.
Installation is carried out in the reverse order. When installing,
observe the following:

Note

Replace gasket.

– Moisten gasket with coolant.

– Replenish coolant
⇒ “1.2 Draining and filling coolant”, page 147 .
Tightening torques
Component Nm
Thermostat cover screws on thermostat housing 7 Nm

166 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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2.7.2 Removing and installing thermostat for

large coolant circuit
Removing
– Remove coolant pump
⇒ “2.4 Removing and installing coolant pump”, page 158 .
– Release the screws in the order -F…A-.
– Remove coolant pump from coolant pump housing.

– Remove thermostat -2- from coolant pump -1-.

Install
Installation is carried out in the reverse order. When installing,
ProCarManuals.com

observe the following:

Note

Replace gasket.

– Moisten gasket with coolant.

– Position thermostat housing on coolant pump.

• The centring bolts on the thermostat must be inserted into the
guides -arrows- on the coolant pump.
– Tighten screws for thermostat housing ⇒ page 156 .
– Install coolant pump
⇒ “2.4 Removing and installing coolant pump”, page 158 .
– Replenish coolant
⇒ “1.2 Draining and filling coolant”, page 147 .
Tightening torque
♦ ⇒ Fig. ““Tightening sequence thermostat housing at coolant
pump - tightening torque and tightening sequence”“ ,
page 156

2.8 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.

2. Coolant pump, regulation of cooling system 167

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Briefly open the cap -arrow- for the coolant expansion reser‐
voir in order to remove the remaining pressure in the coolant
system, then close until it clicks into place.
– Disconnect plug connection from the coolant temperature
sender - G62- .

Note

Place a cloth below to catch any leaking coolant.

– Undo screw -1- and remove coolant temperature sender -

G62- Pos. -2-.

Note

♦ If the O-ring -3- with support ring -4- remains in the cylinder
head, lift out the O-ring with support ring using a wire.
♦ Insert new coolant temperature sender - G62- immediately in‐
to cylinder head in order to avoid loss of coolant.
ProCarManuals.com

Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

Renew O-ring.

– Check coolant level ⇒ page 151 .

Tightening torque
Component Nm
Screw of sender 8 Nm

2.9 Removing and installing coolant temper‐

ature sender at radiator outlet - G83-
Removing
• Engine cold.
– Briefly open the cap -arrow- for the coolant expansion reser‐
voir in order to remove the remaining pressure in the coolant
system, then close until it clicks into place.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .

168 Rep. gr.19 - Cooling

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– Separate electrical plug connection -2-.

Note

Place a cloth below to catch any leaking coolant.

– Pull off holding clamp -3- and take coolant temperature sender
on radiator outlet - G83- out of connection piece.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

♦ Renew O-ring.
♦ Insert new coolant temperature sender - G83- into the con‐
nection piece immediately in order to avoid loss of coolant.

– Remove front noise insulation ⇒ Body Work; Rep. gr. 66 .

– Check coolant level ⇒ page 151 .
ProCarManuals.com

2. Coolant pump, regulation of cooling system 169

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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3 Parts of cooling system engine side

⇒ “3.1 Summary of components”, page 170
⇒ “3.2 Removing and installing coolant pipe”, page 170

3.1 Summary of components

1 - Coolant hose
❑ to cooler for charge air
circuit
2 - Coolant pipe
❑ When removing using a
screwdriver, carefully
lever out of the catch
3 - Bolt
❑ 8 Nm
4 - Coolant hose
❑ from the expansion res‐
ervoir
5 - Coolant hose
ProCarManuals.com

❑ from coolant radiator

6 - Coolant line
7 - Coolant hose
8 - Coolant hose

Note

The arrows which are on the coolant pipes and the coolant hose
ends must stand opposite to each other.

3.2 Removing and installing coolant pipe

Special tools and workshop equipment required
♦ Hose clamps up to ∅ 25 mm - MP7-602 (3094)-
♦ Pliers for spring strap clamps

170 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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Removing

WARNING

Danger of scalding due to hot steam and hot coolant.

♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.

– Open cap -arrow- for coolant expansion tank.

ProCarManuals.com

– Disconnect coolant hoses at coolant pipe with hose clamps -

MP7-602 (3094)- .
– Loosen hose clamps -arrows- and remove coolant hoses.
– Removing the intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 241 .

– Place the intake manifold -1- on the work bench as shown.

– Use a wooden wedge -2- as a support for example.

3. Parts of cooling system engine side 171

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Using the screwdriver in the direction of arrow -2- carefully

press and at the same time raise the coolant pipe -4- in direc‐
tion of arrow -3- until it is released from the locking mechanism.

– Remove the coolant pipe -1- in -direction of arrow- upwards,

and release it from the locking mechanism -2-.
Installing
ProCarManuals.com

– Press the coolant pipe onto the bearings -1- and -2- until it
latches.
– By pulling in the opposite direction, check that both bearings
are locked.

Note

♦ Replace gaskets and O-rings.

♦ Secure all hose connection ends with spring-type clips that
comply with the series design ⇒ ETKA - Electronic Catalogue
of Original Parts .

Installation is carried out in the reverse order. When installing,

note the following:
– Check coolant level ⇒ page 151 .
Tightening torques
♦ ⇒ “3.1 Assembly overview - intake manifold”, page 240

172 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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4 Radiator and radiator fan

⇒ “4.1 Radiator version 1 - Summary of components”,
page 173
⇒ “4.2 Radiator version 2 - Summary of components”,
page 175
⇒ “4.3 Radiator version 3 - Summary of components”,
page 176
⇒ “4.4 Fan shroud with a radiator fan - Summary of components”,
page 178
⇒ “4.5 Fan shroud with two radiator fans - Summary of compo‐
nents”, page 179
⇒ “4.6 Removing and installing radiator”, page 179
⇒ “4.7 Removing and installing fan shroud for radiator fan”, page
182
⇒ “4.8 Removing and installing radiator fan V7 ”, page 184
⇒ “4.9 Removing and installing radiator fan 2 V177 ”, page 185

4.1 Radiator version 1 - Summary of components

ProCarManuals.com

1 - Coolant radiator
❑ installing and removing
⇒ “4.6 Removing and in‐
stalling radiator”,
page 179
❑ fill with fresh coolant af‐
ter replacing
2 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 174
3 - Retaining clip
4 - O-ring
❑ replace after removal
5 - Coolant temperature send‐
er at radiator outlet - G83-
❑ installing and removing
⇒ “2.9 Removing and
installing coolant tem‐
perature sender at radi‐
ator outlet G83 ”,
page 168
6 - O-ring
❑ replace after removal
7 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 174
8 - O-ring
❑ replace after removal
9 - Coolant hose
❑ to remove, raise the holding clamps

4. Radiator and radiator fan 173

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❑ connect ⇒ page 174
10 - Top radiator bearing
❑ If the fuse latches break, you will not need to replace the top radiator bearing.
❑ The fuse is replaced by a special screw ⇒ Electronic Catalogue of Original Parts“ETKA.”
11 - Cooler for charge air circuit
❑ installing and removing ⇒ “4.6 Removing and installing radiator”, page 179
12 - Condenser
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
13 - Bottom radiator bearing
14 - O-ring
❑ replace after removal
15 - Coolant hose
❑ to remove, raise the holding clamps
❑ connect ⇒ page 174
16 - O-ring
❑ replace after removal
ProCarManuals.com

Note

The arrows which are on the coolant pipes and the coolant hose
ends must stand opposite to each other.

Connect coolant hose with quick coupling

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Press coolant hose onto connection -1- until there is an audible
click.
– Press coolant hose down again and check by pulling that the
plug-in connector is fully engaged.

174 Rep. gr.19 - Cooling

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4.2 Radiator version 2 - Summary of components

1 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 176
2 - O-ring
❑ replace after removal
3 - Radiator fan for coolant and
for charge air circuit
❑ removing and installing
⇒ “4.6 Removing and in‐
stalling radiator”,
page 179
❑ fill with fresh coolant af‐
ter replacing
4 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 176
5 - O-ring
ProCarManuals.com

❑ replace after removal

6 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 176
7 - O-ring
❑ replace after removal
8 - Condenser
❑ removing and installing
⇒ Heating, Air Condi‐
tioning; Rep. gr. 87
9 - Top radiator bearing
❑ If the fuse latches break, you will not need to replace the top radiator bearing.
❑ The fuse is replaced by a special screw ⇒ Electronic Catalogue of Original Parts“ETKA.”
10 - Bottom radiator bearing
11 - O-ring
❑ replace after removal
12 - Coolant hose
❑ to remove, raise holding clamps
❑ connect ⇒ page 176

4. Radiator and radiator fan 175

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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Note

The arrows which are on the coolant pipes and the coolant hose
ends must stand opposite to each other.

Connect coolant hose with quick coupling

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Press coolant hose onto connection -1- until there is an audible
click.
– Press coolant hose down again and check by pulling that the
plug-in connector is fully engaged.

4.3 Radiator version 3 - Summary of components

1 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 177
ProCarManuals.com

2 - O-ring
❑ replace after removal
3 - Cooler for charge air circuit
❑ installing and removing
⇒ “4.6 Removing and in‐
stalling radiator”,
page 179
4 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 177
5 - O-ring
❑ replace after removal
6 - Coolant hose
❑ to remove, raise the
holding clamps
❑ connect ⇒ page 177
7 - O-ring
❑ replace after removal
8 - Coolant radiator
❑ installing and removing
⇒ “4.6 Removing and in‐
stalling radiator”,
page 179
❑ fill with fresh coolant af‐
ter replacing
9 - Condenser
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
10 - Top radiator bearing
❑ If the fuse latches break, you will not need to replace the top radiator bearing.
❑ The fuse is replaced by a special screw ⇒ Electronic Catalogue of Original Parts“ETKA.”

176 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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11 - Bottom radiator bearing

12 - O-ring
❑ replace after removal
13 - Coolant hose
❑ to remove, raise holding clamps
❑ connect ⇒ page 177

Note

The arrows which are on the coolant pipes and the coolant hose
ends must stand opposite to each other.

Connect coolant hose with quick coupling

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Press coolant hose onto connection -1- until there is an audible
click.
– Press coolant hose down again and check by pulling that the
plug-in connector is fully engaged.
ProCarManuals.com

4. Radiator and radiator fan 177

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1.2/63; 77 kW TSI engine - Edition 11.2014

4.4 Fan shroud with a radiator fan - Summary of components

1 - Bolt
❑ 5 Nm
2 - Fan shroud
❑ installing and removing
⇒ “4.7 Removing and in‐
stalling fan shroud for
radiator fan”, page 182
3 - Radiator fan - V7-
❑ installing and removing
⇒ “4.8 Removing and
installing radiator fan V7
”, page 184
ProCarManuals.com

178 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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4.5 Fan shroud with two radiator fans - Summary of components

1 - Bolt
❑ 5 Nm
2 - Fan shroud
❑ installing and removing
⇒ “4.7 Removing and in‐
stalling fan shroud for
radiator fan”, page 182
3 - Bolt
❑ 5 Nm
4 - Radiator fan - V7-
❑ installing and removing
⇒ “4.8 Removing and
installing radiator fan V7
”, page 184
5 - Radiator fan 2 - V177-
❑ installing and removing
⇒ “4.9 Removing and
installing radiator fan 2
V177 ”, page 185
ProCarManuals.com

4.6 Removing and installing radiator

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

WARNING

There is risk of injury from radiator fans starting up automati‐

cally.
♦ Before carrying out work in the fan shroud area, discon‐
nect the electrical plug connections.

4. Radiator and radiator fan 179

 Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014

Note

♦ Depending on the vehicle version, 3 radiator versions are in‐

stalled.
♦ Coolant radiator and charge air circulation cooler are removed
together.

♦ Radiator Version 1
⇒ “4.1 Radiator version 1 - Summary of components”,
page 173 .
♦ Radiator Version 2
⇒ “4.2 Radiator version 2 - Summary of components”,
page 175 .
♦ Radiator Version 3
⇒ “4.3 Radiator version 3 - Summary of components”,
page 176 .
Removing
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .
– Removing fan shroud
⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
ProCarManuals.com

– Remove front bumper ⇒ Body Work; Rep. gr. 63 .

Vehicles with radiator version 1
– Raise holding clamp -arrow- and disconnect coolant hose right
above radiator for charge air circuit.
Vehicles with radiator versions 2 and 3:

– Raise holding clamp -1- and remove top right coolant hose
from charge air circuit cooler (bottom right coolant hose al‐
ready removed).
Continued for all vehicles

180 Rep. gr.19 - Cooling

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– Raise holding clamp -arrow- and remove top left coolant hose
from radiator.

– Press the catches for the top radiator bearing -arrows- at the
same time, e..g with screwdrivers, and unclip the bearing on
both sides.
– Partially tilt cooler into the engine compartment.
ProCarManuals.com

Note

If the fuse latches break, you will not need to replace the top ra‐
diator bearing -1- . The fuse is replaced by a special screw -3- ⇒
Electronic Catalogue of Original Parts“ETKA” .

– Unlock the left and right catches from the cooler -1- arrow
-A- and raise the condenser.
– Press the radiator downwards until the radiator bearing de‐
flects at the bottom, to do so, unhook the condenser -2- from
the radiator -1-.
– Strap capacitor to the lock support.
Vehicles with radiator version 1
– Remove the cooler for the charge air circuit from the vehicle
together with the cooler for coolant.

4. Radiator and radiator fan 181

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Press left and right radiator locking lugs simultaneously

-arrow- and remove coolant radiator from the charge air circuit
radiator.
Vehicles with radiator versions 2 and 3:
– Remove the cooler for the charge air circuit from the vehicle
together with the charge air circuit cooler.
Vehicles with radiator version 3

– Unlock catches for charge air circuit -1- -arrows A- from the
radiator fan for coolant -2-.
– Tilt the charge air circuit cooler -1- in direction of arrow -B- and
suspend in the direction of arrow -C-.
ProCarManuals.com

Installing
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:

Note

♦ When there is light pressure on the fins

⇒ “3.5 Assembly of radiators and capacitors”, page 8 .
♦ Replace O-rings.

– Install front bumper ⇒ Body Work; Rep. gr. 63 .

– Install fan shroud
⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
– Connect coolant hoses with quick coupling ⇒ page 174 .
– Replenish coolant ⇒ page 148 .

Note

If the radiator has been replaced, all the coolant must be changed.

4.7 Removing and installing fan shroud for

radiator fan
Special tools and workshop equipment required
♦ Catch pan for workshop crane , e.g. -VAS 6208-

182 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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WARNING

There is risk of injury from radiator fans starting up automati‐

cally.
♦ Before carrying out work in the fan shroud area, discon‐
nect the electrical plug connections.
♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.

Note

Depending on the vehicle version, 3 radiator versions are instal‐

led.

♦ Radiator Version 1
⇒ “4.1 Radiator version 1 - Summary of components”,
page 173 .
♦ Radiator Version 2
ProCarManuals.com

⇒ “4.2 Radiator version 2 - Summary of components”,

page 175 .
♦ Radiator Version 3
⇒ “4.3 Radiator version 3 - Summary of components”,
page 176 .
Removing
– Loosen hose clamp -1- and remove air guide hose.
– Release screw left and right arrow -2-.
– Unclip and remove the air guide on the lock carrier.
Vehicles with radiator versions 1 and 2
– Place a catch pan for workshop crane - VAS 6208- under‐
neath.

– Loosen holding clamp -arrow- and remove bottom right cool‐

ant hose from charge air circuit cooler, allowing coolant to
drain.
Continued for all vehicles

4. Radiator and radiator fan 183

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Remove plug -1- for radiator fan, for this purpose slide screw
clamp backwards arrow -A- and press release button down.
– Press locking lugs for fan shroud left and right simultaneously
-arrow B- and remove fan shroud upwards from the radiator.
Vehicles with radiator version 3
– Partially move the fan shroud to the right and remove upwards
out of the vehicle.
Vehicles with radiator versions 1 and 2
– Remove the fan shroud downwards out of the vehicle.
Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Electrical connections and proper routing ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
– Replenish coolant ⇒ page 151 .
Tightening torque
Component Nm
Screw for cover on air guide 2 Nm
ProCarManuals.com

4.8 Removing and installing radiator fan -

V7-

WARNING

Risk of injury due to radiator fans starting up automatically.

♦ Before carrying out work in the fan shroud area, discon‐
nect the electrical plug connections.

Removing

Note

All cable straps should be fastened again in the same place when
installing.

– Removing fan shroud

⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .

184 Rep. gr.19 - Cooling

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Disconnect electrical plug connections.

– Release screws -arrows- and remove radiator fan - V7- .
Install
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
– Install fan shroud
⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
Tightening torque
Component Nm
Fan screw 5 Nm

4.9 Removing and installing radiator fan 2 -

V177-

WARNING

Risk of injury due to radiator fans starting up automatically.

♦ Before carrying out work in the fan shroud area, discon‐
ProCarManuals.com

nect the electrical plug connections.

Removing

Note

All cable straps should be fastened again in the same place when
installing.

– Removing fan shroud

⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
– Disconnect plug connection -arrow-.
– Remove screws -2- and remove the radiator fan - V177- .
Installing
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
– Install fan shroud
⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
Tightening torque
Component Nm
Fan screw 5 Nm

4. Radiator and radiator fan 185

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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20 – Fuel supply system

1 Fuel tank and fuel delivery unit
⇒ “1.1 Fuel tank - Summary of components”, page 186
⇒ “1.2 Extract fuel from the fuel tank”, page 189
⇒ “1.3 Removing and installing the fuel tank”, page 195
⇒ “1.4 Summary of components - fuel delivery unit and sender for
fuel gauge display”, page 200
⇒ “1.5 Fuel delivery unit with sender for fuel gauge display”, page
201
⇒ “1.6 Removing and installing the sender for fuel gauge display
G ”, page 204
⇒ “1.7 Checking fuel pump”, page 205
⇒ “1.8 Removing and installing fuel pump control unit J538 ”, page
210

Note
ProCarManuals.com

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

type clips ⇒ Electronic catalogue of original parts“ETKA” .
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Fuel hoses can be connected further with push-fit couplings
⇒ “2 Separating push-on couplings”, page 211 .

1.1 Fuel tank - Summary of components

186 Rep. gr.20 - Fuel supply system

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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1 - Screw cap
❑ screw in until there is an
audible click
❑ with securing suspen‐
ded to prevent any loss
at tank fuel filler flap
2 - Earth connection
❑ for fuel filler neck
❑ for discharging the elec‐
trostatic charge
⇒ page 188
3 - Bolt
❑ replace after removal
❑ 8 Nm
4 - Lock ring
❑ loosen and tighten up
with spanner -T30101
(3087)-
❑ 110 Nm
5 - Sealing ring
❑ replace after removal
ProCarManuals.com

❑ install when dry

6 - Fuel delivery unit
❑ with integrated fuel filter,
the fuel filter cannot be
replaced individually
❑ with sender for fuel
gauge display - G-
❑ Summary of compo‐
nents
⇒ “1.4 Summary of com‐
ponents - fuel delivery
unit and sender for fuel
gauge display”, page 200
❑ installing and removing ⇒ “1.5 Fuel delivery unit with sender for fuel gauge display”, page 201
❑ Checking electric fuel pump ⇒ Vehicle diagnostic tester
❑ Fitting position ⇒ page 189
❑ Connect fuel lines ⇒ page 189
❑ Removing and installing fuel gauge sender - G-
⇒ “1.6 Removing and installing the sender for fuel gauge display G ”, page 204 .
7 - Fuel tank
❑ installing and removing ⇒ “1.3 Removing and installing the fuel tank”, page 195
8 - Heat shield
❑ for fuel tank
9 - Circlip
10 - Tensioning strap
❑ Mark installation position before installation
❑ Ensure proper seating
11 - Bolt
❑ replace after removal
❑ 20 Nm + torque a further 90° (1/4 turn)

1. Fuel tank and fuel delivery unit 187

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12 - Mounting bracket
❑ For fuel pump control unit -J538-
❑ Removing and installing fuel pump control unit -J538-
⇒ “1.8 Removing and installing fuel pump control unit J538 ”, page 210
13 - Support
❑ for vehicles with auxiliary heating
❑ for dosing pump -V54-
❑ pay attention to correct fit of the dosing pump in the holder
14 - Fuel feed line
❑ to the engine
❑ pushed into the fuel tank
❑ do not kink
❑ Fit so that it can be heard clicking into place
❑ Unlock the quick couplings and fit together ⇒ “2 Separating push-on couplings”, page 211
15 - Fuel line
❑ for vehicles with auxiliary heating
❑ to the dosing pump -V54-
❑ do not kink
❑ Fitting position ⇒ Heating, Air Conditioning; Rep. gr. 82
❑ Check the quick coupling for firm seating by pulling in the opposite direction!
ProCarManuals.com

❑ Unlock the quick couplings and fit together ⇒ “2 Separating push-on couplings”, page 211
16 - Dosing pump -V54-
❑ for vehicles with auxiliary heating

Earth connection for fuel filler neck

– Connect earth connection as shown in the illustration.
– Ensure proper seating of plug connection.
♦ Plug -2- of the earth connection on the threaded ring -3- of the
fuel filler neck.
– Unhook contact peg -1- of the earth connection in the securing
bore on the fuel tank -4- and press in the distance sleeve -5-.

WARNING

Risk of explosion from electrostatic charge.

♦ After installing, use an ohmmeter to test the electrical con‐
nection of the plate ring on the fuel filler neck at a bare
point on the body.
♦ Specified value approximately 0 Ω.

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Fitting location of the fuel delivery unit

• The marking -2- at the fuel delivery unit closing flange -1- must
be located against arrow -3- at the fuel tank.

Connect the fuel lines to the fuel delivery unit.

1- Fuel feed line to the engine
2- Fuel line to the dosing pump -V54-
ProCarManuals.com

1.2 Extract fuel from the fuel tank

⇒ “1.2.1 Emptying fuel tank when fuel pump is intact”,
page 189
⇒ “1.2.2 Emptying fuel tank when the fuel pump is damaged when
more than 3/4 full”, page 192
⇒ “1.2.3 Emptying fuel tank when the fuel pump is damaged when
less than 3/4 full”, page 193

1.2.1 Emptying fuel tank when fuel pump is

intact
Special tools and workshop equipment required
♦ Fuel extraction device , e. g. -VAS 5190-
♦ Adapter for fuel extraction - VAS 5190 /3-
♦ Removal wedge - 3409-
♦ Remote control - V.A.G 1348/3A-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Adapter - VAS 5565-

Note

If the fuel extraction device - VAS 5190- is still fitted with an ex‐
traction hose with a fixed tip, replace it by the version with a screw-
type tip.

1. Fuel tank and fuel delivery unit 189

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– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .
– Screw fuel extraction adapter - VAS 5190 /2- from fuel extrac‐
tion adapter set - VAS 5190 /10- onto extraction hose.

Note

♦ Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 7 .

– Switch off ignition.

– Pull out the supply line -1- and catch the fuel that flows out with
a cleaning cloth. Unlock the quick coupling and disconnect
⇒ “2 Separating push-on couplings”, page 211 .
ProCarManuals.com

– Connect the fuel extraction device - VAS 5190- with the adapt‐
er for the fuel extraction - VAS 5190 /3- to the fuel feed line.

Caution

Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .

190 Rep. gr.20 - Fuel supply system

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– Unclip the cover -1- using the removal wedge - 3409- .

Vehicles with auxiliary heating

– Disconnect the plug connection of the dosing pump - V54-

-2-.
Continued for all vehicles
– Disconnect plug connection -1-.
– Open shut-off valve at the fuel extraction device - VAS 5190-
until the fuel tank is empty.
ProCarManuals.com

– Connect adapter - VAS 5565- to fuel delivery unit -1-.

– Connect remote control - V.A.G 1348/3A- to adapter -
VAS 5565- and to battery positive terminal in engine compart‐
ment.
– Connect connection -5- (yellow) from the adapter - VAS 5565-
with auxiliary line -3- from the measuring tool set - V.A.G 1594/
C- to the negative pole on the battery.

Note

This step is only intended to ensure that the fuel pump runs when
the engine is switched off.

– Open tank flap unit -2-.

– Clean the area around the fuel filler neck.
– Unscrew the cap -1- for the fuel filler neck.
– Operate the remote control - V.A.G 1348/3A- and the shut-off
cock on the fuel extraction device - VAS 5190- until the fuel
tank is emptied.

Caution

The fuel pump must not run »dry«.

1. Fuel tank and fuel delivery unit 191

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1.2.2 Emptying fuel tank when the fuel pump

is damaged when more than 3/4 full
Special tools and workshop equipment required
♦ Fuel extraction device , e. g. -VAS 5190-

Note

♦ Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 7 .

– In distance -a- from the end of the extraction hose make a

marking -arrow- on the hose.
– Use insulating tape for this purpose.
ProCarManuals.com

Rear axle Distance a in mm

Vehicles with torsion beam rear axle 1,010 mm

– Open tank flap unit -2-.

– Clean the area around the fuel filler neck.
– Unscrew the cap -1- for the fuel filler neck.

Caution

Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

192 Rep. gr.20 - Fuel supply system

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– Push the extraction hose of the fuel extraction device as far

into the fuel tank holder as necessary until the previously ap‐
plied marking -arrow- terminates with the filler neck -2-.
– Drain the fuel tank through the filler neck as much as possible.

Note

♦ In the fuel tank there is a flap -1- on the lower end of the filler
neck, which must not be damaged by the extraction hose of
the fuel extraction device . Therefore, the hose must only be
pushed in up to the previously made marking -arrow-.
♦ If the extraction hose becomes stuck to the check valve while
being pulled out, do not pull the extraction hose violently.
♦ If this is the case, remove the fuel delivery unit and hold the
check valve open by hand. Make sure that your arm does not
come in contact with fuel.

– Carefully pull out the extraction hose.

Note

When no more fuel is extracted, the tank is emptied just enough

ProCarManuals.com

for the sender flange to be opened without danger.

1.2.3 Emptying fuel tank when the fuel pump

is damaged when less than 3/4 full
Special tools and workshop equipment required
♦ Fuel extraction device , e. g. -VAS 5190-
♦ Wrench for union nut - T30101 (3087)-
♦ Removal wedge - 3409-

Note

♦ Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 7 .

– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .

– Unclip cover -1- for the right closing flange with the removal
wedge - 3409- on the retaining tabs -arrows-.

1. Fuel tank and fuel delivery unit 193

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– Unclip sealing grommet -1- downwards from the cover -2-.

– Guide the cover -2- backward at the electric wiring loom -3-.

– Unlock electrical plug connection -1- from closing flange, and

remove.
Vehicles with auxiliary heating
– Unlock plug connection -2- for the dosing pump - V54- and
remove it.
ProCarManuals.com

Continued for all vehicles

– Push up catch -2- in arrow direction -A-.
– To do so, reach between bottom plate and fuel tank with a
finger.
– At the same time, carefully pull the fuel pump control unit -
J538- -1- carefully at the electrical wiring loom -3- out of the
uptake in arrow direction -B-.
– Take out fuel pump control unit - J538- inwards between fuel
tank and bottom plate.
– Put fuel pump control unit - J538- to one side together with the
electrical wiring harness.

– Disconnect fuel line -1- at the closing flange. Unlock the quick
coupling and disconnect
⇒ “2 Separating push-on couplings”, page 211 .
Vehicles with auxiliary heating
– Remove fuel line -2- to the dosing pump - V54- for the auxiliary
heating at the closing flange.
– To do so, open the bottom clamp.
– Carefully pull out fuel line -2-.
Continued for all vehicles

Note

Ensure that the fuel delivery unit is not damaged when loosening
the lock ring of the holder on the flange.

194 Rep. gr.20 - Fuel supply system

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– Open locking ring using union nut wrench - T30101 (3087)- .

– Carefully lift out fuel delivery unit flange -3-.

– Remove gasket -1- and raise the fuel delivery unit flange
slightly higher.

Caution

Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

– Insert suction hose of fuel extractor - VAS 5190- as far as

ProCarManuals.com

possible into fuel tank.

– Extract fuel using the fuel extraction device - VAS 5190- .
If fuel tank needs only to be emptied, re-install the fuel delivery
unit
⇒ “1.5 Fuel delivery unit with sender for fuel gauge display”, page
201 .
Tightening torques
♦ ⇒ “1.4 Summary of components - fuel delivery unit and sender
for fuel gauge display”, page 200
♦ ⇒ Heating, Air conditioning; Rep. gr. 82

1.3 Removing and installing the fuel tank

Special tools and workshop equipment required
♦ Engine and gearbox jack , e.g. -V.A.G 1383A-
♦ Removal wedge - 3409-
♦ Body saw , e. g. -V.A.G 1523 A - or grinder
♦ Protective goggles

Caution

The fuel tank must be empty for weight reasons when removing
it, if necessary suction the fuel out of the fuel tank
⇒ “1.2 Extract fuel from the fuel tank”, page 189 .

1. Fuel tank and fuel delivery unit 195

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Removing

Note

♦ Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ “3.1 Rules of cleanliness”, page 7 .

– Switch off ignition and all electrical loads, and pull out ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip cover -1- for closing flange from holder catches
-arrows- using the removal wedge - 3409- .
– Disconnect plug connection -1- from fuel pump.
Vehicles with auxiliary heating
ProCarManuals.com

– Disconnect plug connection -2- from auxiliary heating dosing

pump.
Continued for all vehicles
– Push up pick-up coupling -2- -arrow A-. To do so, reach be‐
tween bottom plate and fuel tank with a finger.
– Simultaneously pull the fuel pump control unit - J538- -1- at
the electric wiring loom -3- carefully out of the uptake
-arrow B-.

– Take out fuel pump control unit - J538- inwards between fuel
tank and bottom plate.
– Open tank flap.
– Clean the area around the fuel filler neck.

196 Rep. gr.20 - Fuel supply system

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– Unscrew the cap -1- for the fuel filler neck.

Note

Close the opening of the fuel filler neck with a clean cloth so that
no dirt can penetrate.

– Removing the rear right wheel.

– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Remove the rear wheel brake calliper and store to on side ⇒
Suspension; Rep. gr. 46 .
– Disconnect the plug connection from the ABS speed sensor,
right rear wheel, and undo the line from the mounting brackets
at the rear axle ⇒ Suspension; Rep. gr. 45 .

– Remove the vent lines -1- and -2- from the activated charcoal
filter, do so by disconnecting the push-fit couplings
⇒ “2 Separating push-on couplings”, page 211 .
– Loosen ventilation lines from fasteners on the holder
-arrows-.
ProCarManuals.com

– Loosen ventilation line -1- from fastener on the holder

-arrow-.
– Disconnect the exhaust pipe with body saw , e. g. -V.A.G 1523
A - or grinder, and remove the middle- and rear part of the
exhaust system separately
⇒ “1.4 Removing and installing or replacing the middle and
rear silencer”, page 277 .

– Unscrew screws -1- -2- for fuel filler neck.

WARNING

Risk of injury caused by fuel which is under high pressure.

To relieve the pressure in the fuel system, place a clean cloth
around the connection point and carefully loosen the connec‐
tion point.

– Unclip hand-brake cables from the holders.

1. Fuel tank and fuel delivery unit 197

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– Disconnect vent line -3- and fuel line -2-

⇒ “2 Separating push-on couplings”, page 211 .

Note

For vehicles with auxiliary heating, the fuel line -1- for the dosing
pump - V54- must also be disconnected
⇒ “2 Separating push-on couplings”, page 211 .

WARNING

Risk of accident from fuel tank weight.

The fuel tank must be empty for removal.

– Unscrew screw -5-.

– Remove holder for exhaust system retaining strap -arrow-.
– Unscrew fixing screws -3- and remove tensioning strap -7-.
ProCarManuals.com

– Support the fuel tank using the engine and gearbox jack -
V.A.G 1383A- .

198 Rep. gr.20 - Fuel supply system

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– Release fixing screws -2-, -4- and -6-.

– Remove securing nuts for heat shield of fuel tank and remove
protection plate.
– Slightly lower the fuel tank using the engine and gearbox jack
- V.A.G 1383A- .

Note

♦ The aid of a 2nd mechanic is required to remove the fuel tank.

♦ Make sure that the individual cables are not damaged.

– With the aid of a second mechanic, turn the fuel tank to one
side, and lower.
– Pull the filler tube through between the rear axle and body‐
shell.
Install

Note

For vehicles with auxiliary heating and additional heating the dos‐
ing pump - V54- must also be tested for firm seating on the holder.
ProCarManuals.com

– Check both earth connections for corrosion, if necessary re‐

move corrosion.
– Check the fitting position of the earth lead ⇒ page 188 .

Note

♦ The aid of a 2nd mechanic is required to install the fuel tank. .

♦ Make sure that the individual cables are not damaged.

– With the aid of a second mechanic, pull the filler tube between
the rear axle and body and support the fuel tank with engine
and gearbox jack - V.A.G 1383A- .
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
♦ Vent and fuel lines must be laid without any kinks.
♦ Do not mix-up the feed line and the air bleed valve (the air
bleed valve is white, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.
Tightening torques
♦ ⇒ “1.1 Fuel tank - Summary of components”, page 186
♦ ⇒ “1.2 Middle and rear silencer - Summary of components”,
page 274
♦ ⇒ Chassis; Rep. gr. 44 .
♦ ⇒ Chassis; Rep. gr. 46 .
♦ ⇒ Body Work; Rep. gr. 66

1. Fuel tank and fuel delivery unit 199

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1.4 Summary of components - fuel delivery unit and sender for fuel gauge dis‐
play

1 - Fuel delivery unit

❑ with integrated fuel filter,
the fuel filter cannot be
replaced individually
❑ Checking electric fuel
pump ⇒ Vehicle diag‐
nostic tester
❑ installing and removing
⇒ “1.5 Fuel delivery unit
with sender for fuel
gauge display”,
page 201
❑ Fill the vehicle with at
least 5 litres of fuel after
installing
2 - Sealing ring
❑ replace after removal
❑ install when dry
3 - Lock ring
ProCarManuals.com

❑ loosen and/or tighten

using wrench - T30101
(3087)-
❑ 110 Nm
4 - Fuel pump control unit -
J538-
❑ Checking ⇒ Vehicle di‐
agnostic tester
❑ installing and removing
⇒ “1.8 Removing and in‐
stalling fuel pump con‐
trol unit J538 ”,
page 210
5 - Plug connection
❑ For fuel pump control
unit - J538-
❑ Ensure safe locking by pulling
6 - Plug connection
❑ for Fuel pump for predelivery system - G6- and fuel gauge sender - G-
❑ Ensure safe locking by pulling
7 - Fuel feed line
❑ to the engine
❑ do not kink
❑ Fit so that it can be heard clicking into place
❑ Unlock the quick couplings and fit together ⇒ “2 Separating push-on couplings”, page 211
8 - Fuel gauge sender - G-
❑ Check with the fuel pump control unit - J538- ⇒ Vehicle diagnostic tester
❑ installing and removing
⇒ “1.6 Removing and installing the sender for fuel gauge display G ”, page 204

200 Rep. gr.20 - Fuel supply system

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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1.5 Fuel delivery unit with sender for fuel

gauge display
Special tools and workshop equipment required
♦ Removal wedge - 3409-
♦ Key - T30101 (3087)-
Removing
• The fuel tank must not be more than 3/4 full.

Note

♦ If necessary, extract fuel from the fuel tank

⇒ “1.2 Extract fuel from the fuel tank”, page 189 .
♦ Observe the safety instructions before starting fitting work
⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 7 .

– Switch off ignition and all electrical loads, and pull out ignition
key.
ProCarManuals.com

– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .

– Unclip cover -1- for closing flange from holder catches
-arrows- using the removal wedge - 3409- .
– Disconnect plug connection -1- from fuel pump.
Vehicles with auxiliary heating

– Disconnect plug connection -2- from auxiliary heating dosing

pump.
Continued for all vehicles

WARNING

Risk of injury caused by fuel which is under high pressure.

To relieve the pressure in the fuel system, place a clean cloth
around the connection point and carefully loosen the connec‐
tion point.

1. Fuel tank and fuel delivery unit 201

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– Remove fuel line -1- from closing flange

⇒ “2 Separating push-on couplings”, page 211 .
Vehicles with auxiliary heating
– Loosen hose clamp, fuel line -2- to the dosing pump for the
auxiliary heating from the closing flange.
Continued for all vehicles

– Open lock ring with the wrench - T30101 (3087)- .

– Pull sealing flange -2- carefully out of the fuel tank opening.
ProCarManuals.com

202 Rep. gr.20 - Fuel supply system

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Remove sealing ring -1- from fuel tank opening.

WARNING

Beware of fuel flowing out of the fuel pump that is still full -
accident hazard.
Put cleaning cloth underneath to collect fuel.

Note

♦ Remove fuel delivery unit from the fuel tank so that the electric
lines and fuel hoses are not damaged and the float arm of the
sender for 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
– 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.
ProCarManuals.com

– Insert the fuel delivery unit into the fuel tank in such a way that
the float arm of the sender for the fuel gauge display - G- is
not bent.

Caution

Risk of leakage.
The gasket ring must not get damaged or squashed when in‐
serting the sealing flange.

– Press down the closing flange against the spring force and
bring it into the installation position.

• Clutch -2- on closing flange must point to opening -arrow- on

the lock ring and be located between tabs -3- and -4- on the
fuel tank.

1. Fuel tank and fuel delivery unit 203

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– Insert lock ring and tighten using the wrench - T30101 (3087)- .
– Connect fuel line
⇒ “2 Separating push-on couplings”, page 211 .
Vehicles with auxiliary heating

– Attach fuel line to the dosing pump of the auxiliary heating and
additional heating at the closing flange.
Continued for all vehicles
Installation is carried out in the reverse order. Pay attention to the
following:
– After installing the fuel delivery unit, refuel with at least 5 litres
of fuel.

WARNING
ProCarManuals.com

Risk of explosion to fuel tank!

After installing a new fuel tank or completely emptying the fuel
tank, you must replenish with a minimum of 5 litres of fuel right
away. The fuel pump must not be allowed to start when the fuel
tank is completely empty.

Tightening torques
♦ ⇒ “1.4 Summary of components - fuel delivery unit and sender
for fuel gauge display”, page 200

1.6 Removing and installing the sender for

fuel gauge display - G-
Removing

Note

♦ Observe safety instructions

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 7 .

– Remove fuel delivery unit

⇒ “1.5 Fuel delivery unit with sender for fuel gauge display”,
page 201 .
– Disconnect electrical plug connection -1- on the closing flange,
thereby unlocking the plug lock.
– Unhook the electric cable from the holder -arrow- and expose
it.

204 Rep. gr.20 - Fuel supply system

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– Unlock the catch on the uptake clamps -3- and -4-; at the same
time, pull the sender for fuel gauge display -G- -2- upwards.
Install
Installation is carried out in the reverse order. Pay attention to the
following:
– 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.
– Connect all electric cables to fuel delivery unit.

1.7 Checking fuel pump

⇒ “1.7.1 Checking fuel pressure”, page 205
⇒ “1.7.2 Testing holding pressure”, page 206
ProCarManuals.com

⇒ “1.7.3 Checking fuel delivery rate”, page 207

1.7.1 Checking fuel pressure

Special tools and workshop equipment required
♦ Pressure gauge , e.g. -VAS 6550-
♦ Measuring vessel

Note

♦ Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ “3.1 Rules of cleanliness”, page 7 .
♦ Test conditions when working on the fuel supply system
⇒ “2.3 Safety precautions during road tests in which testing
and measuring equipment is used”, page 4 .

– Remove the fuel feed line -2-

⇒ “2 Separating push-on couplings”, page 211 and catch the
fuel which flows out with a cleaning cloth.
– Connect pressure tester - VAS 6550- to fuel supply line with
adapter - VAS 6550/2- .

1. Fuel tank and fuel delivery unit 205

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– Insert hose line - VAS 6550/1- and keep in the fuel-resistant

measuring vessel.

Caution

Risk of fuel dripping out.

♦ Make sure that the shut-off tap -C- is closed.
♦ Lever points in the direction of flow.

– Open shut-off taps -A- and -B- .

– Switch on ignition until bubble-free fuel flows out.
– Close shut-off tap -B- to will build fuel pressure.
– Read off fuel pressure on pressure gauge.
• Specified value: 0.4…0.70 MPa (4…7.0 bar)
If the specification is not attained:
– Perform fuel delivery quantity check
⇒ “1.7.3 Checking fuel delivery rate”, page 207 .
ProCarManuals.com

1.7.2 Testing holding pressure

Special tools and workshop equipment required
♦ Pressure gauge , e.g. -VAS 6550-
♦ Measuring vessel

Note

♦ Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ “3.1 Rules of cleanliness”, page 7 .
♦ Test conditions when working on the fuel supply system
⇒ “2.3 Safety precautions during road tests in which testing
and measuring equipment is used”, page 4 .

– Check leak tightness and while doing so observe pressure

drop at pressure gauge - VAS 6550- .
• The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure again falls below 0.3 MPa (3.0 bar)
• Check line connections between pressure gauge - VAS 6550-
and fuel feed line for leak tightness.
• Inspect pressure measuring device - VAS 6550- for leaks.
• Check fuel lines and its connections for tightness.
If no fault is found:
♦ Non-return valve in the fuel delivery unit is leaking:

206 Rep. gr.20 - Fuel supply system

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Renew fuel delivery unit

⇒ “1.5 Fuel delivery unit with sender for fuel gauge display”,
page 201 .
Assembly is carried out in the reverse order. When installing, ob‐
serve the following:
• Ignition must be switched off.

Note

Reduce fuel pressure before removing the pressure gauge, while

doing so open the shut-off tap -C- and let the fuel drain into the
measuring vessel.

1.7.3 Checking fuel delivery rate

Special tools and workshop equipment required
♦ Pressure gauge , e.g. -VAS 6550-
ProCarManuals.com

♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g.

-V.A.G 1348/3-3-
♦ Auxiliary measuring set - V.A.G 1594 C-
♦ Handheld multimeter - V.A.G 1526B-
♦ Removal wedge - 3409-
♦ Measuring vessel

Note

♦ Safety precautions when working on the fuel supply system

⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ “3.1 Rules of cleanliness”, page 7 .
♦ Test conditions when working on the fuel supply system
⇒ “2.3 Safety precautions during road tests in which testing
and measuring equipment is used”, page 4 .

– Unscrew the cap -1- for the fuel filler neck.

1. Fuel tank and fuel delivery unit 207

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– Remove the fuel feed line -2-

⇒ “2 Separating push-on couplings”, page 211 and catch the
fuel which flows out with a cleaning cloth.
– Connect pressure tester - VAS 6550- to fuel supply line with
adapter - VAS 6550/2- .

– Insert hose line - VAS 6550/1- and keep in the fuel-resistant

measuring vessel.

Caution

Risk of fuel dripping out.

♦ Make sure that the shut-off tap -C- is closed.
♦ Lever points in the direction of flow.
ProCarManuals.com

– Open shut-off taps -A- and -B- .

• The levers are housed in the flow direction.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .

– Loosen catch pegs -arrows- of the cover -1- with removal

wedge - 3409- and remove the cover.

208 Rep. gr.20 - Fuel supply system

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– Disconnect plug connection -1- at the closing flange.

– Connect remote control - V.A.G 1348/3A- with adapter line -

V.A.G 1348/3-3- and with the line from the measuring tool set
- V.A.G 1594/C- to contact -1-.
– Mask second plug contact of the adapter - V.A.G 1348/3-3-
with short-circuit proof tape -arrow-.
– Connect contact -5- with line of auxiliary measuring set - V.A.G
1594/C- to body mass -A-.
– Connect alligator clip to the positive terminal “+” -B-.
ProCarManuals.com

Note

Primary pressure must be built up against which the fuel pump

must work when the fuel delivery flow in the fuel line is being
measured. This primary pressure is set as follows using pressure
gauge VAS 6550:

– Operate remote control - V.A.G 1348/3A- . While doing this,

slowly close the shut-off tap -B- until the pressure gauge dis‐
plays a pressure of 0.4 MPa (4 bar). From this point on do not
move position of shut-off tap.
– Empty measuring glass.
– Activate remote control for 15 seconds.

1. Fuel tank and fuel delivery unit 209

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– Compare fuel quantity delivered with minimum flow quantity in

the diagram cm3/15s.

Note

Voltage at the fuel pump when engine is not running and pump is
approximately 2 volts less than battery voltage.

If the minimum delivery volume is not reached, it can be caused

by the following faults:
♦ Fuel lines squashed.
♦ The fuel filter is clogged.
♦ The fuel pressure sender is defective.
♦ Fuel delivery unit defective.
Installation is carried out in the reverse order.

1.8 Removing and installing fuel pump con‐

trol unit -J538-
Special tools and workshop equipment required
ProCarManuals.com

♦ Removal wedge - 3409-

– Switch off ignition and all electrical loads, and pull out ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Loosen catch pegs -arrows- of the cover -1- with removal
wedge - 3409- and remove the cover.

– Push up pick-up coupling -2- -arrow A-. To do so, reach be‐

tween bottom plate and fuel tank with a finger.
– Simultaneously pull the fuel pump control unit - J538- -1- at
the electric wiring loom -3- carefully out of the uptake
-arrow B-.
– Take out fuel pump control unit - J538- inwards between fuel
tank and bottom plate.
– Disconnect electrical plug connections.
Install
– Push fuel pump control unit - J538- into the uptake and push
in until there is an audible click.
Further installation occurs in reverse order.

210 Rep. gr.20 - Fuel supply system

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2 Separating push-on couplings

Special tools and workshop equipment required
♦ Lever - T10468-

Note

♦ The quick couplings of fuel, vacuum and ventilation lines are

colour marked. Either the colour point at the quick coupling or
the release button has the corresponding colour.
♦ Observe safety measures
⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .

Push-on coupling Colour code on connector

Fuel feed Black
line
Vent line White, beige
Vacuum line green

WARNING
ProCarManuals.com

Fuel supply line is pressurised! Wear safety goggles and safety

clothing, in order to avoid injuries and skin contact with fuel.
Place cleaning cloths around the connection point before de‐
taching hose connections. Reduce pressure by carefully re‐
moving the hose.

Variant 1
Quick coupling with release buttons -arrows- on right and left.

2. Separating push-on couplings 211

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The coupling point -1- in the engine compartment must be held.

– Insert the lever - T10468- between the heat shield and the stop
-arrow- of the fuel line -2- and hold it.
Continued for all socket boxes

Note

When the push-fit coupling is fitted with a plastic circlip, leave it

inserted when removing and installing the quick release.

– Press the push-fit coupling -1- in direction of arrow -A-.

– Press the release buttons and remove the push-fit coupling
-1- from the fuel line -2- in direction of the arrow -B-.
Pay attention to the colour assignment when installing
ProCarManuals.com

⇒ page 211 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!

Variant 2
Quick coupling with pull release -arrow-.

212 Rep. gr.20 - Fuel supply system

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– Press the push-fit coupling -1- in direction of arrow -A-.

– Pull pull-release mechanism -2- in direction of arrow -B-.
– Remove the push-fit coupling -1- from the fuel line -3- in di‐
rection of the arrow -B-.
Pay attention to the colour assignment when installing
⇒ page 211 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!

Variant 3
Quick coupling with front release button -arrow-.
– Press the release button -arrow- and detach the quick cou‐
pling.
ProCarManuals.com

Pay attention to the colour assignment when installing

⇒ page 211 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!

Variant 4
Quick coupling with release buttons -arrows- on right and left.

– Press the push-fit coupling in direction of arrow -A-.

– Press release buttons -arrows- and pull push-on coupling off.
Pay attention to the colour assignment when installing
⇒ page 211 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!

Variant 5
Quick coupling with release buttons -arrows- on right and left.
– Press release buttons -arrows- and pull push-on coupling off.
Pay attention to the colour assignment when installing
⇒ page 211 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!

2. Separating push-on couplings 213

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Variant 6
Quick coupling with release buttons -arrows- on right and left.
– Press push-on coupling -1- in -direction of arrow- and hold
pressed.
– Press release buttons -arrows- and pull push-on coupling off.
Pay attention to the colour assignment when installing
⇒ page 211 .
– Check the quick couplings for firm seating by pulling in the
opposite direction!

Variant 7
Quick coupling -1- with release buttons -arrows- right and left.
– Press push-on coupling -1- in direction of arrow -A- and hold
pressed.
– Press the release buttons -2- in direction of arrow -B- and re‐
move the push-fit coupling -1-.
Pay attention to the colour assignment when installing
⇒ page 211 .
– Check the quick couplings for firm seating by pulling in the
ProCarManuals.com

opposite direction!

214 Rep. gr.20 - Fuel supply system

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3 Accelerator pedal
⇒ “3.1 Assembly overview - accelerator module”, page 215
⇒ “3.2 Removing and installing accelerator module”, page 216
⇒ “3.3 Disconnect connector for accelerator pedal module and fit
on”, page 216

3.1 Assembly overview - accelerator module

1 - Bolt
❑ 6 Nm
2 - Connector
❑ Ensure safe locking by
pulling.
3 - Accelerator pedal module
❑ with accelerator pedal
position sender - G79-
and accelerator pedal
position sender 2 -
G185-
❑ installing and removing
ProCarManuals.com

⇒ page 216

3. Accelerator pedal 215

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3.2 Removing and installing accelerator

module
Removing
– Tilt the cover for underbody -1- towards the front in
-direction of arrow-.

– Disconnect plug connection -2- at the accelerator pedal mod‐

ule ⇒ page 216 .
– Unscrew screw -1-.
– Remove accelerator module -3- from the uptake.
Install
ProCarManuals.com

Installation is carried out in the reverse order.

Caution

There is risk of damaging the surface of the knee airbag.

After completion of assembly work with visual inspection,
check that the knee airbag surface is not damaged.

3.3 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- towards the top in direction of arrow -3-.
The piston slide valve -A- remains in the bottom position.

216 Rep. gr.20 - Fuel supply system

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Fit on connector 1K0 973 706

– Push the socket housing -B- down in -direction of arrow- until
the housing can be heard to lock in place.
The piston slide valve -A- moves automatically upwards.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.

Disconnect connector 8K0 973 706

– Pull piston slide valve -A- (red) upwards in direction of arrow
-1- up to the stop.
– Press the piston slide valve in direction of arrow -2- and dis‐
connect the socket housing -B- in direction of arrow -3-.
The piston slide valve -A- remains in the top position.
ProCarManuals.com

Fit on connector 8K0 973 706

– Push the socket housing -B- down in direction of arrow -1- up
to the stop.
– Lightly press the piston slide valve in direction of arrow -2- and
slide in the direction of arrow -3-.
The piston slide valve -A- can only be pushed downwards if
the socket housing was pushed downwards »up to the stop«.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.

3. Accelerator pedal 217

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4 Activated charcoal filter system

⇒ “4.1 Assembly overview - activated charcoal filter system”, page
218
⇒ “4.2 Removing and installing activated charcoal filter”,
page 218
⇒ “4.3 Checking the fuel tank venting”, page 219

4.1 Assembly overview - activated charcoal filter system

1 - Vent line
❑ For solenoid valve 1 for
activated charcoal filter -
N80-
❑ pushed into the fuel tank
❑ Unlock the quick cou‐
plings and fit together
⇒ “2 Separating push-
on couplings”,
page 211
2 - Bolt
❑ 20 Nm
ProCarManuals.com

3 - Activated charcoal filter

❑ Installation location in
wheelhouse under the
wheelhouse liner
❑ installing and removing
⇒ “4.2 Removing and in‐
stalling activated char‐
coal filter”, page 218
4 - Vent line
❑ to fuel tank
❑ Unlock the quick cou‐
plings and fit together
⇒ “2 Separating push-
on couplings”,
page 211
❑ disconnect and connect
⇒ “2 Separating push-
on couplings”,
page 211

4.2 Removing and installing activated char‐

coal filter
– Observe safety instructions
⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
– Observe rules for cleanliness
⇒ “3.1 Rules of cleanliness”, page 7 .
– Remove right rear wheel ⇒ Chassis; Rep. gr. 44 .

218 Rep. gr.20 - Fuel supply system

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– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.

gr. 66 .
– Disconnect the vent lines -1- and -2- on the activated charcoal
filter ⇒ “2 Separating push-on couplings”, page 211 .
– Loosen ventilation lines from fasteners on the holder
-arrows-.

– Unscrew screw -1-.

– Pull out catch -3- using a screwdriver and pull the activated
charcoal filter -2- down out of the lock -arrow-.
Install
Installation is carried out in the reverse order.
ProCarManuals.com

Tightening torques
♦ ⇒ Body Work; Rep. gr. 66
♦ ⇒ Chassis; Rep. gr. 44

4.3 Checking the fuel tank venting

Special tools and workshop equipment required
♦ Hand vacuum pump , e.g. -V.A.S 6213-
♦ Pressure gauge - VAS 6550 -
♦ Adapter - VAS 6550/3-1 -
♦ Screw plug set for engine , e.g. -VAS 6122-
Test procedure
– Remove the ventilation line -2- from the activated charcoal fil‐
ter to the activated charcoal filter system solenoid valve 1 -
N80- . Unlock the quick coupling and disconnect
⇒ page 211 .

4. Activated charcoal filter system 219

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– Connect the hand vacuum pump -V.A.S 6213- with adapter -

VAS 6550/3-2 - to the vent line as shown.

– Put the change-over ring -1- of the hand vacuum pump -V.A.S
6213- in position -A- for vacuum
– Operate the hand vacuum pump several times.
No vacuum should build up.
If a vacuum builds up.
ProCarManuals.com

– Check the ventilation opening -4- on the activated charcoal

filter -1- for dirt and clean as required.
– Check vent line from activated charcoal filter to engine for
clearance.
If no vacuum builds up:

– Seal connection of the activated charcoal filter -2- with a suit‐

able plug -1- from screw plug set for engine , e. g. -VAS 6122- .
– Operate the hand vacuum pump several times. A vacuum
should build up.
If no vacuum builds up:
– Renew activated charcoal filter
⇒ “4.2 Removing and installing activated charcoal filter”, page
218 .

220 Rep. gr.20 - Fuel supply system

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21 – Turbocharging/supercharging
1 Exhaust gas turbocharger
⇒ “1.1 Summary of components - exhaust gas turbocharger ”,
page 221
⇒ “1.2 Removing and installing exhaust gas turbocharger”,
page 223
⇒ “1.3 Removing and installing charge pressure regulator V465
”, page 227

1.1 Summary of components - exhaust gas

turbocharger
⇒ “1.1.1 Summary of components 1- exhaust gas turbocharger ”,
page 221
⇒ “1.1.2 Summary of components 2- exhaust gas turbocharger ”,
page 222

1.1.1 Summary of components 1- exhaust gas turbocharger

1 - Exhaust gas turbocharger

ProCarManuals.com

❑ installing and removing

⇒ “1.2 Removing and in‐
stalling exhaust gas tur‐
bocharger”, page 223
2 - Bolt
❑ 8 Nm
3 - Supports
4 - O-ring
❑ replace after removal
5 - Gasket
❑ replace after removal
6 - Heat shield
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 8 Nm
9 - Bolt
❑ 8 Nm
10 - Nut
❑ replace after removal
❑ tighten step by step:
1st stage 7 Nm

2nd stage 10 Nm

3rd stage 14 Nm

11 - Bolt
❑ 9 Nm

1. Exhaust gas turbocharger 221

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12 - Release handle
13 - Locking clip
14 - Charge pressure regulator - V465-
❑ installing and removing ⇒ “1.3 Removing and installing charge pressure regulator V465 ”, page 227

1.1.2 Summary of components 2- exhaust gas turbocharger

1 - Oil return-flow line

2 - O-ring
❑ replace after removal
❑ wet with engine oil
3 - Bolt
❑ 9 Nm
4 - O-ring
❑ replace after removal
5 - Bolt
❑ 9 Nm
ProCarManuals.com

6 - Oil feed line

7 - O-ring
❑ replace after removal
❑ wet with engine oil
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ replace after removal
❑ 5 Nm
10 - O-ring
❑ Replace crankcase ven‐
tilation hose Pos. -11- if
it is damaged or leaking
❑ wet with engine oil
11 - Hose
❑ for crankcase ventila‐
tion
12 - Bolt
❑ replace after removal
❑ 5 Nm
13 - O-ring
❑ Replace crankcase ventilation hose Pos. -11- if it is damaged or leaking
❑ wet with engine oil
14 - Exhaust gas turbocharger
❑ installing and removing ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 223
15 - Gasket
❑ replace after removal
16 - Coolant lines
❑ Forward and reverse

222 Rep. gr.21 - Turbocharging/supercharging

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17 - Bolt
❑ 8 Nm
18 - O-ring
❑ replace after removal
❑ wet with engine oil
19 - Bolt
❑ 9 Nm

1.2 Removing and installing exhaust gas

turbocharger
Special tools and workshop equipment required
♦ Screw plug set for engine, e.g. - VAS 6122-
♦ Pliers for spring strap clamps
♦ Release tool - T10527-
♦ Release tool - T10527/1-
Removing
ProCarManuals.com

Note

♦ Observe rules for cleanliness

⇒ “3.1 Rules of cleanliness”, page 7 .
♦ Fit all heat protection sleeves on again in the same place when
installing.

Caution

In case a mechanical damage to the exhaust gas turbocharger

is found, (e.g. damage to the compressor wheel), it is not suf‐
ficient to only replace the turbocharger. In order to avoid con‐
sequential damage, the following tasks must be performed:
♦ Inspect the air filter housing, the air filter element and air
guide hoses for contamination.
♦ Inspect the whole charge-air routing and charge air cooler
for foreign bodies.
♦ If foreign bodies are found in the charge air system, clean
the charge air duct and replace the charge air cooler if
necessary.

– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .

1. Exhaust gas turbocharger 223

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Release screws -1- and remove heat shield for right drive
shaft, if present.

– Screw out the screws -arrows-, remove oil feed line -1- and oil
return pipe -2-.
ProCarManuals.com

– Unscrew screw -2- and remove screw clamp.

– Unscrew screw -1- and nuts -arrows- and strap up catalytic
converter.

– Loosen hose clamps -1- and -2- and remove air guide pipes.
– Expose air guide hoses at the air guide pipe.

224 Rep. gr.21 - Turbocharging/supercharging

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Undo hose clamps -arrows-, remove air guide hose -1-.

– Disconnect plug -1- at charge pressure sender - GX26- .

ProCarManuals.com

– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

– Press release buttons and remove hose -1- to the activated

charcoal filter.
– Unscrew screws -arrows- and remove hose for crankcase
ventilation.

1. Exhaust gas turbocharger 225

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Disconnect plug connection -2-.

– Release screws -arrows- and remove connection piece -1-.

– Loosen hose clamp -2- and remove coolant hose.

– Unscrew -arrows- screws and swivel coolant lines -1- to the
right side.
ProCarManuals.com

– Release screws -arrows- and remove mount with heat shield

-1-.

– Unscrew nuts -arrows- and remove exhaust gas turbocharger.

Install
Installation is carried out in the reverse order. When installing,
observe the following:

226 Rep. gr.21 - Turbocharging/supercharging

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Push screwdriver -2- into the recess -arrow- of the exhaust gas
turbocharger and lever out the sealing ring -1-.

Note

♦ Replace gaskets, O-rings and securing nuts for cylinder head.

♦ Fill the exhaust turbocharger with engine oil at the connection
fitting for the oil feed line.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts“ETKA.”
♦ To ensure the oil supply to the exhaust gas turbocharger,
leave the engine running for about 1 minute after installing the
exhaust gas turbocharger. It is essential to avoid revving up
early.

– Electrical connections and proper routing ⇒ Current flow dia‐

grams, Electrical fault finding and Fitting locations.
– Replenish coolant ⇒ page 148 .
Tightening torques
♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger ”,
page 221
ProCarManuals.com

♦ ⇒ Chassis, axles, steering; Rep. gr. 40

1.3 Removing and installing charge pres‐

sure regulator - V465-
Special tools and workshop equipment required
♦ Rig tool - T40265-
Removing
– Switch off ignition.
– Separate electrical plug connection -1-.
– Pull off lock washer -2- using extractor - T40265- .
– Release screws -arrows- and remove charge pressure regu‐
lator - V465- .
Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Adapting the engine control unit - J623- to the charge pressure
regulator - V465- ⇒ Vehicle diagnostic tester.
Tightening torque
Component Nm
Screw for charge pressure regulator 9 Nm

1. Exhaust gas turbocharger 227

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2 Charge-air system
⇒ “2.1 Summary of components - charge air system”, page 228
⇒ “2.2 Removing and installing charge pressure sender GX26 ”,
page 229
⇒ “2.3 Removing and installing charge air cooler”, page 230
⇒ “2.4 Checking the charge-air system for leak tightness”,
page 232

2.1 Summary of components - charge air system

Note

♦ Before a test or repair, inspect all charge air pipes, charge air hoses and vacuum lines for tight connection
and leak tightness.
♦ Observe rules for cleanliness ⇒ “3.1 Rules of cleanliness”, page 7 .

1 - Coolant hose
2 - Bolt
❑ thread forming
ProCarManuals.com

❑ position and screw in by

to allow the screw to find
the old thread. Next,
tighten screw to the giv‐
en tightening torque.
❑ 15 Nm
3 - Coolant hose
4 - Coolant hose
5 - Charge air cooler
❑ installing and removing
⇒ “2.3 Removing and in‐
stalling charge air cool‐
er”, page 230
❑ fill with fresh coolant af‐
ter replacing
6 - Sealing lip
7 - Gasket
❑ replace after removal
8 - Intake manifold
installing and removing
⇒ “3.2 Removing and installing
intake manifold”, page 241

9 - Screw
❑ Tightening torque and
tightening order
⇒ “3.1 Assembly over‐
view - intake manifold”,
page 240
10 - O-ring
❑ replace after removal

228 Rep. gr.21 - Turbocharging/supercharging

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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11 - Intake manifold pressure sender - GX9-

❑ comprises:
Intake air temperature sender 2 - G299-

Intake manifold pressure sender - G71-

❑ installing and removing
⇒ “5.1 Removing and installing intake manifold pressure sender GX9 ”, page 257
12 - Charge pressure sender - GX26-
❑ comprises:
Charge pressure sender - G31-

Intake air temperature transmitter - G42-

❑ installing and removing ⇒ “2.2 Removing and installing charge pressure sender GX26 ”, page 229
13 - O-ring
❑ replace after removal
14 - Air guide pipe
15 - Inlet connections
16 - O-ring
❑ replace after removal
ProCarManuals.com

17 - O-ring
❑ replace after removal
18 - Bolt
❑ thread forming
❑ position and screw in by to allow the screw to find the old thread. Next, tighten screw to the given tight‐
ening torque.
❑ 7 Nm
19 - Retaining clip
❑ For air guide pipe
20 - Throttle valve module - GX3-
❑ comprises:
Throttle valve module - J338-

Throttle valve drive - G186-

Throttle valve drive angle sender 1 - G187-

Throttle valve drive angle sender 2 - G188-

❑ installing and removing ⇒ “3.3 Removing and installing the throttle valve control unit GX3 ”, page 244
21 - Sealing ring
❑ replace after removal
22 - Gasket
❑ 4 pieces
❑ replace after removal

2.2 Removing and installing charge pres‐

sure sender - GX26-
The charge pressure sender - GX26- consists:
♦ Charge pressure sender - G31-

2. Charge-air system 229

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♦ Intake air temperature transmitter - G42-

Removing
– Separate electrical plug connection -1-.
– Release catches -arrows- and remove the charge pressure
sender - GX26- .
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

♦ Renew O-ring.
♦ If retaining tabs break during removal, fixing screws can be
attached to the sender as a replacement ⇒ Electronic Cata‐
logue of Original Parts“ETKA” . Tightening torque:
⇒ page 230

Tightening torque
Component Nm
Charge pressure sender - GX26- 3 Nm
ProCarManuals.com

2.3 Removing and installing charge air cool‐

er
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm - MP7-602 (3094)-
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Pliers for spring strap clamps
Removing
– Disconnect plug connection -1-.
– Remove AC compressor from holder -arrows- and strap up ⇒
Heating, Air Conditioning; Rep. gr. 87 .
– Place a catch pan for workshop crane - VAS 6208- under‐
neath.
– Removing fan shroud
⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .

230 Rep. gr.21 - Turbocharging/supercharging

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Open the clamp -1- and push hose -arrow- to the side.

– Loosen hose clamps -1- and remove coolant hoses.

– Release screws -arrows- and remove charge air cooler.
ProCarManuals.com

– Pull charge air cooler -1- backwards and forwards simultane‐

ously in -direction of the arrow- out of the intake manifold.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

– Fit sealing strip -1- in -direction of the arrow- to the charge air
cooler -2-.
– Insert new gasket into the groove at the intake manifold.

2. Charge-air system 231

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– Tighten screws -arrows- from centre to outside crosswise.

– Attach hose clamps -1-.

Note

When there is light pressure on the fins

⇒ “3.5 Assembly of radiators and capacitors”, page 8 .

– Install fan shroud

⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
– Check coolant level ⇒ page 151 .
Tightening torques
♦ ⇒ “2.1 Summary of components - charge air system”,
page 228
♦ ⇒ Heating, Air conditioning; Rep. gr. 87 .

2.4 Checking the charge-air system for leak

tightness
Special tools and workshop equipment required
ProCarManuals.com

♦ Charge-air system testing device , e. g. -V.A.G 1687-

Work procedure
– Loosen hose clamps -1- and -2- and remove air guide pipes.

– Connect adapter - V.A.G 1687/15- with -V.A.G 1687/11- to the

exhaust gas turbocharger.
– Connect hose -1- of charge air system tester -V.A.G 1687- to
adapter.

232 Rep. gr.21 - Turbocharging/supercharging

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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-.
• The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect tester for charge air systems - V.A.G 1687- to com‐
pressed air using a commercially available intermediate piece
-1-.

Note

If there is water in the inspection glass, drain water via the drain
plug -6-.

– Open valve -3-.

Caution

Risk of damage owing to pressure being set too high.

♦ The pressure must not be greater than 0.05 MPa (0.5 bar)!
ProCarManuals.com

– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary regulate the pressure to 0.05 MPa (0.5 bar).
– To check the charge air system for leak points, listen, touch or
use commercially available leak search spray or the ultrasonic
measuring device - V.A.G 1842- .

Note

♦ A small amount of air escapes via the valves into the engine.
For this reason no pressure test is possible.
♦ Use of ultrasonic measuring device -V.A.G 1842- ⇒ Operating
instructions .
♦ Before removing the adapter, depressurize the test circuit by
detaching the hose coupling.

Assembling
Assembly is carried out in the reverse order. When installing, ob‐
serve the following:

Note

Replace gaskets and O-rings.

2. Charge-air system 233

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24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Injection system - Fitting location of the injection system”,
page 234

1.1 Injection system - Fitting location of the

injection system
⇒ “1.1.1 Installation location overview - engine compartment”,
page 234
⇒ “1.1.2 Installation overview - engine from front”, page 236
⇒ “1.1.3 Installation overview - engine from rear”, page 237

1.1.1 Installation location overview - engine compartment

Installation location overview - engine compartment

1 - Inlet camshaft control valve

1 - N205-
❑ Summary of compo‐
ProCarManuals.com

nents
⇒ “1.2 Summary of com‐
ponents - camshaft
housing”, page 68
❑ with integrated seal with
oil strainer
2 - Lambda probe 1 in front of
the catalytic converter - GX10-
❑ comprises:
Lambda probe - G39-

Lambda probe heater -

Z19-
❑ Summary of compo‐
nents
⇒ “7.1 Summary of com‐
ponents - lambda
probe”, page 265
3 - Lambda probe 1 after cata‐
lytic converter - GX7-
❑ comprises:
Lambda probe after cat‐
alytic converter - G130-

Lambda probe heater 1

after catalytic converter -
Z29-
❑ Summary of compo‐
nents
⇒ “7.1 Summary of com‐
ponents - lambda
probe”, page 265
4 - Charge pressure regulator - V465-
❑ installing and removing ⇒ “1.3 Removing and installing charge pressure regulator V465 ”, page 227

234 Rep. gr.24 - Mixture preparation - injection

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5 - Engine control unit - J623-

❑ installing and removing ⇒ “8 Engine control unit”, page 268
6 - Coolant temperature sender at radiator outlet - G83-
❑ installing and removing
⇒ “2.9 Removing and installing coolant temperature sender at radiator outlet G83 ”, page 168
7 - Hall sender - G40-
❑ Camshaft position sensor
❑ Summary of components ⇒ “1.1 Assembly overview - ignition system”, page 281
8 - Throttle valve module - GX3-
❑ comprises:
Throttle valve module - J338-

Throttle valve drive - G186-

Throttle valve drive angle sender 1 - G187-

Throttle valve drive angle sender 2 - G188-

❑ Summary of components ⇒ “3.1 Assembly overview - intake manifold”, page 240
9 - Charge pressure sender - GX26-
❑ comprises:
ProCarManuals.com

Charge pressure sender - G31-

Intake air temperature transmitter - G42-

❑ Summary of components ⇒ “2.1 Summary of components - charge air system”, page 228
10 - Intake manifold pressure sender - GX9-
❑ comprises:
Intake air temperature sender 2 - G299-

Intake manifold pressure sender - G71-

❑ Summary of components ⇒ “3.1 Assembly overview - intake manifold”, page 240
11 - Charge air cooler pump - V188-
❑ Summary of components ⇒ “2.2 Summary of components - electric coolant pump”, page 157
12 - Ignition coils with a power output stage
♦ Ignition coil 1 with output stage - N70-
♦ Ignition coil 2 with output stage - N127-
♦ Ignition coil 3 with output stage - N291-
♦ Ignition coil 4 with output stage - N292-
❑ installing and removing ⇒ “1.2 Removing and installing ignition coils with output stage”, page 282

1. Injection system 235

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1.1.2 Installation overview - engine from front

1 - Knock sensor 1 - G61-

❑ Summary of compo‐
nents
⇒ “1.1 Assembly over‐
view - ignition system”,
page 281
2 - Oil pressure switch for re‐
duced oil pressure - F378-
❑ Summary of compo‐
nents
⇒ “4.2 Removing and
installing oil pressure
switch for reduced oil
pressure F378 ”,
page 141
3 - Fuel pressure sender -
G247-
❑ Summary of compo‐
nents
⇒ “4.1 Assembly over‐
view - fuel rail with injec‐
tors”, page 248
ProCarManuals.com

4 - Activated charcoal filter sol‐

enoid valve 1 - N80-
5 - Injectors
♦ Injector, cylinder 1 - N30-
♦ Injector, cylinder 2 - N31-
♦ Injector, cylinder 3 - N32-
♦ Injector, cylinder 4 - N33-
❑ Summary of compo‐
nents
⇒ “4.1 Assembly over‐
view - fuel rail with injec‐
tors”, page 248
6 - Control valve for fuel pressure - N276-
❑ on the high pressure pump
❑ Summary of components ⇒ “6.1 Summary of components - high pressure pump”, page 261
7 - Engine speed transmitter - G28-
❑ Summary of components ⇒ “1.1 Assembly overview - ignition system”, page 281

236 Rep. gr.24 - Mixture preparation - injection

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1.1.3 Installation overview - engine from rear

1 - Oil level and oil temperature

sender - G266-
❑ installing and removing
⇒ “1.4 Removing and in‐
stalling oil level and oil
temperature sender
G266 ”, page 134
2 - Coolant temperature send‐
er - G62-
❑ installing and removing
⇒ “2.8 Removing and in‐
stalling coolant temper‐
ature sender G62 ”,
page 167
ProCarManuals.com

1. Injection system 237

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2 Air filter
⇒ “2.1 Assembly overview - air filter housing”, page 238
⇒ “2.2 Removing and installing air filter housing”, page 239

2.1 Assembly overview - air filter housing

1 - Air guide lower part

❑ on the lock support
2 - air guide pipe top
❑ on the lock support
3 - Cover
❑ for air guide
4 - Bolt
❑ 2 Nm
5 - Air filter lower part
❑ remove mechanical for‐
eign particles
6 - Air filter element
ProCarManuals.com

❑ Change intervals
⇒ Maintenance ; Book‐
let Octavia III
7 - Air filter upper part
8 - Hose
❑ for crankcase ventila‐
tion
9 - Air guide hose
10 - Rubber bearing
11 - Bolt
❑ 2 Nm
12 - Air guide hose
13 - O-ring
❑ replace if damaged
14 - Water drain hose
❑ clean
15 - Bolt
❑ 2 Nm

238 Rep. gr.24 - Mixture preparation - injection

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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2.2 Removing and installing air filter hous‐

ing
Removing
– Pull off air guide hose -2-.
– Pull off -1- air filter housing upwards from the ball pin.
– Loosen hose clamps -3- and -4- and remove air guide pipes.
– Grab air filter housing and remove by pulling it upwards.
Install

Note

♦ If the air filter is heavily soiled or wet, dirt particles or moisture

can enter components and distort the measured values. This
leads to loss of power as a smaller injection quantity is calcu‐
lated.
♦ It is imperative for the air filter housing to be clean.
♦ Hose connections and air guide pipes and hoses must be free
of oil and grease before being installed.
♦ Use a silicone-free lubricant to assemble the air guide hoses.
ProCarManuals.com

♦ Secure all hose connections with hose clamps which comply

with the series design ⇒ Electronic Catalogue of Original
Parts“ETKA.”
♦ When blowing out the air filter housing using compressed air,
cover critical air-carrying components such as air ducts etc,
with a clean cloth. This will prevent any malfunctions.
♦ Observe disposal regulations!

– Remove mechanical foreign particles from the top and bottom

parts of the air filter housing.
– Clean the water drain with compressed air.

2. Air filter 239

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3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 240
⇒ “3.2 Removing and installing intake manifold”, page 241
⇒ “3.3 Removing and installing the throttle valve control unit GX3
”, page 244
⇒ “3.4 Clean throttle valve control unit GX3 ”, page 246

3.1 Assembly overview - intake manifold

1 - Coolant pipe
❑ clipped onto the intake
manifold
2 - Intake manifold
❑ Building unit with charge
air cooler
❑ installing and removing
⇒ “3.2 Removing and in‐
stalling intake manifold”,
page 241
3 - Coolant pipe
ProCarManuals.com

❑ clipped onto the intake

manifold
4 - Screw
❑ Tightening torque and
tightening order
⇒ page 241
5 - O-ring
❑ replace after removal
6 - Charge pressure sender -
GX9-
❑ comprises:
Intake air temperature
sender 2 - G299-

Intake manifold pressure

sender - G71-
❑ installing and removing
⇒ “5.1 Removing and
installing intake mani‐
fold pressure sender
GX9 ”, page 257
7 - Gasket
❑ replace after removal
8 - Charge pressure sender - GX26-
❑ comprises:
Charge pressure sender - G31-

Intake air temperature transmitter - G42-

❑ installing and removing ⇒ “2.2 Removing and installing charge pressure sender GX26 ”, page 229
9 - O-ring
❑ replace after removal

240 Rep. gr.24 - Mixture preparation - injection

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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10 - Inlet connections
11 - O-ring
❑ replace after removal
12 - Air guide pipe
13 - O-ring
❑ replace after removal
14 - Bolt
❑ thread forming
❑ position and screw in by to allow the screw to find the old thread. Next, tighten screw to the given tight‐
ening torque.
❑ 7 Nm
15 - Retaining clip
❑ For air guide pipe
16 - Throttle valve module - GX3-
❑ comprises:
Throttle valve module - J338-

Throttle valve drive - G186-

Throttle valve drive angle sender 1 - G187-

ProCarManuals.com

Throttle valve drive angle sender 2 - G188-

❑ installing and removing ⇒ “3.3 Removing and installing the throttle valve control unit GX3 ”, page 244
❑ cleaning ⇒ “3.4 Clean throttle valve control unit GX3 ”, page 246
❑ After replacing the throttle flap control unit - GX3- this must be readjusted to the engine control unit -
J623- Vehicle diagnosis tester ⇒ Vehicle diagnostic tester
17 - Sealing ring
❑ replace after removal
18 - Vacuum line
19 - O-ring
❑ replace after removal
20 - Vacuum line
21 - O-ring
❑ replace after removal

Intake manifold - tightening torque and tightening order

– Tighten screws in steps as follows:
Stage Screws Tightening torque
1st -Arrows- Insert in the centre, starting alternately,
by hand as far as the stop
2nd -Arrows- In the centre, starting alternately, 8 Nm

3.2 Removing and installing intake manifold

Special tools and workshop equipment required

3. Intake manifold 241

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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♦ Release tool - T10527-

♦ Release tool - T10527/1-
Removing
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 239 .
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .

WARNING

Risk of injury from fuel.

♦ To relieve the fuel pressure, place a clean cloth around
the connection point and loosen the connection point care‐
fully before opening the fuel system.

Caution

Risk of malfunctions caused by soiling.

ProCarManuals.com

♦ ⇒ “2.1 Safety precautions when working on fuel supply

system”, page 2

– First press the hose coupling -1- down, then press release
buttons -arrows-
⇒ “2 Separating push-on couplings”, page 211 .
– Remove hose coupling with pressed release buttons.
– Press release buttons on the hose -2- for the activated char‐
coal filter.
– Disconnect and expose hose.

– Unlock catch -arrow- and remove vacuum hose -1-.

– Expose vacuum hose on the air guide pipe -2-.
– Expose air guide hoses at the charge air pipe.

242 Rep. gr.24 - Mixture preparation - injection

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Undo hose clamps -arrows-, remove air guide hose -1-.

– Disconnect plug -1- at charge pressure sender - GX26- .

ProCarManuals.com

– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

– Release screw -1- and remove clamps -arrows-.

– Disconnect coolant hoses.

3. Intake manifold 243

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– Disconnect electrical plug connections:

1 - For solenoid valve 1 for activated charcoal filter - N80-
3 - for throttle valve control unit - GX3-
4 - Intake manifold pressure sender - GX9-
– Release screw -arrow-.
– Press release buttons and remove hose -2- for activated char‐
coal filter.
– Unclip fuel feed line -5- and coolant line -6- at the intake mani‐
fold and push to the side.

– Disconnect the plug connection -1- from the fuel pressure

sender - G247- .
– Disconnect the electrical plug connections from the oil pres‐
sure switch sender.
ProCarManuals.com

– Loosen hose clamps -2- and remove coolant hoses.

– Remove bolts -arrows-.
– Remove intake manifold -1-.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

Replace gaskets and O-rings.

– Install the noise insulation ⇒ Body Work; Rep. gr. 66 .

– Install air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 239 .
– Replenish coolant
⇒ “1.2 Draining and filling coolant”, page 147 .
Tightening torques
♦ ⇒ “3.1 Assembly overview - intake manifold”, page 240

3.3 Removing and installing the throttle

valve control unit - GX3-
The throttle flap control unit - GX3- comprises:
♦ Throttle valve module - J338-
♦ Throttle valve drive - G186-
♦ Throttle valve drive angle sender 1 - G187-
♦ Throttle valve drive angle sender 2 - G188-

244 Rep. gr.24 - Mixture preparation - injection

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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Special tools and workshop equipment required

♦ Release tool - T10527-
♦ Release tool - T10527/1-
Removing
– Expose air guide hoses at the charge air pipe.
– Undo hose clamps -arrows-, remove air guide hose -1-.

– Disconnect plug -1- at charge pressure sender - GX26- .

ProCarManuals.com

– Unlock catch pegs -arrows- with unlocking tool - T10527- and

release unlocking tool - T10527/1- , remove the air guide pipe
-1-.

3. Intake manifold 245

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Separate electrical plug connection -3-.

– Unscrew the screws -arrows- and remove throttle valve control
unit - GX3- -1- with adapter -2-.
Installing
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
– After replacing the throttle flap control unit - GX3- this must be
readjusted to the engine control unit - J623- ⇒ Vehicle diag‐
nostic tester.
Tightening torque
Component Nm
Screw for throttle flap control unit 7 Nm

3.4 Clean throttle valve control unit - GX3-

Note

♦ If a new engine control unit - J623- is fitted, the throttle valve

control unit must be adapted.
ProCarManuals.com

♦ Soiling and carbonisation in the limit stop can lead to incorrect

adjustment values.
♦ When cleaning the throttle valve housing it must not be
scratched.

Special tools and workshop equipment required

♦ Commercially available Acetone
♦ Paint brush
Work procedure
– Remove throttle valve module - GX3-
⇒ “3.3 Removing and installing the throttle valve control unit
GX3 ”, page 244 .
– Open throttle valve by hand and lock in open position using
wood or a plastic wedge -arrow-.

WARNING

Acetone is highly inflammable.

♦ Accident prevention regulations and the safety instruc‐
tions must be observed when handling easily inflammable
fluids.
♦ Compressed air must not be used for cleaning throttle
valve.
♦ To avoid injury from metal shavings and to avoid skin con‐
tact, wear eye protection and protective clothing.

246 Rep. gr.24 - Mixture preparation - injection

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Thoroughly clean the throttle valve housing using commer‐

cially available Acetone and a paint brush, particularly in the
area -arrows- of the closed throttle valve.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow Acetone to dry off completely.
– Install throttle valve module - GX3-
⇒ “3.3 Removing and installing the throttle valve control unit
GX3 ”, page 244 .
– Erase adapted values and adjust the engine control unit -
J623- to the throttle flap control unit - GX3- ⇒ Vehicle diag‐
nostic tester.
ProCarManuals.com

3. Intake manifold 247

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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4 Injectors
⇒ “4.1 Assembly overview - fuel rail with injectors”, page 248
⇒ “4.2 Removing and installing the fuel distributor”, page 249
⇒ “4.3 Removing and installing injectors”, page 250
⇒ “4.4 Clean injection valves”, page 255

4.1 Assembly overview - fuel rail with injectors

1 - Fuel pressure sender -

G247-
❑ check
⇒ “5.3 Check fuel pres‐
sure sender G247 ”,
page 258
❑ installing and removing
⇒ “5.2 Removing and in‐
stalling fuel pressure
sender G247 ”,
page 257
❑ Moisten the cone with
clean engine oil; the
ProCarManuals.com

thread must not be oiled

❑ 22 Nm
2 - Fuel distributor
❑ installing and removing
⇒ “4.2 Removing and in‐
stalling the fuel distribu‐
tor”, page 249
3 - High pressure tube

WARNING
Risk of injury caused by
fuel which is under high
pressure.
Before
♦ opening the high-
pressure system, the fuel
pressure must be re‐
duced to residual pres‐
sure
⇒ “3.10 Reduce pressure
in the high-pressure sys‐
tem”, page 10 .

❑ replace if damaged
❑ do not change bending form
❑ installing and removing ⇒ “6.3 Removing and installing high pressure pipe”, page 263
❑ 25 Nm
4 - Bolt
❑ installing and removing ⇒ “4.2 Removing and installing the fuel distributor”, page 249
❑ 9 Nm
5 - Support ring
❑ replace after removal
❑ the fuel distributor exerts force via the support ring that holds the injector in the cylinder head
❑ connected with valve Pos. -8-

248 Rep. gr.24 - Mixture preparation - injection

 Octavia III 2013 ➤ , Octavia III 2014 ➤
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6 - O-ring
❑ replace after removal
❑ Moisten with engine oil
7 - Distance ring
❑ replace if damaged
8 - Injector
❑ installing and removing ⇒ “4.3 Removing and installing injectors”, page 250
9 - Combustion chamber sealing ring
❑ Do not grease or treat using any other lubricant
❑ Renew ⇒ “4.3 Removing and installing injectors”, page 250 .

4.2 Removing and installing the fuel distrib‐

utor
Removing

WARNING

Risk of injury caused by fuel which is under high pressure.

ProCarManuals.com

♦ Before opening the high-pressure system, the fuel pres‐

sure must be reduced to residual pressure
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .

Caution

Risk of malfunctions caused by soiling.

♦ ⇒ “2.1 Safety precautions when working on fuel supply
system”, page 2

– Removing the intake manifold

⇒ “3.2 Removing and installing intake manifold”, page 241 .
– Remove high pressure pipe
⇒ “6.3 Removing and installing high pressure pipe”,
page 263 .

4. Injectors 249
 Octavia III 2013 ➤ , Octavia III 2014 ➤
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– Separate electrical plug connection -1-.

Note

Place a cloth below to absorb leaking fuel.

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

tor from the injection valves.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

Renew O-ring.

– Position fuel distributor on the injectors.

– Press fuel distributor first to the right, then to the left onto the
injectors up to the stop.
– Press fuel distributor down firmly in the holder area and tighten
screws by 2 turns.
ProCarManuals.com

– Tighten screws crosswise uniformly.

– Install high pressure pipe
⇒ “6.3 Removing and installing high pressure pipe”,
page 263 .
– Installing the intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 241 .
Tightening torques
Component Nm
Fuel distributor screw 9 Nm
♦ ⇒ “4.1 Assembly overview - fuel rail with injectors”, page 248

4.3 Removing and installing injectors

Special tools and workshop equipment required
♦ Pulling device - T10133- with removal tool - T10133/16A- and
extractor - T10133/19-
Removing

Caution

There is a risk of malfunctions caused by soiling.

♦ ⇒ “3.1 Rules of cleanliness”, page 7

Note

Injectors must not be removed while the engine is cold.

– Removing the intake manifold

⇒ “3.2 Removing and installing intake manifold”, page 241 .

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– Remove fuel distributor

⇒ “4.2 Removing and installing the fuel distributor”,
page 249 .
– Remove O-ring -4- from injector -2-.
– Disconnect the electrical plug connections from affected in‐
jector.

– Lever off caps -1- from injector using a screwdriver -2-.

ProCarManuals.com

– Push impact sleeve -T10133/18- over the injector.

4. Injectors 251
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– Gently apply a few knocks to the impact sleeve to loosen the

injector.

Note

♦ Use a torque wrench to pull out the injector.

♦ Set 5 Nm on the torque wrench.

– Position extractor -T10133/19- at the groove on the injector.

– Position removal tool -T10133/16 A- on extractor.
– Pull the injector out by screwing in the screw -1-.
ProCarManuals.com

– If the limit torque of »5 Nm« has been reached without the

injector becoming loose, the extraction tool must be removed
again. Work on injector again using impact sleeve -
T10133/18- .
– Repeat the procedure for each injector.

Note

♦ Failure to observe the torque threatens the destruction of the

injector.
♦ The combustion chamber sealing ring must always be re‐
placed before the injection valve is pre-installed.

– Remove gasket for intake manifold.

Disassemble injector:
– Pull support ring -5- and distance ring -3- off the injector -2-.
– Carefully remove old combustion chamber sealing ring -1-, to
do so, cut open to the ring using a knife and remove.

Note

Ensure that the injector groove is not damaged. If the groove is

damaged the injector must be replaced.

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Install
– Clean hole in the cylinder head using a nylon cylinder brush -
T10133/4- .

Note

♦ Replace combustion chamber sealing ring and O-ring.

♦ Replace distance ring if it is damaged.

– When reinstalling an injector, clean combustion residues from

groove for the combustion chamber sealing ring and injector
shaft using a clean cloth clean.

– Fit assembly cone -T10133/5- with the new combustion cham‐

ber sealing ring -1- onto the injector -2-.
ProCarManuals.com

– Push combustion chamber sealing ring with assembly sleeve

-T10133/6- as far as possible onto the assembly cone -
T10133/5- .

– Turn assembly sleeve -T10133/6- , push combustion chamber

sealing ring into the sealing ring groove.

4. Injectors 253
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Note

When sliding on the injector the combustion chamber sealing ring

is widened. It must therefore be reduced in width again in two
steps, as described below.

– Press calibrating sleeve -T10133/7- with a gentle rotary move‐

ment (approximately 180°) up to the stop on the injector.
– Turn calibrating sleeve -T10133/7- off again in the opposite
direction.

– Press calibrating sleeve -T10133/8- with a gentle rotary move‐

ment (approximately 180°) up to the stop on the injector.
– Turn calibrating sleeve -T10133/8- off again in the opposite
direction.
ProCarManuals.com

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– Pull support ring -5- and distance ring -3- onto the injector
-2-.
– Before installing injector -2-, moisten new O-ring -4- with clean
engine oil.

Note

The combustion chamber sealing ring -1- must not be oiled.

– Press the injection valves by hand up to the stop into the hole
of the cylinder head (free of oil and grease). Pay attention to
the correct position of the injection valves in the cylinder head.

Note

♦ The injectors must fit easily. If necessary, wait until the width
of the combustion chamber sealing ring has reduced suffi‐
ciently.
♦ Pay attention to the correct seating and fitting position of the
injection valves in the cylinder head.

• The electrical connection of the injector must reach into the

recess provided in the cylinder head.
ProCarManuals.com

– Install fuel distributor

⇒ “4.2 Removing and installing the fuel distributor”,
page 249 .
– Installing the intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 241 .
– Connect vehicle diagnosis tester and perform Targeted Func‐
tion “delete injector adaption values” ⇒ Vehicle diagnostic
tester.
– Switch off ignition.

4.4 Clean injection valves

Special tools and workshop equipment required
♦ Ultrasonic cleaning device - VAS 6418-
♦ Feeder plate for injection units - VAS 6418/1-
♦ Cleaning fluid ⇒ Electronic Catalogue of Original Parts“ETKA”

Note

♦ The ultrasound device must be filled with cleaning agent up to

the top edge of the holes.
♦ Observe the safety and operating instructions of the ultra‐
sound device.

4. Injectors 255
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– Remove injection valves

⇒ “4.3 Removing and installing injectors”, page 250 .
– Insert injectors -1- into the feeder plate for injection units - VAS
6418/1- Pos. -2-.
– Immerse injectors with the feeder plate for injection units - VAS
6418/1- into the cleaning fluid - VAS 6418/2- .
– On the rotating head -4-, set a temperature of 50 °C.
– On the rotating head -5-, set a cleaning time of 30 minutes.
– Switch on ultrasound device using the button -3-.

Note

Once the cleaning temperature has reached 50 °C the set time

begins to elapse.

– Replace the combustion chamber sealing ring at each injector

after cleaning
⇒ “4.3 Removing and installing injectors”, page 250 .
ProCarManuals.com

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5 Senders and sensors

⇒ “5.1 Removing and installing intake manifold pressure sender
GX9 ”, page 257
⇒ “5.2 Removing and installing fuel pressure sender G247 ”, page
257
⇒ “5.3 Check fuel pressure sender G247 ”, page 258

5.1 Removing and installing intake manifold

pressure sender - GX9-
The charge pressure sender - GX9- consists:
♦ Intake air temperature sender 2 - G299-
♦ Intake manifold pressure sender - G71-
Removing
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 239 .
– Disconnect plug connection -arrow-.
– Unlock locking tabs, remove the manifold pressure sender -
GX9- .
ProCarManuals.com

Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

♦ Renew O-ring.
♦ If retaining tabs break during removal, fixing screws can be
attached to the sender as a replacement ⇒ Electronic Cata‐
logue of Original Parts“ETKA” .

– Install air filter housing

⇒ “2.2 Removing and installing air filter housing”, page 239 .
Tightening torque
Component Nm
Intake manifold pressure sender - 3 Nm
GX9-

5.2 Removing and installing fuel pressure

sender - G247-
Special tools and workshop equipment required
♦ Assembly tool - T10118-
♦ Socket insert size 27 - T40218- or commercially available
27 mm socket insert

5. Senders and sensors 257

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Removing
– Separate electrical plug connection -1-.

Note

Place a cloth below to absorb leaking fuel.

– Undo the fuel pressure sender - G247- -2- with the Polydrive
socket width across flats 27 - T40218- .
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

The thread of the fuel pressure sender must not be moistened.

Tightening torque
Component Nm
Fuel pressure sender - G247- 22 Nm
ProCarManuals.com

5.3 Check fuel pressure sender - G247-

Special tools and workshop equipment required
♦ Adapter for measuring method/DSO (3-pin) , e.g. -VAS 5570-
♦ Testing device for pressure sensor e. g. -VAS 6394-
♦ Socket, 27 mm long, commercially available
Work procedure

WARNING

Risk of injury caused by fuel which is under high pressure.

♦ Before opening the high-pressure system, the fuel pres‐
sure must be reduced to residual pressure
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .

Caution

Risk of malfunctions caused by soiling.

♦ ⇒ “3.1 Rules of cleanliness”, page 7

– Remove fuel pressure sender - G247-

⇒ “5.2 Removing and installing fuel pressure sender G247 ”,
page 257 .

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– Moisten the sealing cone of the adapter -VAS 6394/3- with

clean engine oil and screw it into the fuel distributor with
22 Nm.

– Release the screw plug -2- and screw the fuel pressure sender
- G247- into the tester -VAS 6394/1- .
– Connect the pressure line -1- of the tester onto the adapter -
VAS 6394/3- .
ProCarManuals.com

– Use the adapter for measuring method/DSO (3-pin) - VAS

5570- to produce the electrical connection between vehicle
and fuel pressure sender - G247- .

5. Senders and sensors 259

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– Switch on the tester -VAS 6394/1- , for this step, briefly press
the button -A-.

Note

♦ If the button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If the tester -VAS 6394/1- does not indicate 0 MPa (0 bar),
carry out a zero point of the balance ⇒ operating instructions .

– Connect vehicle diagnosis tester ⇒ Vehicle diagnostic tester.

– Start engine and run at idling speed.
– Select the “Engine electronics” in the self-diagnosis.
– Then select “measured values”.
– Select “fuel pressure” in the selection list.
– Compare the displayed tester fuel pressure tester -VAS
6394/1- with the actual value displayed at the vehicle diagno‐
sis tester .
– Read fuel pressure on vehicle diagnosis tester.
• The pressures may deviate maximum 0.5 MPa (5 bar) from
ProCarManuals.com

one another.
– If the deviation is greater than 0.5 MPa (5 bar), replace the fuel
pressure sender - G247- .
– Repeat the test with the new fuel pressure sender - G247- and
compare both measured values.
– If the measurements now match, install new fuel pressure
sender - G247- .
– If the measured values still do not match, test electrical line
connection between fuel pressure sender - G247- and engine
control unit - J623- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
Tightening torque
Component Nm
Fuel pressure sender 22 Nm

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6 High pressure pump

⇒ “6.1 Summary of components - high pressure pump”,
page 261
⇒ “6.2 Removing and installing the high pressure pump”,
page 262
⇒ “6.3 Removing and installing high pressure pipe”, page 263

6.1 Summary of components - high pressure pump

1 - Roller tappet
❑ Moisten with engine oil
during installation
2 - O-ring
❑ replace after removal
❑ Moisten with engine oil
during installation
3 - High pressure pump
❑ with fuel dosage valve -
N290-
❑ do not disassemble
ProCarManuals.com

❑ installing and removing

⇒ “6.2 Removing and in‐
stalling the high pres‐
sure pump”, page 262
4 - High pressure tube

WARNING
Risk of injury caused by
fuel which is under high
pressure.
Before
♦ opening the high-
pressure system, the fuel
pressure must be re‐
duced to residual pres‐
sure
⇒ “3.10 Reduce pressure
in the high-pressure sys‐
tem”, page 10 .

❑ installing and removing

⇒ “6.3 Removing and in‐
stalling high pressure
pipe”, page 263
❑ replace if damaged
❑ Connections must not be damaged
❑ Moisten thread of the union nuts with clean engine oil
❑ 25 Nm
5 - Bolt
❑ replace after removal
❑ Tightening torque and tightening order ⇒ page 263
6 - Hose clamp
7 - Fuel feed line
8 - Electrical plug connection

6. High pressure pump 261

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6.2 Removing and installing the high pres‐

sure pump
Removing
• Engine cold.

WARNING

Risk of injury caused by fuel which is under high pressure.

♦ Before opening the high-pressure system, the fuel pres‐
sure must be reduced to residual pressure
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .

Caution

Risk of malfunctions caused by soiling.

♦ ⇒ “3.1 Rules of cleanliness”, page 7

– Remove high pressure pipe

ProCarManuals.com

⇒ “6.3 Removing and installing high pressure pipe”,

page 263 .
– Separate electrical plug connection -1-.

Note

Place a cloth below to absorb leaking fuel.

– Loosen hose clamp -2- and remove fuel intake hose.

– Unscrew screws -3- and remove high pressure pump with roll‐
er tappet.
Install
– Inspect roller tappet for damage, if necessary replace.
– Moisten roller tappet -1- with clean engine oil.

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– Insert the oiled roller tappet -1- into the camshaft housing.

Note

Renew O-ring.

– Turn crankshaft in direction of engine rotation until the roller

tappet is at the lowest point.
– Insert a new, oiled O-ring -2- into the slot of the high pressure
pump -3-.

High pressure pump - tightening torque and tightening order

To prevent the flange of the high pressure pump from becoming
deformed during installation, attach high pressure pump as fol‐
lows:
ProCarManuals.com

– Tighten screws in steps as follows:

Stage Bolts Tightening torque/torque angle
1st -3- by hand as far as the stop
2nd -3- Tighten by 1 turn alternately until the
flange of the high pressure pump is at
the camshaft housing
3rd -3- 20 Nm
4th -3- 90° (torque a further 90° (1/4 turn)

– Check fuel system for leak tightness.

6.3 Removing and installing high pressure

pipe
Removing
– Remove throttle valve module - GX3-
⇒ “3.3 Removing and installing the throttle valve control unit
GX3 ”, page 244 .

WARNING

Risk of injury caused by fuel which is under high pressure.

♦ Before opening the high-pressure system, the fuel pres‐
sure must be reduced to residual pressure
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .

6. High pressure pump 263

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Caution

Risk of malfunctions caused by soiling.

♦ ⇒ “3.1 Rules of cleanliness”, page 7

Note

Place a cloth below to absorb leaking fuel.

– Unscrew union nuts -arrows- and remove high pressure line.

Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Moisten thread of union nuts with clean engine oil.
– Hand-tighten union nuts for high pressure pipe, ensure that
the fit is tension-free.
– Tighten union nuts.
– Install throttle valve module - GX3-
ProCarManuals.com

⇒ “3.3 Removing and installing the throttle valve control unit

GX3 ”, page 244 .
Tightening torques
Component Nm
Union nut 25 Nm

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7 Lambda probe
⇒ “7.1 Summary of components - lambda probe”, page 265
⇒ “7.2 Removing and installing lambda probe GX10 / GX7 ”, page
266

7.1 Summary of components - lambda

probe

Note

♦ New lambda probes are coated with assembly paste. This

paste must not come into contact with the slots of the lambda
probe body.
♦ For a re-used lambda probe, only coat the thread with hot bolt
paste. This paste must not come into contact with the slots of
the lambda probe body. Hot bolt paste ⇒ Electronic Catalogue
of Original Parts“ETKA”
♦ The electrical cable wire connection of the lambda probe must
be secured again at the same points during installation. Con‐
tact between the electrical cable connection and the exhaust
pipe must be prevented.
ProCarManuals.com

1 - Lambda probe 1 after cata‐

lytic converter - GX7-
❑ comprises:
Lambda probe after cat‐
alytic converter - G130-

Lambda probe heater 1

after catalytic converter -
Z29-
❑ installing and removing
⇒ “7.2 Removing and in‐
stalling lambda probe
GX10 / GX7 ”,
page 266
❑ 55 Nm
2 - Connector
❑ for lambda probe 1
downstream of catalytic
converter - GX7-
3 - Connector
❑ for lambda probe 1 up‐
stream of catalytic con‐
verter - GX10-
4 - Lambda probe 1 in front of
the catalytic converter - GX10-
❑ comprises:
Lambda probe - G39-

Lambda probe heater -

Z19-
❑ installing and removing
⇒ “7.2 Removing and in‐
stalling lambda probe

7. Lambda probe 265

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GX10 / GX7 ”, page 266

❑ 55 Nm

7.2 Removing and installing lambda probe -

GX10- / -GX7-
The Lambda probe 1 in front of catalytic converter - GX10- com‐
prises:
♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-
The Lambda probe 1 downstream of catalytic converter - GX7-
comprises:
♦ Lambda probe after catalytic converter - G130-
♦ Lambda probe heater 1 after catalytic converter - Z29-
Special tools and workshop equipment required
♦ Lambda probe open ring spanner set - 3337-
Removing
– Disconnect electrical plug connections:
ProCarManuals.com

1- for lambda probe 1 upstream of catalytic converter - GX10-

2- for lambda probe 1 downstream of catalytic converter - GX7-

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– Unscrew respective lambda probe using a spanner from the

lambda probe ring spanner set - 3337- .
1- Lambda probe 1 after catalytic converter - GX7-
2- Lambda probe 1 in front of the catalytic converter - GX10-
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note

♦ New lambda probes are coated with assembly paste. This

paste must not come into contact with the slots of the lambda
probe body.
♦ For a re-used lambda probe, only coat the thread with hot bolt
paste. This paste must not come into contact with the slots of
the lambda probe body. Hot bolt paste ⇒ Electronic Catalogue
of Original Parts“ETKA”
♦ The electrical cable wire connection of the lambda probe must
be secured again at the same points during installation. Con‐
tact between the electrical cable connection and the exhaust
pipe must be prevented.
ProCarManuals.com

Tightening torque
Component Nm
Lambda probe 1 after catalytic converter - GX7- 55 Nm
Lambda probe 1 in front of the catalytic convert‐ 55 Nm
er - GX10-

7. Lambda probe 267

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8 Engine control unit

⇒ “8.1 Removing and installing engine control unit J623 without
protective housing”, page 268
⇒ “8.2 Removing and installing engine control unit J623 , engine
control unit with protective housing”, page 268

8.1 Removing and installing engine control

unit - J623- without protective housing
Removing

Note

If the engine control unit is replaced, the vehicle diagnosis tester

must be connected ⇒ Vehicle diagnostic tester and the function
“replace engine control unit” must be carried out.

Caution

If the engine control unit touches the plus pole of the battery,
this will destroy it.
ProCarManuals.com

– Unlock the catch in -direction of the arrow- and remove the

engine control unit -1-.
– Unlock plug connections for engine control unit - J623- and
pull off.
Install
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
After installing a new engine control unit, the following work step
must be performed:
– Connect vehicle diagnosis tester ⇒ Vehicle diagnostic tester.
– Activate the engine control unit in operating mode “Software
version management” or “Targeted functions” under Replace
engine control unit .

8.2 Removing and installing engine control

unit - J623- , engine control unit with
protective housing
Removing
Special tools and workshop equipment required
♦ Hot air blowers - VAS 1978/14A- with push-on nozzle from the
wiring harness repair set - VAS 1978 B-
♦ commercially available miniature grinder

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Removing

Note

If the engine control unit is replaced, the vehicle diagnosis tester

must be connected ⇒ Vehicle diagnostic tester and the function
“replace engine control unit” must be carried out.

Unscrew shear bolts -arrows- to remove the protective housing

-1- as follows:

– In the shear bolt head -1-, using a miniature grinder -2-, make
a slot for a screwdriver.
ProCarManuals.com

Note

♦ The threads of the pull-off screws are equipped with safety

agent. Warming the pull-off screw when grinding a slot for a
screwdriver makes it easier to undo it afterwards.
♦ If the pull-off screws still cannot be undone, warm the, up with
a hot air blower.

Undoing pull-off screws with a hot air blower:

– Set the temperature adjustment potentiometer -2- to maximum

heating performance and set the air flow two stage switch
-3- to position 3.

WARNING

Risk of burns from hot air blower.

♦ Only warm up the pull-off screws with a hot air blower.
♦ By warming the pull-off screws, the cover plate and parts
in its vicinity are heated up strongly too. Where necessary,
protect these parts by a piece of sheet covering.

8. Engine control unit 269

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– Heat the shear bolt head -1- for approximately 20 to 30 sec‐

onds.
Continued for slackened screws:

– Release shear bolt -1- using the screwdriver -2-.

ProCarManuals.com

– Remove protective housing -1-.

Caution

If the engine control unit touches the plus pole of the battery,
this will destroy it.

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– Unlock the catch in -direction of the arrow- and remove the

engine control unit -1-.
– Unlock plug connections for engine control unit - J623- and
pull off.
Install
Installation is carried out in the reverse order. When installing,
observe the following:
– It is imperative for the protective housing to be put back in
place on the engine control unit - J623- .
– Clean the threaded holes for the shear bolts to remove safety
agent residues. Cleaning can be done using a tapper.
– Use new shear bolts.
After installing a new engine control unit, the following work step
must be performed:
– Connect vehicle diagnosis tester ⇒ Vehicle diagnostic tester.
– Activate the engine control unit in operating mode “Software
version management” or “Targeted functions” under Replace
engine control unit .
ProCarManuals.com

8. Engine control unit 271

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26 – Exhaust system
1 Removing and installing exhaust sys‐
tem
⇒ “1.1 Catalytic converter and component parts - Summary of
components”, page 272
⇒ “1.2 Middle and rear silencer - Summary of components”, page
274
⇒ “1.3 Removing and installing catalytic converter with pre-ex‐
haust pipe”, page 275
⇒ “1.4 Removing and installing or replacing the middle and rear
silencer”, page 277
⇒ “1.5 Aligning exhaust system free of stress”, page 279
⇒ “1.6 Align exhaust tailpipe”, page 279
⇒ “1.7 Inspecting the exhaust system for leak tightness”,
page 280

1.1 Catalytic converter and component parts - Summary of components

ProCarManuals.com

1 - Bolt
❑ 20 Nm
2 - Support
❑ replace if damaged
3 - Nut
❑ Tightening torque and
tightening order
⇒ page 277
4 - Bolt
❑ 20 Nm
5 - Nut
❑ Tightening torque and
tightening order
⇒ page 277
6 - Support
7 - Support
8 - Screw
❑ Tightening torque and
tightening order
⇒ page 277
9 - Screw
❑ Tightening torque and
tightening order
⇒ page 277
10 - Exhaust pipe with catalytic
converter
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Do not load decoupler
with tensile stress

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❑ Do not damage wire mesh on decoupling element
❑ protect catalytic converter against shocks and blows
❑ installing and removing
⇒ “1.3 Removing and installing catalytic converter with pre-exhaust pipe”, page 275
❑ Remove the protection for the decoupling element on the spare part as late as possible
❑ Align exhaust system free of stress ⇒ “1.5 Aligning exhaust system free of stress”, page 279
11 - Screw clamp
❑ Tightening torque and tightening order ⇒ page 277
12 - Gasket
❑ replace after removal
13 - Exhaust gas turbocharger
❑ installing and removing ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 223
❑ Tightening torque and tightening order
⇒ “1.1 Summary of components - exhaust gas turbocharger ”, page 221
14 - Nut
❑ 30 Nm
15 - Clamping sleeve
❑ before tightening, align exhaust system free of stress
⇒ “1.5 Aligning exhaust system free of stress”, page 279
❑ Fitting position ⇒ page 273
ProCarManuals.com

❑ Tighten screwed connections uniformly

Installation position of front clamp

– Install clamping sleeve in the position shown.
• Angle -α- = approximately 20°.
• Bolted connection to the right.
• Nuts upwards.

1. Removing and installing exhaust system 273

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1.2 Middle and rear silencer - Summary of components

1 - Retaining strap
❑ replace if damaged
2 - Hanger
❑ replace if damaged
3 - Rear silencer
❑ for first equipment build‐
ing unit with middle si‐
lencer
❑ Replace individually
when carrying out re‐
pairs
❑ installing and removing
⇒ “1.4 Removing and in‐
stalling or replacing the
middle and rear silenc‐
er”, page 277
❑ Separating exhaust
pipes, silencers
⇒ “1.4 Removing and in‐
stalling or replacing the
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middle and rear silenc‐

er”, page 277
❑ Align exhaust system
free of stress
⇒ “1.5 Aligning exhaust
system free of stress”,
page 279
4 - Bolt
❑ 20 Nm
5 - Hanger
❑ replace if damaged
6 - Retaining strap
❑ replace if damaged
7 - The middle silencer
❑ for first equipment building unit with rear silencer
❑ Replace individually when carrying out repairs
❑ installing and removing
⇒ “1.4 Removing and installing or replacing the middle and rear silencer”, page 277
❑ Separating exhaust pipes, silencers
⇒ “1.4 Removing and installing or replacing the middle and rear silencer”, page 277
❑ Align exhaust system free of stress ⇒ “1.5 Aligning exhaust system free of stress”, page 279
8 - Clamping sleeve
❑ before tightening, align exhaust system free of stress
⇒ “1.5 Aligning exhaust system free of stress”, page 279
❑ Fitting position ⇒ page 275
❑ Tighten screwed connections uniformly
9 - Retaining strap
❑ replace if damaged
10 - Hanger
❑ replace if damaged

274 Rep. gr.26 - Exhaust system

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Installation position of rear clamp

– Install clamping sleeve in the position shown.
• Angle -α- = approximately 20°.
• Nuts upwards.
• 30 Nm

1.3 Removing and installing catalytic con‐

verter with pre-exhaust pipe
Special tools and workshop equipment required
♦ Transport security - T10403-
♦ Hot bolt paste ⇒ Electronic Catalogue of Original Parts“ETKA”

Note
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The catalytic converter is removed with the pre-exhaust pipe.

Removing

Note

All cable straps should be fastened again in the same place when
installing.

– Take electrical plug connections -1- and -2- out of the holder,
disconnect and expose electric cables.

Note

♦ Before undoing the coupling point between catalytic converter

and turbocharger, make the position of the clamp
⇒ page 275 !
♦ Mark the part opposite the part to be replaced.
♦ Re-establish the position of the clamp when assembling.

Position of the clamp

1. Removing and installing exhaust system 275

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– Unscrew screw -2- and remove screw clamp.

– Unscrew screws -1- and nuts -arrows-.

– Release screws -arrows- of the holder.

– Remove the tunnel bridge ⇒ Body Work - Assembly work;
Rep. gr. 50 .
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– Release screws -1- and remove heat shield for right drive
shaft, if present.
– Remove plastic cover for floor tunnel ⇒ Body Work; Rep. gr.
50 .

– Remove bolts -arrows-.

– Remove electrical plug connection from holder, disconnect
and expose lambda probe electric cable.

276 Rep. gr.26 - Exhaust system

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– Loosen the clamping sleeve -arrow- and slide it backwards.

– Remove catalytic converter backwards.

Note

♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ Do not bend the decoupling element by pulling it.
♦ Do not damage the wire mesh of the decoupling element.
♦ Secure the decoupling element with the transport security -
T10403- against over-tensioning.

– Push screwdriver -2- into the recess -arrow- of the exhaust gas
turbocharger and lever out the sealing ring -1-.
Install
Installation is carried out in the reverse order. When installing,
observe the following:

Note
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♦ Replace the gasket and the self-locking nuts.

♦ Coat pin bolts and screws of the catalytic converter with hot
bolt paste ⇒ Electronic Catalogue of Original Parts“ETKA” .

– Align exhaust system free of stress

⇒ “1.5 Aligning exhaust system free of stress”, page 279 .

Installing catalytic converter - tightening torque and tightening or‐

der
1st – Position catalytic converter
on exhaust gas turbocharger,
loosely tighten clamp -arrow-
2nd – Loosely screw in screws -3-, • It must still be pos‐
-5- and nuts -1-, -2-, -4- by sible to move the
hand catalytic converter
and the bracket

3rd – Tighten screw clamp -arrow- 15 Nm

4th – Tighten screws and nuts in 20 Nm
the order -1...5-

1.4 Removing and installing or replacing the

middle and rear silencer
Special tools and workshop equipment required
♦ Body saw e.g. -V.A.G 1523 A-
♦ Protective goggles
• The rear axle is not removed when replacing the middle or rear
silencer.
• For individually replacing the middle silencer, a coupling point
is provided in the connecting pipe.
• The coupling point is marked by indentation on the circumfer‐
ence of the exhaust pipe.

1. Removing and installing exhaust system 277

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– When present, remove the underbody rear left trim panel ⇒

Body Work- Assembly work; Rep. gr. 66 .
– Remove the rear tunnel bridge ⇒ Body Work - Assembly work;
Rep. gr. 66 .
– Loosen the clamping sleeve -arrow- and slide it forwards.

– Separate exhaust pipe at the separation point-arrow- with

body saw (right-angled).

WARNING

Risk of accident from silencer weight.

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♦ A second mechanic is required for removing the silencer.

– Remove screws -2- and take out rear silencer -1-.

– Remove screw -3- and remove the middle silencer -1-.
Install
Installation is performed in a similar way in the reverse order. Pay
attention to the following points:

278 Rep. gr.26 - Exhaust system

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– Position clamping sleeve centrally to the side markers during

installation -arrows-.
– Install rear clamping sleeve ⇒ page 275
– Installing front clamping sleeve ⇒ page 273
– Align exhaust system in cold condition free of stress
⇒ “1.5 Aligning exhaust system free of stress”, page 279 .
Tightening torques
♦ ⇒ “1.2 Middle and rear silencer - Summary of components”,
page 274
♦ ⇒ “1.1 Catalytic converter and component parts - Summary of
components”, page 272
♦ Remove the tunnel bridge and underbody cover ⇒ Body Work;
Rep. gr. 66

1.5 Aligning exhaust system free of stress

• The exhaust system is aligned when cold.
– Loosen bolted connections of clamping sleeve -arrow-.
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– Push the rear silencer so far forward until the pre-tensioning

on the retaining strap on the exhaust pipe is -a- = 5 mm.
– Installing the clamping sleeve ⇒ page 273 .
Tightening torques
♦ ⇒ “1.1 Catalytic converter and component parts - Summary of
components”, page 272

1.6 Align exhaust tailpipe

Work procedure
– Align rear silencer in such a way that there is an equal distance
-a- between bumper opening and exhaust tailpipe.
– For centring the exhaust tailpipes, loosen the suspension of
the rear silencer.

1. Removing and installing exhaust system 279

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1.7 Inspecting the exhaust system for leak

tightness
Work procedure
– Start engine and run at idling speed.
– Close off exhaust tailpipes for the duration of the leak test,
using cloths or plugs.
– Check connection points for leak tightness by listening: ex‐
haust manifold at cylinder head, exhaust gas turbocharger at
pre-exhaust pipe, etc.
– Eliminate any leak found.
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280 Rep. gr.26 - Exhaust system

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28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 281
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 282
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 283
⇒ “1.4 Removing and installing Hall sender G40 ”, page 284
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
284

1.1 Assembly overview - ignition system

1 - Bolt
❑ the tightening torque in‐
fluences the knock sen‐
sor function
❑ 20 Nm
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2 - Knock sensor 1 - G61-

❑ installing and removing
⇒ “1.3 Removing and
installing knock sensor
1 G61 ”, page 283
3 - Spark plug
❑ use spark plug wrench
e.g. -3122 B- for remov‐
ing and installing
❑ Change interval ⇒ Main‐
tenance ; Booklet Octa‐
via III
❑ Observe part number ⇒
Electronic Catalogue of
Original Parts “ETKA”
❑ 22 Nm
4 - Ignition coil with a power
output stage
♦ Ignition coil 1 with output
stage - N70-
♦ Ignition coil 2 with output
stage - N127-
♦ Ignition coil 3 with output
stage - N291-
♦ Ignition coil 4 with output
stage - N292-
❑ installing and removing
⇒ “1.2 Removing and in‐
stalling ignition coils with output stage”, page 282
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm

1. Ignition system 281

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7 - Hall sender - G40-

❑ installing and removing ⇒ “1.4 Removing and installing Hall sender G40 ”, page 284
8 - O-ring
9 - Rotor
❑ for engine speed sender - G28-
❑ cannot be removed separately, only with sealing flange Pos. -10-
10 - Sealing flange on the gearbox side
❑ installing and removing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 49
11 - Engine speed transmitter - G28-
❑ installing and removing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 284
12 - Bolt
❑ 5 Nm

1.2 Removing and installing ignition coils

with output stage
Special tools and workshop equipment required
♦ Extractor -T10530-
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Removing
Ignition coils “cyl. 2, 3, 4”
– Loosen hose clamps -1- and -2- and remove air guide pipes.
Continued for all ignition coils

– Disconnect plug connection -2-.

– Unscrew screw -1-.

282 Rep. gr.28 - Ignition system

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– Press extractor -T10530- into the bore of the ignition coil -1-
as far as the stop.
– Tighten nuts -2- in -direction of arrow-.

– Remove ignition coil with extractor -T10530- in

-direction of arrow- out of the camshaft housing.
Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Insert all ignition coils loosely into the spark plug shaft.
– Align ignition coils to the connectors and simultaneously at‐
tach all connections to the ignition coils.
– Press ignition coils onto the spark plugs evenly by hand (do
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not use an impact tool).

Tightening torque
Component Nm
Screw for ignition coil 8 Nm

1.3 Removing and installing knock sensor 1

- G61-
Removing
– Remove AC compressor from holder and strap up ⇒ Heating,
Air Conditioning; Rep. gr. 87 .
– Separate electrical plug connection -1-.
– Release screw -2- and remove knock sensor 1 - G61- .
Install
Installation is carried out in the reverse order. When installing,
observe the following:
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr.
87 .
Tightening torque
Component Nm
Screw for knock sensor 20 Nm

1. Ignition system 283

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1.4 Removing and installing Hall sender -

G40-
Removing
– Loosen hose clamps -1- and -2- and remove air guide pipes.

– Separate electrical plug connection -1-.

– Unscrew screw -2- and remove Hall sender - G40- .
Install
– Installation is carried out in the reverse order.
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Tightening torque
Component Nm
Screw for hall sender 8 Nm

1.5 Removing and installing engine speed

sender - G28-
Special tools and workshop equipment required
♦ Socket insert 4 mm - T10370-
Removing
– Remove the sound dampening system -1- ⇒ Body Work; Rep.
gr. 66 .
– Undo screw -arrow- and place charge air cooler pump - V188-
to one side.

284 Rep. gr.28 - Ignition system

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– Separate electrical plug connection -1-.

– Unscrew screw -2- and pull out engine speed sender - G28- .
Install

Caution

Carefully insert engine speed sender - G28- into the bore.

This prevents the engine speed sensor - G28- from falling be‐
tween the engine and gearbox.

Installation is performed in a similar way in the reverse order. Pay

attention to the following points:
– Install the noise insulation ⇒ Body Work; Rep. gr. 66 .
Tightening torque
Component Nm
Screw for coolant pump 8 Nm
Screw for engine speed sender 5 Nm
ProCarManuals.com

1. Ignition system 285